Method for manufacturing electrical connection module

Abstract

The present disclosure provides a method for manufacturing an electrical connection module. The electrical connection module includes a first connection module and a second connection module. The manufacturing method includes a punching process, a cutting process and a loading process. In the punching process, a blank of the electrical connection module is prepared. A through hole is formed on the blank of the electrical connection module along a straight line parallel to the axial direction and passing through the blank of the electrical connection module. In the cutting process, the blank of the electrical connection module is cut along a direction perpendicular to the straight line to divide the blank of the electrical connection module into the blank of the first connection module and the blank of the second connection module. The through hole on the blank of the first connection module is a first through hole, and the through hole on the blank of the second connection module is a second through hole. In the loading process, the first pin is placed in the first through hole, and the second pin is placed in the second through hole. After the punching process and the cutting process, it can be ensured that the first through hole and the second through hole are aligned with each other along the straight line direction, and the position deviation of the through holes can be avoided.

Description

Technical Field

[0001] The present disclosure relates to the field of medical devices, and in particular, to a method for manufacturing an electrical connection module. Background Art

[0002] In the medical field, electrical stimulation systems have been widely studied and applied for analgesia. The system mainly consists of a pulse stimulator and stimulation electrodes. The connection relies on the corresponding connection between the contacts on the pulse stimulator and the contacts on the stimulation electrodes to realize signal transmission, thereby achieving an analgesic effect. However, as modern medical technology develops in the direction of miniaturization and refinement, the overall size of the electrical stimulation system continues to shrink, which leads to the structure for connecting the pulse stimulator and the stimulation electrode becoming smaller. In a limited and tiny space, it is extremely challenging to ensure the precise corresponding connection of many contacts. At present, this accuracy problem has become a key technical difficulty in the miniaturization process of electrical stimulation systems, and it is urgent to solve it to promote the further development of this technology. Summary of the Invention

[0003] The present disclosure aims to provide a method for manufacturing an electrical connection module to solve the connection accuracy problem faced by the miniaturization of electrical stimulation systems.

[0004] The present disclosure provides a method for manufacturing an electrical connection module. The electrical connection module is suitable for an electrical stimulation system. The electrical stimulation system includes a pulse generator and stimulation electrodes. The electrical connection module is used to electrically connect the pulse generator to the stimulation electrodes. The electrical connection module includes a first connection module and a second connection module. The manufacturing method includes a punching step, a cutting step, and an assembly step. In the punching step, a blank of the electrical connection module is prepared. The blank of the electrical connection module is cylindrical. A through hole is formed in the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module. The radial dimension of the blank of the electrical connection module is less than or equal to 3 mm, the number of through holes is greater than or equal to 24, and each through hole is isolated from each other. In the cutting step, the blank of the electrical connection module is cut in a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of the first connection module and a blank of the second connection module. The through hole formed in the punching step is a first through hole in the blank of the first connection module, and the through hole formed in the punching step is a second through hole in the blank of the second connection module. During the installation process, the first pin is at least partially placed in the first through hole, and the second pin is at least partially placed in the second through hole, wherein the first pin is provided with a socket, and the second pin can be inserted into the socket and electrically connected to the first pin.

[0005] After the punching and cutting steps, the first and second through-holes can be precisely aligned with each other along a straight line, avoiding the possibility of positional deviation of the through-holes due to the small size of the components during separate processing, creating favorable conditions for subsequent high-precision operations, and providing extremely precise placement of the pins within a tiny space, greatly improving the positioning accuracy of the connection structure at a tiny size. During the installation process, the socket provided by the first pin allows the second pin to be accurately inserted to achieve electrical connection. Thanks to the control of the positional accuracy of the first and second through-holes in the previous steps, the electrical connection between the pulse generator and the stimulation electrode can be firmly and reliably achieved, ensuring accurate signal transmission of the electrical stimulation system and its efficient analgesic effect.

[0006] In one exemplary embodiment, the punching process includes a first punching step, during which a diameter of the punched hole is set to a predetermined diameter of one of the first through-hole and the second through-hole. After the first punching step, the punching process further includes a second punching step, during which the diameter of the punched hole is set to a predetermined diameter of the other of the first through-hole and the second through-hole, wherein the predetermined diameter of the first through-hole is different from the predetermined diameter of the second through-hole. Because the second pin needs to be inserted into the receptacle of the first pin to achieve electrical connection, the diameters of the first through-hole and the second through-hole should be different, with the larger diameter being used to receive the first pin and the smaller diameter being used to receive the second pin.

[0007] In an exemplary embodiment, in the punching process, a laser is used to punch holes in the blank of the electrical connection module.

[0008] When manufacturing electrical connection modules, the punching process is crucial for achieving precise connections between the pulse generator and the stimulation electrodes. Traditionally, punching is often done by molding. However, as electrical connection modules move towards miniaturization, this traditional method has exposed many problems. The electrical connection module is small and contains at least 24 through-holes. During molding and pouring, uneven pouring is very likely to occur, and several through-holes are likely to be connected, affecting the independence of the pin connection and the stability of the stimulation signal. Moreover, during the process of removing the needle, due to the small space and fragile hole walls, after the pouring liquid solidifies into the connection module and is removed from the mold, it is easy to damage the through-hole, resulting in several through-holes being connected, and even the shape and size of the hole being changed, which cannot meet the high-precision connection requirements and seriously restricts the manufacturing quality and performance improvement of small electrical connection modules.

[0009] Traditional drilling methods require both a small size and high hardness due to the small size of the electrical connection module and the large number of through-holes required in the module blank. This presents challenges in material selection and increases costs. Furthermore, due to the large number of through-holes in the module blank, even the slightest vibration or deviation of the drill bit during drilling can damage other through-holes.

[0010] Laser drilling can precisely form the first and second through-holes in tiny electrical connection module blanks, effectively avoiding the problem of connected holes caused by uneven liquid injection in traditional mold manufacturing. This ensures the independence and integrity of each through-hole, providing a stable and reliable foundation for pin connections. The non-contact processing characteristics of laser drilling avoid the physical damage to the through-holes caused by the mold withdrawal process during traditional molding, ensuring the shape and dimensional accuracy of the holes and the required precision of the connection structure of the electrical connection module. The high efficiency of laser drilling can also significantly improve production efficiency and promote the mass production of electrical connection modules.

[0011] In one exemplary embodiment, in a first drilling step, a laser with a first beam diameter is used to drill holes in the blank of the electrical connection module. In a second drilling step, the blank of the electrical connection module is further drilled using a laser with a second beam diameter, the second beam diameter being smaller than the first beam diameter. Upon completion of the second drilling step, a through hole is formed in the electrical connection module. In other words, the first through hole and the second through hole are generated continuously.

[0012] During the drilling process in electrical connector module manufacturing, the second pin must be inserted into the first pin's socket to establish an electrical connection, and the two must remain electrically connected. Therefore, the outer diameter of the second pin must be equal to or greater than the inner diameter of the first pin's socket, placing extremely high demands on the concentricity of the two. Furthermore, because the first pin must be inserted into the first through-hole before the second pin can be inserted into the first pin's socket, the first pin's socket must be positioned concentrically with the first pin to ensure accurate insertion. Furthermore, the first and second through-holes must also be concentric. This ensures that the second pin can be accurately inserted into the first pin's socket regardless of how the first pin is inserted into the first through-hole. However, the process of forming the through-holes in the electrical connector assembly blank is continuous and uninterrupted, which means that the laser beam diameter must also change continuously, so the laser beam diameter needs to vary from large to small.

[0013] In this disclosure, during the first drilling step, the first through-hole is created using a laser with a first beam diameter, while the second through-hole is created using a laser with a second beam diameter smaller than the first. Although the drilling process is split into two steps, a unified center positioning reference is used. The equipment uses this to accurately drill holes, and each step strictly controls the center position to prevent deviation. This ensures the concentricity of the first and second through-holes, laying the foundation for precise pin alignment and stable electrical connection.

[0014] During the drilling process, the laser's high energy density, good directionality, and easy focus control properties are utilized to first drill holes in the electrical connection module blank with a larger first beam diameter laser. This is because its concentrated energy allows it to act efficiently on the material. The laser is then quickly switched to a smaller second beam diameter to continue drilling, achieving continuous formation of the first and second through-holes. High-precision finishing is performed throughout the process, with high laser focusing accuracy, effectively avoiding deviations caused by switching or interrupting the drilling process, ensuring through-hole accuracy and quality. At a tiny size, this drilling method fully leverages the advantages of the laser, ensuring a stable electrical connection module structure and reliable electrical connections. This perfectly meets the stringent requirements for precise connections in the electrical stimulation system, greatly improving production accuracy and efficiency.

[0015] In an exemplary embodiment, the change from the first beam diameter to the second beam diameter is continuous from the first punching step to the second punching step, so as to form a first segment having a first diameter, a second segment having a second diameter, and a transition segment between the first segment and the second segment in the through hole, wherein the first diameter is equal to the first beam diameter and the second diameter is equal to the second beam diameter.

[0016] The laser beam diameter continuously changes from the first beam diameter to the second beam diameter, forming a transition section during drilling. The inner diameter of the transition section is between the predetermined sizes of the first and second through-holes. This ensures a continuous and uninterrupted drilling process while ensuring the accuracy of the dimensions of the first and second through-holes. This lays the foundation for a stable electrical connection of the electrical connection module in the electrical stimulation system and improves the reliability and precision of the overall manufacturing process.

[0017] Furthermore, the cutting process includes a first cutting process and a second cutting process. In the first cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the first segment. In the second cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the second segment.

[0018] During cutting, the first section and the second section are cut according to the predetermined length, and the transition section is accurately removed, so that the sizes of the first through hole of the first connecting module blank and the second through hole of the second connecting module blank accurately meet the requirements.

[0019] In one exemplary embodiment, the first and second pins are made of metal. Prior to the mounting step, the manufacturing method further includes a treatment step. In the treatment step, the inner surfaces of the first and second through-holes are metallized. After the mounting step, the manufacturing method further includes a welding step. In the welding step, the first pin is welded to the metallized inner surface of the first through-hole, and the second pin is welded to the metallized inner surface of the second through-hole.

[0020] Traditional adhesive connections introduce additional resistance and capacitance due to the dielectric properties of the adhesive layer, interfering with the proper transmission of electrical signals. Adhesive connections can also degrade over time under stress or when subjected to temperature or humidity fluctuations, increasing the risk of connection failure.

[0021] The metal welding interface provided by the present disclosure has low electrical resistance, which can reduce energy loss and signal attenuation during electrical signal transmission, ensuring that the electrical stimulation signal is transmitted with higher fidelity between the pulse generator and the stimulation electrode, thereby improving the efficiency and accuracy of the electrical stimulation system. The welded connection has better high-temperature resistance. The electrical connection module may generate heat due to the passage of current during operation. The welded structure can maintain the integrity of the connection in higher temperature environments.

[0022] In an exemplary embodiment, during the loading process, the first end of the first pin is extended from the first end surface of the blank of the first connecting module, and the second end of the first pin is aligned with the second end surface of the blank of the first connecting module.

[0023] The first end of the first pin extends from the first end surface of the first connection module blank to connect to the pulse generator's connection circuit board. Aligning the second end of the first pin with the second end surface of the first connection module blank provides structural support for the first pin within the first connection module, thereby preventing contact failure caused by unintended displacement of the second pin during insertion and significantly improving the reliability of the overall electrical connection module structure.

[0024] In an exemplary embodiment, during the insertion process, the first end of the second pin is extended from the first end surface of the second connection module blank to facilitate insertion of the first end of the second pin into the second end of the first pin. The second end of the second pin is extended from the second end surface of the second connection module blank to facilitate connection between the second end of the second pin and the signal transmission wire of the stimulation electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A schematic structural diagram of an electrical stimulation system is shown.

[0026] Figure 2 A partial perspective structural schematic diagram of the electrical stimulation system shown in FIG.

[0027] Figure 3 for Figure 2 A partial enlarged schematic diagram.

[0028] Figure 4 A schematic diagram of the local structure of a traditional pulse generator is shown.

[0029] Figure 5 A schematic diagram of the partial structure of a pulse generator of an electrical stimulation system is shown.

[0030] Figure 6 A schematic diagram of the exploded structure of the first connection module in the electrical connection module is shown.

[0031] Figure 7 A schematic diagram of the exploded structure of the second connection module in the electrical connection module is shown.

[0032] Figure 8 A flow chart of a method for processing an electrical connection module according to an embodiment of the present disclosure is shown.

[0033] Figure 9 Shown according to Figure 8 The processing method flow chart shown is a status diagram of the actual processing process.

[0034] Figure 10 Shown according to Figure 8 A further refinement of the processing method flow chart shown.

[0035] Figure 11 Shown according to Figure 8 Detailed process of one process in the processing method flow chart shown.

[0036] Figure 12 Shown according to Figure 11 The processing method flow chart shown is a schematic diagram of an actual processing structure.

[0037] Figure 13 Shown according to Figure 8 Detailed process of one process in the processing method flow chart shown.

[0038] Figure 14 Shown according to Figure 11 Another actual processing structure schematic diagram is performed according to the processing method flow chart shown.

[0039] Figure 15 Shown according to Figure 13 The actual processing status diagram of the processing method flow chart shown. DETAILED DESCRIPTION

[0040] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the following embodiments, processing of a glass substrate will be described, but the same is true for other brittle material substrates.

[0041] The electrical stimulation system includes a pulse generator 10 and a stimulation electrode 20. The pulse generator 10 is used to generate electrical stimulation pulses, which are delivered to the target tissue via the stimulation electrode 20, thereby achieving electrical stimulation of the target area.

[0042] The pulse generator 10 includes a housing 11 and a main control board 12, a connecting circuit board 14, and a first connecting module 16 located within the housing 11. The main control board 12 is configured to generate electrical stimulation pulses, which are transmitted to the stimulation electrode 20 via the connecting circuit board 14 and the first connecting module 16. The first connecting module 16 includes a plurality of first pins 162, each of which is a long, straight structure. The stimulation electrode 20 includes a plurality of second pins 262, each of which is a long, straight structure and is connected to a corresponding wire in the stimulation electrode 20. The other end of each wire is connected to a pulse output contact of the stimulation electrode 20 for delivering stimulation current to the target site. The plurality of first pins 162 correspond to the plurality of second pins 262. The first end 1621 of each first pin 162 is fixedly connected to the connecting circuit board 14, and the second end 1622 of each first pin 162 is provided with a socket 1623 for receiving the corresponding second pin 262. That is to say, there is no need for indirect connection between the first pin 162 and the connecting circuit board 14 via any form of adapter component (such as an adapter wire). At the same time, the plug-in connection between the first pin 162 and the second pin 262 realizes electrical communication between the first pin 162 and the stimulation electrode 20.

[0043] In conventional neurostimulation systems, such as Figure 4 As shown, after the stimulation electrode 30 is connected to the pulse generator 40, the electrical stimulation pulse generated by the main control board 42 of the pulse generator 40 needs to be transmitted to the stimulation electrode 30 through the connecting circuit board 44, the connecting wire 46 and the electrode receiving component 48. Specifically, the electrode receiving component 48 of the pulse generator 40 needs to be soldered to the connecting circuit board 44 connected to the main control board 42 in the pulse generator 40 that performs the pulse transmission function through a set of connecting wires 46. The connecting wires are connected to the connecting circuit board 44 at one end and to the connecting contacts 482 of the electrode receiving component 48 for contacting the stimulation electrode 30 at the other end. In other words, the electrode receiving component 48 and the connecting circuit board 44 are indirectly connected via the connecting wires 46. Such an indirect connection not only creates considerable difficulty in the assembly work, but also affects the stability of the connection between the connecting wires 46 and the connecting contacts 482, thereby affecting the stability of the stimulation electrode 30 in receiving the electrical stimulation pulses.

[0044] A portion of the first connection module 16 corresponds to the electrode receiving component 48 of a conventional pulse generator 40. The first pin 162 is fixedly connected to the connection circuit board 14 at a first end 1621 and to the stimulation electrode 20 at a second end 1622, thus combining conventional transfer contacts with transfer wires. This simplifies the structure of the pulse generator, improves the connection reliability between the connection circuit board and the first pin, and enhances the production efficiency of the neurostimulation system.

[0045] The connecting circuit board 14 includes a pulse output end 142 for connecting to the first connecting module 16 . The pulse output end 142 has a pulse output end surface 1422 . The pulse output end surface 1422 includes a plurality of pulse output terminals 1424 . Each pulse output terminal 1424 is suitable for connecting to a corresponding first pin 162 .

[0046] The first connection module 16 has a first end surface 164. The first end surface 164 and the pulse output end surface 1422 are both planes. The first end surface 164 is configured to face the pulse output end surface 1422 of the connection circuit board 14.

[0047] The first connection module 16 also has a second end surface 165 , and the second end 1622 of each first pin 162 is exposed to the second end surface 165 . The length of each first pin 162 exposed to the second end surface 165 is the same, and the plug-in mating length of each second pin 262 is the same as that of the first pin 162 .

[0048] The stimulation electrode 20 is adapted for use with the pulse generator 10 as described above and comprises an electrode body 22, at least one lead 28, and a second connection module 26. Each lead 28 extends along the length of the electrode body 22, with one end extending outside the electrode body 22 and the other end connected to a pulse output contact of the stimulation electrode 20 for delivering stimulation current to a target site.

[0049] The second connection module 26 is suitable for docking with the first connection module 16 of the pulse generator 10. The second connection module 26 includes a plurality of second pins 262. The plurality of second pins 262 respectively correspond to the plurality of first pins 162 in the pulse generator 10. The length of each second pin 262 is the same, and the second pins 262 are separated from the electrode body 22.

[0050] The first end 2621 of each second pin 262 is connected to one end of the wire 28 extending from the electrode body 22, and the second end 2622 of each second pin 262 is used to be inserted into the socket 1623 of the corresponding first pin 162. The second end 2622 of each second pin 262 is flush.

[0051] The first connection module 16 and the second connection module 26 together constitute an electrical connection module. The first connection module 16 is a complete structure with a first pin 162 inserted. Prior to this complete structure, the first connection module 16 comprises a first connection module blank 50 and the first pin 162. The second connection module 26 is a complete structure with a second pin 262 inserted. Prior to this complete structure, the second connection module 26 comprises a second connection module blank 60 and the second pin 262.

[0052] The electrical connection module is suitable for an electrical stimulation system. The electrical stimulation system includes a pulse generator and stimulation electrodes. The electrical connection module is used to electrically connect the pulse generator to the stimulation electrodes. The electrical connection module includes a first connection module and a second connection module.

[0053] like Figure 8 As shown, the present disclosure provides a method for manufacturing the electrical connection module. The method 300 for manufacturing the electrical connection module includes a punching step 310 , a cutting step 330 , and an inserting step 350 .

[0054] Punching step 310 : forming a through hole on the blank of the electrical connection module along a straight line that is parallel to the axis of the blank of the electrical connection module and passes through the blank of the electrical connection module.

[0055] Specifically, in the punching process 310, a blank of an electrical connection module is prepared. The blank of the electrical connection module is cylindrical, and the length of the blank of the electrical connection module in the axial direction is greater than 7 mm and the diameter is less than or equal to 3 mm. The blank of the electrical connection module is placed on a punching processing platform. The platform has the function of accurately positioning and stabilizing the blank, and can be accurately docked with the punching equipment. Through fine-tuning, the axis of the blank is completely parallel to the punching straight line preset by the punching equipment, and the blank is ensured to be firmly fixed to prevent any displacement during the punching process. A through hole is formed on the blank of the electrical connection module along a straight line that is parallel to the axial direction of the blank of the electrical connection module and passes through the blank of the electrical connection module. The number of through holes is greater than or equal to 24. The multiple through holes are isolated from each other.

[0056] Cutting process 330 : Cutting the blank of the electrical connection module along a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of a first connection module and a blank of a second connection module.

[0057] Specifically, during the cutting process 330, the axial length of the blank of the first connecting module is at least 5 mm, and the axial length of the blank of the second connecting module is at least 2 mm. The through holes formed during the punching process are first through holes in the blank of the first connecting module, and the number of first through holes is also greater than or equal to 24. The through holes formed during the punching process are second through holes in the blank of the second connecting module, and the number of second through holes is also greater than or equal to 24. After the cutting process, the first through holes and the second through holes are aligned along a straight line.

[0058] The cutting equipment is activated and, according to preset cutting parameters, the electrical connector module blank is cut into a first connector module blank (with an axial length of at least 5 mm) and a second connector module blank (with an axial length of at least 2 mm). During the cutting process, a high-precision positioning and measurement system is used to monitor the cutting position in real time, ensuring that the cut surface is flat and perpendicular to the punch line, ensuring that the first and second through-holes are precisely aligned along the straight line after cutting.

[0059] Loading process 350: placing the first pin at least partially in the first through hole, and placing the second pin at least partially in the second through hole, for example, by gluing or welding.

[0060] Specifically, in the installation process 350, the first pin is provided with a socket at the second end, and the second end of the second pin can be inserted into the socket to be electrically connected to the first pin. The first pin and the second pin are made of metal, such as gold, silver or copper.

[0061] For example, Figure 9 , which shows the physical processing process of the punching step 310 , the cutting step 330 and the loading step 350 in the manufacturing method 300 of the electrical connection module.

[0062] A punching process 310 is performed to punch holes in the blank 1 of the electrical connection module along a straight line parallel to the axis direction. In this example, the total number of holes is 24. A cutting process 330 is performed to divide the blank 1 of the electrical connection module into a blank 50 of the first connection module and a blank 60 of the second connection module at a preset position along a direction perpendicular to the axis. The first through hole 41 and the second through hole 51 are shown. An installation process 350 is performed to insert a plurality of first pins 162 into the corresponding first through holes 41, and a plurality of second pins 262 into the corresponding second through holes 51. The first pin 162 is provided with a socket 1623 on the second end 1622. Each socket 1623 receives the second end 2622 of the corresponding second pin 262.

[0063] After the punching and cutting steps, the first and second through-holes can be precisely aligned with each other along a straight line, avoiding the possibility of positional deviation of the through-holes due to the small size of the components during separate processing, creating favorable conditions for subsequent high-precision operations, and providing extremely precise placement of the pins within a tiny space, greatly improving the positioning accuracy of the connection structure at a tiny size. During the installation process, the socket provided by the first pin allows the second pin to be accurately inserted to achieve electrical connection. Thanks to the control of the positional accuracy of the first and second through-holes in the previous steps, the electrical connection between the pulse generator and the stimulation electrode can be firmly and reliably achieved, ensuring accurate signal transmission of the electrical stimulation system and its efficient analgesic effect.

[0064] Preferably, if Figure 10 3 , the process between the punching process 310 and the cutting process 330 is shown. Before the cutting process 330, the manufacturing method 300 further includes a treatment process 320. Treatment process: metallizing the inner surface of the through hole formed in the punching process 310, for example, by an immersion plating process.

[0065] Specifically, in the processing step 320, the pre-treated blank of the electrical connection component is immersed in a metal salt solution and connected to an electrolysis device. Through electrolysis, zinc or tin metal is evenly deposited on the inner surface of the through-hole to form a metallized layer. During the immersion plating process, the metal deposition rate and thickness are continuously monitored to ensure that the thickness of the inner surface metallized layer does not exceed 0.1 mm, which can be precisely controlled by controlling factors such as the current size and the immersion plating time. After the loading step 350, the manufacturing method 300 also includes a welding step 360. In the welding step 360, the first pin is welded to the metallized inner surface of the first through-hole, and the second pin is welded to the metallized inner surface of the second through-hole.

[0066] Traditional adhesive connections introduce additional resistance and capacitance due to the dielectric properties of the adhesive layer, interfering with the proper transmission of electrical signals. Adhesive connections can also degrade over time under stress or when subjected to temperature or humidity fluctuations, increasing the risk of connection failure.

[0067] The metal welding interface provided by the present disclosure has low electrical resistance, which can reduce energy loss and signal attenuation during electrical signal transmission, ensuring that the electrical stimulation signal is transmitted with higher fidelity between the pulse generator and the stimulation electrode, thereby improving the efficiency and accuracy of the electrical stimulation system. The welded connection has better high-temperature resistance. The electrical connection module may generate heat due to the passage of current during operation. The welded structure can maintain the integrity of the connection in higher temperature environments.

[0068] In one exemplary embodiment, the insertion process includes: extending the first end of the first pin from the first end surface of the blank of the first connecting module. Aligning the second end of the first pin with the second end surface of the blank of the first connecting module. The first end of the second pin extends from the first end surface of the blank of the second connecting module so that the first end of the second pin is connected to the signal transmission wire of the stimulation electrode; and the second end of the second pin extends from the second end surface of the blank of the second connecting module so that the second end of the second pin can be easily inserted into the second end of the first pin.

[0069] The first end of the first pin extends from the first end surface of the first connection module blank to connect to the pulse generator's connection circuit board. Aligning the second end of the first pin with the second end surface of the first connection module blank provides structural support for the first pin within the first connection module, thereby preventing contact failure caused by unintended displacement of the second pin during insertion and significantly improving the reliability of the overall electrical connection module structure.

[0070] The inner diameter of the socket is greater than or equal to the outer diameter of the corresponding second pin to accommodate the second pin. The length of the second pin's second end exposed to the second end surface of the second connection module blank is less than or equal to the depth of the socket for the first pin. This arrangement ensures that the second end surface of the first connection module blank and the second end surface of the second connection module blank meet, thereby improving the connection stability between the first and second connection modules.

[0071] In an exemplary embodiment, Figure 11 As shown, the punching process 310 includes a first punching step 3110. The first punching step 3110: setting the diameter of the punched hole to a predetermined diameter of the first through hole and the second through hole.

[0072] After the first punching step, the punching process further includes a second punching step 3120. The second punching step 3120: setting the punching diameter to the other predetermined diameter of the first through hole and the second through hole, wherein the predetermined diameter of the first through hole is different from the predetermined diameter of the second through hole.

[0073] Since the second pin needs to be inserted into the jack of the first pin to achieve electrical connection, the diameters of the first through hole and the second through hole should be different, with the larger diameter one being used to receive the first pin and the smaller one being used to receive the second pin.

[0074] For example, Figure 12 As shown, the physical processing performed according to the first punching step 3110 and the second punching step 3120 in the manufacturing method 300 of the electrical connection module is a schematic effect.

[0075] Set the drilling parameters, determining the larger diameter of the first and second through-holes as the target diameter for this drilling (for example, set D1 = 0.3mm). During the first drilling step, the punching equipment begins drilling the blank along a predetermined linear trajectory parallel to the blank axis and passing through the blank, forming a hole segment with a diameter of D1. The punching equipment's control system monitors the drilling depth and hole diameter in real time to ensure that the diameter of the first hole segment remains stable around D1. The drilling operation continues until the predetermined drilling depth (for example, set H1 = 5mm) is reached.

[0076] After the first punching step is completed, the second punching step is entered. At this time, the punching diameter parameter of the punching equipment is adjusted to the smaller predetermined diameter of the first through hole and the second through hole (for example, set to D2 = 0.2mm). The punching operation is continued on the already punched through hole along the previous straight punching trajectory to form a hole segment with a diameter of D2. The control system of the punching equipment monitors the punching depth and hole diameter changes in real time to ensure that the diameter of the punched first hole segment is stable at around D2. The punching operation is continued until the predetermined punching depth is reached (for example, set to H2 = 2mm). The processing of the entire through hole is thus completed, so that each through hole consists of a first segment with a diameter of D1 and a second segment with a diameter of D2, corresponding to the different diameter requirements of the first through hole and the second through hole respectively.

[0077] During the punching process, the second punching step may be performed after completing all the first punching steps for all the through holes individually, or the first punching step and the second punching step may be performed consecutively for each through hole, with one through hole being the punching unit.

[0078] In an exemplary embodiment, during the punching process, a laser punching device is used to punch holes in the blank of the electrical connection module using a laser, for example, punching the holes one by one or punching the at least 24 through holes simultaneously.

[0079] The blank of the electrical connection module is placed on a workbench, which can ensure the stability and position accuracy of the blank during the punching process.

[0080] The drilling operation begins, with the laser beam gradually acting on the blank material along a predetermined linear trajectory parallel to and passing through the blank's axis. Because the electrical connection module requires the formation of at least 24 isolated through-holes, the laser drilling equipment uses a precise control system to perform the drilling operation on the blank sequentially according to a pre-set through-hole distribution pattern. During the drilling process, the high energy density of the laser is utilized to rapidly vaporize or melt the material and discharge it, forming individual through-holes. Simultaneously, a real-time monitoring system monitors parameters such as drilling depth, hole diameter, and hole wall flatness. If any deviation is detected, the laser parameters or worktable position are adjusted promptly to make corrections.

[0081] When manufacturing electrical connection modules, the punching process is crucial for achieving precise connection between the pulse generator and the stimulation electrode. Traditional punching often uses molding. However, as electrical connection modules develop towards miniaturization, this traditional method has exposed many problems. The electrical connection module is small and contains at least 24 through-holes. During molding and pouring, uneven pouring is very likely to occur, and several through-holes are likely to be connected, affecting the independence of the pin connection and the stability of the stimulation signal. Moreover, after the pouring liquid solidifies into the blank of the electrical connection module and is removed from the mold, it is easy to damage the through-holes, resulting in several through-holes being connected, and even the shape and size of the holes are changed, which cannot meet the high-precision connection requirements and seriously restricts the manufacturing quality and performance improvement of small electrical connection modules.

[0082] Traditional drilling methods require both a small size and high hardness due to the small size of the electrical connection module and the large number of through-holes required in the module blank. This presents challenges in material selection and increases costs. Furthermore, due to the large number of through-holes in the module blank, even the slightest vibration or deviation of the drill bit during drilling can damage other through-holes.

[0083] Laser drilling can precisely form multiple through-holes of the desired size on tiny electrical connection module blanks, effectively avoiding the problem of interconnected holes caused by uneven liquid injection in traditional mold manufacturing. This ensures the independence and integrity of each through-hole, providing a stable and reliable foundation for pin connections. Laser drilling, with its non-contact processing characteristics, avoids the physical damage to the through-holes caused by the mold removal process during traditional molding, ensuring the shape and dimensional accuracy of the holes and the precision of the connection structure of the electrical connection module. The high efficiency of laser drilling can also significantly improve production efficiency and promote the mass production of electrical connection modules.

[0084] In one exemplary embodiment, in a first drilling step, a laser with a first beam diameter is used to drill holes in the blank of the electrical connection module. In a second drilling step, the blank of the electrical connection module is further drilled using a laser with a second beam diameter, the second beam diameter being smaller than the first beam diameter. Upon completion of the second drilling step, a through hole is formed in the electrical connection module. In other words, the first through hole and the second through hole are generated continuously.

[0085] like Figure 13As shown, in the first drilling step, the laser drilling device 70 is turned on, and the laser L1 with the first beam diameter (for example, set to X mm) is used to start the drilling operation on the blank along a straight line parallel to the axis of the blank of the electrical connection module and passing through the blank. At this time, the laser rapidly acts on the blank material with its high energy density characteristic, gradually forming a blind hole structure with a certain depth H1 and an inner diameter corresponding to the first beam diameter on the blank.

[0086] After the depth H1 is completed in the first drilling step, the second drilling step immediately follows. The diameter of the laser is switched to the second beam diameter (set to Y mm, and Y < X), that is, the laser L2. Without changing the drilling straight-line trajectory and the position of the blank, the laser continues to perform in-depth drilling on the existing blind hole. Due to the smaller second beam diameter, the inner diameter of the hole gradually transitions to the size corresponding to the second beam diameter until the entire through-hole drilling operation is completed, finally forming a continuous first through-hole (corresponding to the part drilled with the first beam diameter) and a second through-hole (corresponding to the part drilled with the second beam diameter) on the blank of the electrical connection module. During the entire drilling process, through the control of the high-precision processing platform and the precise parameter adjustment of the laser drilling device, the seamless connection and continuous progress from the first drilling step to the second drilling step are ensured, effectively guaranteeing the concentricity and dimensional accuracy of the first through-hole and the second through-hole, laying a foundation for the precise docking of the pins and the realization of stable electrical connection in the subsequent process. Here, X and Y are adjusted according to actual needs.

[0087] During the drilling process, by virtue of the characteristics of the laser with high energy density, good directivity and easy focusing control, first drill holes on the blank of the electrical connection module with a laser of a larger first beam diameter. Because its energy is concentrated, it can act on the material efficiently. Subsequently, quickly switch to a laser with a smaller second beam diameter to continue drilling, realizing the continuous formation of the first through-hole and the second through-hole. In the case of small dimensions, such a drilling method gives full play to the advantages of the laser, making the structure of the electrical connection module stable and the electrical connection reliable, perfectly meeting the strict requirements of the precise connection of the electrical stimulation system, and greatly improving the precision and efficiency of production.

[0088] In an exemplary embodiment, the change from the first beam diameter to the second beam diameter is continuous, so as to form a first section with the first diameter, a second section with the second diameter and a transition section between the first section and the second section in the through-hole, where the first diameter is equal to the first beam diameter and the second diameter is equal to the second beam diameter. The cutting process includes selecting a predetermined length to cut the first section from the electrical connection module to form a first blank of the connection module; selecting a predetermined length to cut the second section from the electrical connection module to form a second blank of the connection module.

[0089] As Figure 13-15The laser drilling device 70 is activated, and the initial laser beam diameter is set to D1 (e.g., 0.3 mm). The laser begins to act on the blank along the predetermined drilling line. At this point, the laser, at a stable power and pulse frequency, gradually drills a first section P1 of a through hole with a first diameter (i.e., D1) in the blank, reaching a predetermined depth H1 (e.g., 5 mm). During this process, the device's control system precisely controls the laser's trajectory and energy output, ensuring that the straightness and aperture accuracy of the first section of the through hole remain within strict tolerances.

[0090] Second drilling step: After the first drilling section is completed, the drilling process continues. The equipment's intelligent control system continuously and smoothly reduces the laser beam diameter from the first beam diameter D1 to the second beam diameter D2 (e.g., 0.2 mm). This transition process forms a transition section P3 between the first section P1 and the second section P2. The laser continues drilling along the original drilling trajectory until the through hole in the second section P2 reaches a predetermined depth H2 (e.g., 2 mm). At this point, the entire through hole is complete, including the first section P1 with the first beam diameter D1, the transition section P3, and the second section P2 with the second beam diameter D2.

[0091] like Figure 13 As shown, the cutting process 350 also includes: a first cutting process 3510: cutting at least a portion of the first segment by selecting a predetermined length from the electrical connection module; and a second cutting process 3520: cutting at least a portion of the second segment by selecting a predetermined length from the electrical connection module.

[0092] The electrical connector module blank, with pre-set through-hole lengths H1 and H2, is cut according to the pre-set lengths of the first and second connector module blanks. A cutting tool, perpendicular to the punched line, precisely cuts off at least a portion of the first segment of the electrical connector module, measuring the predetermined length H1, to produce the first connector module blank. The cutting tool then cuts off at least a portion of the second segment of the predetermined length H2, producing the second connector module blank. During the cutting process, the cutting equipment maintains a positioning accuracy of ±0.02mm, ensuring the dimensional accuracy of both the first and second connector module blanks, meeting the requirements for subsequent precision assembly with pins and other components, and guaranteeing high-quality manufacturing of the entire electrical connector module.

[0093] During cutting, the first and second sections are cut to predetermined lengths, and the transition section is precisely removed, ensuring that the first through-hole in the first connection module blank and the second through-hole in the second connection module blank meet the required dimensions. This ensures a continuous and uninterrupted punching process while guaranteeing the accuracy of the dimensions of the first and second through-holes. This lays a solid foundation for the stable electrical connection of the electrical connection module in the electrical stimulation system and improves the reliability and precision of the overall manufacturing process.

[0094] The above description is merely an example of the present application and an illustration of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to the technical solutions formed by the specific combination of the above-mentioned technical features, but also encompasses other technical solutions formed by any combination of the above-mentioned technical features or their equivalents without departing from the inventive concept. For example, a technical solution formed by replacing the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A method for manufacturing an electrical connection module, wherein the electrical connection module is suitable for an electrical stimulation system, wherein the electrical stimulation system includes a pulse generator and a stimulation electrode, wherein the electrical connection module is used to electrically connect the pulse generator to the stimulation electrode, and wherein the electrical connection module includes a first connection module and a second connection module, wherein: The manufacturing method comprises: A punching process, in which a blank of an electrical connection module is prepared, the blank of the electrical connection module being a cylinder with a diameter of less than or equal to 3 mm, and through holes being formed on the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module, wherein the number of the through holes is at least 24, and the punching process includes a first punching step and a second punching step after the first punching step, in which holes are punched on the blank of the electrical connection module using a laser having a first beam diameter, In the second punching step, a laser having a second beam diameter is used to continue punching holes in the blank of the electrical connection module, wherein the second beam diameter is smaller than the first beam diameter, wherein the change from the first beam diameter to the second beam diameter is continuous. After the second punching step is completed, the through hole is formed on the electrical connection module; a cutting step, in which the blank of the electrical connection module is cut along a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of a first connection module and a blank of a second connection module, the through holes formed in the punching step being first through holes in the blank of the first connection module, and the through holes formed in the punching step being second through holes in the blank of the second connection module; and An installation process, in which the first pin is at least partially placed in the first through hole, and the long straight second pin is at least partially placed in the second through hole, wherein the first pin is provided with a socket, the inner diameter of the socket is equal to the outer diameter of the second pin, and the second pin can be inserted into the socket and electrically connected to the first pin, so that the inner surface of the socket is in contact with the outer surface of the second pin.

2. The manufacturing method according to claim 1, characterized in that The change from the first beam diameter to the second beam diameter is continuous to form a first segment with a first diameter, a second segment with a second diameter, and a transition segment between the first segment and the second segment in the through hole, wherein the first diameter is equal to the first beam diameter and the second diameter is equal to the second beam diameter.

3. The manufacturing method according to claim 2, characterized in that The cutting process includes a first cutting process and a second cutting process. In the first cutting process, the electrical connection module selects a predetermined length and cuts off at least a portion of the first segment; in the second cutting process, the electrical connection module selects a predetermined length and cuts off at least a portion of the second segment.

4. The manufacturing method according to claim 1, characterized in that The first pin and the second pin are made of metal; before the cutting process, the manufacturing method further includes a processing process, in which the inner surfaces of the first through hole and the second through hole are metallized; after the loading process, the manufacturing method further includes a welding process, in which the first pin is welded to the metallized inner surface of the first through hole, and the second pin is welded to the metallized inner surface of the second through hole.

5. The manufacturing method according to claim 1, characterized in that A blind hole is provided at the first end of each first pin along the first direction, and the inner diameter of the blind hole is greater than or equal to the outer diameter of the corresponding second pin to receive the second pin.

6. The manufacturing method according to claim 1, characterized in that In the loading process, the first end of the first pin is extended from the first end surface of the blank of the first connecting module, and the second end of the first pin is aligned with the second end surface of the blank of the first connecting module.

7. The manufacturing method according to claim 1, characterized in that In the loading process, the first end of the second pin is extended from the first end surface of the blank of the second connecting module, and the second end of the second pin is extended from the second end surface of the blank of the second connecting module.

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