Arc Percussion Welding for Implantable Device Feedthroughs
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Solution Overview
Problem
Existing electrical interconnection methods for implantable medical devices often require an electronic module assembly (EMA) block, which increases manufacturing costs and occupies space, while also being complex and inefficient in forming reliable connections between feedthroughs and other components.
Innovation Solution
The use of arc percussion welding to create connections between conductor materials, such as a wire and a feedthrough pin with an enlarged head, allowing for direct and reliable electrical connections without the need for an EMA block, enabling connections to be made after hermetic sealing and using a variety of materials like copper, platinum, and alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an EMA block is used to connect feedthroughs to circuitry, then electrical connections can be established, but manufacturing costs increase and device space is occupied
Solution Approach 1:
The patent extracts and eliminates the EMA block from the device architecture by establishing direct wire connections between feedthroughs and circuitry. This removal of the intermediate connection component simplifies the overall device structure while maintaining electrical connectivity, directly addressing the contradiction between connection reliability and device complexity
Solution Approach 2:
The patent merges the functions of the EMA block with the wire connections by directly bonding wires to feedthrough pins and circuitry. This consolidation eliminates the separate EMA component, reducing device complexity and space occupation while preserving the essential electrical interconnection function
2Ease of manufacture
If soldering or brazing processes are used to connect wires to bond pads, then electrical connections can be completed, but the manufacturing process becomes complex
Solution Approach 1:
The patent replaces the thermal-based soldering or brazing processes with a mechanical bonding process. By using arc percussion welding to create direct metal-to-metal bonds between wires and feedthrough pins, the invention eliminates the need for flux, solder, or brazing materials, thereby simplifying the manufacturing process while maintaining precise electrical connections
Solution Approach 2:
The patent changes the bonding mechanism from thermal (soldering/brazing) to mechanical (arc percussion welding). This parameter change in the joining process eliminates complex chemical and thermal steps, simplifying manufacturing while ensuring precise and reliable electrical connections through direct metal bonding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the manufacturing process, reduces costs, and conserves space by eliminating the need for an EMA block, while providing reliable and efficient electrical connections between feedthroughs and other components, enhancing the reliability and efficiency of implantable medical devices.
Implementation Method 1
Arc percussion welding can be used according to the present invention to weld together conductor materials
Data Source
AI summary
An electrical interconnect structure for an implantable medical device includes a feedthrough that has a pin extending therefrom. The pin defines a first end and a middle portion. A bonding surface is formed at the first end of the pin, and the bonding surface has a surface area greater than a cross-sectional area of the pin at its middle portion.