Beta-Titanium Alloy Medical Leads for Weldable Titanium Wire Connections
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Solution Overview
Problem
Existing medical device leads face challenges in weldability between titanium alloy lead wires and platinum alloy electrodes or cobalt-based alloy electrical contacts, leading to reliability concerns and difficulties in achieving desired radiopacity.
Innovation Solution
The use of medical device leads with a lead wire formed of a titanium alloy, an electrode formed of a beta titanium alloy, and an electrical contact formed of a beta titanium alloy, which are weldable and provide improved radiopacity, flexibility, and fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium alloy lead wires are connected to platinum alloy electrodes or cobalt-based alloy electrical contacts, then electrical conductivity is achieved, but weldability deteriorates
Solution Approach 1:
The patent changes the material parameters by transitioning from traditional platinum/cobalt alloys to beta-titanium alloys for both electrodes and electrical contacts. This parameter change in material composition enables improved weldability with titanium alloy lead wires while simultaneously achieving the desired radiopacity properties, thus resolving the manufacturing difficulty without compromising reliability
Solution Approach 2:
The patent employs composite material strategy by using beta-titanium alloys with specific compositional ranges (including elements like Nb, Mo, Ta, Sn, Zr, Al, and V) to create a material system that combines the beneficial properties of both weldability and radiopacity. This composite approach allows the electrical contacts and electrodes to be effectively joined to titanium lead wires while maintaining the necessary imaging properties
2Reliability
If traditional materials are used for electrodes and electrical contacts, then radiopacity is achieved, but weldability to titanium alloy lead wires deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the material composition of electrodes and electrical contacts from traditional platinum or cobalt-based alloys to beta-titanium alloys with specific elemental compositions. This change in material parameters creates compatibility with titanium alloy lead wires, enabling reliable welding while maintaining manufacturing ease
3Reliability
If beta titanium alloys are used for electrodes and electrical contacts, then weldability to titanium alloy lead wires is improved, but material selection complexity increases
Solution Approach 1:
The patent applies local quality by specifying particular beta-titanium alloy compositions for different components (electrodes versus electrical contacts) based on their specific functional requirements. This localized material optimization allows each component to have the ideal composition for its function while maintaining overall system weldability, thereby managing complexity through targeted material selection rather than uniform material application
Solution Approach 2:
The patent manages material selection complexity through parameter changes by establishing specific compositional ranges for beta-titanium alloys (e.g., Nb: 5-25 wt%, Mo: 10-30 wt%, Ta: 1-20 wt%, Sn: 1-10 wt%, Zr: 1-15 wt%, Al: 1-10 wt%, V: 1-15 wt%). These defined parameter ranges standardize the material selection process, making it more manageable while ensuring the desired weldability and performance characteristics
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 configuration enhances the weldability and radiopacity of medical device leads, improving their reliability and performance in delivering electrical stimulation therapy while maintaining flexibility and fatigue resistance.
Implementation Method 1
an electrode on a distal portion of the lead body, the electrode comprising an electrode substrate, wherein the electrode substrate is electrically coupled to the contact substrate via the electrically conductive lead wire
Implementation Method 2
The lead wire may be connected to the electrode substrate and contact substrate by a weld (e.g., a laser weld or resistance weld)
Data Source
AI summary
In some examples, the disclosure relates to a medical device such as an implantable medical lead. The medical lead may include: a lead body including an electrically conductive lead wire; an electrical contact on a proximal portion of the lead body, the electrical contact including a contact substrate; and an electrode on a distal portion of the lead body, the electrode including an electrode substrate, wherein the electrode substrate is electrically coupled to the contact substrate via the electrically conductive lead wire, wherein the lead wire is formed of a composition comprising titanium or titanium alloys, wherein the electrode substrate is formed of a first beta-titanium alloy, and wherein the contact substrate is formed of a second beta-titanium alloy.