Brazed Lead Connector Stack for Fluid-Resistant Stimulation Contacts

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Solution Overview

Problem

Existing implantable electrical stimulation systems face challenges in creating a reliable and fluid-resistant connector for electrical stimulation leads, which is crucial for maintaining the effectiveness and longevity of the stimulation therapy.

Innovation Solution

The development of a connector that includes contact assemblies and non-conductive stack spacers, made from ceramic, crystalline, or glass materials, which are brazed together to form a sealed connector stack that prevents fluid passage, ensuring a reliable electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional connectors are used in implantable electrical stimulation systems, then the device can be manufactured and assembled, but fluid ingress compromises the electrical connections and reduces reliability

Engineering Contradiction:

Improveconnector reliabilityVSAvoidfluid ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector is divided into multiple contact assemblies separated by non-conductive stack spacers, creating discrete sealed compartments for each electrical connection. This segmentation prevents fluid from compromising all connections simultaneously and allows for targeted sealing at each interface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Non-conductive stack spacers serve as intermediary elements between contact assemblies, providing both electrical isolation and fluid sealing. These spacers act as mediators that prevent direct fluid pathways between contacts while maintaining the structural integrity of the connector stack.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple contact assemblies are stacked together to form a connector, then electrical connections are established, but fluid can pass between the contact assemblies compromising the seal

Engineering Contradiction:

Improveelectrical connection capabilityVSAvoidfluid resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The connector integrates multiple contact assemblies and stack spacers into a single brazed assembly, merging electrical connection functions with fluid sealing functions. The brazing process combines these discrete components into a unified structure where electrical and fluid barrier functions coexist.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector employs composite construction combining conductive contact assemblies with non-conductive ceramic, crystalline, or glass stack spacers. This composite approach allows simultaneous achievement of electrical conductivity where needed and electrical isolation plus fluid sealing where required.

Inventive Principle:

Principle #40Composite materials

3Reliability

If non-conductive ceramic, crystalline, or glass materials are used for stack spacers, then fluid sealing and electrical isolation are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidconnector manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical sealing methods with brazing technology, using metallurgical bonding instead of mechanical fastening or sealing. This substitution enables reliable joining of dissimilar materials (metal contacts to ceramic/glass spacers) while maintaining fluid tightness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The brazing process utilizes controlled temperature parameters to join contact assemblies and stack spacers. By carefully controlling the thermal parameters of the brazing process, the patent achieves reliable bonding of temperature-sensitive ceramic or glass materials to metal contacts without compromising material properties.

Inventive Principle:

Principle #35Parameter changes

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

The proposed connector effectively seals against fluid ingress, enhancing the reliability and durability of the electrical stimulation system by preventing moisture and bodily fluids from compromising the electrical connections.

Implementation Method 1

the contact assemblies and stack spacers are brazed together forming a sealed connector stack that resists passage of fluid between the contact assemblies and stack spacers

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 2

the stack spacers are made of a non-conductive ceramic, crystalline, or glass material

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS12343547B2Connectors for an electrical stimulation system and methods of making and using

Publication Date: 2025.07.01 BOSTON SCI NEUROMODULATION CORP

AI summary

A connector that includes contact assemblies and non-conductive stack spacers separating the contact assemblies from each other, the contact assemblies and the stack spacers defining a connector lumen configured to receive a portion of an electrical stimulation lead. The contact assemblies and stack spacers are brazed together forming a sealed connector stack that resists passage of fluid between the contact assemblies and stack spacers. Alternatively or additionally, the stack spacers are made of a non-conductive ceramic, crystalline, or glass material.