C-Shaped Contacts for Implantable Lead Assembly
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Solution Overview
Problem
The assembly of ends of elongated members in implantable electrical stimulation systems is complex, tedious, and expensive, requiring conventional methods that involve ablating the proximal end to expose conductors and placing cylindrical contacts with non-conductive spacers, followed by backfilling and grinding, which can be inefficient and prone to errors.
Innovation Solution
The method involves ablating spaced-apart channels or access ports in the elongated member to expose conductors and using C-shaped contacts that are electrically coupled and closed to form a continuous path around the channels or access ports, simplifying the assembly process and potentially reducing the need for grinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to assemble ends of elongated members (ablating proximal end, placing cylindrical contacts with non-conductive spacers, backfilling, and grinding), then electrical connections are established, but the assembly process becomes complex, tedious, and expensive
Solution Approach 1:
The invention divides the contact assembly process into discrete C-shaped contacts that are individually positioned and secured within separate channels, rather than using a monolithic contact structure. Each C-shaped contact is a separate component that can be independently assembled, simplifying the overall assembly process while maintaining reliable electrical connections.
Solution Approach 2:
Instead of placing contacts over the conductors and then securing them, the invention inverts the approach by first creating channels that accommodate the C-shaped contacts, then positioning the contacts within these pre-formed channels. This reversal of the assembly sequence simplifies the process by providing defined pathways for contact placement and securing.
2Reliability
If conventional assembly methods are used involving multiple steps (ablating, placing contacts, backfilling, grinding), then electrical connections are formed, but the manufacturing cost and time increase
Solution Approach 1:
The invention performs preliminary actions by pre-forming channels in the elongated member before contact assembly. These channels are prepared in advance to precisely accommodate the C-shaped contacts, eliminating the need for post-assembly grinding and backfilling operations. This preliminary preparation significantly reduces assembly time and increases productivity.
Solution Approach 2:
The invention extracts and eliminates unnecessary steps from the conventional assembly process. Specifically, the backfilling and grinding steps are removed entirely, as the C-shaped contacts secured within pre-formed channels provide sufficient mechanical and electrical connection without requiring these additional operations. This extraction of redundant steps directly improves manufacturing efficiency.
3Strength
If C-shaped contacts are used and closed to form continuous paths around channels, then electrical contact is enhanced and durability improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention applies local quality by concentrating the precision requirements specifically at the channel positions where contacts are secured, rather than requiring uniform precision throughout the entire assembly. The channels are strategically positioned at locations that naturally accommodate the C-shaped contacts, localizing the precision requirements to critical areas only. This approach maintains contact durability while reducing overall manufacturing precision demands.
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 approach simplifies the assembly of elongated members by exposing conductors through ablating channels and using C-shaped contacts, which can enhance electrical contact and durability, and may reduce the complexity and cost of the assembly process.
Implementation Method 1
ablating a plurality of spaced-apart channels in proximity to at least one of the proximal end or the distal end of the body to expose at least part of at least one of the plurality of elongated conductors
Data Source
AI summary
A method for forming a lead or lead extension having an arrangement of elongated conductors disposed in a body of a lead or lead extension includes ablating a plurality of spaced-apart channels in proximity to at least one of the proximal end or the distal end of the body to expose at least part of at least one of the conductors. A C-shaped contact is disposed into each of a different one of the transverse channels. Each C-shaped contact is electrically coupled to at least one of the conductors. Each C-shaped contact is closed so that opposing ends of the C-shaped contact are adjacent to one another and aligned over one of the elongated conductors. The two opposing ends of each C-shaped contact is coupled together such that each C-shaped contact forms a continuous path around the arrangement within the transverse channel in which the C-shaped contact is disposed.