Implantable Connector Assembly with Open Bore Windows
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Solution Overview
Problem
Existing implantable medical device connector assemblies face challenges in efficiently connecting medical electrical leads to hybrid circuit boards due to complex assembly processes and the need for additional components like closed conductive windows and overmolding processes.
Innovation Solution
A connector assembly with a molded shell featuring open windows or apertures that allow direct electrical connection between the hybrid circuit board and conductive connectors, reducing the need for additional components and simplifying the assembly process by using a single shot molding process and minimizing interconnect welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If closed conductive windows are used to allow the inner surface of the cylindrical bore to be flush, then the structural integrity and flush surface are improved, but the assembly complexity increases due to the need for additional components and steps
Solution Approach 1:
The patent removes the closed conductive windows from the connector shell design. Instead of having windows that need to be filled and sealed, the shell is molded with an open bore that directly receives the stacked subassembly. This extraction of the windows eliminates the complexity of filling and sealing operations while maintaining the flush surface requirement through direct molding of the bore.
Solution Approach 2:
The design separates the connector shell from the conductive elements. The shell provides the structural housing with an open bore, while the stacked subassembly (containing seals and conductive connectors) is inserted as a separate unit. This segmentation allows each component to be optimized independently and simplifies the overall assembly process.
2Reliability
If traditional embedding methods are used with injection molding or thermoset casting, then conductor protection is improved, but the manufacturing process complexity and production cycle time increase
Solution Approach 1:
The patent combines the connector shell molding and the conductor integration into a single process step. The stacked subassembly is pre-formed and then inserted into the molded shell bore, eliminating the need for separate injection molding or thermoset casting operations to embed conductors. This merging of steps reduces production cycle time while maintaining conductor protection through the sealed bore environment.
3Reliability
If closed conductive windows are used, then electrical connection is achieved, but the number of components and assembly steps increases
Solution Approach 1:
The patent extracts the closed conductive windows from the design and replaces them with an open bore structure. Electrical connections are achieved through direct contact between the stacked subassembly conductors and the shell structure, eliminating the need for window-filling materials and reducing the total component count.
4Reliability
If additional components like closed conductive windows and overmolding are used, then connector functionality is improved, but cost-effectiveness deteriorates
Solution Approach 1:
The patent removes the closed conductive windows and overmolding processes from the manufacturing sequence. The connector shell is molded with an open bore that directly accommodates the stacked subassembly, eliminating material and process steps that increase cost while preserving all necessary connector functionalities through the simplified structure.
Data Source
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AI summary
An implantable medical device connector assembly and method of manufacture thereof are disclosed. The device includes a molded, insulative shell having an inner surface forming a connector bore, a circuit member including one or more traces extending through apertures in the connector shell. One or more conductive members, positioned along the connector bore, are electrically coupled to the traces. Sealing members are positioned between the conductive members.