Crimp Connector with Laser-Cut Splice Opening for Cardiac Leads
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Solution Overview
Problem
Current implantable cardiac electrotherapy leads face high costs and labor-intensive processes due to the use of crimp connectors, which require precise tolerances and often result in scrap material from misplacement or weak welds, necessitating a more efficient and cost-effective connection method between cable conductors and lead shock coils.
Innovation Solution
A crimp connector design featuring a tubular body with pre-drawn tubing, laser-cut splice openings, and an arcuate outer surface that nests against the termination ring, allowing for bidirectional attachment and eliminating the need for insulation removal, with the sharp edge penetrating the insulation jacket for electrical contact, and subsequent welding for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimp connectors are used with wire electrical discharge machining and insulation removal, then electrical contact is achieved, but manufacturing costs increase and labor intensity increases
Solution Approach 1:
The crimp connector is pre-formed with integrated splice openings that expose sharp edges during the crimping process itself, eliminating the need for separate insulation removal operations. The sharp edges are positioned to automatically penetrate the insulation jacket when the connector is crimped onto the conductor, achieving electrical contact as a byproduct of the crimping action rather than requiring preliminary insulation stripping.
Solution Approach 2:
The invention combines multiple functions into a single crimping operation: mechanical attachment of the connector to the conductor, penetration of the insulation jacket, and establishment of electrical contact all occur simultaneously during crimping. This merges what were previously separate steps (insulation removal, connector attachment, electrical contact establishment) into one integrated process.
2Reliability
If traditional crimp connectors with unidirectional design are used, then connection is achieved, but scrap material increases due to reversal and misplacement
Solution Approach 1:
The crimp connector features asymmetric design elements including a keyway that fits into a corresponding key on the conductor, and splice openings positioned at specific locations on the connector body. These asymmetric features ensure the connector can only be properly installed in one orientation, preventing reversal errors and eliminating scrap caused by misplacement.
Solution Approach 2:
The connector design includes self-aligning features where the keyway and key automatically guide proper orientation during installation, and the splice openings are positioned to automatically contact the conductor in the correct orientation. This self-service mechanism prevents operator error and eliminates scrap from misplacement without requiring additional inspection or adjustment steps.
3Strength
If tight tolerances are applied for crimp connector fit and placement, then welding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The connector design segments the welding function from the positioning function. The arcuate outer surface provides a large contact area for welding that is less sensitive to positioning tolerances, while the keyway system handles the precise positioning. This segmentation allows the welding surface to be larger and more tolerant, reducing overall manufacturing complexity.
Solution Approach 2:
The connector features an arcuate outer surface that nests against the arcuate inner surface of the termination ring, creating a curved contact interface for welding. This curved geometry provides a larger effective welding area and is more tolerant of positioning variations compared to a flat surface, reducing the stringency of tolerance requirements while maintaining welding strength.
4Reliability
If insulation removal is performed before crimping, then electrical contact is achieved, but labor intensity and process time increase
Solution Approach 1:
The crimp connector is pre-formed with integrated splice openings that expose sharp edges during the crimping process itself, eliminating the need for separate insulation removal operations. The sharp edges are positioned to automatically penetrate the insulation jacket when the connector is crimped onto the conductor, achieving electrical contact as a byproduct of the crimping action rather than requiring preliminary insulation stripping.
Solution Approach 2:
The invention combines multiple functions into a single crimping operation: mechanical attachment of the connector to the conductor, penetration of the insulation jacket, and establishment of electrical contact all occur simultaneously during crimping. This merges what were previously separate steps (insulation removal, connector attachment, electrical contact establishment) into one integrated process.
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 crimp connector reduces manufacturing costs, minimizes waste, and enhances welding strength, providing a reliable and efficient method for connecting cable conductors to electrodes in implantable cardiac electrotherapy leads, improving the overall production process and reducing the risk of misplacement errors.
Implementation Method 1
the sharp edge penetrates the insulation jacket on the cable connector providing for electrical communication between the crimp connector and the cable connector
Implementation Method 2
welding an outer surface of the crimp connector to an edge of the electrode
Data Source
AI summary
An implantable cardiac electrotherapy lead is disclosed herein. The lead may include an electrode on a distal portion of the lead, a conductor extending proximally through the lead from the electrode, and a crimp connector coupling a distal end of the conductor to the electrode. The connector may include a body with an outer surface, an inner surface, proximal and distal ends, a cavity, and at least one splice opening. The inner surface defines the cavity, the proximal and distal ends respectively define proximal and distal openings leading to the cavity, and the at least one splice opening extends from the outer surface to the inner surface and is oriented generally transverse to an axis extending between the proximal and distal openings.