Eccentric Ring Electrode Low-Melting Bonding
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Solution Overview
Problem
Conventional methods for manufacturing ring electrodes for active implantable medical devices face challenges in connecting small conductor structures with integral bonds without damaging the plastic insulation, and existing solutions are complex, prone to instability, and difficult to execute due to the small size and high precision requirements.
Innovation Solution
A ring electrode design featuring an exterior wall made of a high-melting-point material and a contact element with a lower melting point, allowing for an integral bond formation through heating, which enables secure welding from the outside without damaging the electrode, using materials like Pt, Ir, and active solders, and incorporating a diffusion barrier for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods are used to connect conductor and electrode, then integral bond is achieved, but the plastic insulation is severely damaged
Solution Approach 1:
The electrode is segmented into two distinct material zones: an outer electrode body made of high-melting-point material and an inner contact element made of low-melting-point material. This segmentation allows differential thermal response during welding, enabling the contact element to melt and bond with the conductor while the outer electrode body remains intact and protects the insulation.
Solution Approach 2:
The contact element possesses locally differentiated material properties (lower melting point) compared to the outer electrode body. This local quality change enables selective melting and bonding at the contact interface without affecting the overall structural integrity of the electrode or damaging the surrounding insulation.
2Reliability
If conventional contacting methods are used, then connection is achieved, but the manufacturing process becomes complex
Solution Approach 1:
The contact element is merged with the outer electrode body through a simplified forming process, creating an integrated structure. This merging eliminates the need for separate assembly steps and complex alignment procedures, reducing manufacturing complexity while ensuring stable electrical and mechanical connection.
Solution Approach 2:
The contact element is extracted as a separate low-melting-point material component that can be independently formed and then integrated. This extraction allows for specialized material selection and simplified processing of the contact interface without complicating the overall manufacturing process.
3Ease of manufacture
If the contact element position is not precisely visible from outside, then manufacturing is simpler, but welding precision deteriorates
Solution Approach 1:
The outer electrode body acts as an intermediary structure that transmits thermal energy and mechanical force from the externally accessible region to the internally positioned contact element. This intermediary function enables precise welding of the hidden contact element through the simpler external interface without requiring direct visual access.
Solution Approach 2:
The positioning and bonding process replaces mechanical alignment (which would require visual access) with thermal field control. The low-melting-point contact element responds predictably to applied heat, allowing precise positioning through thermal processing parameters rather than mechanical adjustment.
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 method allows for simple, cost-effective production of ring electrodes with secure and stable connections, ensuring reliable electrical and mechanical contact without compromising the structural integrity of the electrode, suitable for use in cardiac pacemakers and neurostimulation devices.
Implementation Method 1
the second material has a lower melting point than the first material... Heating the contact element and thereby forming an integral bond
Implementation Method 2
Heating the contact element and thereby forming an integral bond... heating the outer side of the exterior wall
Implementation Method 3
the electrode further comprising a diffusion barrier between the first material and the second material
Data Source
AI summary
One aspect relates to a ring electrode for electrical stimulation and/or sensing on the human body, including an outer element and an inner element which is arranged eccentrically within the outer element and is directly connected thereto, wherein the outer element includes a first material, and the inner element includes a second material, the second material having a lower melting point than the first material, wherein the outer element includes a through-opening, and wherein the inner element includes a contacting opening for connecting to a conductor element.