Electrode-Conductor Assembly With Side Openings for Flush Connections
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Solution Overview
Problem
Existing methods for connecting electrical conductors to electrodes in medical devices often result in decreased electrical conductivity and service life due to the need to cut the conductor and improper flush-fitting connections.
Innovation Solution
An electrode-electrical conductor system featuring electrically insulated wires or cables with selective partial openings on one side, allowing for mechanical and electrical connection to electrodes via welding, pressing, swaging, adhesives, brazing, soldering, and/or dimples, without cutting the entire conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole electrical conductor including insulation is cut to connect to the electrode, then the connection can be made, but the electrical conductivity and service life decrease due to improper flush-fitting connections
Solution Approach 1:
The electrical insulation is segmented with selective openings at specific locations, allowing the electrode to be connected only at these predetermined positions. This segmentation enables proper flush-fitting connections while maintaining the integrity and insulation of the rest of the conductor, thereby improving reliability and service life without complicating the manufacturing process.
Solution Approach 2:
The electrical insulation is modified locally at specific positions to create openings, while the rest of the insulation remains intact. This local modification allows the electrode to make proper flush-fitting contact with the conductor at the connection point without compromising the overall insulation and electrical conductivity of the system, resolving the contradiction between connection quality and service life.
2Reliability
If the electrical conductor is cut completely, then the electrode can be connected, but the electrical conductivity decreases
Solution Approach 1:
Instead of cutting the entire electrical conductor, the insulation is segmented with selective openings while the conductor itself remains continuous. This approach maintains the electrical conductivity of the conductor by avoiding complete cuts, while still enabling the electrode to be connected through the insulating openings, thus resolving the contradiction between maintaining conductivity and enabling connection.
Solution Approach 2:
The selective openings in the electrical insulation act as an intermediary that allows the electrode to access and connect to the conductor without requiring the conductor itself to be cut. This intermediary approach preserves the electrical conductivity of the continuous conductor while facilitating the connection process.
3Reliability
If conventional connection methods are used, then the electrode can be connected to the conductor, but the connection is not flush-fitted causing decreased service life
Solution Approach 1:
The selective openings are created in the electrical insulation during the manufacturing process before the final assembly. This preliminary action ensures that the openings are precisely positioned and sized to enable proper flush-fitting connections, eliminating the need for complex precision alignment during assembly and thereby improving both manufacturing precision and service life.
Solution Approach 2:
The electrical insulation is locally modified at specific connection points to create openings that enable precise flush-fitting connections. This local modification ensures that the electrode can be accurately positioned and connected without compromising the overall insulation, thereby improving manufacturing precision and connection quality while maintaining reliability.
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 solution enables a flush-fitted assembly of electrodes to electrical conductors, enhancing electrical conductivity and service life while simplifying manufacturing without complex steps or equipment.
Implementation Method 1
one or more electrode(s), which is/are mechanically and electrically connected to the wire(s) or cable(s) via the one or more partial opening(s) arranged on one side of the wire(s) or cable(s) by welding, pressing, swaging, adhesives, brazing, soldering and/or dimples
Implementation Method 2
one or more electrode(s), which is/are mechanically and electrically connected to the wire(s) or cable(s) via the one or more partial opening(s) arranged on one side of the wire(s) or cable(s) by welding, pressing, swaging, adhesives, brazing, soldering and/or dimples
Data Source
AI summary
One aspect relates to an electrode-electrical conductor system for a medical device. The system includes one or more electrically insulated wire(s) or cable(s) wherein. The electrical insulation includes electrical conductor one or more partial opening(s), which is/are arranged on one side of the wire(s) or cable(s), and one or more electrode(s), which is/are mechanically and electrically connected to the wire(s) or cable(s) via the one or more partial opening(s) arranged on one side of the wire(s) or cable(s). The mechanical and electrical connections are made by welding, pressing, swaging, adhesives, brazing, soldering and/or dimples. One aspect also relates to a method for preparing such an electrode-electrical conductor system.