3D Feedthrough Connector Assembly for Precise Implant Weld Alignment
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Solution Overview
Problem
Existing implantable medical devices face challenges in achieving consistent and robust connections between connectors and feedthrough pins due to the difficulty in managing and positioning multiple separate connector wires during manufacturing, leading to improper placement and performance issues.
Innovation Solution
Utilizing additive manufacturing to create a connector assembly with pre-formed, 3-dimensional shapes and contoured connection sections that allow for precise alignment and robust weld connections between feedthrough pins and electrical contacts, including features like thinned portions, openings, and staggered structures to facilitate line-of-site welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate connector wires are used during manufacturing, then flexibility in routing is improved, but manufacturing precision and connection consistency deteriorate
Solution Approach 1:
The patent combines multiple separate connector wires into a single integrated connector assembly with pre-formed 3-dimensional shapes. This integration maintains the necessary routing flexibility while ensuring consistent positioning and alignment of all electrical contacts during manufacturing, eliminating the placement variability associated with handling multiple separate wires.
Solution Approach 2:
The connector assembly is pre-formed into its final 3-dimensional configuration before installation, with all electrical contacts and connection sections already positioned in their correct spatial relationships. This preliminary formation ensures manufacturing precision is achieved without requiring complex positioning operations during final assembly.
2Device complexity
If traditional connector designs are used, then device complexity is reduced, but connection reliability and weld integrity deteriorate
Solution Approach 1:
The connector assembly incorporates localized contoured connection sections with specific geometric features (such as thinned portions, openings, and staggered structures) at critical connection points. These local variations in geometry enhance weld accessibility and connection reliability without requiring complex structures throughout the entire connector assembly.
Solution Approach 2:
The patent transitions from traditional 2-dimensional flat connector designs to 3-dimensional contoured shapes with varying cross-sections. This dimensional enhancement provides multiple surfaces and geometries that facilitate line-of-site welding and improve connection integrity while maintaining overall structural simplicity.
3Ease of manufacture
If uniform cross-section connectors are used, then manufacturing simplicity is improved, but weld accessibility and connection quality deteriorate
Solution Approach 1:
The connector features contoured sections with non-uniform cross-sections that create localized thinned portions and openings at connection points. These local geometric modifications provide excellent weld accessibility and surface area for welding operations, while the majority of the connector maintains a simpler uniform structure for ease of manufacturing.
Solution Approach 2:
The connector design incorporates variations in cross-sectional parameters (thickness, width, shape) at specific locations to optimize weld characteristics. These parameter changes create ideal geometries for welding operations without fundamentally complicating the overall manufacturing process.
Data Source
AI summary
An implantable medical device can include a housing including electronic devices within the housing, a header attached to the housing and including one or more bores, and a plurality of connectors extending from the housing to the header and coupled to a plurality of electrical contacts within the one or more bores, wherein at least one of the plurality of connectors includes a first end coupled to a feedthrough pin on the housing and second end coupled to one of the plurality of electrical contacts, wherein the first end includes a contoured shape configured to provide a feedthrough connection section having a non-uniform cross-section.