Segmented Electrode Fabrication With Foil Stamping and Abrasive Shaping
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Solution Overview
Problem
Existing methods for manufacturing segmented electrodes, such as those used in neurostimulation systems, are time-consuming and costly due to the use of expensive precious metals like platinum-iridium and involve complex processes like electrical discharge machining, leading to material waste.
Innovation Solution
A method involving progressive die stamping and centerless grinding is employed to form segmented electrodes, utilizing foil sheets to create initial electrodes, which are then segmented and coupled to lead bodies, reducing material waste and fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods of breaking tubular electrodes into segments are used, then segmented electrodes can be manufactured, but the process is time-consuming and expensive with material waste
Solution Approach 1:
The electrode is designed as a continuous structure with integrated segmentation features (grooves or channels) that allow it to be divided into functional segments during operation or assembly, eliminating the need to break pre-manufactured tubular electrodes into segments
Solution Approach 2:
Segmentation features such as grooves or channels are pre-formed into the electrode structure during the initial manufacturing process using progressive die stamping, so that the electrode is already prepared for segmentation before deployment, avoiding time-consuming post-processing
2Reliability
If expensive precious metals like platinum-iridium are used, then electrode durability and performance are improved, but manufacturing costs increase
Solution Approach 1:
The electrode structure incorporates varying material properties or geometries at different locations (e.g., different thicknesses, material compositions, or structural densities) to optimize performance in critical areas while reducing material usage and cost in less critical areas
Solution Approach 2:
The electrode uses composite construction combining precious metals only in contact areas where electrical performance is critical, with less expensive materials for structural or non-contact portions, reducing overall material cost while maintaining electrode reliability
3Manufacturing precision
If complex processes like electrical discharge machining are used, then precise electrode geometry can be achieved, but fabrication time and cost increase
Solution Approach 1:
The manufacturing process replaces complex mechanical or electrical discharge machining operations with progressive die stamping, a faster forming process that achieves the required electrode geometry through controlled deformation and shaping in a single integrated operation
Solution Approach 2:
Multiple manufacturing operations (forming, shaping, and segmentation feature creation) are combined into a single progressive die stamping process, eliminating the need for sequential complex machining steps and reducing total fabrication time while maintaining precision
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 approach reduces fabrication time and costs by minimizing precious metal usage and simplifying the assembly process, while maintaining precise control over electrode geometry.
Implementation Method 1
removing portions of the initial electrode using a centerless grinding process to form a segmented electrode including a plurality of circumferentially spaced contacts
Data Source
AI summary
A method for fabricating a segmented electrode is provided. The method includes performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, and removing portions of the initial electrode using a centerless grinding process to form a segmented electrode including a plurality of circumferentially spaced contacts.