Guide Hub Aligning Lead Filars to Connector Tabs
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Solution Overview
Problem
The challenge lies in reliably and efficiently fixing small lead filars to an end connector in implantable medical devices, which requires high skill and time due to their tiny dimensions and complex alignment needs.
Innovation Solution
A medical device lead connection assembly featuring a guide hub that aligns lead filars onto end connector connection tabs using a tubular guide hub with circumferentially disposed guide elements, allowing for increased coil pitch and reliable filar management, enabling precise alignment and welding even with small diameter filars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and joining of small filars to end connector connection points is performed, then connection precision can be achieved, but the process requires high skill and craftsmanship and takes significant time
Solution Approach 1:
The guide hub serves as an intermediary device that facilitates the alignment and joining of filars to connection points. It provides guide elements that physically guide the filars into proper alignment with connection points, eliminating the need for manual alignment while maintaining precision. This intermediary structure resolves the contradiction by providing automated guidance that reduces both skill requirements and time while preserving alignment accuracy.
Solution Approach 2:
The guide hub is pre-configured with guide elements positioned at specific locations corresponding to connection points. This preliminary arrangement of alignment features allows filars to be automatically guided into correct positions during the joining process, eliminating the need for manual alignment operations and significantly reducing joining time while maintaining precision.
2Volume of moving object
If the dimensions and size of implantable medical devices are decreased, then device miniaturization is achieved, but fixing filars to end connectors becomes even more difficult
Solution Approach 1:
The guide hub introduces localized structural features (guide elements) at specific positions within the connector assembly. These localized guide structures provide precise alignment pathways for filars at critical connection points, enabling reliable fixing even in miniaturized devices where overall dimensions are reduced. The local quality of guided alignment compensates for the reduced margin for error in small-scale manufacturing.
Solution Approach 2:
In miniaturized devices, the guide hub acts as a scaled-down intermediary structure that maintains the alignment function despite reduced overall device size. The guide elements provide proportional guidance features that accommodate smaller filars and connection points, making the fixing process equally manageable in miniaturized configurations as in larger devices.
3Reliability
If multiple small filars are aligned and joined to corresponding connection points, then electrical coupling is achieved, but the process requires high skill and craftsmanship
Solution Approach 1:
The guide hub serves as a mediating structure that simultaneously guides multiple filars into their respective connection points. The multiple guide elements arranged circumferentially provide parallel alignment pathways, ensuring that all filars are correctly positioned before joining. This intermediary guidance system maintains high electrical coupling reliability while dramatically reducing operation complexity by eliminating the need for skilled manual alignment of multiple small components.
Data Source
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AI summary
A medical device lead connection assembly includes an end connector element including a plurality of fixed connection element tabs extending from the end connector element to a tab distal end. A lead body includes a plurality of lead filars extending through the lead body and coupled to a corresponding fixed connection tab. A tubular guide hub extends from a hub proximal end to a hub distal end. The tubular guide hub includes a plurality of guide elements circumferentially disposed about an outer surface of the guide hub. The hub distal end is disposed within the lead body and the hub proximal end received within connection element tabs, and selected guide elements contact selected lead filars.