Implantable Header Subassembly Fusing for Conductor Spacing

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Solution Overview

Problem

Manufacturing methods for implantable pulse generator headers struggle to maintain the required spacing between internal electrical conductors and antennas, affecting the proper functionality of deep brain stimulation devices.

Innovation Solution

A method and system involving a first and second split web assembly, where a conductor assembly and antenna assembly are positioned between the split webs, and the assembly is fused together under controlled temperature and pressure to form a subassembly that secures the conductor and antenna assemblies in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manufacturing methods are used to assemble header components, then the manufacturing process is simpler and faster, but the spacing between internal electrical conductors and antennas cannot be maintained with required precision

Engineering Contradiction:

Improvespacing between internal electrical conductors and antennasVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The header is divided into multiple components (conductor assembly, antenna assembly, insulator assembly) that are manufactured separately and then assembled using a modular tooling system. This segmentation allows each component to be precision-manufactured independently while maintaining overall spacing requirements through the modular assembly approach.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A specialized tooling assembly acts as an intermediary during manufacturing, providing precise positioning features and spacing references that ensure correct positioning of conductors and antennas relative to each other. This tooling mediator translates design spacing requirements into physical positioning during the assembly process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If required spacing between internal electrical conductors is maintained using traditional methods, then proper functionality is ensured, but the manufacturing difficulty increases significantly

Engineering Contradiction:

Improveproper functionality of IPGVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Positioning features, spacing references, and alignment mechanisms are built into the tooling assemblies before the actual component assembly takes place. This preliminary preparation of the manufacturing system ensures that when components are assembled, the required spacing and positioning are automatically achieved without requiring complex manual adjustments or measurements during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical measurement and adjustment systems with precision-machined tooling fixtures that physically constrain components to correct positions. Instead of relying on operator skill to measure and position components, the mechanical tooling system itself enforces the correct spacing through its geometry and positioning features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively secures the conductor and antenna assemblies, ensuring accurate positioning and orientation, which is crucial for the proper functioning of implantable pulse generators in neurostimulation systems.

Implementation Method 1

heating the top and bottom platens until a predetermined temperature and a predetermined pressure are reached

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

compressing the top and bottom platens together... until a predetermined temperature and a predetermined pressure are reached

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 3

such that first split web is fused to the second split web to form the subassembly

Methodology Applied

Scientific EffectFusion: Welding

Data Source

PatentUS11478651B2Systems and methods for manufacturing header subassembly

Publication Date: 2022.10.25 PACESETTER INC

AI summary

The present disclosure provides systems and methods for assembling a subassembly for use in manufacturing an implantable device header. A method includes placing a first split web into a top platen, placing a second split web into a bottom platen, placing a conductor assembly and an antenna assembly in the bottom platen on top of the second split web, compressing the top and bottom platens together, heating the top and bottom platens until a predetermined temperature and a predetermined pressure are reached, such that first split web is fused to the second split web to form the subassembly, separating the top and bottom platens, and removing the formed subassembly.