Implantable Medical Connector Assembly with Nested Feedthrough
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Solution Overview
Problem
The challenge in implantable neuromodulation systems is to miniaturize components while maintaining high functionality and reliability, particularly in accommodating increased numbers of lead electrodes for patient comfort without compromising system handling.
Innovation Solution
The development of advanced connector assemblies that include a feedthrough assembly with a ferrule and insulator, a sealing member, and a design allowing for secure electrical coupling of conductors to the neuromodulation device, featuring a 'snap fit' mechanism and flexible substrate for strain relief, enabling efficient routing and secure attachment of medical electrical leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of lead electrodes is increased to provide more stimulation sites, then the functionality of the neuromodulation system is improved, but the size and complexity of the connector assembly increases
Solution Approach 1:
The connector assembly employs a nested structure where the lead connector is received within a device connector housing. The feedthrough assembly is nested within the device connector, with the insulator surrounding the ferrule. This nesting arrangement allows multiple components to be integrated in a compact configuration, accommodating increased electrode density without proportionally increasing overall assembly complexity.
Solution Approach 2:
The connector assembly is divided into distinct functional segments: the lead connector with conductors, the feedthrough assembly with ferrule and insulator, and the device connector housing. This segmentation allows each component to be optimized independently for its specific function while maintaining overall system compactness when assembled together.
2Volume of moving object
If the connector assembly is miniaturized to improve patient comfort, then the implant size is reduced, but the reliability of electrical connections may be compromised
Solution Approach 1:
The feedthrough assembly utilizes composite construction with a ferrule (conductive material) surrounded by an insulator (non-conductive material). This composite structure enables compact design while maintaining electrical connection integrity through the ferrule and preventing interference between adjacent conductors through the insulator, thus preserving reliability in a miniaturized format.
Solution Approach 2:
The insulator surrounding the ferrule acts as a protective cushion that maintains proper spacing and prevents electrical interference between adjacent feedthroughs. This protective structure is built into the design beforehand, ensuring connection reliability is maintained even as the overall assembly size is reduced.
3Volume of moving object
If the connector assembly is miniaturized to improve patient comfort, then the implant size is reduced, but the ease of handling during implantation may be worsened
Solution Approach 1:
The connector assembly incorporates flexible elements including the flexible substrate and strain relief features that allow the assembly to adapt to handling forces during implantation. This dynamic flexibility enables the miniaturized connector to be manipulated and positioned more easily despite its compact size, maintaining surgeon control and ease of operation.
Solution Approach 2:
The flexible substrate and strain relief structures provide controlled flexibility to the miniaturized connector assembly. These flexible elements allow the connector to bend and conform during implantation procedures, making it easier to handle and position the smaller device without compromising structural integrity or connection reliability.
4Quantity of substance
If multiple conductors are routed through a compact feedthrough assembly, then the electrode density is increased, but the manufacturing precision required increases
Solution Approach 1:
The feedthrough assembly design serves multiple functions simultaneously: the ferrule provides electrical connection, the insulator provides electrical isolation and mechanical support, and the combined structure provides strain relief. This multi-functionality allows a standardized component design to accommodate multiple conductors without requiring unique precision features for each conductor, thereby managing manufacturing precision requirements.
Solution Approach 2:
The nested arrangement of ferrule within insulator creates a standardized modular unit that can be replicated for multiple conductors. This modular nesting pattern simplifies manufacturing by establishing a repeatable assembly process, reducing the precision burden that would otherwise arise from routing multiple conductors through a compact space.
Data Source
AI summary
A device connector assembly includes a plurality of electrical contacts and a sealing member including a corresponding plurality of apertures; each electrical contact extends within a corresponding aperture of the plurality of apertures such that each contact is accessible for coupling with a corresponding connector element of a lead connector. The lead connector elements protrude from a first side of an insulative substrate of the lead connector, and may be coupled to the contacts of the device connector assembly by aligning each connector element with the corresponding aperture of the sealing member, and applying a force to a second side of the insulative substrate, opposite the first side, in order to press each connector element into engagement with the corresponding contact.