Implantable Feedthrough Nailhead Snap-Fit Connection
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Solution Overview
Problem
The existing methods for creating electrical connections in implantable medical devices, such as pulse generators and cardiac function management devices, are cumbersome and time-consuming, involving multiple steps like wire bending and adhesive application, which increases manufacturing time and cost while exposing components to physical damage.
Innovation Solution
The implementation of a feedthrough system using a nailhead with a protruded tip and a ribbon wire with a snap-fit pattern, allowing for secure and efficient electrical connections between components, including a battery cell or capacitor, and the main circuit board, through a method that includes snap-fitting and subsequent laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire bending and adhesive application methods are used for electrical connections, then reliable electrical connections can be achieved, but manufacturing time increases and components are exposed to physical damage
Solution Approach 1:
The patent extracts and eliminates the adhesive application step from the traditional wire connection process. By using a ferrule crimp connection method, the adhesive step is removed entirely, reducing manufacturing time and complexity while maintaining reliable electrical connections between the feedthrough wire and connector block.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (ferrule crimp connection). The ferrule is crimped onto the wire to create a secure mechanical and electrical connection, eliminating the need for adhesive application and curing time.
2Ease of manufacture
If traditional wire bending and multiple adhesive applications are used, then electrical connections can be established, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate operations (wire routing, bending, adhesive application, and connection) into a single integrated ferrule crimp operation. The ferrule serves as both the connection terminal and the bonding mechanism, combining electrical connection and mechanical securing in one step, thereby simplifying the manufacturing process.
Solution Approach 2:
The patent removes multiple adhesive application steps and wire bending operations from the manufacturing process. By using pre-formed ferrules that are simply crimped onto straight wires, the complex multi-step process is reduced to a single straightforward operation, lowering both device complexity and manufacturing cost.
3Reliability
If wire bending and tubing installation are performed manually, then connections can be made, but manufacturing cost increases and components are exposed to physical damage
Solution Approach 1:
The patent replaces manual wire bending and tubing installation with an automated ferrule crimping system. The crimping tool automatically secures the ferrule onto the wire, eliminating manual manipulation that could damage components. This mechanical automation reduces manufacturing cost and protects component integrity.
Solution Approach 2:
The ferrule is pre-formed and positioned on the wire before the crimping operation. This preliminary preparation allows for automated, precise crimping without manual wire manipulation, reducing the risk of physical damage to the wire or surrounding components during the connection process.
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 simplifies the connection process, reduces device size, enhances assembly yield, minimizes manual interaction, and decreases the need for bending and adhesive application, thereby lowering manufacturing time and costs while protecting components from damage.
Implementation Method 1
subsequent attachment of the ribbon wire to the nailhead. The subsequent attachment can include an adhesive or welding, such as laser welding
Data Source
AI summary
The present subject matter provides feedthrough or interconnect systems for components of an implantable medical device and methods for their manufacture. A feedthrough system includes a wire or nailhead having a protruded tip. The wire or nailhead extends from an aperture in an encasement of a first component and is connected to a terminal conductor adapted to electrically connect to circuitry within the encasement. A ribbon wire has a distal end adapted to electrically connect to a second component and a proximal end having a pattern adapted to fit to the protruded tip of the wire or nailhead to provide for subsequent attachment of the ribbon wire to the nailhead.