Implantable Lead Proximal End Shared Connector Design
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Solution Overview
Problem
The high cost and complexity of manufacturing both active and passive electrical leads for medical devices, such as pacemakers and defibrillators, arise from their distinct system designs and assembly processes, which require different components and tooling.
Innovation Solution
Designing a proximal end for implantable electrical leads with shared components, including a connector pin, inner and outer coils, and insulating tubing, where the connector pin can be rotated to actuate the active mechanism in active leads, but is fixed in passive leads, allowing for common parts and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active and passive leads are designed with different system designs and assembly processes, then functional requirements are met, but manufacturing cost and complexity increase
Solution Approach 1:
The patent applies universality by designing a common proximal end structure for both active and passive leads, including shared components such as the connector pin, insulator, and sealing elements. This unified design allows the same basic structure to serve both lead types, reducing overall system complexity while maintaining the ability to meet different functional requirements through optional actuation mechanisms
2Reliability
If different components and tooling are used for active and passive leads, then specific functional needs are satisfied, but manufacturing cost increases
Solution Approach 1:
The patent enables universal manufacturing processes by standardizing the proximal end components across both active and passive leads. The same connector pin, insulator, and sealing structures can be manufactured using identical tooling and assembly processes, eliminating the need for separate production lines and reducing manufacturing costs while still accommodating different distal end requirements
Solution Approach 2:
The patent segments the lead into modular components, where the proximal end is standardized and can be universally manufactured, while the distal end maintains variability to meet specific functional requirements. This segmentation allows independent optimization of manufacturing processes for each module, reducing overall production complexity and cost
3Adaptability or versatility
If separate assembly processes are used for active and passive leads, then functional differentiation is achieved, but production efficiency decreases
Solution Approach 1:
The patent establishes a universal assembly process for the proximal end of both active and passive leads, allowing manufacturers to use the same assembly line, tooling, and procedures for the majority of the lead structure. This unified approach significantly improves production efficiency by eliminating the need for separate assembly processes, while functional differentiation is maintained through optional components and final assembly variations
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 the cost of tooling, manufacturing, and assembly by allowing most parts to be shared between active and passive leads, thereby lowering overall production expenses while maintaining functional differences.
Implementation Method 1
an inner coil crimped to the connector pin
Data Source
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AI summary
A proximal end of an implantable lead may include a unitary connector pin having a socket end, a conductor end, and a necked-down portion arranged therebetween, where the conductor end includes a crimp cavity with an inner surface and a proximal end of the conductor is arranged in the crimp cavity, and a pin sleeve sleevably engaging the proximal end of the conductor and crimping the proximal end of the conductor against the inner surface, the proximal end may also include a unitary ring connector having a band portion, a notch portion, and a crimp portion where the crimp portion includes a crimp cavity with an inner surface and a proximal end of the conductor is arranged in the crimp cavity, and a ring sleeve sleevably engaging the proximal end of the conductor and crimping the proximal end of the conductor against the inner surface creating a crimp connection.