Implantable Lead Connector Assembly for Thin-Wire Welding
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Solution Overview
Problem
The existing methods for electrically connecting conductive wires to implantable medical device connectors, such as those used in cardiac stimulation and neuromodulation devices, often damage the wires due to mechanical stress and energy release during welding or crimping, especially when wire diameters are less than 150 micrometers.
Innovation Solution
The use of a first hypotube as an intermediate between the conductive wire and the connector's hypotube allows for a secure and reliable electrical connection, with the first hypotube being welded to the connector's hypotube and accommodating the size difference between the wire and the connector, and laser welding is employed to ensure a waterproof and precise connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or crimping is used to connect conductive wires to the connector, then electrical connection is achieved, but the conductive wires are damaged due to mechanical stress and energy release
Solution Approach 1:
A first hypotube is introduced as an intermediary component between the conductive wire and the second hypotube of the connector. This intermediate hypotube receives the conductive wire and protects it from direct exposure to mechanical stress and energy during welding or crimping operations, thereby preventing wire damage while still achieving reliable electrical connection.
Solution Approach 2:
The connection system is divided into multiple segments: the conductive wire, the first hypotube (intermediate), and the second hypotube (connector). This segmentation allows the connection process to be distributed across multiple components, with the first hypotube specifically designed to absorb and protect against harmful mechanical stress and energy during the connection process.
2Device complexity
If the diameter of conductive wires is reduced below 150 micrometers, then lead complexity is reduced, but the risk of wire damage during connection increases
Solution Approach 1:
The first hypotube serves as a protective intermediary that enables the use of thin conductive wires (diameter < 150 micrometers) by shielding them from damage during connection operations. This allows the lead to maintain simplicity with thinner wires while the intermediate hypotube handles the protective function.
3Reliability
If a first hypotube is added as an intermediate component, then wire protection and connection reliability are improved, but device complexity increases
Solution Approach 1:
The first hypotube is nested within or alongside the second hypotube of the connector, creating a compact multi-layer structure. This nesting arrangement allows the intermediate protective component to be integrated into the existing connector architecture without significantly increasing overall device complexity or size.
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 method reduces the risk of wire damage during connection, facilitates assembly, and enhances the reliability and quality of the electrical connection, even for thin wires, by using a first hypotube to protect the wire and allowing for easier welding outside the connector.
Implementation Method 1
the electrical connection between the conductive wire and the connector is formed by a first hypotube welded to the conductive wire and welded to a second hypotube of the electrical connector
Implementation Method 2
laser welding is employed to ensure a waterproof and precise connection
Data Source
AI summary
The present invention relates to an implantable lead comprising at least one conductive wire and one electrical connector, the electrical connector configured to be connected to an implantable medical device such as a cardiac stimulation, defibrillation and/or neuromodulation device, wherein the electrical connection between the conductive wire and the connector is effected by a first hypotube welded to the conductive wire and welded to a second hypotube of the electrical connector. The present invention also relates to a method for electrically connecting the at least one conductive wire of the implantable lead to the electrical connector.