Integrated Injection-Molded Sealing Element for Cardiac Electrode Tips
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Solution Overview
Problem
Conventional manufacturing methods for electrode tips for implantable cardiac electrodes are time-consuming, costly, and require complex assembly processes, often resulting in insufficient sealing and high friction, which limits design flexibility and increases the risk of electrical shorts and coagulation.
Innovation Solution
An electrode tip with an integrated injection-molded sealing element, formed from materials like liquid silicone rubber or thermoplastic elastomers, which is directly produced within the housing, eliminating the need for separate assembly and providing a fluid-tight seal and reduced friction, allowing for cost-effective and automated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional assembly methods (individual injection-molded sealing ring, threaded joint, or O-ring clamping) are used to assemble sealing into electrode tip components, then sealing function is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The sealing element is integrated directly into the electrode tip housing through a single injection molding process, merging the sealing function with the housing structure. This eliminates the need for separate sealing components and their assembly, reducing manufacturing complexity while maintaining reliable sealing functionality.
Solution Approach 2:
The housing is designed to serve multiple functions: structural support, fluid sealing, and electrical insulation. By integrating the sealing element into the housing itself rather than using separate components, the housing becomes a multi-functional component that eliminates the need for additional sealing parts and assembly steps.
2Reliability
If individual components are assembled with tight tolerances to reduce deficient products, then sealing quality improves, but manufacturing cost increases
Solution Approach 1:
By combining the sealing element and housing into a single injection-molded component, the patent eliminates the need for tight assembly tolerances between separate parts. The single-shot molding process inherently ensures consistent sealing quality without requiring costly precision assembly operations or tight tolerance specifications on multiple components.
Solution Approach 2:
The sealing element is formed as an integral part of the housing during the initial injection molding process, before any assembly operations. This preliminary formation of the sealing structure eliminates the need for subsequent assembly operations and tolerance control, reducing manufacturing cost while maintaining sealing quality.
3Strength
If threaded joint is established between shaft and bushing, then connection is achieved, but friction increases and sealing becomes insufficient
Solution Approach 1:
The patent replaces the threaded mechanical connection system with a friction-fit design where the electrode lead is held in place by friction between the lead insulation and the housing interior surface. This substitution eliminates the threaded joint's high friction and insufficient sealing problems while maintaining adequate connection strength for the application.
4Reliability
If additional parts are assembled into electrode tip, then sealing and structural functions are achieved, but design flexibility is limited due to handling space requirements
Solution Approach 1:
By merging the sealing element with the housing into a single integrated component, the patent eliminates the need for additional separate parts that would require handling space. This integration provides greater design flexibility, allowing the electrode tip to be miniaturized and adapted to various configurations without the constraints of assembling multiple components in a small space.
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
The solution enables efficient sealing, reduces the risk of electrical shorts and coagulation, simplifies manufacturing, and enhances design flexibility by eliminating the need for complex assembly and reducing friction, thus improving the functionality and reliability of implantable cardiac electrodes.
Implementation Method 1
The sealing element consists of an injection-moldable material and forms an integral part of the housing. The housing comprises a sealing chamber and an injection channel, wherein the injection-moldable material is arranged within the sealing chamber and the injection channel.
Implementation Method 2
the sealing element serves for sealing the electrode lead feed section in a fluid tight manner against the electrode lead receiving section
Data Source
AI summary
An electrode tip for an implantable cardiac electrode, wherein the electrode tip comprises a housing having an electrode lead feed section, an electrode lead receiving section and a sealing element arranged between the electrode lead feed section and the electrode lead receiving section. The sealing element serves for sealing the electrode lead feed section in a fluid tight manner against the electrode lead receiving section, when an electrode lead is arranged within the electrode lead feed section and the electrode lead receiving section and is surrounded by the sealing element. According to an aspect of the invention, the sealing element consists of an injection-moldable material and constitutes a non-removable sealing portion forming an integral part of the housing.