Injection Molded IPG Connector Assembly Withstand Molding Pressure
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Solution Overview
Problem
Current header casting manufacturing processes for implantable pulse generators are time-consuming and costly due to the need for multiple skill-intensive operations, including pre-casting the header and a lengthy backfill process to secure the connector assemblies.
Innovation Solution
A connector assembly design that allows for injection molding of the header over the connector assembly, eliminating the need for a pre-cast header and backfill process, featuring a configuration with insulator rings and spring housings that can withstand injection molding pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-cast header with manual insertion and backfill process is used, then the connector assembly can be securely attached to the header, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The patent combines the header and connector assembly into a single integrated component by injection molding the connector assembly directly into the header housing. This eliminates the separate backfill process and manual assembly steps, achieving both secure attachment (through integrated molding) and improved manufacturing efficiency (by reducing process steps).
Solution Approach 2:
The connector assembly is pre-positioned within the header cavity before the final injection molding step. This preliminary positioning allows the molten polymer to flow around and secure the connector assembly in its exact desired location, ensuring reliable attachment while eliminating the need for post-assembly backfilling operations.
2Manufacturing precision
If multiple skill-intensive operations are performed for header assembly, then the connector assembly can be properly positioned and electrically connected, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple separate operations (header casting, connector positioning, electrical connection, and sealing) into a single injection molding process. The connector assembly is positioned and secured, and electrical connections are established all within the same molding cycle, reducing process complexity while maintaining precision through the inherent accuracy of injection molding.
Solution Approach 2:
The injection molding process itself performs multiple functions simultaneously: it positions the connector assembly, secures it to the header, provides electrical connections through conductive materials, and creates sealing barriers. The process serves multiple purposes that would traditionally require separate skilled operations.
3Ease of operation
If the header openings are made larger to allow manual insertion of connector assemblies, then the assembly process becomes easier, but the backfill process becomes more lengthy and expensive
Solution Approach 1:
Instead of making the header openings larger to facilitate insertion and then backfilling the excess space, the patent inverts the approach by using the injection molding process to create the header around the connector assembly. The openings are formed to the exact size needed, eliminating the need for backfilling while maintaining ease of assembly through the molding process itself.
Data Source
AI summary
A pulse generator comprises a header connector assembly coupled with a housing. The header connector assembly includes a connector assembly and a header enclosing the connector assembly. The connector assembly includes an electrically insulative segment, a first electrically conductive segment, and a second electrically conductive segment axially spaced apart from the first electrically conductive segment by the electrically insulative segment. Each electrically conductive segment includes a connector ring, a spring housing and a spring supported by the spring housing. The connector ring and spring housing are in electrical communication with each other. The electrically insulative segment includes an insulator ring that is positioned between the first and second electrically conductive segments. The insulator ring includes a first end and a second end axially opposite the first end. The first end includes a first recess that opens axially and receives therein a portion of the first electrically conductive segment.