Implantable Pulse Generator Feedthru Design for Space and Cost Reduction
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Solution Overview
Problem
The existing methods for manufacturing implantable pulse generators, such as defibrillators and pacemakers, face challenges in reducing manufacturing costs, optimizing wire usage, and streamlining the assembly process due to the need for lengthy feedthru wires and through-hole connections, which waste space and increase material costs.
Innovation Solution
The implementation of a feedthru design with a generally planar electrically conductive interface that allows for a feedthru wire to pass through a core without requiring a through-hole, enabling a pick-and-place manufacturing process that reduces material usage and assembly time, while maintaining electrical contact with the pulse generator's components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a through-hole connection method is used for feedthru wires, then electrical connection is achieved, but manufacturing time increases and space is wasted
Solution Approach 1:
The patent extracts the through-hole connection step from the manufacturing process by using a feedthru design where the wire passes through a pre-formed opening in the PCB rather than requiring a through-hole to be drilled and prepared. This eliminates the time-consuming through-hole preparation and alignment steps while maintaining reliable electrical connection.
Solution Approach 2:
The feedthru opening is pre-formed in the PCB before wire installation, allowing the wire to be simply placed through the opening and secured. This preliminary action eliminates the need for time-consuming through-hole drilling, cleaning, and alignment operations during assembly.
2Reliability
If lengthy feedthru wires are used for through-hole connections, then electrical connection is established, but material costs increase
Solution Approach 1:
The patent removes the unnecessary length of wire required for through-hole penetration and secures it with a feedthru design where the wire simply passes through a pre-formed opening. This extraction of the excessive wire length requirement directly reduces material costs while maintaining electrical connection reliability.
3Reliability
If through-hole connections are used, then electrical connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the complex through-hole connection process (drilling, cleaning, alignment, securing) and replaces it with a simpler feedthru design where the wire passes through a pre-formed opening. This reduction in process steps directly lowers manufacturing complexity while maintaining electrical connection reliability.
4Reliability
If feedthru wires pass through PCB through-holes, then electrical connection is established, but space within the device is wasted
Solution Approach 1:
The patent removes the space-consuming through-hole structure and replaces it with a feedthru design where the wire passes through a minimal opening. This extraction of the excessive space requirement allows for better space utilization within the pulse generator device while maintaining electrical connection.
Data Source
AI summary
Disclosed herein is an implantable pulse generator feedthru configured to make generally planar electrical contact with an electrical component housed within a can of an implantable pulse generator. The feedthru may include a feedthru housing including a header side and a can side, a core within the feedthru housing, a generally planar electrically conductive interface adjacent the can side, and a feedthru wire extending through the core. The feedthru wire may include an interface end and a header end, wherein the header end extends from the header side and the interface end is at least one of generally flush with the generally planar interface and generally recessed relative to the generally planar interface.