Laminated Micro-Circuit Contact Assembly for Implantable Leads
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Solution Overview
Problem
Existing implantable electrical stimulation systems face challenges in creating reliable and consistent electrical connections between electrodes and lead conductors, which can be costly and labor-intensive, often resulting in inconsistent performance.
Innovation Solution
The development of an electrical stimulation lead with a contact assembly that includes micro-circuits formed along layered elements, where micro-circuits are laminated between non-conductive substrates and mechanically coupled to form a composite structure, providing a simpler and more reliable electrical connection between contacts and lead-body conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to create electrical connections between electrodes and lead conductors, then reliable electrical connections can be achieved, but the manufacturing process becomes costly and labor-intensive
Solution Approach 1:
The patent combines multiple functions into the contact assembly structure: the layered elements with micro-circuits serve as both the electrical connection pathway and the structural support for contacts, eliminating the need for separate connection components and reducing manufacturing steps
Solution Approach 2:
The micro-circuits are pre-formed on the layered elements during manufacturing, establishing electrical connection pathways before final assembly. This preliminary formation of conductive traces simplifies the overall manufacturing process by eliminating subsequent complex wiring steps
2Reliability
If traditional electrical connection methods are used, then connections can be established, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual or complex mechanical connection processes with a laminated composite structure where electrical connections are formed through controlled lamination and circuit trace deposition, enabling automated manufacturing and improving production efficiency
Solution Approach 2:
The contact assembly uses a composite laminated structure combining conductive and non-conductive layers, allowing electrical connections to be integrated into the material structure itself rather than requiring separate assembly steps, thereby improving manufacturing efficiency
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 solution simplifies the manufacturing process, reduces costs, and ensures consistent and reliable electrical connections, enhancing the performance and efficiency of implantable electrical stimulation systems.
Implementation Method 1
micro-circuits are laminated between non-conductive substrates and mechanically coupled to form a composite structure
Data Source
AI summary
First contacts are disposed along a distal end portion or a proximal end portion of a lead body of an electrical stimulation lead. A contact assembly is disposed along the other of the distal end portion or the proximal end portion of the lead body. The contact assembly includes a tubular-shaped composite structure formed from multiple layered elements mechanically coupled together and rolled together into a tube. Each of the layered elements includes a first electrically-nonconductive substrate, a second electrically-nonconductive substrate, and micro-circuits laminated therebetween. Second contacts are disposed over the composite structure and electrically coupled to a first end portion of at least one of the micro-circuits. Lead-body conductors electrically couple the first contacts to the second contacts. Each of each of the lead-body conductors is attached to a second end portion of at least one of the micro-circuits.