Laser Welded Wire Joints for Implantable Pulse Generators
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Solution Overview
Problem
The miniaturization of implantable medical devices, such as implantable pulse generators, poses challenges in making robust and durable electrical connections in small, constrained areas, which are prone to complications like lead breakage, migration, and erosion, especially when used for peripheral nerve stimulation where current SCS devices are not optimally designed.
Innovation Solution
A method involving biocompatible wires and connecting pieces, where resistance welding and energy beam welding techniques are used to create secure joints, with the option of enclosing welds in a non-conductive material, and using a cap permeable to body fluids to protect the connections, allowing for flexible placement and reduced risk of complications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of implantable devices is minimized, then implantability and recovery time are improved, but the reliability of electrical connections deteriorates due to constrained access and visibility in small volumes
Solution Approach 1:
The patent applies preliminary action by performing resistance welding to pre-secure the wire to the connecting piece before the energy beam welding process. This preliminary mechanical and electrical bonding ensures proper positioning and initial structural integrity, allowing the subsequent laser welding to focus on creating a durable, hermetic seal without worrying about wire displacement or misalignment during the process.
Solution Approach 2:
The patent replaces traditional mechanical connection methods with energy beam welding (laser welding). Instead of using mechanical fasteners, crimp connections, or soldering that would require complex tooling and provide limited strength in small spaces, the invention uses concentrated energy beam welding to create strong, precise metallurgical bonds between the wire, connecting piece, and seal, achieving superior connection reliability in miniaturized devices.
2Ease of manufacture
If traditional welding methods are used in small constrained areas, then manufacturing simplicity is maintained, but connection durability and resistance to lead breakage deteriorate
Solution Approach 1:
The patent replaces traditional mechanical connection methods with energy beam welding (laser welding). Instead of using mechanical fasteners, crimp connections, or soldering that would require complex tooling and provide limited strength in small spaces, the invention uses concentrated energy beam welding to create strong, precise metallurgical bonds between the wire, connecting piece, and seal, achieving superior connection reliability in miniaturized devices.
Solution Approach 2:
The patent applies parameter changes by utilizing the focused, high-energy density characteristics of laser beams to achieve welding temperatures and penetration depths that are not attainable with conventional welding methods in small spaces. The energy beam parameters (power, duration, focus point) are precisely controlled to create strong, localized bonds without excessive heat affect zones that could compromise the integrity of the miniaturized device components.
3Strength
If multiple welding passes are performed to ensure connection durability, then connection strength is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent replaces traditional mechanical connection methods with energy beam welding (laser welding). Instead of using mechanical fasteners, crimp connections, or soldering that would require complex tooling and provide limited strength in small spaces, the invention uses concentrated energy beam welding to create strong, precise metallurgical bonds between the wire, connecting piece, and seal, achieving superior connection reliability in miniaturized devices.
Solution Approach 2:
The patent applies parameter changes by utilizing the focused, high-energy density characteristics of laser beams to achieve welding temperatures and penetration depths that are not attainable with conventional welding methods in small spaces. The energy beam parameters (power, duration, focus point) are precisely controlled to create strong, localized bonds without excessive heat affect zones that could compromise the integrity of the miniaturized device components.
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 enhances the reliability and durability of connections within implantable devices, reducing the risk of complications and improving the longevity of the devices, especially when used for peripheral nerve stimulation by providing a robust and flexible connection solution.
Implementation Method 1
resistance welding one of the biocompatible wires and the connecting piece together
Implementation Method 2
energy beam welding the one of the biocompatible wires and the connecting piece together
Data Source
AI summary
Methods of making an implantable pulse generator are disclosed herein. The implantable pulse generator can include a body defining an internal volume and a plurality of wires extending from out of the internal volume of the body. Some of these wires can be connected, either directly or indirectly to a lead via a welded joint. The welded joint can be created by first resistance welding and then laser welding some of the wires to a connector.