Medical Lead Connection Assembly for Precise Filar Welding
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Solution Overview
Problem
The challenge lies in efficiently and effectively connecting small, delicate filars to end connectors in implantable medical devices, such as pacemakers and neurostimulators, which requires high skill and time due to their small size and complexity.
Innovation Solution
A method involving overlapping and deflecting the end portion of a lead filar within an elastic range to form a weld joint with a connection element, utilizing surface tension to align and secure the filar, thereby forming a robust and repeatable weld without additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual alignment and joining methods are used for small filars, then connection precision can be achieved, but the process requires high skill level and takes excessive time
Solution Approach 1:
The patent replaces manual mechanical alignment and joining operations with an automated laser welding system. The laser beam automatically positions and welds the filar to the connector contact, eliminating the need for manual skill-based alignment while significantly reducing joining time. The system uses laser positioning and automated control to achieve precise connections without human intervention.
Solution Approach 2:
The patent changes the joining process parameters from manual mechanical operations to controlled laser parameters (power, duration, focal position). By controlling laser energy delivery, the system achieves precise welding of small filars to connector contacts automatically, resolving both the precision and time constraints of traditional methods.
2Volume of moving object
If device dimensions are reduced to improve miniaturization, then implantable device size decreases, but fixing filars to end connectors becomes more difficult
Solution Approach 1:
The patent replaces difficult manual manipulation of tiny filars with laser-based joining. The laser system can precisely target and weld extremely small filar ends to connector contacts without requiring manual dexterity, making the manufacturing process easier despite the reduced component sizes.
Solution Approach 2:
The patent separates the filar preparation and joining operations into distinct steps: positioning the filar end close to the contact, then applying laser energy to create a localized weld. This segmentation allows each step to be optimized independently, making the overall process easier to execute on miniaturized components.
3Reliability
If multiple small filars need to be connected to corresponding connection points, then electrical coupling is achieved, but the complexity and time required increases significantly
Solution Approach 1:
The patent uses a universal laser welding approach that can join any filar to any connector contact point using the same basic process and equipment. This multi-functional method eliminates the need for different joining techniques for different filar configurations, reducing overall process complexity while maintaining reliable electrical coupling for all connections.
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 allows for efficient and effective connection of lead filars to connection elements, even on small diameters, providing a robust and reliable weld joint that reduces stress and aligns the filars, facilitating the assembly of implantable medical device leads.
Implementation Method 1
A method includes melting a portion of a lead filar with another lead filar or connection tab or element
Implementation Method 2
utilizing surface tension to align and secure the filar
Data Source
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AI summary
A method of forming a medical device lead connection element is described. The method includes positioning an end portion of a lead filar to overlap a lead end connection element such that the positioning creates mutual interference between the lead filar and the lead end connection element, and forming an interference configuration. Then melting the end portion of the lead filar to form a weld joint and allowint the end portion of the lead filar to move towards the end connection element.