Implantable Lead Connector Layout for Axial Feedthrough Welding

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Solution Overview

Problem

Conventional implantable medical device connectors require extra space for perpendicular welding of feedthrough wires, necessitating larger device headers and limiting the density of electrical contacts.

Innovation Solution

The connector design allows for axial welding of feedthrough wires within the connector housing, reducing the need for additional fixtures and enabling closer placement of connectors to the hermetic electronic enclosure, thereby facilitating a more compact and reliable connection system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If perpendicular welding of feedthrough wires is used, then welding can be performed with conventional fixtures, but increased free space is required within the device header

Engineering Contradiction:

Improvewelding processVSAvoiddevice header volume

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent inverts the conventional welding approach by switching from perpendicular welding to axial welding. The attachment hole axis is offset from and non-parallel to the bore hole axis, enabling the feedthrough wire to be welded axially to the connector housing rather than perpendicularly. This inversion of the welding direction eliminates the need for additional free space within the device header while maintaining manufacturability through automated laser welding processes.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If perpendicular welding is used, then conventional welding fixtures can be employed, but the connectors must be positioned farther from the hermetic electronic enclosure

Engineering Contradiction:

Improvewelding fixture compatibilityVSAvoidconnector positioning distance

Core Design Contradiction:

Ease of manufactureVSLength of moving object

Solution Approach 1:

The patent changes the welding direction from perpendicular to axial, which allows connectors to be positioned closer to the hermetic electronic enclosure. The offset attachment hole geometry enables axial welding access without requiring the connectors to be positioned far from the enclosure, thereby reducing wire routing length and improving device compactness.

Inventive Principle:

Principle #13The other way round (Inversion)

3Volume of moving object

If axial welding is implemented, then device header size is reduced, but welding requires precise alignment without fixtures

Engineering Contradiction:

Improvedevice header volumeVSAvoidwelding alignment precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent incorporates preliminary alignment features in the connector housing design, including the specifically positioned attachment hole that is offset from the bore hole axis. This preliminary geometric configuration ensures that the feedthrough wire is pre-aligned with the welding area before the welding process begins, enabling precise axial welding without requiring external fixtures or jigs during the welding operation.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If conventional connector design is used, then manufacturing is simpler, but wire routing operations within the header are increased

Engineering Contradiction:

Improveconnector manufacturingVSAvoidwire routing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent inverts the conventional connector design by implementing axial welding capability through an offset attachment hole. This design change allows connectors to be positioned closer to the hermetic electronic enclosure, which directly reduces wire routing operations and length within the header, thereby improving productivity and manufacturing efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

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 design reduces the device header size, allows for higher channel counts, improves welding reliability, and enables automation of the assembly process, resulting in a smaller, less invasive implant with reduced wire routing and improved weld joints.

Implementation Method 1

a spring (430) disposed within the bore hole of the bore portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a seal (420) coupled to the bore portion... to seal against the lead to inhibit ingress of fluids or other contaminants

Methodology Applied

Scientific EffectSealing:

Implementation Method 3

allow for axial laser welding between the feedthrough wire 180 and the connector housing 110

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS12589251B2Connector for implantable medical device

Publication Date: 2026.03.31 GREATBATCH LTD

AI summary

In various examples, a connector for an implantable medical device is configured to accept a lead therein and electrically couple to a lead contact of the lead. The connector includes a connector housing, which includes a bore portion including a bore hole therethrough. The bore hole includes a bore hole axis, the bore hole being sized and shaped to accept the lead within the bore hole. An attachment portion is coupled to the bore portion. The attachment portion includes an attachment hole within the attachment portion sized and shaped to accept a feedthrough wire within the attachment hole. The attachment hole includes an attachment hole axis offset from and non-parallel to the bore hole axis.