Implantable Lead Electrical Connector Cap Design
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Solution Overview
Problem
Existing implantable leads face weaknesses at the junction where the lead body meets the connector portion, prone to mechanical stress and potential breakage due to fatigue, and require multiple interconnections that are difficult to standardize across different connectivity standards.
Innovation Solution
An electrical connector cap with an elongated body and through holes that houses the interconnections, reducing the number of connections in the lead body and standardizing the connector for use with both IS-4 and DF-4 standards, thereby minimizing mechanical stress and facilitating manufacturing in a single production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead body and connector portion are manufactured as separate components requiring multiple interconnections, then the electrical connectivity is achieved, but the junction area becomes prone to mechanical stress and fatigue breakage
Solution Approach 1:
The patent integrates the connector portion directly into the lead body by forming the electrically conductive lines to extend through the lead body and connect directly to the connector contacts, eliminating separate interconnection components. This merging reduces the number of junctions and potential failure points while maintaining electrical connectivity.
Solution Approach 2:
The patent extracts the problematic intermediate interconnection components (such as separate connectors, welds, or joints) from the system. By having the electrically conductive lines extend directly from the electrodes through the lead body to the connector portion, the design removes the vulnerable junction areas that were previously necessary for connecting separate components.
2Adaptability or versatility
If different connector standards (IS-4 and DF-4) are accommodated with separate manufacturing processes, then compatibility with multiple standards is achieved, but manufacturing complexity and production line requirements increase
Solution Approach 1:
The patent designs the lead body and connector portion with a universal structure that can accommodate both IS-4 and DF-4 connector standards. The electrically conductive lines are configured to extend through the lead body in a manner that is compatible with both standards, allowing a single manufacturing process to produce leads that can be used with either connector type.
Solution Approach 2:
The patent utilizes parameter changes in the connector portion design (such as the configuration of contact pins or rings) to accommodate different standards while maintaining the same fundamental lead body structure. This allows the same manufacturing process to produce variations that meet different connector standards by adjusting specific dimensional or configurational parameters rather than requiring entirely different production lines.
Data Source
AI summary
The present disclosure relates to an electrical connector cap, in particular for an implantable lead, the electrical connector cap comprising an elongated body having at least one lumen and at least one through hole extending from an outer surface of the elongated body into the lumen, and at least one electrically conductive member arranged on an outer circumference of the elongated body over said at least one through hole of the elongated body. Furthermore, said at least one electrically conductive member comprises at least one through hole (extending from an outer surface of the electrically conductive member into the lumen through said at least one through hole of the elongated body. The disclosure further relates to implantable lead assemblies comprising said electrical connector cap, and to an implantable lead member usable with said electrical connector cap.