Lead Connector Distal Frame Wire Positioning
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Solution Overview
Problem
Conventional injection molding processes for manufacturing implantable medical lead connectors face challenges in maintaining tight tolerances, leading to high production costs and low yields due to issues like shorting, flash, and complex mold tool requirements.
Innovation Solution
The use of a separately formed distal frame to securely position conductive wires within the mold cavity, simplifying the mold tool, and eliminating the need for post-processing by integrating with the mold material to form a contiguous body, thereby reducing shorts and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding process is used to manufacture lead connectors, then the connector body can be formed, but tight tolerances cannot be maintained leading to high production costs and low yields
Solution Approach 1:
The mold cavity is divided into multiple sections with precisely positioned guide pins and registration features. The mold is segmented into movable and stationary halves with precise mating surfaces, allowing each section to be independently manufactured to tight tolerances and then assembled to maintain overall precision throughout the injection molding process.
2Ease of manufacture
If conventional injection molding process is used, then manufacturing can proceed, but issues like shorting and flash occur requiring post-processing
Solution Approach 1:
The mold cavity and core are pre-configured with precisely positioned guide pins, registration features, and flashing prevention elements before the injection molding process begins. These preliminary structural arrangements ensure proper alignment and prevent flash and shorting defects during material injection, eliminating the need for post-processing repairs.
3Manufacturing precision
If complex mold tool requirements are used to achieve tight tolerances, then precision can be maintained, but device complexity increases
Solution Approach 1:
The mold tool incorporates self-aligning features such as guide pins that automatically position mold sections, registration features that self-correct minor misalignments, and built-in flashing prevention elements. These self-service mechanisms maintain tight tolerances without requiring complex external positioning systems or manual adjustment procedures.
Data Source
AI summary
A method of manufacturing a lead connector for an implantable medical device including connecting proximal ends of a plurality of conductive wires to an inner surface of a corresponding ring contact, placing a distal frame over distal ends of each of conducive wire of the plurality of conductive wires, the distal ends passing through corresponding shafts in the distal frame from a rear face of the distal frame and extending beyond a front face of the distal frame, arranging the distal frame along with the conductive wires and corresponding ring contacts within a mold cavity, filling the mold cavity with a mold material, the mold material abutting the rear face of the distal frame, and removing a resulting lead connector from the mold cavity.