Lead Connector Assembly With Pretested Hermetic Core Seals
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Solution Overview
Problem
The existing process for constructing a lead connector assembly for implantable medical devices is slow due to the use of multiple adhesive curing steps, which increases manufacturing time and cost, and lacks effective means for testing hermeticity, potentially leading to unreliable assemblies.
Innovation Solution
A lead connector assembly using rigid insulative cores with alternating series of elastomer seals and header contacts, which are interference fit and self-align, allowing for hermetic testing before final assembly, reducing the need for adhesive curing and enabling efficient construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple adhesive curing steps are used in the construction process, then the assembly is secure and hermetic, but the manufacturing time and cost increase
Solution Approach 1:
The patent extracts and eliminates the adhesive curing steps from the construction process by using a pre-assembled hermetic connector assembly that requires no adhesives. The connector assembly is provided as a complete unit with hermetic seals already integrated, removing the need for separate adhesive application and curing operations while maintaining hermetic integrity.
Solution Approach 2:
The hermetic connector assembly is pre-assembled with all hermetic sealing components integrated before being installed in the implantable medical device. This preliminary assembly ensures hermetic integrity is built-in from the start, eliminating the need for subsequent adhesive curing steps and accelerating the overall manufacturing process.
2Strength
If multiple adhesive curing steps are used, then the components are well-bonded, but the manufacturing cost increases
Solution Approach 1:
The patent removes adhesive materials and curing processes from the manufacturing workflow by utilizing a hermetic connector assembly where bonding is achieved through mechanical interference fits and precision-machined mating surfaces. This extraction of adhesive requirements eliminates material costs and processing expenses associated with adhesive application and curing.
3Reliability
If hermetic testing is performed after final assembly, then defects are detected, but the testing process is complex and time-consuming
Solution Approach 1:
The hermetic connector assembly is designed with built-in hermetic sealing features that prevent defect formation rather than relying on complex post-assembly testing. The precision-machined seals and interference-fit connections ensure hermetic integrity is established during assembly, simplifying or eliminating the need for elaborate testing procedures.
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 approach speeds up manufacturing, reduces costs by minimizing adhesive use, and ensures hermetic integrity through pre-assembly testing, enhancing the reliability of the lead connector assembly.
Implementation Method 1
Alternating series of elastomer seals and header contacts, which are interference fit and self-align
Implementation Method 2
The recesses are configured to receive feedthrough pins to be welded to the contacts accessible through the contact openings in the recesses
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention discloses a lead connector assembly for an implantable medical device, comprising at least first and second cores formed of a rigid insulative material, each core having a long axis, each core comprising short sides perpendicular to its long axis, and long sides parallel to its long axis, wherein the first and second cores are positioned such that a first long side of the first core is facing a first long side of the second core, wherein the cores each comprise a core opening along its long axis; an affixing means on its first long side connected to the first side of the other core; a plurality of contact openings along and perpendicular to its long axis; and a connector block having a lead opening configured to receive a proximal end of a medical lead and to pass the proximal end along its long axis through its core opening.