Implantable Medical Lead Proximal End Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and complexity of manufacturing both active and passive implantable electrical leads for medical devices arise from their distinct system designs and assembly processes, which differ significantly due to functional differences in their proximal ends.
Innovation Solution
Designing a proximal end for implantable electrical leads that includes a longitudinally extended, electrically conductive connector pin and inner and outer coils, with a connector insulator and ring connector, allowing for shared components between active and passive leads, reducing tooling, manufacturing, and assembly costs by minimizing differences in system designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distinct system designs and assembly processes are used for active and passive leads, then the functionality of each lead type is optimized, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent applies universality by designing a common proximal end structure for both active and passive leads, where the connector assembly, insulator, and sealing components are identical. The only difference between active and passive leads is the distal end mechanism, allowing the proximal end to serve multiple lead types universally. This reduces design complexity and manufacturing costs while maintaining functional performance through standardized interfaces and assembly processes.
2Reliability
If distinct system designs and assembly processes are used for active and passive leads, then the functionality of each lead type is optimized, but the manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by making the proximal end components universal across both active and passive lead types. The connector assembly, insulator, sealing elements, and conductor arrangements are identical, allowing a single manufacturing process and tooling setup to produce both lead types. Only the distal end mechanisms differ, so the majority of the lead structure can be manufactured once and used for both applications, significantly reducing per-unit costs.
Solution Approach 2:
The patent merges the proximal end designs of active and passive leads into a single unified structure. By combining the connector assembly, insulator, sealing, and conductor interfaces into one common design, the patent eliminates redundant manufacturing steps and components. This merging allows shared tooling, assembly fixtures, and quality control processes, thereby reducing overall manufacturing cost while maintaining the functional requirements of both lead types.
3Reliability
If distinct assembly processes are used for active and passive leads, then the specific requirements of each lead type are met, but the production efficiency decreases
Solution Approach 1:
The patent improves production efficiency by establishing a universal assembly process for the proximal end of both active and passive leads. The connector assembly, insulator installation, sealing application, and conductor termination steps are identical for both lead types, allowing a single assembly line to produce both products without reconfiguration. This universality eliminates the need for separate assembly processes, tools, and fixtures, thereby increasing throughput and productivity while still meeting the specific functional requirements of each lead type through modular distal end attachments.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A proximal end of an implantable lead may include a connector insulator having a center bore, a unitary connector pin fixedly disposed in the center bore of the connector insulator where the unitary connector pin includes a socket end configured for insertion into an electrical stimulation device and a conductor end electrically crimped to the first conductor, and a unitary ring connector having a band portion concentrically arranged around and insulated from the conductor end of the unitary connector pin and a crimp portion electrically crimped to the second conductor.