Implantable Lead Reflow Bonding Manufacturing
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Solution Overview
Problem
Conventional manufacturing techniques for implantable leads are limited in adapting to rapid changes in customer needs and incorporating enhancements, with bonding operations requiring significant time and extrusion techniques restricted by clearance issues and inability to incorporate novel components.
Innovation Solution
The use of reflow technology to manufacture implantable leads, where a core with a longitudinal lumen is surrounded by an extruded jacket made of reflowable material, allowing for bonding and incorporation of lead components, thereby enhancing versatility and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bonding techniques are used to manufacture implantable leads, then components can be assembled, but multiple independent bonding operations with cure times and pre/post-processing times significantly increase manufacturing time
Solution Approach 1:
The patent combines multiple separate bonding operations into a single integrated reflow process. The jacket material serves as both the structural component and the bonding agent, allowing simultaneous bonding of multiple components (coil, braid, electrodes) during one heating cycle rather than requiring sequential bonding operations with multiple cure times.
Solution Approach 2:
The jacket material performs multiple functions: it provides structural protection, serves as the bonding medium for attaching components to the core, and enables the reflow manufacturing process. This multi-functionality eliminates the need for separate bonding materials and processes for each component.
2Ease of manufacture
If conventional extrusion techniques are used to manufacture implantable leads, then components can be formed, but clearance requirements between mating parts restrict downsizing and prevent incorporation of novel components
Solution Approach 1:
The patent changes the manufacturing parameter from cold extrusion with rigid clearance requirements to thermal reflow processing. This allows the jacket material to flow and conform to the core and components, eliminating the need for clearance gaps and enabling tighter tolerances and smaller component sizes.
Solution Approach 2:
The patent uses a composite structure where the jacket material (which is reflowable) is combined with the core and various components. This composite approach allows the jacket to bond to different materials (core, coil, braid) through the reflow process, enabling integration of novel components that would not be compatible with conventional extrusion techniques.
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 simplifies the incorporation of components and enhancements, reduces manufacturing time, and increases the flexibility of implantable leads to meet industry and customer needs, while providing improved operability and decreased costs.
Implementation Method 1
applying heat to cause the material of the jacket to reflow and bond to the core
Implementation Method 2
applying heat to cause the material of the jacket to reflow and bond to the core
Data Source
AI summary
A method of manufacturing an implantable lead includes providing a core including at least one longitudinal lumen; providing a jacket comprising a reflowable material; positioning the core at least partially within the jacket; and, after positioning, applying heat to cause the material of the jacket to reflow and bond to the core. An implantable lead includes a core including at least one longitudinal lumen; and a jacket comprising a reflowable material. The core may be at least partially disposed within the jacket with the material of the jacket reflow-bonded to the core. The implantable lead may further include at least one lead component associated with at least one of the core and the jacket.