Lead Connection Assembly Using Weld-Pool Alignment for Fine Filars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in efficiently and effectively connecting small-diameter lead filars to end connectors in implantable medical devices, which requires high skill and time due to their tiny dimensions and complex alignment.
Innovation Solution
A method involving overlapping and deflecting the end portion of a lead filar within an elastic range to form a weld joint by melting the overlap region, utilizing surface tension to align and secure the filar with a connection element, thereby forming a robust and repeatable weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual alignment and joining methods are used for small-diameter filars, then connection precision can be achieved, but the process requires high skill level, takes excessive time, and reduces productivity
Solution Approach 1:
The filars are pre-positioned within the lead body in a controlled manner before the final connection step. This preliminary positioning ensures that when the filars reach the connector, they are already close to their target positions, reducing the complexity of final alignment and enabling faster automated connection processes
Solution Approach 2:
The patent replaces manual mechanical alignment and joining operations with automated positioning systems and laser welding technology. This substitution eliminates the need for skilled manual manipulation while achieving precise connections through automated control systems
2Adaptability or versatility
If the number of connectors and filars increases to maintain functionality, then device capability is preserved, but the complexity of aligning and joining each filar increases significantly
Solution Approach 1:
Multiple filars are bundled together within the lead body and positioned as a group rather than individually. This merging approach allows all filars to be connected to their respective connectors simultaneously through a single automated process, rather than requiring separate manual operations for each filar
Solution Approach 2:
The lead body structure serves multiple functions: it protects the filars, maintains their relative positions, guides them to the correct connectors, and enables automated connection. This multi-functional design simplifies the overall connection process despite having multiple filars and connectors
3Volume of moving object
If device dimensions are reduced to meet miniaturization requirements, then implantable device size decreases, but the difficulty of fixing and aligning small filars to connectors increases
Solution Approach 1:
The patent replaces manual mechanical manipulation of tiny filars with automated laser welding technology. This substitution makes it feasible to connect extremely small filars to connectors with precision that would be impossible to achieve through manual operations, thereby enabling device miniaturization
Solution Approach 2:
The patent changes the connection method from mechanical manipulation to thermal welding. By using laser-induced heating to melt and fuse the filar to the connector, the process becomes independent of the filar's small dimensions, making miniaturization feasible
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 method efficiently and effectively connects lead filars to connection elements, even on small diameters, forming a robust weld joint that relieves stress and aligns the filars, facilitating the assembly of implantable medical device leads and extensions.
Implementation Method 1
allowing surface tension of the weld pool to align and secure the molten end portion of the lead filar with the connection element
Implementation Method 2
melting a portion of the lead filar with either the second lead filar or connection tab, relieves the flexural stress and aligns the lead filar
Data Source
AI summary
A method of forming a medical device lead connection element is described. The method includes positioning an end portion of a lead filar to overlap a lead end connection element such that the positioning creates mutual interference between the lead filar and the lead end connection element, and forming an interference configuration. Then melting the end portion of the lead filar to form a weld joint and allowint the end portion of the lead filar to move towards the end connection element.