Screwless Leaf Spring Connector for Implantable Medical Devices
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Solution Overview
Problem
The existing screw connection systems for implantable medical devices are cumbersome, costly, and pose risks of damage and improper connection, requiring specialized tools and increasing the size of the device, while also being complex and expensive to produce.
Innovation Solution
A leaf spring system that provides a tool-free mechanism for securing a plug within the connector housing of an active implantable device, ensuring mechanical and electrical connection without screws, allowing for easy connection and disconnection from one side, and is integrated into the small volume of the connector head for minimal invasiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection system is used to secure the plug, then the mechanical retention force and electrical contact quality are improved, but the device complexity, manufacturing cost, and required tooling increase
Solution Approach 1:
The invention extracts the screw and threading components from the connection system, replacing them with a simplified plug-and-socket mechanism. The plug is inserted directly into the socket without requiring screws, threads, or specialized tools, thereby eliminating the complexity associated with screw connection systems while maintaining reliable mechanical retention through precise geometric fitting and elastic sealing elements.
Solution Approach 2:
The connection system is designed to be self-securing through the interference fit between the plug and socket. The elastic sealing element automatically engages with the plug upon insertion, providing both sealing and mechanical retention without requiring external tools or additional fastening operations. The system self-regulates the connection state through its geometric and material properties.
2Reliability
If a screw connection system is used, then the electrical contact quality is improved, but the manufacturing cost and production complexity increase
Solution Approach 1:
The invention removes screws, threading operations, and torque-limiting mechanisms from the manufacturing process. The plug and socket are manufactured as precision-molded components with integrated electrical contacts and sealing elements, eliminating multiple machining steps and assembly operations required for screw-based systems. This reduces both direct manufacturing costs and indirect costs related to tooling and quality control.
Solution Approach 2:
The invention combines multiple functions into single integrated components. The electrical contacts, mechanical retention features, and sealing elements are all incorporated into the monolithic plug and socket structures. This integration eliminates the need for separate manufacturing and assembly of screws, washers, and seals, thereby reducing overall manufacturing cost and complexity.
3Reliability
If a screw connection system is used, then the mechanical retention is improved, but the risk of damage and improper connection increases
Solution Approach 1:
The connection system provides visual and tactile feedback that automatically indicates when proper connection has been achieved. The elastic sealing element engages with the plug in a predetermined sequence, creating audible clicks or tactile sensations that confirm correct positioning and engagement. This self-indicating mechanism eliminates the risk of improper connection without requiring surgeon training or specialized tools.
Solution Approach 2:
The invention incorporates compliant sealing elements and stress-distributing geometric features that prevent damage during connection. The elastic material absorbs insertion forces and distributes them evenly across the plug and socket interfaces, preventing stress concentrations that could cause cracking or deformation. The design anticipates and accommodates variations in insertion force and alignment, protecting the components from damage.
4Reliability
If a screw connection system is used, then the connectivity standard requirements are met, but the device size and invasiveness increase
Solution Approach 1:
The invention removes the bulk associated with screw heads, torque-limiting mechanisms, and sealing caps from the connector design. The plug and socket are designed as compact, streamlined components that meet all IS-1 standard requirements for mechanical retention force and electrical contact resistance without the additional volume required by screw-based systems. This reduction in size decreases the invasiveness of the implantable device.
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
The leaf spring system offers a simple, cost-effective, and secure connection that maintains low contact resistance and is suitable for manual use by doctors, reducing the need for specialized tools and minimizing the risk of damage, while being adaptable to smooth surfaces and reducing the metal mass for improved electromagnetic compatibility.
Implementation Method 1
A leaf spring system that provides a tool-free mechanism for securing a plug within the connector housing
Implementation Method 2
maintains low contact resistance and is suitable for manual use by doctors
Data Source
AI summary
A screwless quick connection system for connecting a lead connector to a generator of an active implantable medical device is shown and described. The connector head includes a housing receiving a plug of a lead connector. A mechanism for locking the plug into the housing is provided by a U-folded leaf spring. Each branch of the U is provided with a respective hole sized so that the plug passes through the holes on both branches when it is inserted into the housing. The blade is deformable between a free state, in the absence of plug, and a deformed state, with the plug inserted therein. In the free state, both holes are misaligned, while in the deformed state they are aligned. In this way, an edge of both holes exerts by reaction a radial stress force against the smooth outer surface of the plug inserted therein.