Medical Lead Joint Interfacial Layer Bonding
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Solution Overview
Problem
Forming strong and low-profile joints between fluoropolymer materials and non-fluoropolymer materials in medical electrical leads is challenging, particularly in connector and electrode subassemblies, where the lubricity of fluoropolymers complicates the bonding process.
Innovation Solution
An interfacial layer with two sections, one made from thermoplastic fluoropolymer and the other from a non-fluoropolymer material, is used to bond the inner insulative layer to the insulative sidewall, with grooves on the fluoropolymer section enhancing the bond, and suitable bonding techniques like thermal or adhesive bonding are employed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fluoropolymer materials are used to provide lubricious and insulative layers, then lubricity and insulation are improved, but bonding strength with non-fluoropolymer materials deteriorates
Solution Approach 1:
The interfacial layer is divided into two distinct sections: a first section made from fluoropolymer material that bonds to the inner insulative layer, and a second section made from non-fluoropolymer material that bonds to the insulative sidewall. This segmentation allows each section to be optimized for its specific bonding function while maintaining the overall structural integrity of the joint.
Solution Approach 2:
The interfacial layer serves as an intermediary component between the fluoropolymer inner insulative layer and the non-fluoropolymer insulative sidewall. By introducing this intermediate layer with dual-material construction, the patent enables bonding between materials that would otherwise be difficult to bond directly, while preserving the lubricious properties of the fluoropolymer section.
2Ease of operation
If fluoropolymer materials are used in lead construction, then lubricious properties are improved, but joint profile height increases
Solution Approach 1:
The interfacial layer is constructed with different materials in different local sections to achieve different functions. The first section uses fluoropolymer material to provide local lubricious properties where needed, while the second section uses non-fluoropolymer material optimized for bonding to the insulative sidewall, allowing the joint to achieve both lubricity and low profile without compromising either property throughout the entire structure.
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 solution provides a strong and reliable joint that maintains the lubricious properties of fluoropolymers while ensuring a secure connection, improving the manufacturing and functional aspects of medical electrical leads.
Implementation Method 1
Bonding according to the invention may comprise any known bonding technique, including adhesive bonding, thermal bonding, and the like.
Implementation Method 2
Bonding according to the invention may comprise any known bonding technique, including adhesive bonding, thermal bonding, and the like.
Data Source
AI summary
A joint between an insulative sidewall of a medical electrical lead subassembly and an underlying fluoropolymer layer includes an interfacial layer. A first section of the interfacial layer is bonded to the fluoropolymer layer and is formed by a thermoplastic fluoropolymer; a second section of the interfacial layer extends adjacent the first section and is bonded to the insulative sidewall. The insulative sidewall, of the subassembly, and the second section, of the interfacial layer, are each formed from a material that is not a fluoropolymer. A recess is formed in the first section of the interfacial layer and the second section of the interfacial layer extends within the recess.