Metal Connector Enclosure for Miniaturized Medical Lead Connections

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Solution Overview

Problem

Medical devices with polymer connector enclosures face challenges in miniaturization due to the need for significant volume and large wall thickness, which also leads to lead damage during insertion due to concentricity deviations and high insertion forces.

Innovation Solution

A medical device with a metallic connector enclosure featuring thin walls and precisely machined inner surfaces, allowing for a strong and compact design with non-conductive spacers to isolate lead connectors and reduce insertion force, and a method involving a metallic weld for attachment to the can, creating a hermetic seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a polymer connector enclosure is used, then the device can be manufactured with standard processes, but the device volume increases and miniaturization is inhibited

Engineering Contradiction:

ImprovemanufacturabilityVSAvoiddevice volume

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent changes the material parameter from polymer to metal (titanium or stainless steel), which fundamentally alters the strength-to-volume ratio. This material parameter change enables the connector enclosure to achieve the same structural strength with significantly reduced volume, directly resolving the contradiction between ease of manufacture and device volume.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction by combining metal connector enclosure with polymer insulation materials and seal components. This composite approach maintains manufacturability through standardized assembly processes while achieving miniaturization through the high strength-to-volume ratio of the metal enclosure.

Inventive Principle:

Principle #40Composite materials

2Strength

If polymer wall thickness is increased to support lead connectors, then structural strength is adequate, but device miniaturization is inhibited

Engineering Contradiction:

Improveconnector enclosure strengthVSAvoiddevice volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent changes the material parameter from polymer to metal, which increases the strength-to-volume ratio by a factor of 10 or more. This allows the connector enclosure walls to be significantly thinner while maintaining adequate structural strength to support lead connectors, directly resolving the contradiction between strength and device volume.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent segments the structural support function from the enclosure function by using the metal connector enclosure body to provide both structural strength and containment. This eliminates the need for thick polymer walls and separate support structures, enabling miniaturization while maintaining strength.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If inner surface deviation from ideal shape is large, then manufacturing is simpler, but lead insertion force increases and lead damage occurs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlead insertion force

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent changes the manufacturing method parameter from molding (polymer) to machining (metal), which enables much tighter tolerances and smaller surface deviations. This parameter change resolves the contradiction by allowing precise inner surfaces that reduce lead insertion force while maintaining manufacturing feasibility through standard machining processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the molding process with a machining process, replacing a method that inherently produces larger surface deviations with one that can achieve precise dimensional control. This substitution enables the inner surfaces to closely match the ideal shape, reducing friction and insertion force on the leads.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 metallic connector enclosure enables miniaturization of medical devices, reduces lead insertion force, and minimizes damage by providing a strong, precise, and hermetically sealed environment for medical leads.

Implementation Method 1

a metallic weld to the can

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11224753B1Medical devices including connector enclosures with feedthrough passageways

Publication Date: 2022.01.18 MEDTRONIC INC

AI summary

Medical devices provide metallic connector enclosures. The metallic connector enclosures may be constructed with relatively thin walls in comparison to polymer connector enclosures to aid in miniaturizing the medical device. The metallic connector enclosures may be constructed with interior surfaces that deviate less from an ideal inner surface shape in comparison to polymer connector enclosures to allow for better concentricity of electrical connectors. The metallic connector enclosures may include a panel that allows access to the cavity of the connector enclosure where set screw blocks, lead connectors, spacers, seals, and the like may be located. Furthermore, the lead connectors within the metallic connector enclosures may be separated from the metallic connector enclosure by being positioned within non-conductive seals that reside within features included in cavity walls of the connector enclosure. Similarly, set screw blocks may be separated from the metallic connector enclosure by non-conductive spacers present within the cavity.