Modular Implantable Lead Connector Assembly Design
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Solution Overview
Problem
Current implantable medical electrical lead connectors lack flexibility in manufacturing various configurations, as they are often designed to specific standards that require all contact surfaces and sealing surfaces even when some are inactive, limiting modular assembly and increased manufacturing complexity.
Innovation Solution
A modular lead connector assembly with a core circuit, contact circuit, and insulation bulk, featuring conductive cores and contact rings with bends, allowing for independent construction and incorporation into different lead types and configurations, facilitated by a transition fitting and multi-point contact for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are designed to conform to industry standards (IS-4/DF-4) with all contact surfaces and sealing surfaces, then compatibility and reliability are improved, but manufacturing complexity and flexibility deteriorate
Solution Approach 1:
The connector is divided into modular components: a reusable insulative body conforming to IS-4/DF-4 standards, and interchangeable contact assemblies. Each contact assembly includes contact surfaces, sealing surfaces, and conductor pins that can be independently manufactured and assembled. This segmentation allows the insulative body to be produced once to standard specifications, while only the contact assemblies need to be customized for different configurations, thereby reducing overall manufacturing complexity while maintaining standard compatibility.
Solution Approach 2:
The insulative body is designed as a universal component that conforms to industry standards and can accommodate multiple contact configurations. The standardized outer diameter, sealing surfaces, and contact surface arrangements allow the same insulative body to work with different contact assemblies for various lead types (active fixation, passive fixation, different electrode configurations). This universality enables a single insulative body design to serve multiple functions across different connector variants.
2Reliability
If all contact surfaces and sealing surfaces are included in every connector, then standard compliance is improved, but manufacturing flexibility and adaptability deteriorate
Solution Approach 1:
The connector is divided into modular components: a reusable insulative body conforming to IS-4/DF-4 standards, and interchangeable contact assemblies. Each contact assembly includes contact surfaces, sealing surfaces, and conductor pins that can be independently manufactured and assembled. This segmentation allows the insulative body to be produced once to standard specifications, while only the contact assemblies need to be customized for different configurations, thereby reducing overall manufacturing complexity while maintaining standard compatibility.
Solution Approach 2:
The insulative body is designed as a universal component that conforms to industry standards and can accommodate multiple contact configurations. The standardized outer diameter, sealing surfaces, and contact surface arrangements allow the same insulative body to work with different contact assemblies for various lead types (active fixation, passive fixation, different electrode configurations). This universality enables a single insulative body design to serve multiple functions across different connector variants.
3Reliability
If connector designs are standardized with uniform outer diameter and specific configurations, then compatibility is improved, but design flexibility and modular assembly capability deteriorate
Solution Approach 1:
The connector is divided into modular components: a reusable insulative body conforming to IS-4/DF-4 standards, and interchangeable contact assemblies. Each contact assembly includes contact surfaces, sealing surfaces, and conductor pins that can be independently manufactured and assembled. This segmentation allows the insulative body to be produced once to standard specifications, while only the contact assemblies need to be customized for different configurations, thereby reducing overall manufacturing complexity while maintaining standard compatibility.
Solution Approach 2:
The insulative body is designed as a universal component that conforms to industry standards and can accommodate multiple contact configurations. The standardized outer diameter, sealing surfaces, and contact surface arrangements allow the same insulative body to work with different contact assemblies for various lead types (active fixation, passive fixation, different electrode configurations). This universality enables a single insulative body design to serve multiple functions across different connector variants.
Data Source
AI summary
An implantable lead connector assembly includes core and contact circuits held together and isolated from one another by insulation. The core circuit includes a conductive core and a conductor pin, which has a proximal end coupled to an outer surface of the core, and a distal end spaced outward from the outer surface and protruding distally from the insulation. Insulation sealing surfaces extend on either side of an outer contact surface of each contact circuit, and the sealing and contact surfaces define a uniform outer diameter of the assembly. A conductor pin of each contact circuit has a proximal end coupled to an inner surface of a contact ring of the corresponding circuit, and a distal end that protrudes distally from the insulation. The insulation may be formed by injection molding, and then outer surfaces of the molded insulation and contact ring(s) are ground down to the uniform outer diameter.