Molded Header Layout for Implantable Antenna and Charging Coil
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Solution Overview
Problem
Existing implantable signal generators face challenges in positioning communication antennas and charging coils, leading to difficulties in updating operational parameters and charging efficiency, increased complexity, and higher manufacturing costs due to poor design and shielding interference.
Innovation Solution
The use of molded headers that pre-form openings to precisely position and encase communication antennas and charging coils, reducing manufacturing complexity and costs while enhancing charging efficiency and signal reception.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If communication antennas and charging coils are positioned outside the implantable signal generator casing, then signal reception and charging efficiency are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent integrates the communication antenna and charging coil into the molded header structure, combining multiple functional components into a single integrated unit. This merging approach maintains the performance benefits of external positioning while reducing overall device complexity and manufacturing costs through consolidation.
Solution Approach 2:
The molded header serves multiple functions simultaneously: it provides structural support, positions the antenna and coil precisely, provides electromagnetic shielding, and facilitates manufacturing. This multi-functionality eliminates the need for separate components for each function, reducing device complexity while maintaining performance.
2Strength
If metal shells or casings are used for shielding, then structural protection is provided, but electromagnetic interference increases and charging efficiency decreases
Solution Approach 1:
Instead of using a complete metal shell that provides uniform shielding throughout, the patent applies electromagnetic shielding selectively only in the regions where the antenna and coil are located within the molded header. This localized shielding approach provides necessary protection against interference while minimizing the negative impact on charging efficiency and signal reception.
Solution Approach 2:
The molded header acts as an intermediary structure between the metal casing and the sensitive electronic components. It provides the necessary electromagnetic shielding and positioning while preventing direct contact between the metal shell and the antenna/coil, thereby reducing electromagnetic interference and improving charging efficiency.
3Reliability
If precise positioning of communication antennas and charging coils is achieved, then signal reception and charging efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The molded header is designed with pre-formed cavities and mounting structures that automatically position the antenna and coil at the correct locations during the molding process. This preliminary positioning action eliminates the need for complex post-assembly adjustments and simplifies the manufacturing process while ensuring precise component placement.
Solution Approach 2:
By integrating the positioning structures directly into the molded header design, the patent combines the positioning function with the structural support function. This merging of functions simplifies manufacturing compared to using separate positioning mechanisms and reduces the number of assembly steps required.
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 molded headers facilitate efficient charging and improved signal reception, reduce electromagnetic interference, and lower manufacturing costs, enabling robust and economical production of implantable signal generators.
Implementation Method 1
a charging coil that allows a battery in the implantable signal generator to be recharged from an external power source
Implementation Method 2
a communication antenna that allows operational parameters of a stimulation system to be altered, without necessitating a hard-wired external connection
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Molded headers, implantable signal generators having molded headers, and associated systems and methods are disclosed herein. An implantable signal generator in accordance with a particular embodiment includes a can having a shell and a battery positioned at least partially within the shell. An output terminal can be operably coupled to the battery and positioned to provide electrical power to a signal delivery device. A pre-molded header having a plurality of openings can be coupled to the can, and the output terminal can be positioned at least partially within an individual opening.