Multilayer Ring Electrode with Sacrificial Cores for Diffusion Bonding
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Solution Overview
Problem
The manufacturing of ring electrodes for active implantable medical devices is costly and complex due to the small component size and noble metal losses during machining, and there is a challenge in permanently connecting multiple parts to ensure stability against mechanical and thermal loading, which can lead to delamination.
Innovation Solution
A manufacturing method involving the use of an outer tube and inner tubes with sacrificial cores, where the inner tubes are arranged eccentrically and drawn together to form a composite tube, allowing for the removal of sacrificial material to create openings and improve stability through diffusion bonding, reducing the need for expensive machining and minimizing noble metal losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to manufacture ring electrodes, then manufacturing precision can be achieved, but noble metal losses increase and manufacturing cost increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forming the composite tube with multiple layers, selective removal of sacrificial material, and final electrode formation. This allows precise control over material removal and minimizes noble metal loss by only removing necessary sacrificial materials rather than machining the final electrode shape from solid noble metal
Solution Approach 2:
Sacrificial materials (such as base metals or organic materials) are used as temporary structures during manufacturing that are intentionally designed to be removed later. These disposable sacrificial cores allow the noble metal to form the final electrode shape without excessive material loss, as the sacrificial material can be selectively removed through chemical etching or other non-mechanical means
2Ease of manufacture
If multiple parts are assembled to form ring electrode, then manufacturing flexibility improves, but connection stability deteriorates under mechanical and thermal loading
Solution Approach 1:
Multiple tube layers (outer tube, inner tubes with sacrificial cores) are combined into a single composite tube structure through diffusion bonding. This merging process creates a unified multilayer structure where the boundaries between individual components are eliminated at the atomic level, ensuring stable connections that can withstand mechanical and thermal loading without delamination
Solution Approach 2:
The diffusion bonding process utilizes parameter changes (temperature, time, pressure) to transform the physical and chemical state of the tube materials. By heating the composite tube to enable atomic diffusion between layers, the materials transition from discrete assembled parts to a bonded integrated structure with enhanced interlayer adhesion and mechanical stability
3Strength
If diffusion bonding is used to connect tube layers, then connection strength improves, but manufacturing process complexity increases
Solution Approach 1:
The tube layers are assembled into the correct composite structure before the diffusion bonding process. This preliminary arrangement of layers with sacrificial cores in specific positions allows the subsequent bonding process to simply consolidate the pre-positioned components, rather than requiring complex in-situ bonding operations during final electrode formation
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
This method enables the cost-effective production of ring electrodes with improved stability, reducing delamination and noble metal losses, while providing secure electrical and mechanical connections for medical devices.
Implementation Method 1
the composite tube obtained subsequent to step (e) is heated to a temperature of at least 50%, preferably at least 60% or 65% of the melting temperature of the material of the outer tube or the first inner tube, in order to interconnect the outer element and the first inner element and, where applicable, the second inner tube by means of diffusion
Data Source
AI summary
One aspect relates to a method for a ring electrode, including: providing an outer element with an outer tube and providing a first inner element with a first inner tube having a first core made of a sacrificial material. A material of the outer element and a material of the first inner element have a similar microstructure. A second inner element is provided with a second core made of a sacrificial material; A connection tube is formed by arranging the first inner element and the second inner element within the outer element. The first inner element and the second inner element are arranged concentrically. The composite tube is drawn in a longitudinal direction of the composite tube. The material of the outer element and the material of the first inner element maintain a simialar microstructure. A connection tube disc is seperated from the connection tube. The sacrificial material of the first core is removed and the sacrificial material of the second core is removed to obtain a contacting opening in the ring electrode.