Multistranded Conductor Assembly for In Vivo Fatigue Resistance

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Solution Overview

Problem

Multistranded conductors in medical implants face challenges with durability and electrical performance due to repeated flexing and bending, leading to potential damage and compromised signal quality, especially when using fine wires.

Innovation Solution

A new assembly sequence for multistranded conductors involving same-direction twists and wraps of wire bundles, combined with specific coatings, enhances wire density and fatigue resistance, improving electrical performance and signal fidelity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If very fine wires are used in multistranded conductors, then flexibility and electrical performance are improved, but durability and resistance to fatigue failure deteriorate due to repeated flexing and sharp bends

Engineering Contradiction:

ImproveflexibilityVSAvoiddurability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The conductor is divided into multiple individual fine wires (28-500 wires) arranged in bundled structures (sub-bundles and bundles), where each wire is insulated individually. This segmentation allows the conductor to maintain flexibility from the fine individual wires while the bundled structure provides collective strength and fatigue resistance, resolving the contradiction between flexibility and durability.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If conventional multistranded conductor assembly sequences are used, then manufacturing simplicity is maintained, but wire density and fatigue resistance are insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfatigue resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The conductor employs a nested bundled structure where sub-bundles of insulated wires are grouped into larger bundles, which are then arranged in the final conductor configuration. This nested arrangement increases wire density and ensures optimal packing, thereby enhancing fatigue resistance while maintaining a systematic manufacturing process that does not significantly complicate production.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If repeated flexing and sharp bends occur over long periods, then device adaptability to dynamic in vivo environments is improved, but stress and strain lead to damage of individual wires

Engineering Contradiction:

Improveadaptability to dynamic environmentsVSAvoidwire integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

Each individual wire is provided with insulation coating before being assembled into bundles, and the bundled structure itself acts as a cushioning mechanism. This prior protection distributes stress and strain across multiple wires and the bundled structure during repeated flexing, preventing damage to individual wires while allowing the conductor to adapt to dynamic in vivo environments.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20260060564A1Multistranded Conductors Adapted to Dynamic In Vivo Environments

Publication Date: 2026.03.05 FOUNDRY INNOVATION & RES 1 LTD

AI summary

Multistranded conductors adapted to in vivo environments and methods of making same are disclosed, wherein specific configurations, sequences and directions of wire wraps provide implantable multistranded coils with increased cycle life in in vivo environments as well as desirable electrical performance characteristics.