Neurodiagnostic Needle Electrode Assembly with Heat Shrink Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing manufacturing techniques for neurodiagnostic needle electrode pairs, such as injection molding, are costly and do not provide a cost-effective alternative for producing ergonomic and fluid-resistant hubs that maintain inter-needle rigidity and consistent spacing.

Innovation Solution

A neurodiagnostic needle electrode pair assembly is manufactured using a pair of needle electrodes connected to leadwires via electrical connections, with a needle spacer having parallel holes to define spacing and a heat shrink tube covering the connections, providing a cost-effective and ergonomic solution that maintains inter-needle rigidity and fluid resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If injection molding is used to manufacture needle electrode pairs, then ergonomic hubs with fluid resistance and inter-needle rigidity are achieved, but production cost increases

Engineering Contradiction:

Improvefluid resistanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a heat shrink tube (flexible shell) to provide fluid resistance and protection for the electrical connections instead of using injection molded plastic housing. This thin film approach achieves the required fluid barrier function at lower cost while maintaining reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent introduces a hub assembly as an intermediary component that provides ergonomic handling and structural support, separate from the needle electrode pair itself. This allows the hub to be manufactured independently using cost-effective methods while maintaining the required mechanical properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If injection molding is used to manufacture needle electrode pairs, then ergonomic hubs with inter-needle rigidity are achieved, but production cost increases

Engineering Contradiction:

Improveinter-needle rigidityVSAvoidproduction cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent divides the needle electrode assembly into separate components: needle electrodes, hub assembly, and electrical connections. This segmentation allows each component to be manufactured independently using optimal methods, reducing overall production cost while maintaining inter-needle rigidity through the hub structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a composite structure combining metal needle electrodes with a plastic or polymer hub assembly. This composite approach provides the necessary mechanical rigidity and ergonomic properties while being more cost-effective than injection molding the entire assembly as a single piece.

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional manufacturing methods are used, then electrical connections are protected, but production cost increases

Engineering Contradiction:

Improveelectrical connection protectionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a heat shrink tube (flexible shell) to protect electrical connections from fluid exposure and mechanical damage. This thin film protection method is more cost-effective than injection molding while providing equivalent reliability for electrical connection protection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs a disposable hub assembly that provides protection for electrical connections during use and can be discarded after a single use, eliminating the need for expensive durable housing while maintaining protection reliability throughout the device's service life.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 allows for a cost-effective production of neurodiagnostic needle electrode pairs with ergonomic hubs that maintain inter-needle rigidity and fluid resistance, enhancing the durability and functionality of the devices while reducing production costs.

Implementation Method 1

a recovered heat shrink tube covering the needle spacer, the respective electrical connections and the distal ends of the leadwires

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS20240407728A1Neurodiagnostic needle electrode pair assembly and method of manufacture

Publication Date: 2024.12.12 ROCWORKS LLC

AI summary

A neurodiagnostic needle electrode pair assembly is provided that includes a pair of needle electrodes connected to a pair of leadwires by respective electrical connections between proximal ends of the needle electrodes and distal ends of the leadwires. The neurodiagnostic needle electrode pair assembly includes a needle spacer which has parallel holes in a spaced apart relationship. The needle electrodes extend into and through the parallel holes that define a spacing between the needle electrodes. The neurodiagnostic needle electrode pair assembly includes a recovered heat shrink tube covering the needle spacer, the respective electrical connections and the distal ends of the leadwires. A method of manufacturing a neurodiagnostic needle electrode pair assembly is also provided.