Offset Ribbon Conductor Segments for Implantable Pulse Generator Welding
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Solution Overview
Problem
Conventional resistance welding methods for connecting ribbon conductors to ring connectors in implantable pulse generators often result in weld defects due to unbalanced interface resistance and limited contact areas, leading to reduced weld strength and reliability.
Innovation Solution
The use of ribbon conductors with offset segments, where each segment provides substantially equal resistance during welding, reduces high current concentrations and imbalances, improving weld quality and strength by ensuring balanced contact and resistance at the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resistance welding methods are used to connect ribbon conductors to ring connectors, then the manufacturing process is simple, but weld defects occur due to unbalanced interface resistance and limited contact areas
Solution Approach 1:
The ribbon conductor is divided into multiple segments with offset contact points instead of a single continuous contact area. This segmentation distributes the welding current across multiple separate zones, preventing current concentration and ensuring balanced interface resistance at each weld point, thereby eliminating weld defects while maintaining manufacturing simplicity
Solution Approach 2:
The offset segments create locally optimized contact areas at each welding point, where each segment provides substantially equal resistance independently. This local quality enhancement ensures consistent weld strength across all connection points without requiring complex manufacturing processes
2Reliability
If offset segments are used in the ribbon conductor, then weld quality and strength are improved, but the conductor structure becomes more complex
Solution Approach 1:
The conductor is segmented into offset sections that can be formed through straightforward manufacturing techniques such as stamping or bending, maintaining relative structural simplicity while achieving the reliability benefits of distributed contact points and balanced interface resistance
Solution Approach 2:
Multiple offset segments are combined into a single integrated conductor component that performs both electrical conduction and welding function, eliminating the need for separate contact elements and reducing overall assembly complexity despite the segmented structure
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 approach enhances the surface quality, strength, and consistency of welds between ribbon conductors and ring connectors, reducing the occurrence of weld defects and improving the overall reliability of the electrical connection.
Implementation Method 1
each of the first conductor segment and the second conductor segment being resistance welded to the connector
Implementation Method 2
resistance welded to the connector by passing a current between the first electrode and the second electrode
Data Source
AI summary
Disclosed herein is an implantable electronic device for use with an implantable medical lead. The implantable electronic device includes a housing and a header connector assembly coupled to the housing and adapted to receive the proximal lead end of the implantable medical lead. The header connector assembly includes a connector assembly including a connector, a feedthrough extending through the housing, and a conductor coupling the feedthrough to the connector. The conductor includes a first conductor segment and a second conductor segment offset from the first conductor segment and each of the first conductor segment and the second conductor segment are resistance welded to the connector.