Offset Segment Ribbon Conductors for Pacemaker Header Welding
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Solution Overview
Problem
Conventional methods for resistance welding ribbon conductors to connectors in implantable electronic devices, such as pacemakers and neurostimulators, often result in weld defects due to unbalanced interface resistance and localized heating, leading to poor weld quality and strength, especially when welding flat conductors to curved connectors.
Innovation Solution
The use of ribbon conductors with offset segments, where each segment is resistance welded separately to ensure balanced resistance and contact area, reducing high current concentrations and imbalances that cause excessive heating and weld defects, thereby improving weld appearance, strength, and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional resistance welding is used to join ribbon conductors to connectors, then the manufacturing process is simple and fast, but weld defects occur due to unbalanced interface resistance and localized heating
Solution Approach 1:
The conductor is divided into multiple segments with different cross-sectional areas along its length. This segmentation allows different portions of the conductor to have different resistance values, enabling balanced interface resistance distribution during resistance welding. The segmented structure ensures uniform current density and prevents localized overheating, thereby improving weld quality without requiring complex welding processes.
2Manufacturing precision
If flat conductors are welded to curved connectors, then the manufacturing process is simple, but poor weld quality results due to unbalanced contact area and current concentration
Solution Approach 1:
The conductor is designed with varying cross-sectional areas at different locations to create local quality variations. Specifically, the conductor has a first cross-sectional area at the first interface with the connector and a second cross-sectional area at the second interface, where these areas are specifically designed to balance the interface resistance. This local quality adjustment ensures uniform current distribution and consistent weld quality when welding flat conductors to curved connectors.
3Reliability
If single-segment conductors are used for resistance welding, then the conductor structure is simple, but weld defects occur due to high current concentrations and unbalanced interface resistance
Solution Approach 1:
The conductor is divided into multiple segments with different cross-sectional areas along its length. This segmentation allows different portions of the conductor to have different resistance values, enabling balanced interface resistance during resistance welding. The segmented structure ensures uniform current density and prevents localized overheating, thereby improving weld quality without requiring complex welding processes.
Solution Approach 2:
The conductor's cross-sectional area parameter is varied along its length to optimize electrical and mechanical properties. By changing the cross-sectional area from a first value at the first interface to a second value at the second interface, the conductor achieves balanced interface resistance and uniform current distribution, improving reliability of electrical connections while maintaining manufacturability.
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 reliability and durability of electrical connections between conductors and connectors by minimizing weld defects and ensuring consistent, high-quality welds, even when welding flat or curved conductors to curved connectors.
Implementation Method 1
each of the first conductor segment and the second conductor segment being resistance welded to the connector
Implementation Method 2
The first conductor segment and the second conductor segment are then resistance welded to the connector by passing a current between the first electrode and the second electrode
Data Source
Figure 1~2
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Figure 4
AI summary
Disclosed herein is an implantable electronic device (20) for use with an implantable medical lead. The implantable electronic device (20) includes a housing (24) and a header connector assembly (200) coupled to the housing (24) and adapted to receive the proximal lead end (10) of the implantable medical lead. The header connector assembly (200) includes a connector assembly (100) including a connector (104), a feedthru (106) extending through the housing (24), and a conductor (110) coupling the feedthru (106) to the connector (104). The conductor (110) includes a first conductor segment (112A) and a second conductor segment (112B) offset from the first conductor segment (112A) and each of the first conductor segment (112A) and the second conductor segment (112B) are resistance welded to the connector (104).