Optical Feedthrough Laser Puncture for Medical Device Material Release

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Solution Overview

Problem

The manufacturing of medical devices, particularly those designed for chronic implantation, is complex due to the need for hermetic sealing and sterilization, which complicates the process of loading and releasing materials within the device.

Innovation Solution

The use of an optical feedthrough assembly that allows radiant energy to puncture a seal disc, enabling the release of materials into a medical device chamber, simplifies the manufacturing process by allowing material loading and release at any advantageous stage, thereby improving the device's flow through the manufacturing operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hermetic sealing and sterilization are implemented for chronic implantable medical devices, then device reliability and safety are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedevice reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process is segmented into independent stages: device assembly with sealed compartments, material loading into discrete cups, and final material release via laser puncture. This allows each compartment to be manufactured and tested independently before final assembly, reducing overall manufacturing complexity while maintaining hermetic sealing requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Materials are pre-loaded into sealed cups during manufacturing, and the device compartments are hermetically sealed before final assembly. The actual material release into the chamber is deferred to a later stage via laser puncture of the seal disc, allowing preliminary preparation without compromising the hermetic seal integrity during manufacturing.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If material loading and release occur after device assembly, then hermetic sealing is maintained, but manufacturing lead-time increases

Engineering Contradiction:

Improvehermetic sealing integrityVSAvoidmanufacturing lead-time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Materials are pre-loaded into cups and sealed during the manufacturing process, and device compartments are hermetically sealed before final assembly. The actual material release into the chamber is deferred to a later stage via laser puncture of the seal disc, allowing preliminary preparation without compromising the hermetic seal integrity during manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The traditional mechanical opening of hermetic seals for material loading is replaced with an optical system. A laser beam is transmitted through an optical feedthrough to puncture the seal disc from the outside, eliminating the need for mechanical access to the sealed chamber and maintaining hermetic integrity throughout the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If quality attributes are measured on the final device, then comprehensive quality assurance is achieved, but manufacturing costs and lead-time increase

Engineering Contradiction:

Improvequality assuranceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Quality assurance is segmented into multiple stages: verification of hermetic sealing on individual compartments during assembly, validation of material loading in sealed cups, and final integration testing. This allows quality attributes to be measured on individual components rather than requiring complete device assembly, reducing manufacturing costs and lead-time while maintaining comprehensive quality assurance.

Inventive Principle:

Principle #1Segmentation

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 reduces lead-time and scrap costs by enabling independent and parallel processing of device compartments, allowing for earlier measurement of key quality attributes on less expensive components, rather than on the final device.

Implementation Method 1

Radiant energy may be transferred across an optical feedthrough embedded in a shell of a medical device chamber. Utilizing radiant energy to release a material within a medical device

Methodology Applied

Scientific EffectRadiant energy: Thermal Radiation

Implementation Method 2

a radiant energy source that shines a beam through the optical feedthrough assembly to puncture the seal disc

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS8192418B2Releasing a material within a medical device via an optical feedthrough

Publication Date: 2012.06.05 MEDTRONIC INC

AI summary

In general, the disclosure is directed toward releasing material within a medical device via an optical feedthrough. A system for releasing material with a medical device comprises a cup that holds a material, wherein the cup includes a discharge port, a seal disc that seals the material within the cup, an optical feedthrough assembly coupled to the cup, a shell that defines a chamber within a medical device, wherein the optical feedthrough assembly is coupled to the shell, and a radiant energy source that shines a beam through the optical feedthrough assembly to puncture the seal disc to allow the material to enter the chamber via the discharge port.