Pigtail Spring PCB Connector for Solder-Free IMD Feedthroughs
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Solution Overview
Problem
Existing implantable medical devices (IMDs) face challenges in efficiently connecting feedthrough wires to printed circuit boards (PCBs) without the need for soldering, which complicates the manufacturing process and can lead to reliability issues.
Innovation Solution
The use of a pigtail spring connector, specifically a gold-coated wire coil with a diminishing diameter design, is employed to connect feedthrough wires to PCBs, allowing for a secure and solder-free attachment through a tack-welding method, facilitating easier assembly and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect feedthrough wires to PCBs, then electrical connection reliability is improved, but manufacturing complexity and process time increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical mechanical system) with a mechanical compression system. The pigtail spring connector uses a spring-loaded compression mechanism to create reliable electrical connections without soldering, thereby reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The pigtail spring connector acts as an intermediary component between the feedthrough wire and the PCB. It provides a standardized mechanical interface that simplifies the connection process, allowing for easy assembly and disassembly without requiring complex soldering procedures.
2Strength
If soldering is used to connect feedthrough wires to PCBs, then electrical connection strength is improved, but manufacturing time and productivity decrease
Solution Approach 1:
The pigtail spring connector is pre-formed with its spring characteristics and connection geometry before assembly. This preliminary preparation allows for rapid assembly operations where the connector simply needs to be compressed into place, significantly reducing manufacturing time compared to soldering while maintaining connection strength.
Solution Approach 2:
The spring-loaded connector introduces dynamic mechanical properties to the connection system. The spring provides continuous contact pressure that maintains electrical connection strength while allowing for thermal expansion and mechanical stress absorption, ensuring reliable connections during assembly and operation.
3Ease of manufacture
If solder-free connection methods are used, then manufacturing ease is improved, but connection reliability may deteriorate
Solution Approach 1:
The pigtail spring connector utilizes a curved/coiled spring geometry that provides mechanical compliance and continuous contact pressure. This curved structure allows the connector to maintain reliable electrical contact while accommodating manufacturing tolerances and assembly variations, ensuring connection reliability without requiring soldering.
Solution Approach 2:
The spring connector changes the connection mechanism from permanent (soldered) to reversible mechanical compression. By controlling parameters such as spring wire diameter, coil density, and overall spring dimensions, the connector provides sufficient contact pressure for reliable electrical connection while maintaining ease of manufacture and assembly.
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 solution provides a reliable and efficient method for connecting feedthrough wires to PCBs within IMDs, enhancing manufacturing ease and reducing the risk of solder-related errors, while maintaining the integrity of electrical connections.
Implementation Method 1
a pigtail spring connector (220) to connect the feedthrough wire to the PCB
Implementation Method 2
allowing for a secure and solder-free attachment through a tack-welding method
Data Source
AI summary
An implantable medical device can include a housing including electronic devices within the housing; a header attached to the housing and including one or more bores; and a feedthrough assembly between the housing and the header; wherein the electronic devices include a PCB electronically connected to the header by a feedthrough wire running from the feedthrough assembly to the PCB, wherein the feedthrough wire is connected to the PCB with a pigtail spring connector.