Preformed Wire Routing for Implantable Feedthrough Connections
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Solution Overview
Problem
The high cost and complexity of electrical connections in implantable medical devices (IMDs) arise from the use of long, expensive platinum group metal feedthrough pins, which are prone to damage during handling and assembly, and the limitations of stamped ribbons in navigating complex routing profiles.
Innovation Solution
The use of preformed wires with multiple turns to engage stub feedthrough pins, reducing material and assembly costs by eliminating the need for long feedthrough pins and allowing for more flexible routing configurations, with the wires being physically and electrically attached using welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long platinum group metal feedthrough pins are used for electrical connections, then electrical connection reliability is improved, but cost and device complexity increase
Solution Approach 1:
The electrical connection path is segmented into multiple components: a preformed wire with proximal turns for attachment to the feedthrough pin, a midsection for routing, and a distal end for attachment to the electrical contact. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining reliability.
Solution Approach 2:
The preformed wire acts as an intermediary element between the feedthrough pin and the electrical contact. Instead of using a single long feedthrough pin that extends from the connector block to the header, the wire mediates the connection, allowing for flexible routing and simplified assembly.
2Reliability
If long feedthrough pins are used, then electrical connection is achieved, but handling and assembly become more difficult
Solution Approach 1:
The wire is preformed with specific proximal turns configured for attachment to the feedthrough pin before assembly. This preliminary configuration of the wire geometry simplifies the assembly process, as the wire is already shaped to engage with the feedthrough pin and route to the electrical contact, reducing handling difficulty.
3Ease of manufacture
If stamped ribbons are used for wire routing, then assembly is simplified, but complex routing profiles cannot be achieved
Solution Approach 1:
The wire geometry parameters are changed from a flat stamped ribbon to a three-dimensional preformed wire with specific turns and routing sections. This allows the wire to achieve complex routing profiles while maintaining assembly simplicity through the preformed configuration.
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 the complexity and cost of electrical connections while maintaining performance, providing a more robust and efficient assembly process with reduced risk of damage during handling, and enabling easier inspection and bonding of wires.
Implementation Method 1
The preformed wire can be shaped to route a distal portion of the preformed wire to an electrical contact of the header when the proximate portion of the preformed wire engages the feedthrough pin
Data Source
AI summary
Systems and methods to couple electrical contacts of a header of a medical device to respective feedthrough pins of a connector block of a medical device housing using a preformed wire are disclosed. The preformed wire can include a proximate portion comprising a number of turns shaped to engage a feedthrough pin. The number of turns of the preformed wire, once engaged with the feedthrough pin, can physically separate a major portion of the preformed wire from the connector block and the housing. The major portion of the preformed wire can be shaped to route a distal portion of the preformed wire to a first electrical contact of the header when the proximate portion of the preformed wire engages the feedthrough pin.