Implantable Pulse Generator Connector Design for Miniaturization
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Solution Overview
Problem
Conventional spinal cord stimulation (SCS) systems face challenges in reducing the size of the pulse generator due to the size constraints imposed by conventional annular electrical connectors, which hinder the miniaturization of the device.
Innovation Solution
The design incorporates a flex film component within the stimulation lead and a header portion with a lid component that compresses terminal bond pads into electrical contact with feedthroughs, allowing for a high-density connection and reducing the size of the pulse generator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional annular electrical connectors are used in the pulse generator header, then reliable electrical connectivity is achieved, but the size of the pulse generator increases
Solution Approach 1:
The electrical connection system is segmented into discrete components: a flat connector board with multiple contact points, individual bond pads on the lead, and a compression lid. This segmentation allows for a more compact arrangement compared to conventional annular connectors, reducing the overall pulse generator volume while maintaining reliable electrical connectivity through multiple discrete contact points.
Solution Approach 2:
The invention transitions from a three-dimensional annular connector structure to a two-dimensional flat connector board layout. By arranging contact points in a planar configuration rather than a volumetric annular structure, the electrical connection system occupies less space, thereby reducing pulse generator size while preserving connectivity reliability through multiple contact points distributed across the plane.
2Ease of operation
If the pulse generator size is reduced, then implantation ease is improved, but the risk of damage from patient movement increases
Solution Approach 1:
The compression lid merges multiple functions into a single component: it provides mechanical compression to ensure electrical contact, structural support for the connector board, and sealing protection for the internal components. This consolidation creates a more robust and durable connection system that can withstand patient movement while maintaining a compact form factor for easier implantation.
Solution Approach 2:
The compression lid is designed with a curved or domed structure that distributes compressive forces evenly across the bond pads and connector board. This curved geometry enhances the durability of electrical connections by preventing point-load stress concentrations, thereby improving connection reliability while maintaining a compact overall size.
3Device complexity
If conventional annular connectors are used, then electrical connectivity is maintained, but device complexity increases
Solution Approach 1:
The invention extracts the essential function of electrical connectivity from the complex annular connector structure and implements it through a simplified flat connector board with discrete contact points. By removing the annular structure and retaining only the necessary electrical contact function, the header structure complexity is reduced while electrical connectivity reliability is maintained through the simplified but effective bond pad-to-contact-point connections.
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 configuration enables a more compact pulse generator while maintaining effective electrical connectivity, facilitating easier implantation and reducing the risk of damage from patient movement.
Implementation Method 1
the header portion of the pulse generator comprises a lid component to compress the terminal bond pads of the stimulation lead into electrical contact with conductors of feedthroughs of the pulse generator
Data Source
AI summary
In one embodiment, a stimulation system for generating and delivering electrical stimulation pulse to tissue of a patient, comprises: a pulse generator for generating electrical pulses, the pulse generator comprising a housing portion and a header portion with feedthroughs extending from the housing portion into the header portion; and a stimulation lead comprising a flex film component enclosed in a lead body of insulative material, the flex film component including a plurality of electrically isolated conductors extending along a substantial length of the stimulation lead, the stimulation lead further comprising a plurality of electrodes electrically coupled to the conductors, the flex film component comprising a proximal portion that is exposed out of the insulative material of the lead body and includes a plurality of terminal bond bands, the terminal bond bands being electrically coupled to the conductors; and wherein the header portion of the pulse generator comprises a lid component to compress the terminal bond pads of the stimulation lead into electrical contact with conductors of feedthroughs of the pulse generator.