Ring Electrode Diffusion-Bonded Structure to Reduce Noble Metal Loss
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Solution Overview
Problem
The production of ring electrodes for active implantable medical devices is costly and complex due to the need for expensive noble metals and complex machining processes, which often results in material losses and stability issues like delamination, especially in multilayer designs under mechanical and thermal stress.
Innovation Solution
A method involving the use of a composite tube formed by arranging eccentric inner elements within an outer element, with a diffusion agent facilitating an integral connection through diffusion bonding, allowing for the removal of sacrificial materials to create openings and improve stability, reducing the need for expensive noble metals and complex machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If ring electrodes are produced by conventional machining and spark erosion, then the electrode structure can be formed, but noble metal losses are considerable and production costs are high
Solution Approach 1:
The patent applies preliminary action by forming the complete ring electrode structure through diffusion bonding of multiple layers before any material removal. The sacrificial material is already in place within the diffusion-bonded structure, eliminating the need for subsequent complex machining and spark erosion operations that would cause noble metal losses.
Solution Approach 2:
The patent employs composite materials by creating a multilayer structure consisting of noble metal layers and sacrificial material layers that are diffusion-bonded together. This composite structure allows the sacrificial material to be removed later, revealing the final electrode geometry without requiring extensive machining of the expensive noble metal.
2Loss of substance
If ring electrodes are made from multiple parts to reduce material usage, then noble metal losses are reduced, but the parts become detached under mechanical and thermal stress
Solution Approach 1:
The patent uses diffusion bonding as an intermediary process that creates a metallurgical bond between the noble metal layers and sacrificial material layers. This diffusion bond acts as a strong intermediary connection that prevents delamination under mechanical and thermal stress, while still allowing the sacrificial material to be removed to form the final electrode structure.
Solution Approach 2:
The diffusion-bonded multilayer composite structure integrates multiple materials (noble metal and sacrificial material) into a unified whole. The diffusion bonding process creates strong interfacial bonds between layers, ensuring the composite structure maintains stability and resists delamination during subsequent processing and under operational stress.
3Productivity
If conventional machining methods are used, then the ring electrode structure can be formed, but the production process is complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-assembling the complete multilayer structure with sacrificial material in place before any final processing. The diffusion bonding of layers is performed beforehand, creating a ready-to-process composite tube that can be directly transformed into the final electrode product, eliminating the need for complex subsequent machining operations.
Solution Approach 2:
The patent applies the extraction principle by removing the sacrificial material from the diffusion-bonded composite structure to reveal the final electrode geometry. This extraction process is simpler than conventional machining because it only requires removing the sacrificial material, not shaping the expensive noble metal, thereby simplifying the production process and improving productivity.
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 method enables the cost-effective production of ring electrodes with improved stability and resistance to delamination, minimizing material losses and simplifying the manufacturing process while maintaining mechanical and thermal integrity.
Implementation Method 1
forming an integral connection between the outer element and the first inner element by means of the diffusion agent
Implementation Method 2
the composite tube is heated to connect the outer element to the first inner element and optionally the second inner tube by diffusion bonding
Data Source
AI summary
One aspect relates to a method for producing a ring electrode, including providing an outer element including an outer tube; providing a first inner element, including a first inner tube having a first core made of a sacrificial material, a material of the outer element and a material of the first inner element having a similar microstructure to each other; providing a second inner element, including a second core made of a sacrificial material; forming a composite tube by arranging the first inner element and the second inner element inside the outer element, the first inner element and the second inner element being arranged eccentrically; drawing the composite tube in a longitudinal direction of the composite tube, the material of the outer element and the material of the first inner element retaining a similar microstructure; separating a composite tube disk from the composite tube; removing the sacrificial material of the first core; and removing the sacrificial material of the second core to obtain a contacting opening in the ring electrode.