Ring Electrode Fabrication for Miniaturized Geometry Control
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Solution Overview
Problem
Conventional processes for preparing ring electrodes for medical devices are costly and limited in terms of miniaturization and geometry flexibility, often requiring complex and expensive equipment.
Innovation Solution
A process involving a monolithic metal precursor with sacrificial core elements is used to form a ring electrode, allowing for precise control over dimensions and geometry through electrical discharge machining or additive manufacturing, enabling the creation of miniaturized electrodes with desired shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining processes (turning, spark erosion) are used to manufacture ring electrodes, then the manufacturing precision and geometry control are improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The invention applies preliminary action by pre-forming the ring electrode geometry through additive manufacturing or other forming processes before final precision machining. The rough shaping is done in advance using less complex equipment, and only final precision adjustments are made through machining, thereby reducing the reliance on complex machining equipment while maintaining geometric precision.
Solution Approach 2:
The invention substitutes complex mechanical machining systems with additive manufacturing processes for the primary shaping of ring electrodes. Additive manufacturing uses material deposition and fusion rather than mechanical removal, eliminating the need for complex lathes, mills, and spark erosion equipment while achieving the required geometric precision directly through digital modeling and controlled deposition.
2Manufacturing precision
If conventional machining processes are used, then the manufacturing precision is improved, but the loss of time and productivity decrease
Solution Approach 1:
The invention performs preliminary shaping through additive manufacturing, which builds the electrode geometry in a single continuous process rather than through multiple sequential machining operations. This preliminary formation of the bulk geometry reduces the subsequent machining time required for precision adjustments, thereby reducing total manufacturing cycle time while maintaining geometric precision.
Solution Approach 2:
The invention replaces time-consuming mechanical machining operations with faster additive manufacturing processes for the primary shaping stage. Additive manufacturing can build complex geometries in hours rather than the days required for conventional multi-step machining, dramatically reducing manufacturing cycle time while achieving the required precision through digital control.
3Ease of manufacture
If tube components are used as starting materials, then the ease of manufacture is improved, but the adaptability and geometry flexibility are limited
Solution Approach 1:
The invention applies universality by using additive manufacturing as a universal starting point that can produce any ring electrode geometry, size, or configuration from a digital model. This single method replaces the need for multiple specialized tube components with different wall thicknesses and dimensions, providing universal access to all geometries while maintaining ease of manufacture through standardized digital design and printing processes.
Solution Approach 2:
The invention enables parameter changes by allowing any geometric parameter (outer diameter, inner diameter, wall thickness, cross-sectional shape) to be freely adjusted through digital modeling in additive manufacturing. Unlike tube components where geometry is constrained by available stock dimensions, additive manufacturing allows continuous variation of all parameters, providing unlimited geometry flexibility while maintaining ease of manufacture through software-controlled processes.
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 process allows for the production of ring electrodes with precise dimensions and geometry, overcoming the limitations of conventional methods by providing greater flexibility and accuracy in shape and size, suitable for use in medical devices.
Implementation Method 1
forming the composite precursor obtained in step b) to obtain a formed composite having a smaller outer diameter than the composite precursor obtained in step b)
Implementation Method 2
precise control over dimensions and geometry through electrical discharge machining
Data Source
Figure 1~2
Figure 3A~3B
AI summary
The present invention relates to a process for preparing a ring electrode comprising the steps of a) providing a monolithic metal precursor, wherein the monolithic metal precursor comprises an outer tube forming a first cavity of the precursor, and wherein the outer tube has a wall comprising in one section an inner tube forming a second cavity of the precursor; b) preparing a composite precursor by inserting a first sacrificial core element into the first cavity of the precursor provided in step a) and a second sacrificial core element into the second cavity of the precursor provided in step a); c) forming the composite precursor obtained in step b) to obtain a formed composite having a smaller outer diameter than the composite precursor obtained in step b); d) separating a composite disk from the formed composite obtained in step c); e) removing the first and the second sacrificial core element from the composite disk obtained in step d). The invention further refers to a composite for preparing a ring electrode, and to a ring electrode for a medical device, preferably for an active implantable medical device.