Miniaturized Ring Electrode Fabrication With Sacrificial Cores
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Solution Overview
Problem
Conventional processes for manufacturing ring electrodes for medical devices are costly and limited in terms of miniaturization and geometric flexibility, often requiring complex equipment and techniques that restrict the achievable dimensions and shapes.
Innovation Solution
A process involving a monolithic metal precursor with integrated sacrificial core elements is used to form a composite, which is then processed to achieve a ring electrode with precise dimensions and shapes, allowing for greater flexibility in geometry and miniaturization by using methods like EDM or additive manufacturing.
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 can be achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the ring electrode structure through additive manufacturing with integrated sacrificial cores positioned before final processing. The sacrificial cores are embedded during the forming stage, eliminating the need for complex post-manufacturing operations like spark erosion and multiple machining steps, thereby reducing equipment complexity while maintaining precision
Solution Approach 2:
The patent changes the manufacturing parameter from subtractive machining to additive forming combined with sacrificial material removal. This parameter change allows the electrode to be formed directly with precise dimensions through controlled additive processes, avoiding the need for complex machining equipment while achieving the required manufacturing precision
2Manufacturing precision
If conventional machining processes are used, then manufacturing precision can be achieved, but the loss of time and productivity decrease due to multiple work steps
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. The ring electrode structure and sacrificial cores are formed simultaneously in one process step, eliminating the sequential operations of machining, spark erosion, and material removal that characterize conventional methods, thereby reducing manufacturing cycle time while maintaining precision
Solution Approach 2:
The sacrificial cores are positioned and integrated during the initial additive manufacturing stage, performing the function of defining internal geometry beforehand. This preliminary action eliminates the need for subsequent complex machining operations, reducing both time and steps required to achieve final precision dimensions
3Ease of manufacture
If tube components are used as starting materials, then the ease of manufacture improves, but the adaptability of geometry and shape is limited
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from using pre-formed tube components to direct additive manufacturing of the ring electrode structure. This parameter change enables complete geometric freedom in designing electrode shapes, wall thicknesses, and internal features, while the process remains manufacturable through standardized additive processes and sacrificial core techniques
Solution Approach 2:
The patent segments the electrode design into an outer structure and internal sacrificial cores that can be independently designed and positioned. This segmentation allows the outer geometry to be optimized for performance while the sacrificial cores define internal cavities and channels, providing adaptability without requiring complex tube component assemblies
4Manufacturing precision
If conventional processes are used, then manufacturing precision can be maintained, but the quantity of substance lost increases due to excess material removal
Solution Approach 1:
The sacrificial cores are embedded during the additive manufacturing process to define the final internal geometry beforehand. This preliminary action allows the outer structure to be formed with exact dimensions and minimal material, as the sacrificial cores occupy only the space needed for internal cavities, eliminating the material waste associated with subtractive machining
Solution Approach 2:
The patent changes from subtractive manufacturing (removing excess material) to additive manufacturing with sacrificial cores (building only necessary material). This parameter change ensures that material is deposited only where needed for the final electrode structure, dramatically reducing material waste while achieving precise dimensions
Data Source
AI summary
One aspect relates to a process for preparing a ring electrode including the steps of a) providing a monolithic metal precursor, wherein the monolithic metal precursor includes an outer tube forming a first cavity of the precursor, and wherein the outer tube has a wall including 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 a) and a second sacrificial core element into the second cavity of the precursor provided in a); c) forming the composite precursor obtained in b) to obtain a formed composite having a smaller outer diameter than the composite precursor obtained in b); d) separating a composite disk from the formed composite obtained in c); e) removing the first and the second sacrificial core element from the composite disk obtained in d).