Deep-Drawn Ring Electrode Sleeve for Low-Waste Mass Production
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Solution Overview
Problem
Current methods for producing ring electrodes for electrophysiological and neuromedical applications are costly, complex, and inefficient, resulting in significant precious metal waste and variability in component geometry due to the use of turning processes, which are unsuitable for rapid and inexpensive mass production.
Innovation Solution
A method involving the deep drawing of a metallic band with repeating structures to form sleeves with varying diameters, using biocompatible materials like noble metals or their compounds, allowing for quick and cost-effective production with minimal waste, and enabling easy redesign of the sleeve shape and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If turning process is used to produce sleeves from rod, then sleeves can be manufactured, but great loss of precious metal occurs and processing time is long
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive turning (removing material) to additive forming (shaping material). The metallic band is formed into sleeve shape through deep drawing and forming processes, transforming the production approach to minimize material waste while maintaining productivity.
Solution Approach 2:
The patent uses a mold or die to copy the desired sleeve geometry directly onto the metallic band. The forming process creates a precise replica of the target sleeve shape, eliminating the need for iterative material removal and achieving both high precision and material efficiency.
2Manufacturing precision
If turning process is used to produce sleeves, then sleeves can be manufactured, but tool wear occurs and component geometry varies
Solution Approach 1:
The patent replaces the mechanical cutting system (turning tools) with a forming system. Instead of cutting and removing material, the process uses deep drawing and forming operations that shape the metallic band into the final sleeve geometry, eliminating tool wear and improving dimensional consistency.
Solution Approach 2:
The desired sleeve geometry is pre-programmed into the forming mold or die. The metallic band is then formed directly into the final shape in one or fewer operations, eliminating the need for multiple machining steps and tool changes, thereby improving precision and simplifying manufacturing.
3Manufacturing precision
If complex sleeve structures with different diameters are produced by turning, then desired accuracy can be achieved, but processing time increases to 2-3 minutes per sleeve
Solution Approach 1:
The forming process is segmented into discrete steps (deep drawing, forming operations) that can be performed sequentially or in parallel. Multiple sleeves can be formed from a single metallic band in one continuous operation, dramatically increasing production rate while maintaining precision through controlled forming parameters.
Solution Approach 2:
The forming process creates a continuous flow of production where the metallic band is continuously transformed into finished sleeves without interruption. The process eliminates idle time between operations and maintains continuous material flow, achieving high productivity without sacrificing geometric accuracy.
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 efficient and cost-effective production of high-quality ring electrodes with reduced material waste and minimal geometric variation, suitable for electrophysiological and neuromedical applications, while minimizing the risk of damage to electrical wires during processing.
Implementation Method 1
several of the at least one surface of the repeating structures are brought into a sleeve shape in several forming steps by deep drawing and/or another forming technique
Data Source
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AI summary
The invention relates to a method for manufacturing a sleeve (1) for constructing a ring electrode for electrophysiological and neuromedical applications from a metallic strip (10), wherein the strip (10) and the sleeve (1) manufactured therefrom consist of a biocompatible metal or a biocompatible metallic compound, wherein repeating structures are stamped into the strip (10), wherein the repeating structures each have at least one surface (14) which is connected via at least one web (24) to at least one outer strip (16), wherein at least one outer strip (16) connects the repeating structures to each other at the edge, subsequently several of the at least one surface (14) of the repeating structures are formed into a sleeve shape (28, 30) in several forming steps by deep drawing and/or another forming technique, and the sleeve shape (28, 30) is subsequently die-cut.such that the sleeve (1) has a first tubular section (2) with a larger diameter and a second tubular section (3) with a smaller diameter, wherein the first section (2) with the larger diameter has a larger outer diameter and inner diameter (D1) than the second section (3) with the smaller diameter, and the two sections (2, 3) are integrally connected. The invention also relates to a sleeve (1) for electrophysiological applications or a neuromedical sensor or electrophysiological ring electrode manufactured with such a sleeve (1), and to an electrophysiological ring electrode, in particular a stimulation ring electrode and/or measuring ring electrode, for cardiac rhythm management (CRM) or neurostimulation, comprising such a sleeve (1).