Multi-foil Ringlet Coupler for Implantable Pulse Generator Headers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing implantable pulse generator headers face challenges in maintaining a balance between mechanical and electrical properties, including fragile connectors, potential shorts, insufficient mechanical retention, and manufacturing tolerances, which affect the reliability and efficiency of electrical connections.
Innovation Solution
A ringlet coupler with a conductive ringlet and housing design, featuring smoothly curved foils and reduced diameter sections for secure electrical and mechanical connection, fabricated using high-speed machining for efficient assembly and made from biocompatible materials like nickel-cobalt-chromium alloys, allowing for flexible insertion and retention of lead pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional electrical connectors are used in IPG headers, then assembly is simple, but the connectors are fragile and provide insufficient mechanical retention
Solution Approach 1:
The electrical connector is segmented into multiple foils (typically three) arranged radially around the central axis. Each foil acts as an independent contact element, distributing the mechanical and electrical load across multiple points rather than relying on a single fragile connector structure. This segmentation provides both enhanced mechanical retention through multiple contact points and maintained simplicity in the overall assembly process.
2Reliability
If conventional electrical contacts are used, then manufacturing is straightforward, but there is risk of shorts and insufficient electrical contact reliability
Solution Approach 1:
The foils are configured with curved surfaces that conform to the cylindrical geometry of the IPG header and the spherical or cylindrical shape of the lead pin. This curvature ensures optimal contact surface area between the electrical contacts and the pin, improving electrical reliability by preventing point-contact failures and shorts. The curved geometry is achieved through standard fabrication processes such as stamping or molding, maintaining ease of manufacture while enhancing contact reliability.
3Reliability
If multiple electrical contacts are provided, then electrical connectivity is improved, but the risk of shorts between adjacent contacts increases
Solution Approach 1:
An insulating barrier or spacing structure is provided between adjacent foils to prevent electrical shorts while maintaining proper electrical connectivity. The insulating material acts as an intermediary element that electrically isolates the conductive foils from each other, eliminating the risk of shorts between adjacent contacts. This approach allows multiple electrical contacts to be provided for improved connectivity without compromising safety through short circuit prevention.
4Manufacturing precision
If precise manufacturing tolerances are maintained, then connection precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The electrical connector incorporates elastic or flexible elements in the foils that provide mechanical compliance and self-adjustment during assembly. This dynamic characteristic allows the connector to accommodate variations in manufacturing tolerances of the IPG header and lead pin without requiring extremely tight precision. The elastic deformation of the foils compensates for dimensional variations, achieving reliable electrical and mechanical connection while maintaining ease of manufacture with standard tolerances.
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
The ringlet coupler provides improved electrical contact and mechanical holding force, reducing the risk of shorts and ensuring secure pin retention, while being cost-effective and easy to manufacture, thus enhancing the reliability of implantable pulse generator systems.
Implementation Method 1
the foils are equally spaced about this channel. When the ringlet is placed in the housing, the apex of each foil is in contact with the inner surface of the housing. When a lead pin is inserted into the channel, the reduced diameter sections simultaneously engage the lead pin to form an electrical connection
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A multi-foil ringlet in combination with a cylindrical housing provides advantageous results when employed as a contact of a header of an implantable pulse generator. The multi-foil ringlet provides a superior electrical connection between the header and a lead pin inserted into the header.