Multi-foil Ringlet Coupler for IPG Header Pin Retention
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Solution Overview
Problem
Existing implantable pulse generator (IPG) header designs face challenges in balancing mechanical and electrical properties, including fragile connectors, potential shorts, inadequate mechanical retention, and manufacturing tolerances, which affect the efficiency and reliability of electrical connections and device longevity.
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 engagement, fabricated using high-speed machining for efficient assembly and made from biocompatible materials like nickel-cobalt-chromium alloys, allowing for flexible insertion and secure pin retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional electrical connectors are used in IPG headers, then the device can be manufactured with conventional methods, but the connectors are fragile and prone to mechanical failure
Solution Approach 1:
The electrical connector is divided into multiple foils (typically three) that are arranged radially around the lead pin. Each foil independently contacts the lead pin, providing distributed mechanical support and electrical connection. This segmentation allows the connector to flex and accommodate manufacturing tolerances while maintaining reliable contact and mechanical retention.
Solution Approach 2:
The foils are designed to be flexible rather than rigid, allowing them to dynamically adjust to the lead pin's position and accommodate manufacturing variations. The foils can elastically deform during insertion and maintain continuous contact, providing both mechanical retention and electrical connection while absorbing stress that would otherwise cause failure.
2Reliability
If conventional electrical connectors are used, then manufacturing processes are simpler, but the connectors are prone to shorts and electrical failures
Solution Approach 1:
Each foil is electrically isolated from the others along its length, with electrical contact occurring only at specific localized points where the foils converge on the lead pin. This local quality approach ensures that electrical current flows only through the intended path via the lead pin, preventing shorts between adjacent foils while maintaining reliable electrical connection.
Solution Approach 2:
The foils are nested radially around the lead pin, with each foil positioned in its own radial zone. This nested arrangement, combined with electrical isolation between foils, prevents electrical interference and short circuits while allowing all foils to simultaneously contact the lead pin for reliable multi-channel electrical connection.
3Manufacturing precision
If precise manufacturing tolerances are enforced for connector assembly, then connection reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The connector design changes the critical parameter from precise positional alignment to radial convergence. The foils are arranged radially around the lead pin and make contact at their inner edges, which naturally converge at the center. This geometric arrangement tolerates variations in foil length and positioning while ensuring reliable contact, significantly reducing manufacturing precision requirements.
Solution Approach 2:
The foils are made from conductive polymer composite materials that combine electrical conductivity with mechanical flexibility. This composite material property allows the foils to maintain electrical contact while accommodating manufacturing tolerances through elastic deformation, reducing the need for tight assembly tolerances and simplifying manufacturing.
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 reliable connection and retention of lead pins, while being cost-effective and easy to manufacture, thus enhancing the performance and longevity of IPG devices.
Implementation Method 1
an electrically conductive ringlet made from a biocompatible conductive material... When a pin of a medical lead is inserted into the channel, the reduced diameter sections simultaneously engage the pin to form an electrical connection
Implementation Method 2
the reduced diameter sections simultaneously engage the pin to form an electrical connection... the reduced diameter sections cooperate with the foils and the housing to mechanically secure the pin to the ringlet
Implementation Method 3
made from biocompatible materials like nickel-cobalt-chromium alloys... ensuring reliable connection and retention of lead pins, while being cost-effective and easy to manufacture, thus enhancing the performance and longevity of IPG devices
Data Source
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.