Sacrificial-Layer Metal Forming for Miniaturized Implant Electrodes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional processes for manufacturing medical electrodes, such as ring electrodes, are costly and limited in terms of miniaturization and geometry flexibility due to the use of complex and expensive equipment, restricting the shape and dimensions of the final product.
Innovation Solution
A process involving a composite of a sacrificial outer element and a monolithic metal precursor, where the sacrificial elements are selectively removed to achieve a shaped metal product with reduced dimensions and varied geometry, allowing for precise control over the final shape and size, particularly suitable for medical devices like implantable electrodes.
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 surface finish can be achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The invention applies preliminary action by pre-forming the electrode structure as a tube with integrated cavity during the tube drawing process itself, rather than forming the structure and then performing separate machining operations. The tube wall thickness and cavity geometry are controlled during the forming process, eliminating the need for subsequent turning and spark erosion operations.
Solution Approach 2:
The invention extracts the cavity formation step from the traditional machining sequence by integrating it into the tube drawing process. Instead of removing material through spark erosion to create the cavity, the cavity is formed directly during tube formation by controlling the tube wall thickness distribution, thereby simplifying the manufacturing process.
2Ease of manufacture
If tube components are used as starting materials for ring electrode manufacturing, then the production process can be simplified, but the geometry flexibility and shape variations are limited
Solution Approach 1:
The invention applies dynamics by making the tube wall thickness a variable parameter during the drawing process rather than a fixed dimension. By dynamically adjusting the reduction ratio and drawing conditions, different wall thickness profiles can be achieved, enabling various electrode geometries including non-circular cross-sections and asymmetric designs while maintaining the simplified tube-based manufacturing approach.
3Reliability
If traditional machining processes are used, then established manufacturing methods can be applied, but miniaturization capability is limited
Solution Approach 1:
The invention applies preliminary action by pre-forming the complete electrode structure including the cavity during the tube drawing process at the required final dimensions. This eliminates the need for subsequent material removal operations that would be difficult to perform on miniaturized components, thereby enabling reliable manufacturing of very small electrodes while maintaining process reliability through established tube drawing technology.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a process for preparing a shaped metal product, wherein a monolithic metal precursor surrounded by a sacrificial outer element is formed to smaller dimensions, and the sacrificial material is subsequently removed. The invention further provides a composite for preparing a shaped metal product, and a shaped metal product. Such shaped metal products can be used to manufacture an active implantable medical device or sensor.