Sacrificial-Layer Metal Forming for Miniaturized Ring Electrodes
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Solution Overview
Problem
Conventional processes for manufacturing medical electrodes, such as ring electrodes, are limited by geometry, dimensions, and shape, requiring expensive and complex equipment, which restricts miniaturization and flexibility in design.
Innovation Solution
A process involving a sacrificial outer element and a monolithic metal precursor, where the precursor is inserted into the outer element and a sacrificial core element is inserted into the precursor, forming a composite that is then reduced in diameter while maintaining the original geometry, allowing for the creation of shaped metal products with greater flexibility in dimensions and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining processes are used to manufacture ring electrodes, then manufacturing precision can be achieved, but device complexity and production cost increase significantly
Solution Approach 1:
The electrode geometry is pre-formed in a larger scale using simple casting or molding techniques before the miniaturization process. This preliminary shaping action allows complex geometries to be established early in the process, avoiding the need for complex machining equipment in subsequent steps.
Solution Approach 2:
The invention uses a nested structure where a core element is placed inside a tube element, and the entire assembly is subjected to plastic deformation. This nesting approach allows the complex final geometry to emerge from simpler component assembly rather than complex machining.
2Manufacturing precision
If conventional machining processes are used to manufacture ring electrodes, then manufacturing precision can be achieved, but production cost increases significantly
Solution Approach 1:
The process uses inexpensive sacrificial core elements and simple molding tools that can be easily replaced or reused. The core elements serve their purpose during forming and are then removed, eliminating the need for expensive, precision-maintaining equipment.
Solution Approach 2:
The invention changes the manufacturing parameters from precision machining (high cost) to plastic deformation and chemical etching (low cost). By controlling temperature, pressure, and etching conditions rather than machine tool precision, production cost is significantly reduced while maintaining geometric accuracy.
3Ease of manufacture
If tube components with fixed wall thickness are used as starting materials, then manufacturing is simplified, but geometry flexibility of the final electrode is limited
Solution Approach 1:
The electrode is divided into multiple components (core element, tube element) that can be independently designed and manufactured with standard geometries. The assembly and deformation process then combines these simple components into complex final geometries, achieving both manufacturing simplicity and design flexibility.
Solution Approach 2:
The process transitions from static tube components with fixed geometry to a dynamic forming process where the geometry evolves through plastic deformation. The tube and core are deformed together under controlled conditions, allowing the final geometry to be adapted to various electrode design requirements.
4Ease of manufacture
If the outer shape of tube components is limited to circular, then manufacturing is simplified, but shape flexibility of the final electrode is restricted
Solution Approach 1:
The desired final shape is pre-planned in the design of the core element and tube assembly before deformation. By carefully designing the initial configuration of these simple circular components, the final non-circular electrode shapes are predetermined and achieved through the deformation process without requiring complex tooling.
Solution Approach 2:
The invention uses asymmetric positioning and sizing of the core element within the tube, and asymmetric deformation conditions, to generate diverse outer shapes from simple circular starting materials. The asymmetric arrangement during forming allows the final electrode to achieve complex geometries including non-circular cross-sections.
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 process enables the production of medical devices with precise control over geometry and shape, achieving miniaturization and reducing production costs by using less complex and expensive methods.
Implementation Method 1
forming the composite precursor obtained in step 4) to obtain a formed composite having a smaller outer diameter than the diameter of the composite precursor obtained in step 4)
Data Source
AI summary
One aspect 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. One aspect 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.