Sectional Interconnect Ribbon for Implantable Medical Device Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming connector assemblies in implantable medical devices face challenges such as conductor shifting during injection molding, leading to shorts or loss of electrical connections, especially in complex designs where conductors cannot be stamped as a single unit from a planar sheet, resulting in increased scrap rates and manufacturing variability.
Innovation Solution
A sectional interconnect ribbon is formed from multiple separately-formed sections that are mechanically joined to create an integral assembly, allowing for a more efficient and less error-prone assembly process by embedding the ribbon and connection elements within a core, which is then overmolded with a biocompatible thermoplastic material, reducing the likelihood of conductor shifting and enabling more complex designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conductors are positioned within a mold and insulating material is injected at high pressures, then the manufacturing process is automated and manual steps are eliminated, but the position of the conductors shifts during injection, causing shorts or loss of electrical connections
Solution Approach 1:
The connector assembly manufacturing process is divided into two separate injection molding steps: first forming the core with conductors embedded, then forming the outer housing. This segmentation allows conductors to be secured in the core before the high-pressure injection of the outer housing material, preventing conductor displacement while maintaining automation.
Solution Approach 2:
The core is formed first with conductors already positioned and secured within it, before the outer housing is injected. This preliminary action of creating the core structure with embedded conductors ensures that conductors are protected from displacement during the subsequent high-pressure injection process.
2Volume of moving object
If multiple conductors are closely spaced to reduce assembly dimensions, then the connector assembly becomes more compact, but shorts are more likely to occur between conductors that shift during injection molding
Solution Approach 1:
Dividing the injection process into core formation and outer housing formation allows conductors to be closely spaced in the core while the outer housing provides additional structural support and isolation that prevents shorts, even when conductors are in close proximity.
3Ease of manufacture
If conductors are manually routed and adhesive is applied, then the process is straightforward and easy to implement, but manual variables are introduced into the manufacturing process
Solution Approach 1:
Manual adhesive application and conductor routing are replaced with an automated injection molding system that forms the core with embedded conductors. This substitution eliminates manual variables while maintaining ease of manufacture through automation, achieving both consistency and simplicity.
Data Source
AI summary
A sectional interconnect ribbon for use in a connector assembly for an implantable medical device is formed of two ore more separately-formed sections which are mechanically joined together to form an integral assembly. The sectional interconnect ribbon, as well as at least one connection element, is embedded within the connector assembly.