Segmented Electrode Structure for Implantable Medical Leads

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Solution Overview

Problem

Conventional manufacturing of implantable medical leads is labor-intensive and difficult due to the manual manipulation and welding of elongated conductors to electrodes, which also poses challenges in achieving electrical isolation due to the close proximity of conductors.

Innovation Solution

The design of an implantable segmented electrode structure with a plurality of electrode surfaces connected to prongs, which are aligned and electrically connected to elongated conductors, reducing the need for manual manipulation and enhancing electrical isolation through a hollow, machined, and laser-cut configuration from a single conductive material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual manipulation and welding of elongated conductors to electrodes is used, then electrical connection is achieved, but manufacturing complexity and labor intensity increase

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrode structure and elongated conductors are merged into a single integrated component manufactured from a single piece of conductive material. The laser cutting process simultaneously creates both the electrode surfaces and the conductor pathways, eliminating the need for separate assembly and welding operations while maintaining reliable electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The manual mechanical manipulation and welding process is replaced with an automated laser cutting system. The laser precisely cuts and shapes the conductive material to form both electrodes and conductors in one automated operation, eliminating manual labor and associated complexities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Volume of moving object

If elongated conductors are positioned close to electrodes, then space efficiency is improved, but electrical isolation becomes difficult to achieve

Engineering Contradiction:

Improvespace efficiencyVSAvoidelectrical interference

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The conductive material is segmented by laser cutting into distinct regions: electrode surfaces, conductor pathways, and insulating barriers. The insulating barriers are automatically created during the same laser cutting process that forms the conductors and electrodes, providing electrical isolation without requiring additional components or assembly steps.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If conventional manufacturing processes are used, then flexibility in design is maintained, but manufacturing cycle time and costs increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmanufacturing cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple manual manufacturing steps are replaced with a single automated laser cutting system. The laser can be programmed to cut complex electrode and conductor patterns directly from a single piece of conductive material, dramatically reducing manufacturing cycle time while maintaining design flexibility through software-controlled patterning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach reduces manufacturing cycle time, costs, and scrap rates while improving performance by minimizing electrical interference and facilitating automated welding and electrical isolation.

Implementation Method 1

The intermediate structure is laser cut into the segmented electrode structure

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11154713B2Electrode structure for implantable medical leads

Publication Date: 2021.10.26 MEDTRONIC INC

AI summary

An implantable segmented electrode structure may be configured to conduct electrical signals between elongated conductors of an implantable medical lead and respective portions of tissue of a patient. The implantable medical lead may extend from an implantable medical device that is implanted within the patient. The segmented electrode structure includes a plurality of separate electrode surfaces. The electrode surfaces are at a plurality of different axial positions and angular positions within the implantable segmented electrode structure. The segmented electrode structure additionally includes a plurality of prongs. The prongs extend axially from a proximal end of the segmented electrode structure through the segmented electrode structure. Each prong may electrically connect to one of the electrode surfaces. The prongs may terminate distally at respective electrode surfaces. Each prong may be configured to electrically connect to one of the elongated conductors.