Segmented Medical Lead Assembly for Stable Electrodes and Isolation

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Solution Overview

Problem

Existing medical lead manufacturing processes face challenges in securely attaching electrodes to the lead body and achieving precise placement of conductors, leading to potential issues with electrode stability and current leakage.

Innovation Solution

The use of preformed segments, including electrically conductive rings and insulator portions, allows for the secure assembly of medical leads. These preforms are configured to be precisely fitted onto a conductor assembly, ensuring stable and accurate placement of electrodes and conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manufacturing processes are used to attach electrodes to the lead body, then the manufacturing process is simpler, but electrode stability and precision of conductor placement deteriorate

Engineering Contradiction:

Improveprecision of conductor placementVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming electrode and terminal segments with integrated conductor placement features before final assembly. The preforms include precisely formed conductor channels and electrode structures that are prepared in advance, ensuring accurate conductor placement during assembly without requiring complex real-time manufacturing processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent divides the lead into separate preformed segments (electrode preforms and terminal preforms) that can be manufactured independently with high precision. Each segment contains pre-formed conductor channels and electrode structures, allowing for precise conductor placement in each segment before final assembly into the complete lead.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If traditional electrode attachment methods are used, then the manufacturing process is easier, but electrode stability deteriorates

Engineering Contradiction:

Improveelectrode stabilityVSAvoidease of manufacturing process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent merges the electrode structure with the conductor support structure into integrated preformed segments. The electrode preforms combine electrode elements, conductor channels, and attachment features into single unified components that maintain electrode stability while simplifying the assembly process through pre-integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

3Reliability

If conventional lead assembly methods are used, then the assembly process is simpler, but current leakage increases

Engineering Contradiction:

Improveresistance to current leakageVSAvoidcomplexity of assembly process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces insulator portions as intermediary elements between conductors and electrode structures. These insulator portions are integrated into the preformed segments and provide electrical isolation, preventing current leakage while maintaining the simplicity of the assembly process through pre-positioned insulator structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If preformed segments are used for lead assembly, then manufacturing precision and electrode stability improve, but the device complexity increases

Engineering Contradiction:

Improveprecision of conductor placementVSAvoidcomplexity of preformed segment structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple functions (electrode support, conductor placement, insulation, and attachment) into single integrated preformed segments. This consolidation reduces the number of separate components and assembly steps, thereby reducing overall device complexity while maintaining high manufacturing precision through the pre-integrated design of each segment.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12329960B2Medical lead with segmented electrodes

Publication Date: 2025.06.17 MEDTRONIC INC

AI summary

A medical lead system includes a lead body, a plurality of electrical conductors, and a plurality of electrodes. The lead body may include a distal end and a proximal end defining a longitudinal axis of the lead body. The plurality of electrical conductors extending about the longitudinal axis of the lead body. The plurality of electrodes is positioned around an outer perimeter of the lead body. An inner surface of each of the plurality of electrodes defines an inner perimeter. Each respective electrode of the plurality of electrodes is electrically coupled to a respective electrical conductor of the plurality of electrical conductors. Each electrode of the plurality of electrodes includes at least one electrode locking feature extending into the lead body from the inner perimeter.