Segmented Medical Lead Electrodes for Secure Anchoring and Leakage Control
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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 electrode and terminal segments, which include electrically conductive rings and insulator portions, allows for the secure coupling of electrodes to conductors and the formation of a medical lead with improved stability and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrode attachment methods are used, then the manufacturing process is simpler, but electrode stability and security of attachment deteriorate
Solution Approach 1:
The electrode is divided into multiple segments that can be independently positioned and secured within the lead body. Each segment can be separately attached to conductors and insulated, allowing for precise placement and secure attachment while maintaining manufacturing feasibility through modular assembly
Solution Approach 2:
An insulator material is introduced as an intermediary between the electrode segments and the lead body. This insulator provides both electrical isolation and mechanical support, enabling secure attachment of electrodes while preventing current leakage, thus resolving the contradiction between reliability and manufacturing complexity
2Reliability
If precise conductor placement is not prioritized, then the manufacturing process is faster, but current leakage increases
Solution Approach 1:
Conductors are pre-positioned and secured within the lead body before electrode attachment. This preliminary action ensures precise conductor placement is achieved beforehand, allowing for efficient subsequent electrode installation while maintaining current leakage resistance through proper conductor positioning and insulation
Solution Approach 2:
The lead structure utilizes composite materials including insulating materials and conductive materials in specific configurations. These composite structures provide both electrical isolation to prevent current leakage and mechanical frameworks that enable efficient manufacturing through integrated design
3Manufacturing precision
If electrodes are not securely anchored, then the lead structure is simpler, but electrode stability and precision deteriorate
Solution Approach 1:
Electrode segments are nested within the lead body structure, with each electrode positioned in a dedicated cavity or channel. This nesting arrangement provides precise electrode placement through predefined positions while maintaining a compact and organized lead structure that does not significantly increase overall complexity
Solution Approach 2:
The lead structure incorporates localized features such as specific cavity shapes, anchoring points, and insulation layers at precise locations where electrodes will be placed. These local quality enhancements provide high manufacturing precision for electrode placement without requiring complex features throughout the entire lead structure
Data Source
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.