Segmented Ring Electrode Production via Support Structure Extraction
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Solution Overview
Problem
Existing methods for producing segmented electrodes, such as those used in medical applications like pacemakers, face challenges in separating individual segments while maintaining stability, often requiring labor-intensive external support structures that increase material usage and are not flexible for producing components with small dimensions or complex shapes.
Innovation Solution
A process involving a metal pipe with a support structure that is removed using a chemical etching process, allowing for the formation of segmented ring-shaped electrodes with improved stability and electrical properties by introducing an electrically insulating material between segments, which are then connected through a substance-to-substance bond or positive fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If external support structures are used to stabilize the overall construction during production, then the stability of the electrode construction is improved, but the material usage increases and the processing time increases due to labor-intensive removal
Solution Approach 1:
The support structure is completely removed from the electrode construction after serving its stabilizing function during production. This extraction principle eliminates the need for permanent support structures, reducing material usage while maintaining construction stability during the critical production phase.
Solution Approach 2:
The support structure is installed beforehand to provide stability during production operations. This preliminary action ensures that the electrode construction remains stable during segment separation and assembly, and the support structure is designed to be easily removable after it has served its purpose.
2Stability of the object's composition
If external support structures are used to stabilize the overall construction during production, then the stability of the electrode construction is improved, but the processing time increases due to labor-intensive removal
Solution Approach 1:
The support structure is completely removed from the electrode construction after serving its stabilizing function during production. This extraction principle eliminates the need for permanent support structures, reducing material usage while maintaining construction stability during the critical production phase.
Solution Approach 2:
The support structure is installed beforehand to provide stability during production operations. This preliminary action ensures that the electrode construction remains stable during segment separation and assembly, and the support structure is designed to be easily removable after it has served its purpose.
3Ease of manufacture
If injection molding technology with specifically adapted tools is used, then the production process is standardized, but the flexibility to make smaller adaptations is reduced
Solution Approach 1:
The electrode is divided into separate segments that can be produced independently and then assembled. This segmentation allows for flexible adaptation of individual segments without requiring complete retooling, while still maintaining a standardized overall production process through modular assembly procedures.
Solution Approach 2:
The support structure serves multiple functions: it stabilizes the electrode construction during production, provides a framework for segment assembly, and can be easily removed afterward. This multi-functionality reduces the need for specialized tools and procedures, enhancing both standardization and flexibility.
4Volume of moving object
If thin film technologies are used to produce components with small dimensions, then the production of small components is enabled, but the long-term stability of the produced components is reduced
Solution Approach 1:
The electrode construction combines different materials with complementary properties: conductive materials for electrical functionality, insulating materials for electrical isolation, and support structure materials for mechanical stability. This composite approach enables small component dimensions while maintaining long-term stability through the synergistic properties of the combined materials.
Solution Approach 2:
The support structure is installed beforehand to provide stability during production operations. This preliminary action ensures that the electrode construction remains stable during segment separation and assembly, and the support structure is designed to be easily removable after it has served its purpose.
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 reduces material usage, processing time, and enhances flexibility, providing improved stability and electrical properties for segmented electrodes, enabling efficient production of components with complex shapes and small dimensions.
Implementation Method 1
removing the support structure from the pipe, in particular by means of a chemical process, in particular an etching process
Data Source
AI summary
One aspect is a process for producing a segmented electrode, including providing a pipe made of metal having an outer side and an inner side, wherein the inner side of the pipe forms a hollow space. A support structure is arranged in the hollow space, so that the support structure mechanically stabilizes the pipe. Intermediate spaces are formed in the pipe, which define a plurality of segments in the pipe. An electrically insulating material is introduced into the intermediate spaces and thus forming electrically insulating areas, wherein a boundary layer is in each case defined between the segments and the areas. The pipe is cut so that several segmented ring-shaped electrodes are formed therefrom. The support structure is removed from the pipe.