Separable 3D Connector Header for High-Density Neural Leads
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Solution Overview
Problem
Conventional neuromodulation devices face challenges in achieving high-density neural interfaces due to bulky and non-scalable interconnections between lead assemblies and electrical circuits, limiting the number of electrodes and requiring permanent connections that are difficult to upgrade or replace.
Innovation Solution
The development of a medical device with a header featuring a housing with retractable contacts and connection terminals, allowing for a scalable, three-dimensional design that maintains contact pressure and enables reliable, non-permanent connections between the lead assembly and electronics module, accommodating higher electrode counts and facilitating targeted therapy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of electrodes and channels is increased to achieve high-density neural interfaces, then the electrode count and therapy targeting capability are improved, but the connector size and complexity increase, making reliable connections difficult to maintain
Solution Approach 1:
The connector is divided into two separate components: a header attached to the electronics module and a separate connector attached to the lead assembly. This segmentation allows the complex high-density connection interface to be split into manageable parts that can be independently optimized and assembled, reducing the overall complexity while maintaining high electrode count capability
Solution Approach 2:
The connector design transitions from a planar two-dimensional connection interface to a three-dimensional structure with retractable contacts that extend vertically into the connector cavity. This dimensional change allows for higher density connections by utilizing the third dimension (depth) rather than only expanding in the horizontal plane
2Reliability
If permanent connections are used to ensure reliable electrical connections, then connection reliability is improved, but the ability to upgrade or replace electronics is lost, and tissue damage risk increases during removal
Solution Approach 1:
The connector employs dynamic retractable contacts that can be extended or retracted as needed. During normal operation, the contacts are extended to ensure reliable electrical connection. During upgrade or replacement procedures, the contacts can be retracted to minimize tissue damage and allow for safe disconnection, providing both reliability and adaptability
Solution Approach 2:
The separable connector acts as an intermediary component between the permanent lead assembly and the replaceable electronics module. This intermediary allows the lead to remain permanently implanted while the electronics can be upgraded or replaced by simply detaching and reattaching the connector, maintaining both connection reliability and system upgradeability
3Reliability
If conventional bulky interconnections are used, then connection reliability is maintained, but the device size increases and scalability is limited
Solution Approach 1:
The retractable contacts are nested within the connector housing, extending into the cavity only when needed for connection. This nesting approach allows the connector to maintain a compact form factor when not in use while providing full connection capability when activated, reducing overall volume while maintaining reliability
Data Source
AI summary
The present disclosure relates to implantable neuromodulation devices and methods of fabrication, and in particular to a separable high density connectors for implantable neuromodulation devices. Particularly, aspects of the present disclosure are directed to a medical device comprising an electronics module and a header for connecting the electronics module to a lead assembly. The header includes: a housing that includes (i) a cavity having a central axis or plane and an internal surface, and (ii) an opening aligned with the central axis or plane of the cavity, an array of retractable contacts extending from the internal surface towards the central axis or plane of the cavity, and an array of connection terminals on the housing, where each connection terminal of the array of connection terminals is: (i) electrically connected to the electronics module, and (ii) electrically connectable to a retractable contact of the array of retractable contacts.