Shaped Mesh Contact Assemblies for Electrical Stimulation Leads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forming implantable electrical stimulation leads are labor-intensive and can result in inconsistent electrical connections due to blind welding and inconsistent pitches between contacts, which complicates the assembly process and affects the reliability of the stimulation systems.
Innovation Solution
The use of a contact assembly formed from shaped mesh with annular grooves and conductor apertures allows for the secure coupling of electrodes and terminals, facilitating consistent and efficient assembly by sliding contacts into the grooves and using conductors that extend through the mesh, thereby improving the structural integrity and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional blind welding methods are used to form electrical connections, then the assembly process can be completed, but the electrical connections become inconsistent and reliability decreases
Solution Approach 1:
The contact assembly is segmented into multiple annular grooves that are precisely formed in the lead body, with each groove designed to receive a specific contact. This segmentation approach replaces blind welding with a structured groove system that ensures consistent positioning and electrical connection for each contact, thereby improving both reliability and manufacturing precision.
Solution Approach 2:
The annular grooves act as an intermediary structure between the contacts and the lead body, providing a predefined pathway and positioning mechanism. This intermediary groove structure eliminates the variability of blind welding by offering a consistent geometric reference that ensures uniform electrical connections across all contacts.
2Productivity
If conventional assembly methods are used, then the lead can be manufactured, but the process becomes labor-intensive and complex
Solution Approach 1:
The annular grooves are preliminarily formed in the lead body during the lead manufacturing process, before contacts are installed. This preliminary action of creating the groove structure in advance simplifies the subsequent assembly process, as contacts can be directly placed into the pre-formed grooves without requiring complex alignment or welding operations, thereby improving productivity and reducing assembly complexity.
3Manufacturing precision
If contacts are positioned without annular grooves, then the assembly process may be simpler, but the pitch consistency between contacts becomes inconsistent
Solution Approach 1:
The annular grooves provide localized structural features at specific positions along the lead body, with each groove tailored to receive a contact at the precise required pitch. This local quality approach ensures that each contact position has the exact geometric reference needed for consistent pitch, while the overall manufacturing process remains straightforward through the use of standardized groove formation techniques.
Data Source
AI summary
An electrical stimulation lead includes a lead body with electrodes disposed along the distal end portion of the lead body and terminals disposed along the proximal end portion of the lead body. Conductors electrically couple the terminals to the electrodes. A contact assembly is disposed at one of the proximal end portion or the distal end portion of the lead body. The contact assembly is formed from a shaped mesh and includes annular grooves defined along an outer surface of the shaped mesh; and a stylet tube disposed in a contact assembly lumen. Each of the conductors extends along at least a portion of the shaped mesh within the contact assembly lumen and external to the stylet tube. For each of the annular grooves, one of the electrodes or one of the terminals is disposed in the annular groove.