Sleeve Electrode Contacting Method for Medical Devices
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Solution Overview
Problem
Existing methods for electrical contacting of small conductors and electrodes in medical devices face challenges such as resource consumption, instability, and material fatigue, particularly in the micrometer range, leading to unreliable connections and increased need for surgical interventions.
Innovation Solution
A system comprising a sleeve-shaped electrode with an internal and external side, a channel, and an opening that surrounds the conductor, allowing for a durable mechanical and electrical connection through direct bonding or force-locking methods, ensuring stability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welded connection is used at the end of the electrode, then electrical connection is established, but the connection is susceptible to fatigue fracturing and plastic insulation is damaged
Solution Approach 1:
The electrode end is segmented into multiple hollow spaces instead of a solid structure, allowing the conductor to be positioned within these spaces. This segmentation distributes mechanical stresses and prevents fatigue fracturing at a single connection point, while the hollow spaces protect the plastic insulation from damage during the connection process.
Solution Approach 2:
The conductor is nested within the hollow spaces of the electrode structure. The conductor passes through the electrode wall and is positioned inside the hollow spaces, creating a nested configuration where the conductor is protected by the electrode structure, eliminating the need for external welding that would damage the insulation.
2Strength
If conventional crimp method is used, then mechanical connection is established, but the surface structure of the electrode is destroyed
Solution Approach 1:
The hollow spaces are pre-formed in the electrode structure before the conductor is inserted. This preliminary preparation eliminates the need for subsequent crimping or deformation operations that would destroy the electrode surface structure. The conductor is simply positioned within the pre-created hollow spaces, maintaining the electrode's original surface integrity.
3Reliability
If additional connecting pieces are used, then connection is established, but resource consumption increases
Solution Approach 1:
The connection function is merged into the electrode structure itself through the hollow spaces. The electrode wall with its hollow spaces serves both as the electrical connection element and as the mechanical support structure, eliminating the need for separate connecting pieces. This integration reduces material consumption while maintaining connection reliability.
Solution Approach 2:
The electrode structure is designed to perform multiple functions: it provides electrical connection through the hollow spaces, mechanical support for the conductor, and protection for the plastic insulation. This multi-functionality eliminates the need for additional specialized connecting components, reducing overall material consumption.
4Manufacturing precision
If micro-slide method is used, then connection is established, but manufacturing tolerances lead to contact instability
Solution Approach 1:
The electrode hollow spaces are designed with optimized dimensional parameters that accommodate normal manufacturing tolerances. The hollow spaces provide sufficient clearance and structural flexibility to absorb variations in conductor positioning without compromising contact stability. This parameter optimization makes the connection robust against manufacturing tolerances while maintaining precise electrical contact.
Data Source
AI summary
One embodiment relates to a system for reception and/or emission of an electrical signal from or into the human or animal body, including at least one insulated electrical conductor; a sleeve-shaped electrode that is electrically connected to the electrical conductor and includes an internal side, an external side, a channel, and an opening in a wall of the channel. The channel defines a longitudinal axis along which the conductor is arranged in the channel. A material of the electrode surrounds the entire circumference of the opening; the electrical conductor is guided through the opening between the internal side and the external side of the opening transverse to the longitudinal axis of the channel; and the electrical conductor is connected to the electrode within the opening directly in firmly-bonded and/or force-locking manner such that a durable mechanical and electrical connection between the electrical conductor and the electrode is established.