Self-Aligning Spring Contact Assembly for Misaligned Lead Connectors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Medical device connectors often become misaligned, leading to stretching, deformation, or damage of contacts when the proximal end of a lead is inserted, which can result in inconsistent electrical connections and reduced device performance.

Innovation Solution

A connector design featuring a conductive spring retained within a connector block with flanges, allowing for movement to accommodate misalignment, ensuring the spring positions itself concentrically with the lead, thus avoiding damage and maintaining consistent contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If connectors are fixed in position within the connector block, then manufacturing precision is improved, but adaptability to misalignment deteriorates

Engineering Contradiction:

Improveconnector alignmentVSAvoidmisalignment accommodation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The contact is designed with dynamic characteristics through a spring mechanism that allows the contact to move and self-align with the lead contact during insertion. The spring enables the contact to dynamically adjust its position to accommodate misalignment between the connector block and lead, while maintaining reliable electrical connection.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The contact utilizes changes in physical parameters (position, force) through spring compression and expansion to adapt to misalignment. The spring mechanism changes the contact's positional parameter dynamically during insertion, allowing the contact to find its correct alignment position despite initial misalignment of the connector block.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If connectors are made movable to accommodate misalignment, then adaptability is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improvemisalignment accommodationVSAvoidconnector alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The spring acts as an intermediary element between the fixed connector block and the movable contact. This intermediary mechanism absorbs the misalignment tolerance while maintaining precise electrical contact, decoupling the precision requirements of the connector block from the alignment requirements of the contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connector assembly is segmented into fixed components (connector block) and movable components (contact with spring mechanism). This segmentation allows each component to be manufactured with standard tolerances while the assembly as a whole achieves precise alignment through the movable contact's self-positioning capability.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If rigid contacts are used in misaligned connectors, then device complexity is reduced, but contact reliability deteriorates due to stretching and deformation

Engineering Contradiction:

Improveconnector structureVSAvoidcontact integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The contact incorporates a flexible spring mechanism that can bend and deform elastically to accommodate misalignment during insertion. This flexibility prevents the contact from being stretched or permanently deformed, maintaining contact integrity and reliability while managing the complexity through a well-established spring design.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The design prevents contact stretching and deformation, ensuring reliable electrical connections and consistent performance even with misaligned connectors, maintaining the same insertion force across multiple insertions.

Implementation Method 1

The spring may be formed from a material with shape-memory, and may be configured to be compressed for insertion through one of the first flange or the second flange, and to at least partially expand into an expanded state

Methodology Applied

Scientific EffectShape memory: Shape Memory Alloy

Implementation Method 2

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Implementation Method 3

The spring may have a biasing structure configured to physically contact the lead contact when the proximal end is inserted into a final position within the connector contact assembly

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS20240198115A1Connector contact for electrical stimulation system

Publication Date: 2024.06.20 BOSTON SCI NEUROMODULATION CORP

AI summary

A system for making an electrical connection to a lead contact may include a connector contact assembly. The assembly may include a connector block configured to receive and retain a conductive spring within an interior of the block. The block may have an open center portion and first and second ends with first and second flanges. The spring may be formed from a material with shape-memory, and may be configured to be compressed for insertion through one of the flanges, and to at least partially expand into an expanded state such that the spring is retained between the flanges. The spring may have a biasing structure to physically contact the lead contact. The system is capable of accommodating misaligned connectors, as each conductive spring is able to position itself concentrically with a lead body without stretching or deforming.