Electrical Termination Unit With Pre-Positioned Leads
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Solution Overview
Problem
Existing electrical termination solutions for microelectronic devices, particularly implantable medical devices, require complex tooling and manual intervention for metallurgical connections, leading to misalignment, high-voltage issues, and increased costs due to the need for detailed visual inspections and bulky connectors.
Innovation Solution
An electrical termination unit comprising a carrier with metal tabs and connection areas that securely position electrical leads via interference or transition fits, allowing for automated metallurgical connections without manual alignment, facilitating the use of small, compact designs suitable for microelectronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and securing of terminations is performed during metallurgical attachment, then alignment precision can be maintained, but the process becomes time-consuming and costly requiring detailed visual inspections
Solution Approach 1:
The patent applies preliminary action by pre-securing the electrical leads to the carrier board with alignment features before the metallurgical attachment process. The alignment features (such as guide pins or positioning structures) are already in place to maintain precise alignment during welding, brazing, or soldering, eliminating the need for manual alignment during the attachment process itself. This preparatory positioning enables automated high-speed assembly while maintaining manufacturing precision.
2Reliability
If existing connector solutions are used for metallurgical connections, then connection reliability can be achieved, but the device volume becomes too large for microelectronic assemblies
Solution Approach 1:
The patent applies segmentation by dividing the connector system into separate functional components: a carrier board that holds multiple electrical leads with alignment features, and individual termination points for metallurgical attachment. This modular segmentation allows each component to be optimized independently, enabling reliable connections while reducing overall connector volume to suit microelectronic assemblies such as implantable medical devices.
Solution Approach 2:
The patent merges multiple functions into the carrier board structure: it serves as both the support substrate for electrical leads and the alignment reference for metallurgical attachment. By combining the lead holder and alignment feature into a single integrated component, the design eliminates the need for separate bulky connectors while maintaining connection reliability through precise positional control.
3Manufacturing precision
If complex tooling and manual intervention are used for securing terminations, then alignment accuracy is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies self-service by incorporating alignment features directly into the carrier board and termination structure. The electrical leads are pre-positioned and self-aligned using features such as guide pins, positioning slots, or geometric constraints built into the carrier board. This self-aligning mechanism eliminates the need for complex external tooling or manual intervention during metallurgical attachment, reducing manufacturing complexity while maintaining precise termination alignment.
Data Source
AI summary
An electrical termination unit for a microelectronic device, the electrical termination unit including, a carrier; and at least one metal tab being attached to the carrier; wherein the carrier is provided with at least one connection area where one electrical lead is to be electrically connected to one metal tab, and wherein the at least one connection area is configured to retain the least one electrical lead at least in one spatial dimension in a defined position relative to the one metal tab prior to a metallurgical connection process.