Textured Insulative Layer for Medical Lead Conductor Friction

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Solution Overview

Problem

Medical devices, such as implantable leads, face challenges in minimizing friction between components during assembly and use, leading to increased manufacturing costs and complexity due to the need for processing aids like vacuum or solvents to reduce frictional forces.

Innovation Solution

The implementation of a textured external surface on the outer insulative layer of the conductor assembly, which includes raised surface features or a polymeric element extruded or molded around the conductor member, minimizes frictional forces between the textured surface and the smooth inner surface of the conductor lumen, thereby reducing the need for such aids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a smooth inner surface of the conductor lumen is used, then manufacturing precision is improved, but friction between the conductor assembly and the lumen increases

Engineering Contradiction:

Improvesmoothness of conductor lumen inner surfaceVSAvoidfrictional force between conductor assembly and lumen

Core Design Contradiction:

Manufacturing precisionVSForce

Solution Approach 1:

The patent applies a textured coating to the outer surface of the conductor assembly at the specific location where it contacts the conductor lumen inner surface. This creates a localized change in surface properties (reduced friction coefficient) without altering the smoothness requirement of the lumen itself, thus resolving the contradiction between manufacturing precision and friction reduction.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the surface friction parameter by applying a textured coating to the conductor assembly outer surface. This coating modifies the coefficient of friction between the conductor assembly and the conductor lumen, allowing the lumen to remain smooth for manufacturing precision while the coated surface reduces friction during assembly and lead movement.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If processing aids like vacuum or solvents are used to reduce friction, then ease of manufacture is improved, but device complexity increases

Engineering Contradiction:

Improveassembly process easeVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The textured coating on the conductor assembly outer surface provides self-lubricating properties that reduce friction during assembly and lead movement without requiring external processing aids like vacuum or solvents. This eliminates the need for additional manufacturing equipment and process steps, thereby improving ease of manufacture while avoiding increased device complexity.

Inventive Principle:

Principle #25Self-service

3Force

If a textured external surface is applied to the conductor assembly, then friction is reduced, but manufacturing precision of the surface may be compromised

Engineering Contradiction:

Improvefrictional force reductionVSAvoidsurface uniformity

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The textured coating is applied only to the outer surface of the conductor assembly where contact with the conductor lumen occurs, leaving other critical surfaces (conductor core, electrical contacts) with high manufacturing precision. This localized application resolves the contradiction by providing friction reduction only where needed while maintaining precision elsewhere.

Inventive Principle:

Principle #3Local quality

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

This configuration enhances the manufacturability and ease of assembly of medical devices by reducing frictional resistance, potentially lowering costs and improving the longevity and performance of medical leads by minimizing wear and tear.

Implementation Method 1

The textured external surface of the outer insulative layer is configured to minimize friction between the textured external surface and the substantially smooth inner surface of the conductor lumen

Methodology Applied

Scientific EffectFriction reduction through surface texturing: Friction

Data Source

PatentEP3184144B1Lead with an inner conductor provided with a textured insulative layer

Publication Date: 2022.05.11 CARDIAC PACEMAKERS INC

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AI summary

Described is a medical device lead (14) including a lead body (36) having a conductor lumen (44, 46, 48) including an inner surface. The lead also includes a conductor assembly (38, 40, 42) extending through the conductor lumen, the conductor assembly comprising a conductor member (50, 54, 56) and an outer insulative layer (52, 58, 60), and an electrode coupled to the conductor cable. The outer insulative layer includes a textured external surface (62, 64, 66) that reduces the coefficient of friction between the outer insulative layer and the inner surface of the conductor lumen through which the conductor assembly extends. Methods of forming the conductor assembly are also described.