Thermoplastic Support Bonding for Implantable Electrodes

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Solution Overview

Problem

Existing methods for manufacturing implantable paddle electrodes struggle with simple, reproducible, and automated attachment of electrode elements to the support, which is crucial for precise placement and efficient energy delivery.

Innovation Solution

The method involves heating the electrode element and/or the support, typically made of a thermoplastic material, to a temperature near the melting point, allowing the electrode element to be pressed into the support, forming an integrally bonded connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrode elements are attached to the support using conventional methods (adhesives, mechanical fastening), then the attachment process becomes complex and difficult to automate, but the manufacturing precision and reliability of attachment are improved

Engineering Contradiction:

Improveease of manufactureVSAvoiddevice complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by heating the thermoplastic support to its melting temperature, changing its physical state from solid to softened/melted state. This allows the electrode elements to be pressed into and bonded with the support material, creating an integral connection without adhesives or mechanical fasteners. The temperature parameter change enables both ease of manufacture and high attachment reliability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional mechanical attachment methods (adhesives, mechanical fastening) with a thermal bonding process. By heating the thermoplastic support and pressing electrode elements into it, the method substitutes chemical and mechanical fastening systems with a thermal-mechanical bonding process that is simpler to automate and produces integral bonds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If electrode elements are manually attached to the support, then placement precision is improved, but productivity and manufacturing efficiency deteriorate

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidproductivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies self-service by having the heated thermoplastic support material itself perform the bonding function. When electrode elements are pressed into the heated support, the softened support material automatically bonds to the electrode elements through pressure and cooling, eliminating the need for separate fastening operations and enabling automated high-speed attachment while maintaining precision.

Inventive Principle:

Principle #25Self-service

3Strength

If the support material is heated to high temperature for bonding, then the bonding strength is improved, but the risk of damaging electrode elements or surrounding components increases

Engineering Contradiction:

Improvebonding strengthVSAvoidobject-affected harmful factors

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by heating only the specific region of the thermoplastic support where electrode elements need to be attached. The heating is localized to the bonding area rather than the entire device, allowing high temperature bonding strength in the attachment zone while preventing damage to other components. The heated support material bonds electrode elements locally without exposing the entire device to harmful temperatures.

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 approach enables a simple, automatable, and precise method for attaching electrode elements to the support, enhancing the manufacturing efficiency and ensuring accurate placement for targeted stimulation.

Implementation Method 1

the at least one electrode element and/or the support are heated and the at least one electrode element is pressed against the support

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

heating the at least one electrode element and/or the support to a temperature which is at or near the melting temperature of the support material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

When the at least one electrode element is attached to the support, heat is transferred from the electrode element to the support and heats the support

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 4

the support becomes soft when heated and the at least one electrode element may thus be pressed at least partially into the support, thereby forming an integrally bonded connection

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentEP4087642B1Method for producing an implantable electrode device

Publication Date: 2025.06.11 BIOTRONIK SE & CO KG

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AI summary

In a method for producing an implantable electrode device (1), an electrically insulating support (14) and at least one electrically conductive electrode element (12) are provided in order to attach the at least one electrode element (12) to the support (14). To attach the at least one electrode element (12) to the support (14), the at least one electrode element (12) and/or the support (14) are heated and the at least one electrode element (12) is pressed against the support (14).