Titanium Implantable Control Module Housing Design
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Solution Overview
Problem
Current implantable electrical stimulation systems face challenges in designing a durable and efficient control module with a metal electronics housing that can effectively seal and interlock, particularly when using materials like grade 23 titanium alloy, which is difficult to mold into small radii features.
Innovation Solution
The control module is constructed using a metal electronics housing formed from bent sheets of grade 23 titanium alloy, with sealed seams and interlocking features such as dovetail designs, and a feedthrough assembly that includes non-conductive blocks and conductive feedthroughs to securely house an electronic subassembly and connect leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If grade 23 titanium alloy is used for the metal electronics housing, then mechanical strength and durability are improved, but manufacturing complexity increases due to difficulty in molding small radii features
Solution Approach 1:
The metal electronics housing is divided into multiple separate components (first major surface component, second major surface component, and bottom plate) that are joined together through sealed seams. This segmentation allows each component to be manufactured independently using bending processes suitable for grade 23 titanium alloy, avoiding the need to mold complex small radii features in a single piece while maintaining overall structural strength and durability.
2Reliability
If sealed seams are used to join metal housing components, then sealing effectiveness is improved, but manufacturing precision requirements increase
Solution Approach 1:
Interlocking features are incorporated into the housing components before assembly. These features are formed during the bending process of grade 23 titanium alloy sheets, creating mechanical engagement structures that guide and maintain proper alignment during assembly. This preliminary formation of alignment features reduces the precision required during the actual sealing operation, as the interlocking structures inherently position components correctly.
3Stability of the object's composition
If interlocking features are added to housing components, then structural stability is improved, but device complexity increases
Solution Approach 1:
The interlocking features are integrated directly into the bent metal sheet components during the forming process, rather than being added as separate elements. The first and second major surface components include interlocking features that are formed as part of the bending operation on grade 23 titanium alloy sheets. This merging of the interlocking feature creation into the existing manufacturing process provides structural stability without significantly increasing overall device complexity.
Data Source
AI summary
An implantable control module for an electrical stimulation system includes a connector housing including a connector having one or more ports and connector contacts disposed within the connector; a metal electronics housing coupled to the connector housing; an electronic subassembly disposed within the metal electronics housing; and a feedthrough assembly disposed between the connector housing and the metal electronics housing and including at least one non-conductive block and conductive feedthroughs extending through the at least one non-conductive block and electrically coupling the electronic subassembly to the connector contacts. The metal electronics housing includes a metal sheet bent to form at least a portion of the first major surface and at least a portion of the second major surface. The first major surface has a length and includes a first sealed seam extending along an entirety of the length of the first major surface.