Battery assembly for a medical device

Abstract

A battery assembly for an implantable medical device is disclosed. The battery assembly includes: an electrode stack comprising a plurality of electrode plates, wherein the plurality of electrode plates includes a first electrode plate and a second electrode plate, the first electrode plate including a first tab extending from the first electrode plate; the second electrode plate including a second tab extending from the second electrode plate; a spacer between the first tab and the second tab; and a rivet extending through the first tab, the second tab, and the spacer, wherein the rivet is configured to mechanically attach the first tab, the second tab, and the spacer to one another.

Description

Technical Field

[0001] This disclosure relates to batteries, and more specifically, to batteries for medical devices. Background Technology

[0002] For example, implantable medical devices (IMDs) include multiple devices for delivering treatment (e.g., electrical simulations or medications) to a patient, monitoring the patient's physiological parameters, or both. IMDs typically contain numerous functional components encapsulated within a housing. The housing is implanted into the patient's body. For instance, the housing may be implanted into a recess formed in the patient's torso. The housing may contain various internal components such as batteries and capacitors to deliver energy for the treatment delivered to the patient and / or to power circuitry for monitoring the patient's physiological parameters and controlling the functionality of the medical device. Summary of the Invention

[0003] In some aspects, this disclosure relates to battery assemblies, for example, used in medical devices, and techniques for manufacturing battery assemblies.

[0004] In one example, this disclosure relates to a battery assembly for an implantable medical device. The assembly may include: an electrode stack comprising a plurality of electrode plates, wherein the plurality of electrode plates include a first electrode plate and a second electrode plate, the first electrode plate including a first terminal piece extending from the first electrode plate; the second electrode plate including a second terminal piece extending from the second electrode plate; a spacer between the first terminal piece and the second terminal piece; and a rivet extending through the first terminal piece, the second terminal piece, and the spacer, wherein the rivet is configured to mechanically attach the first terminal piece, the second terminal piece, and the spacer to each other. In another example, this disclosure relates to an implantable medical device including such a battery assembly within a housing of the implantable medical device, and processing circuitry configured to control the delivery of electrical therapy from the implantable medical device to a patient using power supplied by the battery assembly.

[0005] In another example, this disclosure relates to a battery assembly for an implantable medical device. The assembly may include: a battery housing; an electrode stack including a plurality of electrode plates, wherein the plurality of electrode plates include a first stack of anode tabs extending from an anode plate of the electrode stack and a second stack of cathode tabs extending from a cathode plate of the electrode stack, wherein the first stack of anode tabs is adjacent to the second stack of anode tabs and a gap separates the first stack of anode tabs from the second stack of anode tabs; and a pad located on a top tab of at least one of the first stack of anode tabs or the second stack of anode tabs, wherein the pad is located between at least one of the first tabs of the first stack of anode tabs or the second stack of anode tabs and the battery housing. In another example, this disclosure relates to an implantable medical device including such a battery assembly within a housing of the implantable medical device, and processing circuitry configured to control the delivery of electrical therapy from the implantable medical device to a patient using power supplied by the battery assembly.

[0006] Details of one or more embodiments of this disclosure are set forth in the following drawings and description. Other features, objects, and advantages of this disclosure will be apparent from the description and drawings, and from the claims. Attached Figure Description

[0007] Figure 1 A conceptual diagram illustrating an example medical device system that can be used to deliver treatment to a patient.

[0008] Figure 2 To explain Figure 1 A conceptual diagram of a partial exploded view of the IMD.

[0009] Figure 3 and 4 A conceptual diagram illustrating a portion of an example battery assembly according to an example of this disclosure.

[0010] Figure 5 This is a conceptual diagram illustrating a portion of an example battery assembly containing stacked electrode tabs and spacers.

[0011] Figure 6 To explain Figure 5 A conceptual diagram of a cross-sectional view of the stacked connectors and spacers.

[0012] Figure 7 A conceptual diagram illustrating an example rivet that can be included in a battery assembly.

[0013] Figure 8 A conceptual diagram illustrating an example assembly used to form a battery assembly containing rivets.

[0014] Figure 9 A flowchart illustrating an example technique according to this disclosure.

[0015] Figure 10 A conceptual diagram illustrating a portion of an example battery assembly according to an example of this disclosure.

[0016] Figure 11 To explain Figure 10 The example gasket shown in the image is a conceptual diagram.

[0017] Figure 12 A conceptual diagram illustrating an example battery that includes example pads. Detailed Implementation

[0018] Various medical devices may utilize one or more batteries as a power source to provide operating power. For example, an implantable medical device (IMD) that provides cardiac rhythm management therapy to a patient may include a battery to power the generation of electrical therapy or other functions of the IMD. For ease of illustration, examples of this disclosure will be described primarily with respect to batteries used in IMDs that provide cardiac rhythm management therapy. However, as will be apparent from the description herein, examples of this disclosure are not limited to IMDs that provide such therapy. For example, in some cases, one or more of the example batteries described herein may be used by a medical device configured to deliver electrical stimulation to a patient in the form of neurostimulation therapy (e.g., spinal cord stimulation therapy, deep brain stimulation therapy, peripheral nerve stimulation therapy, pelvic floor stimulation therapy, etc.). In some instances, the example batteries of this disclosure may be used in a medical device configured to monitor one or more patient physiological parameters (e.g., by monitoring the patient's electrical signals alone or in conjunction with the delivery of therapy to the patient).

[0019] In some instances, the battery of an IMD may comprise multiple electrode plates (e.g., both anode and cathode plates) stacked on top of each other, each of which contains a terminal block extending therefrom. The terminal blocks of the anode plates may be aligned with each other in the stack and electrically connected to each other to form the anode of the battery. In this sense, the terminal block stack can serve as an electrical interconnect between the anode plates. Similarly, the terminal blocks of the cathode plates may be aligned with each other in the stack and electrically connected to each other to form the cathode of the battery. In some instances, such a battery may be referred to as a planar battery.

[0020] In some instances, in each anode and cathode tab stack, spacers may be located between adjacent individual tabs in the tab stack, such that each individual tab is separated from its adjacent tab by the spacers. The spacers may be conductive to electrically couple the respective tabs in the stack to each other and, at least partially, define electrical interconnections between the respective plates of the electrodes. For each electrode, the tabs in the tab and spacer stacks may be attached to each other by one or more side-mounted laser-welded members spanning the height of the tab stack.

[0021] In some instances, due to the nature of the spacer and terminal block interconnect design, the terminals of the electrode stack can flex or bend. This can cause stress on the material, potentially leading to failure of the side welds and / or insulation.

[0022] In some instances, stacked plate-shaped battery interconnect spacers may undergo “fanning out” (e.g., opening like pages in a bound book) due to mechanical forces exerted by the expansion of the electrode stack (e.g., during battery discharge). The applied forces can cause the spacer stack to shift, resulting in an electrical short circuit with the surrounding battery housing, and / or causing laser-welded components on the interconnect spacer stack to fail.

[0023] In some instances, such as when the electrode stack expands during battery life, the laser-welded components on the sides of the interconnect spacer stack are subjected to mechanical loads. Electrode stack expansion may be attributed to plate warping or cathode expansion during battery discharge. As described above, mechanical loads on the interconnect spacer stack can cause the interconnect spacer stack to “fan out,” much like a book with its many pages open.

[0024] According to at least some embodiments of this disclosure, a battery assembly comprising electrode tab stacks may include spacers of varying thicknesses and / or may include multiple spacers between individual tabs. The spacer and tab stacking sequence may be adapted to provide a desired deflection / bending that reduces material stress in the interconnects and adjacent electrode materials. In some embodiments, predictive models may be used to predict the desired stacking sequence, for example, using spacers of the desired thickness. In some embodiments, the model may take into account sources of variation in the components used to produce the battery assembly. For example, modeling may be used to assess variations in the thickness of the spacers and associated tabs. The model may be used to strategically place the spacers based on inferred or measured variations in each component of the stacked assembly.

[0025] Alternatively, battery assemblies according to some embodiments of this disclosure may include rivets passing through orifices in the tab / spacer stack (e.g., through holes in or near the center of the tab stack). The rivets prevent mechanical “fanning out” of the spacers. The rivets may be a section of wire mechanically fastened and / or laser-welded to the outermost tabs of the stacked assembly (e.g., the top and bottom tabs of the tab stack). The rivets may be configured to counteract forces exerted by the expansion of the electrode stack.

[0026] Alternatively or concurrently, battery assemblies according to some embodiments of this disclosure may include one or more spacers (also referred to as gaskets) between the interconnect spacer tab stack and the surrounding battery housing (e.g., between the top of the spacer tab stack and the surrounding battery housing). In some embodiments, the gaskets may be formed of a polymeric material that acts as an electrical insulator to prevent electrical short circuits. The gaskets occupy the space between the interconnect spacer stack and the housing wall, thus limiting the “fan-shaped spread” of stress imposed on the laser-welded joints. The gaskets can transfer the forces of electrode expansion away from the interconnect laser-welded joints and impart those forces to the more robust battery housing walls.

[0027] In some instances, a gasket may be a relatively simple molded polymer component added during assembly, or it may be an integral feature designed as another insulator (e.g., a top space insulator, a stacked insulator, and / or a feedthrough insulator). In some instances, a "gasket" may be attached as a foldable feature that allows for ease of assembly while also preventing the unintentional omission of a gasket during battery assembly.

[0028] Figure 1 This is a conceptual diagram illustrating an example medical device system 10 that can be used to provide electrotherapy to a patient 12. The patient 12 is typically, but not necessarily, human. System 10 may include an IMD 16 and an external device 24. Figure 1 In the example described herein, IMD16 has a battery 26 located within the outer casing 40 of IMD16. The battery 26 may be a primary battery or a secondary battery.

[0029] While examples of this disclosure are described primarily with respect to a battery 26 positioned within the housing 40 of IMD 16 for delivering electrical therapy to the heart of patient 12, in other instances, battery 26 may be used in conjunction with other implantable medical devices. For example, battery 26 may be used with implantable drug delivery devices, implantable monitoring devices that monitor one or more physiological parameters of patient 12, implantable neurostimulators (e.g., spinal cord stimulators, deep brain stimulators, pelvic floor stimulators, peripheral nerve stimulators, etc.). Furthermore, while examples of this disclosure are described primarily with respect to implantable medical devices, the examples are not limited thereto. Specifically, some examples of the batteries described herein may be employed in any medical device that includes non-implantable medical devices. For example, example batteries may be used to power medical devices configured to deliver therapy to a patient externally or via a transdermal lead or drug delivery catheter.

[0030] exist Figure 1In the examples depicted, IMD 16 is connected (or “coupled”) to leads 18, 20, and 22. IMD 16 may be a device for providing cardiac rhythm management therapy to the heart 14, for example, and may include an implantable pacemaker, cardioreverter, and / or defibrillator that provides therapy to the heart 14 of the patient 12, for example, via electrodes coupled to one or more of leads 18, 20, and 22. In some instances, IMD 16 may deliver pacing pulses but not cardioreverting or defibrillating shocks, while in other instances, IMD 16 may deliver cardioreverting or defibrillating shocks but not pacing pulses. Additionally, in other instances, IMD 16 may deliver pacing pulses, cardioreverting shocks, and defibrillating shocks.

[0031] The IMD 16 may include necessary or desired electronics and other internal components for performing functions associated with the device. In one example, the IMD 16 includes one or more of the following: processing circuitry, memory, signal generation circuitry, sensing circuitry, telemetry circuitry, and power supply. Generally, the memory of the IMD 16 may contain computer-readable instructions that, when executed by the processor of the IMD, cause the processor to perform various functions of the device as described herein. For example, the processing circuitry of the IMD 16 may control the signal generator and sensing circuitry according to instructions and / or data stored in the memory to deliver treatment to the patient 12 and perform other functions related to treating the patient's condition with the IMD 16.

[0032] The IMD 16 may include or be one or more processors or processing circuitry, such as one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field-programmable arrays (FPGAs), or other equivalent integrated or discrete logic circuitry. Therefore, the terms “processor” and “processing circuitry” as used herein may refer to any of the foregoing structures or any other structures suitable for implementing the techniques described herein.

[0033] Memory can contain any volatile or non-volatile medium, such as random access memory (RAM), read-only memory (ROM), non-volatile RAM (NVRAM), electrically erasable programmable ROM (EEPROM), flash memory, etc. Memory can be a storage device or other non-transitory medium.

[0034] As an example, the signal generation circuitry of the IMD 16 can generate an electrical therapy signal delivered to the patient 12 via electrodes on one or more of leads 18, 20, and 22 to provide a pacing signal or cardioversion / defibrillation shock. The sensing circuitry of the IMD 16 can monitor electrical signals from the electrodes on leads 18, 20, and 22 of the IMD 16 to monitor the electrical activity of the heart 14. In one example, the sensing circuitry may include a switching circuit to select which of the available electrodes on leads 18, 20, and 22 of the IMD 16 are used to sense cardiac beats. Additionally, the sensing circuitry of the IMD 16 may include multiple detection channels, each of which includes an amplifier and an analog-to-digital converter for digitizing the signals received from the sensing channels (e.g., electrocardiographic signal processing by the processing circuitry of the IMD).

[0035] The telemetry circuitry of IMD 16 can be used to communicate with another device (e.g., external device 24). Under the control of the processing circuitry of IMD 16, the telemetry circuitry can receive downlink telemetry from external device 24 and transmit uplink telemetry to said external device by means of an antenna that can be internal and / or external.

[0036] Various components of the IMD 16 can be coupled to a power source, such as battery 26. Battery 26 can be a primary lithium battery or a secondary lithium (rechargeable) battery, but other types of battery chemistry are also considered. Battery 26 may be able to maintain its charge for several years. Generally, battery 26 can supply power to one or more electrical components of the IMD 16, such as signal generation circuitry, to allow the IMD 16 to deliver treatment to patient 12, for example, in the form of monitoring one or more patient parameters, delivery of electrical stimulation, or delivery of a therapeutic drug fluid. Battery 26 may contain a lithium-containing anode and cathode, which contain active materials that react with lithium electrochemistry within an electrolyte to generate electricity. A wide variety of battery types and

[0037] Leads 18, 20, and 22 coupled to IMD 16 can extend into the heart 14 of patient 12 to sense the electrical activity of heart 14 and / or deliver electrical therapy to heart 14. Figure 1In the example shown, the right ventricle (RV) lead 18 extends through one or more veins (not shown), the superior vena cava (not shown), and the right atrium 30, and enters the right ventricle 32. The left ventricle (LV) coronary sinus lead 20 extends through one or more veins, the vena cava, and the right atrium 30, and enters the coronary sinus 34, reaching the region of the free wall of the left ventricle 36 adjacent to the heart 14. The right atrium (RA) lead 22 extends through one or more veins and the vena cava, and enters the right atrium 30 of the heart 14. In other examples, in addition to or instead of delivering treatment via electrodes through intravascular leads 18, 20, 22, the IMD 16 may also deliver treatment to the heart 14 from an extravascular tissue site. In the illustrated example, there is no electrode in the left atrium 36. However, other examples may include electrodes in the left atrium 36.

[0038] IMD 16 can be coupled to an electrode of at least one of leads 18, 20, 22. Figure 1 (Not shown) to sense electrical signals (e.g., cardiac signals) accompanying depolarization and repolarization of the heart 14. In some instances, the IMD 16 provides pacing pulses to the heart 14 based on the cardiac signals sensed within the heart 14. The electrodes of the IMD 16 for sensing and pacing can be configured as unipolar or bipolar. The IMD 16 can also deliver defibrillation and / or cardioversion therapy via electrodes located on at least one of leads 18, 20, 22. The IMD 16 can detect arrhythmias of the heart 14, such as fibrillation of ventricles 32 and 36, and deliver defibrillation therapy to the heart 14 in the form of an electric shock. In some instances, the IMD 16 can be programmed to deliver progression of therapy (e.g., electric shocks with increasing energy levels) until the fibrillation of the heart 14 ceases. The IMD 16 can detect fibrillation by employing one or more fibrillation detection techniques known in the art. For example, the IMD 16 can identify cardiac parameters of heart signals (e.g., R waves, and detect fibrillation based on the identified cardiac parameters).

[0039] In some instances, external device 24 may be a handheld computing device or a computer workstation. External device 24 may include a user interface that receives input from a user. The user interface may include, for example, a keypad and a display, which may be, for example, a cathode ray tube (CRT) display, a liquid crystal display (LCD), or a light-emitting diode (LED) display. The keypad may take the form of a numeric keypad associated with specific functions or a reduced set of keys. External device 24 may additionally or alternatively include a peripheral pointing device, such as a mouse, via which the user can interact with the user interface. In some embodiments, the display of external device 24 may include a touchscreen display, via which the user can interact with programmer 24.

[0040] Users such as doctors, technicians, other clinicians or nurses, or patients can interact with external device 24 to communicate with IMD 16. For example, users can interact with external device 24 to retrieve physiological or diagnostic information from IMD 16. Users can also interact with external device 24 to program IMD 16 (e.g., select values ​​for operating parameters of IMD 16).

[0041] External device 24 may communicate with IMD 16 wirelessly using any technology known in the art. Examples of communication technologies may include, for example, low-frequency or radio-frequency (RF) telemetry, but other technologies are also contemplated. In some instances, external device 24 may include a communication head that can be positioned close to the patient's body near the IMD 16 implantation site to improve the quality or security of communication between IMD 16 and external device 24.

[0042] exist Figure 1 In the example depicted, IMD 16 is connected (or “coupled”) to leads 18, 20, and 22. In this example, leads 18, 20, and 22 are connected to IMD 16 using connector block 42. For example, leads 18, 20, and 22 are connected to IMD 16 using lead connector ports in connector block 42. Once connected, leads 18, 20, and 22 are in electrical contact with the internal circuitry of IMD 16. Battery 26 may be positioned within housing 40 of IMD 16. Housing 40 may be hermetically sealed and bio-inert. In some examples, housing 40 may be formed of a conductive material. For example, housing 40 may be formed of materials including, but not limited to, titanium, stainless steel, etc.

[0043] Figure 2 for Figure 1 The concept diagram of IMD 16 shows that portions of connector block 42 and housing 40, not shown, have been removed to illustrate some of the internal components within housing 40. IMD 10 includes housing 40, control circuitry 44 (which may contain processing circuitry), battery 26 (e.g., organic electrolyte battery), and capacitor 46. Control circuitry 44 may be configured to communicate via leads 18, 20, and 22 (in... Figure 2 (Not shown) Controls one or more sensing and / or therapeutic delivery processes from IMD 16. Battery 26 includes a battery assembly housing 50 and an insulator 48 (or liner) disposed therearound. Battery 26 charges capacitor 46 and powers control circuitry 44.

[0044] Figure 3 and 4 This is a conceptual diagram illustrating aspects of example battery 26. Battery 26 includes a bottom housing portion 50A and a top housing portion 50B (in... Figure 2The battery 26 is shown in the diagram. The assembly includes a housing 50, a feedthrough terminal 56, and an electrode assembly 58. Electrolyte can be filled into the housing 50 via a fill port (not shown). The housing 50 fills the electrode assembly 58 with electrolyte. The top portion 50B and the bottom portion 50A of the housing can be soldered or otherwise attached to seal the battery 26 encapsulation within the housing 50. The feedthrough assembly 56, formed by pins 62 and an insulating component / ring 64, is electrically connected to jumper pins 60B. The connection between pins 62 and jumper pins 60B allows positive charge to be delivered from the electrode assembly 58 to electronic components outside the battery 26.

[0045] As mentioned above, the fill port (not shown) allows the introduction of a liquid electrolyte into the electrode assembly 58. The electrolyte creates an ion pathway between the anode and cathode of the electrode assembly 58. During the electrochemical reactions with these electrodes, the electrolyte acts as a medium for the migration of ions between the anode and cathode.

[0046] Electrode assembly 58 is depicted as a stacked assembly. The anode includes an assembly of electrode plates 72 (containing individual anode electrode plates 76A) having a bundle of terminals 76 (containing individual terminals 76A) extending therefrom and electrically coupled via a conductive coupler 80 (also referred to as an anode current collector). Although not labeled, one or more spacers (e.g., conductive spacers) may be located between corresponding terminals in the bundle of terminals 76. The conductive coupler 80 may be a pin extending vertically through the bundle of terminals 76 and the spacers located between the corresponding terminals. Alternatively or additionally, one or more solder joints 90 may also electrically couple the bundle of terminals 76 and the spacers. According to at least some embodiments of this disclosure, as described below, the conductive coupler 80 may be a rivet extending vertically through the bundle of terminals 76 and the spacers, the rivet also mechanically attaching the individual terminals 76 and the spacers to each other.

[0047] Each anode electrode plate 72A includes a current collector or grid 82, a terminal block 76A extending therefrom, and electrode material. The electrode material (or anode material) may contain elements from Group IA, Group IIA, or Group IIIB of the periodic table (e.g., lithium, sodium, potassium, etc.), their alloys, intermetallic compounds (e.g., Li-Si, Li-B, Li-Si-B, etc.), or alkali metals in metallic form (e.g., lithium, etc.).

[0048] The cathode terminal 68 can be constructed in a similar manner to the anode terminal 66. The cathode includes an assembly of electrode plates 74 (including individual cathode electrode plates 74A), from which an assembly of terminals 78 (including individual terminals 78A) extends. Figure 5As indicated, for example, one or more spacers (e.g., conductive spacers 86A-86C) may be located between corresponding terminals in the terminal assembly 78. A conductive coupler 84 connects the terminal assembly 78 and the spacers 86. The conductive coupler 84 or other cathode current collector may be connected to the conductive member 60A. The conductive member 60A, shaped as a spacer, may comprise titanium, aluminum / titanium clad metal, or other suitable materials. The conductive member 60A allows the cathode terminal 68 to be electrically coupled to electronic components outside the battery 26. Each terminal in the terminal assembly 78 (including, for example, individual terminal 78A) may additionally or alternatively be attached to each other via laser welding member 92.

[0049] According to at least some examples of this disclosure, as described below, the conductive coupler 84 may be a rivet extending vertically through the assembly of terminals 78 and the spacer 86, the rivet also mechanically attaching the individual terminals 76 and the spacer 86 to each other.

[0050] Each cathode electrode plate 74A includes a current collector (not shown) or grid, electrode material, and terminals 78A extending therefrom. Terminals 78A include conductive materials (e.g., aluminum, etc.). The electrode material (or cathode material) may comprise metal oxides (e.g., vanadium oxide, vanadium silver oxide (SVO), manganese dioxide, etc.), a mixture of carbon monofluoride and said manganese dioxide (e.g., CFx + MnO2), combined vanadium silver oxide (CSVO), lithium ions, other rechargeable chemicals, or other suitable compounds.

[0051] Figure 5 This is a conceptual schematic diagram illustrating an enlarged view of part of the cathode terminal 68 of battery 26. Figure 6 for Figure 5 The image shows a cross-sectional view of the stacked cathode tabs 78. As shown, the electrode plate 74 of the cathode 66 includes cathode electrode plates 74A, 74B, 74C (etc.) in a stacked configuration. Cathode tabs 78A, 78B, 78C extend from the cathode electrode plates 74A, 74B, 74C, respectively, and exhibit the same stacking configuration as the electrode plates 74. At least one spacer is located between each respective tab. For example, spacer 86A is located between tab 78A and tab 78B, and two spacers 86B and 86C are located between tab 78B and tab 78C.

[0052] For ease of description and explanation, it is not included. Figure 5 and 6 All terminals and spacers of cathode stack 68 are marked in the middle. However, it should be understood that the descriptions of terminals 78A-78C and spacers 86A-86C also apply to... Figure 5 and 6Any of the terminals and spacers shown. Additionally, although the cathode stack 68 is described... Figure 5 However, after consideration, the same configuration can be applied to Figure 3 The anode stack 66 of battery 26 shown in the image.

[0053] In some instances, spacer 86A ensures that terminals 78A and 78B extend substantially straight from plates 74A and 74B, respectively, and do not bend during the sub-assembly process to connect the terminal assembly 78 (containing, for example, individual terminals 78A) for the cathode stack 68. While a single spacer 86A is depicted as being placed between two terminals, more than one spacer may be placed between two terminals, such as spacer 86B and 86C between terminals 78B and 78C.

[0054] Spacers 86A-86C may include conductive materials, such as those that electrically interconnect each of the terminals. For the electrode plates associated with the anode stack 66, titanium and its alloys or other suitable materials are used. For the electrode plates associated with the cathode stack 68, titanium, nickel, aluminum, their alloys or other suitable materials are used.

[0055] Spacers 86A-86C may comprise a variety of shapes. Exemplary spacers include substantially H-shaped spacers, substantially rectangular spacers, circular spacers, or spacers comprising at least one triangular shape (e.g., a single triangle, a hexagon, etc.). Spacers 86A-86C may be Figure 5 The individual thicknesses marked in the z-direction have different or substantially the same thickness, for example, to achieve different design criteria. Thicker electrode plates, for instance, may require thicker spacers. Figure 5 In some examples, spacer 86A may have a thickness substantially the same as that of spacer 86B, but spacer 86C may be thinner than spacers 86A and 86B. In some examples, the thickness of the spacer may range from about 0.005 inches to about 0.030 inches, but other values ​​are covered. Examples of spacers 86A-86C may include one or more of the example spacers described in U.S. Patent Application Publication 2009 / 0197180.

[0056] In some instances, the number of spacers and the thickness of individual spacers between the terminals of the cathode stack 68 and the anode stack 66 can be selected to minimize the bending of the terminals while still fitting them into the battery housing 50.

[0057] like Figure 5 and 6 As shown, the cathode stack 68 may include an extension through the aperture 94 (in Figure 4The rivet 84 (shown in the image) has an opening extending in the z-direction through the cathode tab assembly 78 (including, for example, individual tabs 78A), spacer 86, and conductive plate 60A. The rivet 84 includes a body 96, a head 100, and a deformable tail 98. The body 96 may be a solid body (e.g., as shown in the image). Figure 6 (as shown in the image) or a body containing an internal cavity (e.g., such as Figure 8 (As shown in the diagram). The head 100 has a flange portion located below the conductive plate 60A. Similarly, the deformed tail 98 has a flange portion located above the terminal piece 78A, which is a stacked "top" terminal piece. Figure 5 and 6 In one example, spacer 86D is located between tail 98 and terminal piece 78A. In such examples, spacer 86D may be thicker and structurally more rigid than terminal piece 78A, for example, to prevent the head 98 of rivet 84 from "pulling through" terminal piece 78A in the absence of spacer 86D. In other examples, tail 98 may be directly adjacent to terminal piece 78A.

[0058] The flanged shape of the head 100 and the deformable tail 98 allows the rivet 84 to fasten or otherwise mechanically attach the cathode tab 78, spacer 86, and conductive plate 60A to each other and prevents the stack from separating. As will be described in further detail below, prior to deformation, the tail 98 can be inserted into the orifice 94 such that it extends away from the top of the stack of tab 78, spacer 86, and conductive plate 60A. Subsequently, the tail 98 deforms to form a flange and attach the stack of tab 78, spacer 86, and conductive plate 60A together.

[0059] Rivet 84 secures and defines the thickness of the stack of terminals 78, spacers 86, and conductive plates 60A in the z-direction to correspond to the thickness of the body 96 in the z-direction. In some instances, rivet 84 may apply a compressive force between the head 100 and the tail 98, for example, to counteract a force in another direction that would otherwise cause the terminals 78 and spacers 86 to separate. In this way, during the operating life of the battery 26, the stack of terminals 78 is prevented from, for example, “fanning out,” such as in the z-direction, and the terminals 78 are prevented from losing electrical interconnection with each other.

[0060] In some instances, rivets 84 are configured to hold the stack of terminals 78 together so that weld 92 does not accept “book-opening” mechanical loads. Weld 92 may be present in an assembly of rivets 84 contained within the stack of terminals 78 to provide, for example, a robust electrical connection between the respective terminals. Over the long term, corrosion and surface oxidation can degrade the quality of the interfacial contact, thus necessitating welds.

[0061] In some instances, the height of rivet 84 (in the Z direction) is selected based on the stack modeling described above. The modeling work can suggest using only one rivet for all production variation options, or if the variation is too large, individual tie / spacer stacks can be actively measured during manufacturing, and then any of several pre-made rivet heights can be selected for a particular stack.

[0062] Rivet 84 may be formed of any suitable material, such as stainless steel (e.g., 300 series stainless steel), Monel alloy, or other nickel-copper alloys and / or nickel. In some instances, rivet 84 may be a conductive material, such that rivet 84 is used to electrically couple individual terminals 78, spacers 86, and conductive plates 60A together, for example, individually or in combination with other features such as weldment 92 and / or conductive spacers 86. In other instances, rivet 84 may be formed of an electrically insulating material.

[0063] Figure 7 A photograph is provided to illustrate an example rivet 84 that may be used in this disclosure. The rivet 84 includes a head 100, a tail 98, and a body 96 extending between the head 100 and the tail 98. For example, the rivet 84 is shown positioned at the tail 98 as... Figure 6 The state before deformation is shown in the diagram. The body 96 of rivet 84 has a smaller extension through... Figure 5 and 6 The outer diameter D of the orifice 94 of the stacked terminal 78, spacer 86, and conductive plate 60A shown is [not specified]. In some instances, the body 96 of the rivet 85 may have an outer diameter of about 28 mils or less, for example, the diameter of the head 100 and the deformed tail 98 may be about 40 mils or more. In instances where the body 96 comprises an inner cavity rather than being solid, the thickness of the body wall may be about 5 mils. In some instances, the total length of the rivet 84 from the head 100 to the tail 98 may be about 272 mils or less. In some instances, the total height (in the Z direction) of the combination of the terminal 78 and spacer 86 may be about 0.230 inches (e.g., + / - 0.03 inches). Other values ​​are covered.

[0064] Figure 8 The diagram illustrates an example device 106 for deforming the tail 98 to form a stacked assembly when arranged with cathode tab 78 and spacer 86, in which tab 78 and spacer 86 are attached to each other via rivets 84. Figure 9 A flowchart illustrating an example technique for attaching the connector 78 and the spacer 86 to each other via rivets 84. For ease of description, details will be provided. Figure 8 The device 106 shown in the text is described Figure 9 Example techniques.

[0065] like Figure 9As shown, the connector 78 and spacer 86 can be stacked on the body 96 of the rivet 84 (102). For example, the orifices 94 of individual connectors 78 and individual spacers 86 can be sequentially placed above the tail 98 onto the body 96 in a desired order and arrangement, for example in Figure 8 In the arrangement shown, in other instances, the connector 78 and spacer 86 may initially be arranged in a stacked manner, with the orifices aligned (e.g., using retaining pins) and then placed as a single stack on the body 96 above the tail 98. Stacking may be achieved manually or by a robotic assembly device (e.g., a pick-and-place robot).

[0066] Once the terminal block 78 and spacer 86 are assembled above the rivet 84, the tail 98 can deform to attach the terminal block 78 and spacer 86 to the stacked arrangement (104). For example, a retractable support 110 can be used to press the forging 108 against the retaining pin 112 into the tail 98, for example, by compressive force, so that the edges of the tail 98 deform outward and form as... Figure 8 The flange end is shown in the figure. In some instances, the weld 92 may be formed subsequently in the connector 78 and spacer 86, for example by laser welding or other suitable process, after the rivet 84 has been installed. Alternatively, the weld 92 may be formed before the rivet 84 is installed.

[0067] Figure 9 The example illustrates only one example of a technique for deforming the tail 98 of rivet 84 within an orifice 94 in the stack of connector 78 and spacer 86 to attach connector 78 and spacer 86 to each other. Other suitable techniques and other types of rivets may be employed, such as rivets with a solid body.

[0068] As mentioned above, some examples of battery assemblies of this disclosure may additionally or alternatively include a pad on the "top" of the stack of terminals 78 and spacers 86, for example, to prevent the terminals 78 from "fanning out" as described herein. Figure 10 This is a schematic diagram illustrating an example of a battery 26 including a gasket 114. (See attached diagram.) Figure 10 As shown, the gasket 114 is located on the stack of the terminal piece 78 and the spacer 86 of the cathode stack 68. Figure 10 In one example, the gasket 114 is not directly on top of the terminal block 78A, but is separated from it by a spacer 86D. In other examples, the gasket 114 may be directly on the terminal block 78A. Although Figure 10 Not shown, but in some instances, depending on the material used to form the gasket 114, the weld 92 may extend along the side of the stacked assembly to include the gasket 114.

[0069] Additionally, spacer 114 is located on the stack of terminals 76 of the anode stack 66 in a similar manner. Spacer 114 is a single component spanning the gap 116 between the stack of terminals 78 of the cathode stack 68 and the stack of terminals 76 of the anode stack 66, and also includes spacers (not labeled) between individual terminals in the stack. While spacer 114 is... Figure 10 In one instance, it is a single component, but in other instances, battery 26 may include a pad located on the stack of terminals and spacers for cathode stack 68 and another pad located on the stack of terminals and spacers for anode stack 66.

[0070] In some instances, the spacer 114 may be incorporated as an integral feature of another component (e.g., an insulating component), rather than as a separate component. For example, in some instances, the spacer 114 may be part of another typical insulator used to isolate the polarities within the battery 26, such as a top space insulator, a stack insulator, and / or a feedthrough insulator. In some instances, the spacer 114 may be attached or otherwise incorporated as a foldable feature of the component to facilitate the assembly of the battery 26 while also preventing unintentional misinstallation during the assembly of the battery 26.

[0071] although Figure 10 Not shown in the diagram, but the battery housing 50 is assembled with a sealed or otherwise attached portion 50B to form the top portion 50B of the housing 50. Figure 2 When the top portion 50B of the battery housing 50 is shown in the diagram and the bottom portion 50A is also shown, the thickness of the gasket 114 (in the z-direction) can be selected such that the top surface of the gasket 114 contacts the inner surface of the top portion 50B of the battery housing 50. In some instances, the contact between the top surface of the gasket 114 and the inner surface of the top portion 50B of the housing 50 can apply a compressive force (by...). Figure 10 Arrow 120 indicates (indicated by) or other means to prevent the cathode stack 68 and anode stack 66 from fanning out. For example, when the top portion 50B is attached to the bottom portion 50A of the housing 50, for example via a welded joint around the periphery of the housing 50 at the junction between the top portion 50B and the bottom portion 50B, the compressive force 120 can be applied through the gasket 114 to the stack of cathode 68 tabs 78 and anode 66 tabs 76 between the top portion 50B and the bottom portion 50A. In this way, the compressive force 120 can prevent the stack of cathode 68 tabs 78 and anode 66 tabs 76 from “fanning out”, for example, during the operating life of the battery 26.

[0072] The gasket 114 can be formed of any suitable material. In some examples, the gasket 114 can be formed of an electrically insulating material, for example, to prevent electrical coupling between the cathode stack 68 and the anode stack 66 through the gasket 114 and / or electrical coupling between the cathode stack 68 and / or the anode stack 66 and the housing 50. Examples of insulating materials may include polypropylene, polyethylene, etc. In other examples, the gasket 114 can be formed of a conductive material such as titanium, stainless steel, etc. In some examples, the spacer 86D between the top terminals 78A of the cathode 68 and the spacer between the gasket 114 and the top terminals 76A of the anode 66 can be electrically insulating to prevent electrical coupling between the respective electrode terminals and the gasket 114. In other examples, the gasket 114 can be configured such that a compressive force is applied once the cathode stack 68 and / or the anode stack 66 begins to fan out, for example at some point during the operating life of the battery 26.

[0073] Figure 11 This is a schematic diagram illustrating an example of gasket 114. As shown, gasket 114 does not have a constant thickness, but rather exhibits a thickness T1 on one side and a thickness T2 on the other side. This difference in this case can be considered as the difference between the distance between the tab / spacer stack of cathode stack 68 and the inner surface of the top portion 50B of housing 50 when housing 50 is assembled around the internal components of battery 26, compared to the distance between the tab / spacer stack of anode stack 66 and the inner surface of the top portion 50B of housing 50.

[0074] As shown, in some instances, gasket 114 may include posts 122A and 122B. Post 122A may be configured to fit within a portion of an aperture 94 in the stack of tabs 78 and spacers 86 of the cathode stack 68. Similarly, post 122B may be configured to fit within a similar aperture in the stack of tabs / spacers of the anode stack 66. This feature facilitates registration or alignment of gasket 114 relative to the anode stack 66 and cathode stack 68, and holds gasket 114 in place, for example, before, during, and / or after assembly of the top portion 50B and bottom portion 50A of housing 50. Such a design can be used where rivets (e.g., rivet 84) do not extend through the stack of tabs and spacers of the anode and cathode stacks. For instances containing rivets in one or both of the anode and cathode stacks, gasket 114 may include different... Figure 11 Another type of registration feature shown in the diagram (e.g., a groove in the pad 114 instead of the protrusions of posts 122A and 122B, for example) makes both the rivet and the pad prevent the stacked terminals from fanning out during the battery's operating life.

[0075] Figure 12A conceptual diagram illustrating another example, battery 126. Battery 126 may be similar to other battery assemblies described herein, and similar features are similarly numbered. Figure 12 This illustration illustrates an example where a gasket 114 is used between the inner surface of the top portion 50B of the housing 50 and the cathode stack 68 and anode stack 66. As described above, the contact between the top surface of the gasket 114 and the inner surface of the top portion 50B of the housing 50 can apply a compressive force (by...). Figure 12 (The two arrows in the diagram indicate) or otherwise prevent the cathode stack 68 and anode stack 66 from fanning out. For example, when the top portion 50B is attached to the bottom portion 50A of the housing 50, for example via a welded joint around the periphery of the housing 50 at the junction between the top portion 50B and the bottom portion 50B, a compressive force can be applied through the shim 114 to the stack of cathode 68 tabs 78 and anode 66 tabs 76 between the top portion 50B and the bottom portion 50A. In this way, the compressive force can prevent the stack of cathode 68 tabs 78 and anode 66 tabs 76 from “fanning out,” for example, during the operating life of the battery 126. In some instances, the shim 114 may be configured such that the compressive force is applied once the cathode stack 68 and / or anode stack 66 begin to fan out, for example at some point during the operating life of the battery 126.

[0076] Various examples have been described in this disclosure. These and other examples are within the scope of the appended clauses and claims.

[0077] Clause 1. A battery assembly for an implantable medical device, the assembly comprising: an electrode stack including a plurality of electrode plates, wherein the plurality of electrode plates includes a first electrode plate and a second electrode plate, the first electrode plate including a first terminal extending from the first electrode plate, and the second electrode plate including a second terminal extending from the second electrode plate; a spacer between the first terminal and the second terminal; and

[0078] A rivet extending through the first terminal piece, the second terminal piece, and the spacer, wherein the rivet is configured to mechanically attach the first terminal piece, the second terminal piece, and the spacer to each other.

[0079] Clause 2. The assembly according to Clause 1, wherein the rivet includes a flared head, a deformed tail, and a rivet body extending between the flared head and the deformed tail, wherein the flared head is on a first side of the electrode stack, and the deformed tail is on a second side of the electrode stack.

[0080] Clause 3. The assembly according to Clause 1, wherein the spacer includes a first spacer, wherein the plurality of electrode plates include a third electrode plate, the third electrode plate including a third terminal piece extending from the third electrode plate, wherein the second terminal piece is between the first terminal piece and the third terminal piece, the assembly further including a second spacer between the third terminal piece and the second terminal piece, wherein the rivet extends through the third terminal piece and the second spacer.

[0081] Clause 4. The assembly according to Clause 3, wherein the first spacer has a first thickness different from the second thickness of the second spacer.

[0082] Clause 5. The assembly according to Clause 1, wherein the spacer includes a first spacer, and the assembly further includes a second spacer between the first terminal piece and a second terminal piece adjacent to the first spacer.

[0083] Clause 6. The assembly according to Clause 1, further comprising a weldment on the electrode stack, the weldment extending from the first terminal block across the spacer to the second terminal block.

[0084] Clause 7. The assembly according to Clause 1, wherein the first electrode plate is the top plate of the plurality of electrode plates of the electrode stack, the assembly further comprising: a battery housing surrounding the electrode stack; and a gasket located on top of the first terminal piece between the first terminal piece and the inner surface of the battery housing.

[0085] Clause 8. The assembly according to Clause 7, wherein the first electrode plate includes a first anode plate and the second electrode plate includes a second anode plate, wherein the plurality of electrode plates further include a first cathode plate and a second cathode plate, the first cathode plate including a third terminal piece extending from the first cathode plate, the second cathode plate including a fourth terminal piece extending from the second cathode plate, wherein the third terminal piece and the second terminal piece are stacked adjacent to the first terminal piece and the second terminal piece, and wherein a top spacer spans the gap between the first terminal piece and the third terminal piece.

[0086] Clause 9. The assembly according to Clause 7, wherein the top spacer is formed of an electrically insulating material to electrically isolate the first terminal block from the battery housing.

[0087] Item 10. A battery assembly for an implantable medical device, the assembly comprising: a battery housing; an electrode stack including a plurality of electrode plates, wherein the plurality of electrode plates include a first stack of anode tabs extending from an anode plate of the electrode stack and a second stack of cathode tabs extending from a cathode plate of the electrode stack, wherein the first stack of anode tabs is adjacent to the second stack of anode tabs and a gap separates the first stack of anode tabs from the second stack of anode tabs; and a pad located on a top tab of at least one of the first stack of anode tabs or the second stack of anode tabs, wherein the pad is located between at least one of the first tabs of the first stack of anode tabs or the second stack of anode tabs and the battery housing.

[0088] Clause 11. The battery assembly according to Clause 10, wherein the spacer spans the gap between the first terminal block stack and the second terminal block stack.

[0089] Clause 12. The assembly according to Clause 10, wherein the gasket is formed of an electrically insulating material to electrically isolate the first and second terminal stacks from the battery housing.

[0090] Clause 13. The assembly according to Clause 10, wherein the battery housing is configured to apply compressive force to the first terminal block stack and the second terminal block stack via the gasket.

[0091] Clause 14. The assembly according to Clause 10, wherein the second terminal block stack comprises a first cathode terminal block and a second cathode terminal block, the assembly further comprising a first spacer located between the first cathode terminal block and the second cathode terminal block.

[0092] Clause 15. The assembly according to Clause 14, further comprising a second spacer between the first cathode terminal and the second cathode terminal, wherein the first spacer has a thickness less than the thickness of the second spacer.

[0093] Clause 16. The assembly according to Clause 14, wherein the second terminal block stack includes a third cathode terminal block, and the assembly further includes a second spacer between the second cathode terminal block and the third cathode terminal block.

[0094] Clause 17. The assembly according to Clause 16, wherein the first spacer has a thickness less than that of the second spacer.

[0095] Clause 18. The assembly according to Clause 10, further comprising rivets extending through the second tab stack to mechanically attach the individual tabs of the second tab stack to each other.

[0096] Clause 19. The assembly according to Clause 18, wherein the rivet includes a flared head, a deformed tail, and a rivet body extending between the flared head and the deformed tail, wherein the flared head is on a first side of the second tab stack, and the deformed tail is on a second side of the second tab stack.

[0097] Clause 20. The assembly according to Clause 10, further comprising a weld on the second terminal block stack extending from the top terminal block of the second terminal block stack to the bottom terminal block of the second terminal block stack.

[0098] Clause 21. The assembly according to Clause 10, wherein the welded element extends to the gasket.

[0099] Clause 22. The assembly according to Clause 10, wherein the gasket includes a first protrusion configured to engage with an aperture in the first terminal block stack and a second protrusion configured to engage with an aperture in the second terminal block stack.

[0100] Clause 23. The assembly according to Clause 10, wherein the gasket is configured to transfer compressive force from the battery housing to at least one of the first terminal block stack or the second terminal block stack.

[0101] Article 24. An implantable medical device comprising: an outer shell;

[0102] Processing circuitry; and the battery assembly of item 1, within the housing, wherein the processing circuitry is configured to use power supplied by the battery assembly to control the delivery of electrical therapy from the implantable medical device to the patient.

[0103] Article 25. An implantable medical device comprising: an outer shell;

[0104] Processing circuitry; and the battery assembly of item 10, within the housing, wherein the processing circuitry is configured to use power supplied by the battery assembly to control the delivery of electrical therapy from the implantable medical device to the patient.

[0105] Article 26. A method comprising any one of Articles 1-25.

Claims

1. A battery assembly for an implantable medical device, the assembly comprising: an electrode stack comprising a plurality of electrode plates, wherein the plurality of electrode plates comprises a first electrode plate including a first tab extending from the first electrode plate; and a second electrode plate including a second tab extending from the second electrode plate; a spacer between the first tab and the second tab; and a rivet extending through the first tab, the second tab, and the spacer, wherein the rivet is configured to mechanically attach the first tab, the second tab, and the spacer to one another; wherein the spacer comprises a first spacer, the assembly further comprising a second spacer between the first tab and a second tab adjacent to the first spacer.

2. The assembly of claim 1, wherein the rivet comprises a flared head, a deformed tail, and a rivet body extending between the flared head and the deformed tail, and wherein the flared head is on a first side of the electrode stack and the deformed tail is on a second side of the electrode stack.

3. The assembly of claim 1, wherein the first spacer has a first thickness that is different than a second thickness of the second spacer.

4. The assembly of any of the above claims, further comprising a weld on the electrode stack extending from the first tab to the second tab across the spacer.

5. The assembly of claim 1 or 2, wherein the first electrode plate is a top plate of the plurality of electrode plates of the electrode stack, the assembly further comprising: a battery housing surrounding the electrode stack; and a gasket on top of the first tab between the first tab and an inner surface of the battery housing.

6. The assembly of claim 5, wherein the first electrode plate comprises a first anode plate and the second electrode plate comprises a second anode plate, wherein the plurality of electrode plates further comprises a first cathode plate including a third tab extending from the first cathode plate and a second cathode plate including a fourth tab extending from the second cathode plate, wherein the third tab and the second tab are stacked adjacent to the first tab and the second tab, and wherein a top spacer spans a gap between the first tab and the third tab.

7. The assembly of claim 5, wherein the top spacer is formed of an electrically insulating material to electrically isolate the first tab from the battery housing. ​ ​

Images