Feedthrough pin configured for laser welding

Abstract

The invention relates to a feedthrough pin assembly and a technology related to the feedthrough pin assembly. An example of a feedthrough pin assembly includes a feedthrough pin including an elongated portion having a first radius and an enlarged portion having a second radius. The first radius is smaller than the second radius. The feedthrough pin assembly can also include a spring plate having an opening having an opening radius less than the second radius, the spring plate being circumferentially oriented around the first portion of the elongated portion. The feedthrough pin assembly also includes an annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion. The feedthrough pin assembly also includes a translucent ferrule distal of the spring plate and positioned circumferentially around a second portion of the elongated portion.

Description

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 476,906, filed Dec. 22, 2022, the entire content of which is incorporated herein by reference. Technical Field

[0002] The present disclosure generally relates to medical devices and components that can be used in medical devices, such as feedthrough pins. Background Art

[0003] Some types of implantable medical devices (IMDs), such as cardiac pacemakers or implantable cardioverter defibrillator systems, can be used to provide cardiac sensing and therapy to a patient through one or more electrodes. Some IMDs include one or more feedthrough pins for various applications within the implantable medical device. Some implantable medical devices use feedthrough pins as electrical connections to the terminals of a hermetically sealed battery within the implantable medical device.

[0004] Feedthrough pins can be used to electrically connect an internal portion of the IMD to an external component. In particular, feedthrough pins can be used to electrically connect an internal electrode of a hermetically sealed battery to an external circuit or harness. Feedthrough pins that make electrical connections to components can be electrically insulated using a non-conductive material to prevent accidental electrical grounding of the feedthrough pins. When feedthrough pins are used to pass through a hermetic barrier, using an insulator around the feedthrough pins can present new challenges. Summary of the Invention

[0005] In accordance with the techniques of the present disclosure, an implantable medical device utilizing a hermetically sealed battery can be connected to an electrical harness or circuit using feedthrough pins. A feedthrough pin assembly that can be configured to connect to the hermetically sealed battery described herein can be configured to facilitate the use of laser welding techniques. Laser welding can be used to weld a feedthrough pin to a spring plate by directing laser energy to a proximal end of the feedthrough pin. To electrically connect the feedthrough pin to other electrical components without electrically grounding the feedthrough pin, an insulator can be circumferentially disposed around the feedthrough pin. An example of an insulator that can be circumferentially oriented around the feedthrough pin is an insulating ferrule. The ferrule can be translucent, which can be an inherent property of some insulating materials. When the insulator is translucent, stray laser energy can propagate through the insulator to components distal to the proximal end of the feedthrough pin. Stray laser energy can be potentially damaging because it can cause unintended heating. In accordance with the techniques of the present disclosure, the stray laser energy can be absorbed or reflected by the feedthrough pin assembly, thereby reducing the risk of damage due to unintended heating.

[0006] In one example, a feedthrough pin assembly includes: a feedthrough pin having an elongated portion with a first radius and an enlarged portion with a second radius, the first radius being less than the second radius; a spring plate having an opening with an opening radius less than the second radius, the spring plate being circumferentially oriented around the elongated portion; an annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion; and a translucent ferrule positioned distally of the spring plate and circumferentially located around a second portion of the elongated portion.

[0007] In another example, a technique for manufacturing a feedthrough pin assembly may include: obtaining a feedthrough pin having an elongated portion with a first radius and an enlarged portion with a second radius, the first radius being less than the second radius; orienting a spring plate having an opening with an opening radius less than the second radius, wherein the first radius is less than the second radius; circumferentially orienting the spring plate around the elongated portion, the spring plate including an opening having an opening radius less than the second radius; forming an annular window by a circumferential gap between the spring plate and the first portion of the elongated portion; and positioning a translucent ferrule distally of the spring plate and circumferentially positioning the translucent ferrule around a second portion of the elongated portion.

[0008] In another example, a technique for laser welding a feedthrough pin may include: orienting a feedthrough pin assembly toward a laser energy source, the feedthrough pin assembly including: a feedthrough pin including an elongated portion with a first radius and an enlarged portion with a second radius, wherein the first radius is less than the second radius; a spring plate including an opening having an opening radius less than the second radius, the spring plate being circumferentially oriented around the first portion of the elongated portion; an annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion; and a translucent ferrule positioned distally of the spring plate and circumferentially located around a second portion of the elongated portion; and activating the laser energy source to emit laser energy toward the feedthrough pin assembly, wherein the enlarged portion of the feedthrough pin assembly performs at least one of: attenuating or reflecting at least a portion of the emitted laser energy.

[0009] This summary is intended to provide an overview of the subject matter described in this disclosure. It is not intended to provide an exclusive or exhaustive interpretation of the devices and methods described in the following figures and description. Further details of one or more examples are set forth in the following figures and description. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1Is a conceptual diagram illustrating an example of an implantable medical device (IMD) operating within a patient according to various examples described in the present disclosure.

[0011] Figure 2 Is a conceptual diagram illustrating an example of a feedthrough pin assembly 200 serving as a battery connection according to one or more examples of the present disclosure.

[0012] Figure 3 Is a conceptual diagram illustrating a technique for laser welding a feedthrough pin assembly according to one or more techniques of the present disclosure.

[0013] Figure 4 Is a conceptual diagram illustrating an example of a feedthrough pin and ferrule configured to laser weld a feedthrough pin assembly according to one or more examples of the present disclosure.

[0014] Figure 5 Is a conceptual diagram illustrating an example of a feedthrough pin and ferrule configured to laser weld a feedthrough pin assembly according to one or more examples of the present disclosure.

[0015] Figure 6 Is a flowchart illustrating an example of a technique for forming a feedthrough pin assembly according to one or more examples of the present disclosure.

[0016] Figure 7 Is a flowchart illustrating an example of a technique for laser welding a feedthrough pin according to one or more examples of the present disclosure.

[0017] Figure 8 Is a flowchart illustrating an example of a technique for manufacturing a feedthrough pin assembly according to one or more examples of the present disclosure.

[0018] Figure 9 Is a flowchart illustrating an example of a technique for laser welding a feedthrough pin assembly according to one or more examples of the present disclosure. Detailed Description

[0019] An implantable medical device (IMD) may include an airtight seal housing and / or airtight seal components within the airtight seal housing. The IMD may also include one or more feedthrough pins positioned within a portion of the airtight seal housing of the device. The feedthrough pins may be used to electrically connect components enclosed by the airtight seal housing to components or objects external to the housing. In one example, internal components of the IMD (e.g., a battery) may be airtight sealed by a component housing (e.g., a battery housing). In other examples, the feedthrough pins may be used to electrically connect internal components (e.g., a pulse generator) enclosed by the device housing to tissue external to the IMD housing. The feedthrough pins may be partially disposed within an airtight barrier that forms a part of the airtight seal housing.

[0020] In some examples, a feedthrough pin may be partially disposed within an airtight barrier of a housing, with a proximal end extending proximally of the airtight barrier and a distal end extending distally of the airtight barrier. The distal end of the feedthrough pin and the proximal end of the feedthrough pin may be configured to be electrically coupled to an electrical component or body tissue. In some examples, a slit may be formed between the feedthrough pin and the surrounding housing to maintain the airtight property of the airtight barrier.

[0021] In some examples, a spring plate may be oriented on a proximal surface of the airtight barrier, the spring plate having an opening through which the proximal end of the feedthrough pin extends. The slit may be configured to completely fill a portion of the opening between the spring plate and the feedthrough pin. The slit may be made of a conductive material so as to electrically connect the spring plate to the feedthrough pin. In some examples, the feedthrough pin may be sealed to the plate using pin-to-plate welding. Laser welding techniques may be used to form the pin-to-plate welding to melt the proximal end of the feedthrough pin. The laser welding techniques may also cause the edges of the opening in the spring plate to melt, thereby forming a weld between the melted proximal end of the feedthrough pin and the surrounding spring plate.

[0022] In some examples, the distal end of the feedthrough pin may be configured to be electrically coupled to an energy source (such as a battery). For example, the energy source may be electrically coupled to the distal end of the feedthrough pin. The energy source may be surrounded by an airtight housing, and the feedthrough pin passes through an opening in a portion of the housing (e.g., the airtight barrier). Laser welding the proximal end of the feedthrough pin to the spring plate may electrically connect the energy source to an electrical component that is electrically coupled to the spring plate via an electrical connection through the feedthrough pin.

[0023] In some examples, the energy source may be a battery used in an IMD. Some examples of battery types that may be used in an IMD include lithium ion, lithium polymer, lithium-sulfur dioxide, and lithium iodine-polyvinyl pyridine. In some examples, the energy source may be a supercapacitor or a wired temporary energy source. The energy source may be rechargeable. In some examples, the energy source may be a reactive single-use battery having an expected charge life that exceeds the expected operating life of the IMD.

[0024] The energy source housing may be metallic. The metallic housing may be conductive. The conductive energy source housing may be grounded, thereby having a relative ground potential with respect to any other electrical potential measured within the IMD. In some cases, the metallic housing may airtight seal the internal components of the energy source.

[0025] In an example IMD (such as those in which the energy source is a battery), portions of the battery may include a solution within an energy storage, electrodes, and a battery housing. The solution may be incompatible with components external to the battery housing. An airtight battery housing can be used to prevent components from being accidentally exposed to the solution. In particular, if the solution reservoir is not airtight within the battery housing, components external to the battery housing that are incompatible with the solution may be damaged. The housing can also prevent internal battery components from being accidentally exposed to foreign object debris (FOD). Although feedthrough pins can pass through the airtight barrier of the airtight housing, additional sealing techniques can be used to maintain an airtight seal between the feedthrough pins and the barrier.

[0026] In some examples, an opening in the airtight barrier of the housing can be used to feed a feedthrough pin into the battery. The gap between the feedthrough pin and the edge of the opening can be airtight sealed. In some examples, the gap can be sealed via a laser welding technique. In some examples, the circular edge surface of the feedthrough pin can be circumferentially wrapped in an electrical insulator before being partially fed through the opening. The insulator can maintain electrical isolation between the conductive material of the feedthrough pin and the metal battery housing. An example of the insulator is an insulating ferrule.

[0027] The insulating ferrule can be made of glass or plastic having a high resistance level. The glass or plastic insulating ferrule can be translucent or transparent to optical electromagnetic energy. In particular, the glass or plastic insulating ferrule can be translucent or transparent to the light energy typically used in laser welding.

[0028] When laser welding a feedthrough pin, in some examples, the laser can be directed to irradiate the proximal end of the feedthrough pin. The electromagnetic energy absorbed by the feedthrough pin may cause the temperature of the metal in the feedthrough pin at the site of the irradiated light to increase. If the temperature of the metal increases significantly, the metal may melt, producing a welding material that may flow into the surrounding material. In the case of welding a feedthrough pin disposed in the metal housing of a battery, the melted feedthrough pin can be welded to the surrounding metal plate (e.g., a spring plate) of the metal battery housing.

[0029] Throughout this disclosure, references to "electromagnetic energy", "laser energy", or "laser" should be interpreted in the context of a welding laser that is generated to laser weld a medical device. A welding laser external to the medical device can be used to fabricate a medical device or components of a medical device. Generally, such electromagnetic energy or laser can be refracted or reflected from metallic materials, dielectric materials, or permeable materials, causing stray laser light to propagate in an unintended direction. The stray laser light may irradiate an unintended material or component, causing accidental heating. Accidental heating of an unintended component may damage components of a medical device (e.g., an IMD) during fabrication.

[0030] When laser welding a feedthrough pin (e.g., creating a pin-board laser weld), a feedthrough component having a shoulder feedthrough pin can limit the transmission of laser energy in the feedthrough pin. One or more techniques are disclosed for reducing the heating of unintended components due to stray welding laser energy during pin-board laser welding. The techniques of the present disclosure can allow a washer-flanged feedthrough pin (e.g., a feedthrough pin having an enlarged portion configured to shield laser energy) to reduce stray laser energy projected through a gap between the feedthrough pin and a surrounding spring plate. The shielding effect of the flanged feedthrough pin can reduce unintended heating.

[0031] Figure 1 is a conceptual diagram illustrating an example of an IMD 14 operating within a patient 12 in accordance with various examples described in the present disclosure. The systems, devices, and techniques described in the present disclosure can include an example configuration of feedthrough pins (not shown in Figure 1 positioned within the IMD 14 for connecting an energy source to the IMD 14, as illustrated and described with respect to Figure 1 . For the purposes of this description, knowledge of cardiovascular anatomy and function is assumed, and details are omitted unless to the extent necessary or desirable to explain the context of the techniques of the present disclosure. The IMD 14 can include one or more feedthrough pins assembled using laser welding techniques. The IMD 14 can be implanted at or near a site of the heart 17 of the patient 12. The IMD 14 can have a hermetically sealed housing and / or include a hermetically sealed component package. The systems, devices, and techniques described herein can provide feedthrough pins for electrical connection between components within the IMD 14. The systems, devices, and techniques described herein can provide feedthrough pins for electrical connection between components having the IMD 14 and components or tissue external to the IMD 14. In particular, the feedthrough pins can be partially disposed within the hermetically sealed housing of a component within the IMD 14 and within the hermetically sealed housing of the IMD 14. Although described with respect to a medical device system including the IMD 14, in other examples, the techniques of the manufacturing techniques for feedthrough pins disclosed herein can be applied to other types of devices. Examples of other types of devices can include aerospace devices, semiconductor packages, and other devices in industries that utilize hermetic package sealing techniques.

[0032] The IMD 14 can use feedthrough pins in various applications. Some of these applications can include using the feedback pins as battery contacts, as signal connectors, or as other electrical connections made across a hermetic seal barrier. In some examples, the feedthrough pins can be used to connect IMD 14 leads (not illustrated) to the body of the IMD 14. The IMD 14 can be implanted outside the chest of the patient 12 (e.g., subcutaneously implanted in Figure 1the illustrated pectoral muscle location). In other examples, the IMD 14 can be positioned near or just below the sternum at the level of the patient 12's heart, e.g., at least partially within the cardiac silhouette. In other examples, the IMD 14 can be implanted proximate to, attached to, or on the epicardium of the heart 17, as Figure 1 shown. In other examples, the IMD 14 can be positioned at other locations on the patient 12, including for monitoring and stimulating the tibial nerve, sacral nerve, spinal cord, vagus nerve, deep brain stimulation located at or near one or more organs or other locations.

[0033] The IMD 14 includes a plurality of electrodes ( Figure 2 ), and can be configured to sense electrocardiogram (ECG) and other bioelectrical signals via the plurality of electrodes. The electrodes can be integrated with the hermetically sealed housing of the IMD 14. In some examples, the electrodes can be integrated with the housing using the feedthrough manufacturing techniques of the present disclosure. In various examples, the IMD 14 can represent a cardiac monitor, defibrillator, cardiac resynchronization pacemaker / defibrillator, pacemaker, ventricular assist device, implantable pressure sensor, nerve stimulator, glucose monitor, drug pump, pulse wave velocity measurement device, or any other implantable or external medical device.

[0034] For the remainder of the present disclosure, a general reference to the IMD 14 can collectively refer to any example including the IMD 14, and a general reference to the sensor circuit can collectively refer to any feedthrough pin used as an electrical connector.

[0035] Figure 2 is a conceptual diagram illustrating an example of a feedthrough pin assembly 200 serving as a battery connection portion 212 according to one or more examples of the present disclosure. The feedthrough pin assembly 200 can include a feedthrough pin 210 partially disposed within an opening of a translucent ferrule 220. The feedthrough pin assembly 200 can also include a spring plate 230 circumferentially oriented around the feedthrough pin 210.

[0036] In some examples, the feedthrough pin 210 can have elongated portions 218A to 218B (at Figure 2is shown in the example as being vertically oriented along the vertical axis 256) and an enlarged portion 214. The elongated portions 218A to 218B may include a first elongated portion 218A and a second elongated portion 218B. The first elongated portion 218A may be proximal to both the enlarged portion 214 and the second elongated portion 218B. The enlarged portion 214 may be proximal to the second elongated portion 218B. The first elongated portion 218A may have a first radius 250 corresponding to the outer radius of the outer curved sidewall of the first elongated portion 218A. When the radius belongs to the first radius and the second radius, the radius shall be interpreted as the radius of a cross-section taken along a plane parallel to the proximal surface of the spring plate 230. As used herein, the radius is not necessarily limited to the radius of a circular cross-section of the device, but may include polygons, ellipses, or other two-dimensional (2D) shapes. When the cross-section is not circular, the radius is defined as half the length of the longest chord of the cross-section, which longest chord extends linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section. The enlarged portion 214 may have a second radius 252 corresponding to the outer radius of the outer curved sidewall of the enlarged portion 214. In some examples, the enlarged portion 214 may be spherical. In some examples, the enlarged portion 214 may have a second radius 252, which is defined as the distance of half the longest chord of a cross-section of the enlarged portion, where the cross-section is taken parallel to the proximal surface of the spring plate 230. The chord may be defined as the distance of a straight-line segment between any two points of a cross-section of the enlarged portion 214. The longest chord may be defined as a chord of a cross-section of the enlarged portion 214 taken parallel to the surface of the spring plate 230 such that the chord is greater than all other intercepted chords of the cross-section. The second elongated portion 218B may have an outer radius 254 corresponding to the outer radius of the outer curved sidewall of the second elongated portion 218B. In some examples, the first radius 250 may be the same length as the third radius 254. When the radius belongs to the third radius, the radius shall be interpreted as the longest radial straight line from the center of the feedthrough pin to a point on the inner edge of the spring plate 230 defined by the annular window 240. The center of the feedthrough pin may be the vertical axis 256. Both the first radius 250 and the third radius 254 may be less than the second radius 252.

[0037] In some examples, the first elongate portion 218A may be partially disposed within an opening in the spring plate 230. The opening within the spring plate 230 may have a third radius 254 corresponding to the radius of a circular void, opening, hole, or notch within the spring plate 230. The third radius 254 of the void also corresponds to the outer radius of the annular window 240. In some examples, the third radius 254 may be less than the second radius 252 of the enlarged portion 214 and greater than the first radius 250 of the first elongate portion 218A. When the first elongate portion 218A is partially disposed within the opening in the spring plate 230, the spring plate 230 may be circumferentially oriented about the first elongate portion 218A.

[0038] The feedthrough pin assembly 200 may include an annular window 240 formed by a circumferential gap between the spring plate 230 and the first elongate portion 218A of the feedthrough pin 210. The dimensions of the annular window 240 may be configured based on the first radius 250 of the first elongate portion 218A and the third radius 254 of the opening within the spring plate 230. In some examples, the annular window 240 may be designed to have specific dimensions. In some examples, the annular window 240 may be the result of a design margin for the feedthrough pin 210 having a first radius 250 that is less than or equal to the third radius 254 of the opening in the spring plate 230.

[0039] In some examples, the proximal end of the feedthrough pin 210 may be proximal to the spring plate 230, thereby forming a portion of the feedthrough pin 210 that extends above the proximal surface of the spring plate 230. The portion of the feedthrough pin 210 that extends above the spring plate 230 may be configured to be welded using a laser welder. In some examples, the length of the portion of the feedthrough pin 210 that extends above the spring plate 230 may be 0.003 inches. In some examples, the feedthrough pin 210 may include a heat dissipating material. The heat dissipating material may include at least one of steel, silver, gold, or copper, or other conductive materials that melt in the presence of a laser. In various examples, the material of the feedthrough pin 210 may include titanium, titanium alloy, niobium, platinum, platinum alloy. In some examples, the material may include grade 23 titanium.

[0040] In some examples, the feedthrough pin 210 may include an enlarged portion 214 having a second radius 252 that may be greater than a third radius 254 of the annular window 240. The enlarged portion 214 may be distal to the annular window 240 and proximal to the translucent ferrule 220. The second radius 252 may be greater than a third radius 254 of the second elongated portion 218B. In some examples, the enlarged portion may be cylindrical, spherical, oval, polyhedral, geometric, or some three-dimensional (3D) asymmetric form. The second radius 252 should be interpreted as the radius of a cross-section of the enlarged portion 214 taken parallel to the proximal surface of the spring plate 230. In some examples, a cross-section of the enlarged portion 214 taken parallel to the proximal surface of the spring plate 230 may not be circular. When the cross-section is not circular, the second radius is defined as half the length of the longest chord of the cross-section that extends linearly from a point on the outer surface of the cross-section to another point on the outer surface of the cross-section.

[0041] In some examples, the translucent ferrule 220 may be formed circumferentially around the second elongated portion 218B of the elongated portions 218A to 218B of the feedthrough pin 210. The shape of the translucent ferrule 220 may be cylindrical, and the translucent ferrule has an opening extending from a proximal circular surface to a distal circular surface. The translucent property of the translucent ferrule 220 may be the result of the translucent material from which the translucent ferrule 220 is made. The translucent ferrule 220 may be made of a translucent glass, plastic, or crystal that provides little attenuation to the laser welding light. In various examples, the translucent ferrule may include glass. In some examples, at least a portion of the translucent ferrule may be configured to do at least one of the following: attenuate or reflect at least a portion (such as a majority) of the laser welding light.

[0042] In some examples, the spring plate 230 may comprise a metallic material such as copper, steel, zinc, titanium, titanium alloy, niobium, platinum, platinum alloy, or other metallic materials compatible with laser welding metals. In various examples, the material of the spring plate 230 may include titanium, titanium alloy, niobium, platinum, platinum alloy. In some examples, the material may include grade 9 titanium (e.g., TI GR9). The spring plate 230 may have an opening having a third radius 254 that is less than a second radius 252 of an enlarged portion 214 of the feedthrough pin 210. The spring plate 230 may be circumferentially oriented about a first elongate portion 218A of the elongate portions 218A-218B of the feedthrough pin 210. The spring plate 230 may be configured to receive molten fill metal generated by laser melting a proximal end of the first elongate portion 218A of the feedthrough pin 210. The spring plate 230 may be configured to create a thin annular window that is wide enough to account for variations in feedthrough pin width and feedthrough pin placement, but thin enough to allow molten fill metal to flow between the feedthrough pin 210 and the spring plate 230. In some examples, the spring plate 230 may be formed of a copper layer disposed as a trace layer on a printed circuit board (PCB). In some examples, the spring plate 230 may have a material thickness configured to reflect or attenuate a majority of the laser welding light. In some examples, the material thickness of the spring plate 230 may be 0.004 inches. In some examples, the spring plate 230 may be configured to function as an electrical contact to connect the feedthrough pin 210 to an electrical component within the IMD.

[0043] In some examples, the annular window 240 may include a circumferential gap disposed between one of the first elongate portion 218A and the second elongate portion 218B and the opening in the spring plate 230. The annular window 240 may be configured to have a third radius 254 that is less than the second radius 252 of the enlarged portion 214. The annular window 240 may be transparent to light including the laser welding light. The annular window 240 may be configured to receive molten fill metal generated from the proximal end of the feedthrough pin 210. In some examples, the annular window 240 may be an electrically insulating structure. The insulating annular window 240 may be configured to provide electrical isolation between the feedthrough pin 210 and the spring plate 230 prior to laser welding. During laser welding, filling the annular window 240 with fill metal generated from the molten proximal end of the feedthrough pin 210 may provide an electrical connection from the battery 260 to the electrical component within the IMD via the feedthrough pin 210.

[0044] In some examples, the battery 260 can be distal to the distal end of the feedthrough pin 210. In some examples, the battery 260 can be cylindrical, having a circular proximal surface and a circular distal surface. The battery 260 can include an electrode exposed on the circular proximal surface. The feedthrough pin 210 can include a distal end of the battery connection portion 212 configured to the battery 260. The feedthrough pin 210 can be configured to be electrically coupled to the battery 260 via the battery connection portion 212. The electrode exposed on the circular proximal surface can be electrically coupled to the distal end of the feedthrough pin 210. When the proximal end of the feedthrough pin 210 is welded to the spring plate 230, the battery 260 can be electrically coupled to the spring plate 230 via the battery connection portion 212 and the feedthrough pin 210.

[0045] In some examples, the feedthrough pin 210 can be non-centered within the opening of the spring plate 230. The annular window 240 can be asymmetric. In some examples, the enlarged portion 214 can be asymmetric with respect to the feedthrough pin 210. The enlarged portion 214 can be oriented to block the line of sight between the asymmetric annular window 240 and the proximal surface of the translucent ferrule 220.

[0046] Figure 3 is a conceptual diagram illustrating a technique for laser welding a feedthrough pin assembly 300 in accordance with one or more techniques of the present disclosure. The technique can include orienting the feedthrough pin assembly 300 toward laser energy 370 generated by a laser source. The feedthrough pin assembly 300 can include a feedthrough pin 310, a spring plate 330, an annular window 340 (similar to Figure 2 the annular window 240) and a translucent ferrule 320. The feedthrough pin 310 can include a first elongated portion 318A proximal to the enlarged portion 314. The feedthrough pin 310 can also include a second elongated portion 318B distal to the enlarged portion 314 and partially disposed within the translucent ferrule 320. The technique can also include activating the laser energy source to emit laser energy 370 toward the proximal end 316 of the first elongated portion 318A of the feedthrough pin 310.

[0047] In some examples, the first elongate portion 318A may have a radius equal to the first radius 350 of the second elongate portion 318B. Here, the first radius 350 and the radius of the first elongate portion 318A are measured from the vertical axis 356. In various examples, the enlarged portion 314 of the feedthrough pin 310 may be configured to reflect and / or absorb (e.g., attenuate) most of the stray laser energy irradiated on the enlarged portion 314 from the laser energy source. In various examples, the enlarged portion 314 may have a second radius 352 corresponding to the outer radius of the outer curved sidewall of the enlarged portion 314. The second radius 352 may be configured to be greater than the third radius 354 of the opening in the spring plate 330. In some examples, the radius of the first elongate portion 318A may be different from the first radius 350 of the second elongate portion 318B. In some examples, both the radius of the first elongate portion 318A and the first radius 350 may be less than the second radius 352.

[0048] The welding laser may be aligned such that the laser energy 370 directly irradiates the proximal end 316 of the first elongate portion 318A of the feedthrough pin 310. In some examples, the welding laser energy may have a direct radiation of 4.568345 gigawatts per square meter (e.g., 4568345000 W / m 2 )). The welding laser may melt the proximal end 316, thereby creating an annular window 340 that is partially filled 342. The unfilled portion of the annular window 340 with the molten filler metal may allow the stray laser energy to pass through the annular window 340. Through the annular window 340, the stray laser energy from the laser energy 370 may irradiate the enlarged portion 314 of the feedthrough pin 310, thereby shielding the energy. Shielding the stray laser energy may prevent the stray laser energy from further propagating through the translucent ferrule 320. Prevention may occur when the enlarged portion 314 is proximal to the translucent ferrule 320. In some examples, the enlarged portion 314 may be distal to the translucent ferrule 320. When the enlarged portion 314 is distal to the translucent ferrule 320, the shielding of the stray laser energy may occur after the stray laser energy has propagated through the translucent ferrule 320.

[0049] In some examples, shielding of stray laser energy can prevent the energy from irradiating the proximal end of the battery 360. The battery 360 can be connected to the feedthrough pin 310 via the battery connection 312. The battery connection 312 can be made between the distal end of the second elongated portion 318 and the proximal surface of the battery 360. Preventing stray laser energy from irradiating the battery 360 can limit the risk of battery damage due to overheating from the stray laser energy. In particular, limiting the amount of laser energy irradiating the proximal surface of the battery 360 can limit the amount of heating the battery 360 experiences from the stray laser energy. In some examples, the stray laser energy may irradiate electronic devices located on or near the proximal surface of the battery 360. Shielding the laser energy can also prevent thermal damage to these electronic devices in the presence of stray laser energy.

[0050] In some examples, a portion of the translucent ferrule 320 can be configured to do at least one of the following: reflect or absorb at least a portion (e.g., most) of the laser welding light or laser energy. In one example, an opaque glass can be used to reflect or absorb the stray laser energy. In another example, the translucent ferrule 320 can be coated or plated with an optically reflective or absorptive material. The material can be configured to absorb the laser energy so that the laser energy dissipates uniformly as heat above the battery surface.

[0051] Figure 4 is a conceptual diagram illustrating an example of a feedthrough pin and ferrule configured for laser welding of a feedthrough pin assembly. The feedthrough pin 410 can include elongated portions 418A to 418B and an enlarged portion 414. In some examples, the first elongated portion 418A can be proximal to both the enlarged portion 414 and the second elongated portion 418B. The second elongated portion 418B can be distal to the enlarged portion 414. In various examples, the second elongated portion 418B can be partially disposed within the translucent ferrule 420.

[0052] In some examples, the enlarged portion 414 may include a first enlarged portion 415A and a second enlarged portion 415B. The first enlarged portion 415A and the second enlarged portion 415B may be separated by an intermediate portion 413. In various examples, the first elongated portion 418A may have a first radius 450 measured from the vertical axis 456. The first radius 450 of the first elongated portion 418A may be less than a second radius 452 of the first enlarged portion 452, also measured from the vertical axis 456. The second radius 452 of the first enlarged portion 415A may be longer than the outer axial radius of the intermediate portion 413. The outer axial radius 453 of the second enlarged portion 415B, measured from the vertical axis 456, may be greater than the outer axial radius of the intermediate portion 413, measured from the vertical axis 456. In some examples, the outer axial radius 453 of the second enlarged portion 415B may be the same length as the second radius 452. In some examples, the outer axial radius of the intermediate portion 413 may have the same length as the first radius 450 of the first elongated portion 418A. In some examples, the outer axial radius of the intermediate portion 413 may have the same radius as the outer axial radius of the second elongated portion 418B. In some examples, the outer axial radius 432 of the second elongated portion 418B may have the same length as the first radius 450, which has the same outer axial radius, may be approximately the same, with small variations in width and thickness due to manufacturing variability.

[0053] In some examples, when the enlarged portion 414 is proximal to the translucent ferrule 420, both the first enlarged portion 415A and the second enlarged portion 415B may be proximal to the translucent ferrule 420. In some examples, when the enlarged portion 414 is distal to the translucent ferrule 420, both the first enlarged portion 415A and the second enlarged portion 415B may be distal to the translucent ferrule 420. In some examples, the first enlarged portion 415A may be proximal to the translucent ferrule 420, the second enlarged portion 415B may be distal to the translucent ferrule, and the intermediate portion 413 may be disposed within the opening of the translucent ferrule 420 (e.g., Figure 4 not illustrated).

[0054] In some examples, both the first enlarged portion 415A and the second enlarged portion 415B may be configured to perform at least one of the following: reflect or absorb a portion (e.g., a majority) of the stray laser energy. In some examples, a portion of the first enlarged portion 415A or the second enlarged portion 415B may be configured to absorb the stray, while the remaining portion may be configured to reflect the stray laser energy.

[0055] In some examples, a sub - portion 417 of the second elongated portion 418B of the feed - through pin 410 can be proximal to the proximal surface of the translucent ferrule 420 and distal to the enlarged portion 414. In some examples, the sub - portion 417 can be oriented within the intermediate portion 413 (e.g., Figure 4 not illustrated in

[0056] ). The sub - portion 417 can form a first air gap between the translucent ferrule 420 and the second enlarged portion 415B, for example, for heat dissipation purposes. In some examples, the sub - portion 417 can have a length corresponding to the distance between the distal surface of the second enlarged portion 415B and the proximal surface of the translucent ferrule 420. In some examples, the length of the sub - portion 417 can be equal to or greater than 0.0005 inches but less than or equal to 0.004 inches.

[0057] In some examples, a second air gap can be formed proximal to the second enlarged portion 415B and distal to the first enlarged portion 415A. The second air gap can be formed by an outer axial radius difference between the intermediate portion 413 and the first enlarged portion 415A. In some examples, the second air gap can be formed by an outer axial radius difference between the intermediate portion 413 and the second enlarged portion 415B.

[0058] The intermediate portion 413 can have an outer axial radius equal to the outer axial radius of the first elongated portion 418A of the feed - through pin 410. In some examples, the outer axial radius of the intermediate portion 413 can have an outer axial radius equal to the outer axial radius of the second elongated portion 418B. In some examples, the intermediate portion 413 can extend a distance equal to the thickness of the first enlarged portion 415A or the second enlarged portion 415B.

[0059] Figure 5FIG. 0 is a conceptual diagram illustrating an example of a feedthrough pin 510 and a translucent ferrule 520 configured to laser weld a feedthrough pin assembly according to one or more examples of the present disclosure. The feedthrough pin 510 may include a first elongated portion 518A proximal to the enlarged portion 514. The enlarged portion 514 may be proximal to the second elongated portion 518B. In some examples, the first elongated portion 518A may be partially disposed within an opening of the translucent ferrule 520. The enlarged portion 514 may be distal to the translucent ferrule 520.

[0060] In some examples, the first elongated portion 518A may have a first radius 550 measured from the vertical axis 556, which may be shorter than a second radius 552 of the enlarged portion 514 also measured from the vertical axis 556. In various examples, an outer axial radius of the second elongated portion 518B measured from the vertical axis 556 may be the same length as the first radius 550.

[0061] In some examples, the translucent ferrule 520 may be substantially transparent to laser welding light. In particular, stray laser energy propagating through the annular window may enter the translucent ferrule 520 from the proximal end of the translucent ferrule 520. In some examples, the translucent ferrule 520 may be configured to do one of the following: absorb or reflect a portion of the laser. The stray laser energy may propagate through the translucent ferrule 520 and irradiate the enlarged portion 514. The enlarged portion 514 may be configured to do one of the following: reflect or absorb most of the stray laser energy. In some examples, a portion of the translucent ferrule 520 may be configured to absorb laser energy by dissipating the energy as heat on a surface away from the battery or other electronic components.

[0062] The enlarged portion 514 may be configured to do at least one of the following: substantially reflect or attenuate the irradiating stray laser energy propagating through the translucent ferrule 520. The enlarged portion 514 may reduce the intensity of the stray laser energy distal to the distal end of the enlarged portion 514. The enlarged portion 514 may comprise at least one of copper, steel, silver, or aluminum. In some examples, the enlarged portion 514 may include an electromagnetic reflection or absorption coating to reflect or attenuate the laser energy, respectively.

[0063] In some examples, the enlarged portion 514 may have a first outer axial radius greater than the outer axial radius of the first elongated portion 518A. In some examples, the enlarged portion 514 may have an outer axial radius greater than the outer axial radius of the second elongated portion 518B.

[0064] Figure 6It is a conceptual diagram illustrating an example of a feedthrough pin 610 having an inclined reflective edge 655. In some examples, the feedthrough pin 610 may include a first elongated portion 618A and a second elongated portion 618B separated by an enlarged portion 614, and the enlarged portion is configured to have an inclined reflective edge 655. In some examples, the first elongated portion 618A may have a first radius 650, which is measured as an outer axial radius starting from the vertical axis 656. Measured from the vertical axis 656, the first radius 650 may be greater than the second radius 652. In some examples, the first radius 650 may be 0.006 inches.

[0065] In some examples, the enlarged portion 614 having an inclined reflective edge 655 may be designed to have a bending radius 654. The inclined reflective edge 655 may be configured to reflect and / or absorb stray laser energy. In various examples, the enlarged portion 614 having an inclined reflective edge 655 may be proximal to the translucent ferrule 620. In some examples, the enlarged portion 614 having an inclined reflective edge 655 may be distal to the translucent ferrule 620 (e.g., Figure 6 not illustrated in the figure).

[0066] In some examples, the enlarged portion 614 may have an edge thickness 658. The enlarged portion may contain the material that makes up the first elongated portion 618A and the second elongated portion 618B which are made elongated. The edge thickness may be designed to prevent stray laser from passing through its material. In some examples, the edge thickness 658 may be shorter than the second radius 652. In some examples, the edge thickness may be twice the length of the bending radius 654. In some examples, the edge thickness 658 may be 0.002 inches.

[0067] In some examples, the inclined reflective edge 655 may have a curved surface with a bending radius 654, and the curved surface is designed to reflect light similar to a convex mirror. In some examples, the inclined reflective edge 655 may be designed to have a bending radius 654 to direct the reflected stray laser energy towards a part of the feedthrough pin assembly. In some examples, the bending radius 654 may have a value equal to or less than 0.001 inches.

[0068] In some examples, the part of the feedthrough pin assembly towards which the laser energy is directed may be capable of absorbing the laser energy without being damaged. In some examples, the reflected stray laser energy may be reflected to the inner surface of the opening that houses the translucent ferrule and the feedthrough pin. In some examples, the inclined reflective edge 655 may be configured to directly reflect the stray laser energy to a second reflective surface, such as a corner reflector.

[0069] Figure 7FIG. 0 is a conceptual diagram illustrating an example of a feedthrough pin assembly 700 having a corner reflector 731 configured for laser welding, according to one or more examples of the present disclosure. In some examples, the feedthrough pin 710 is configured to reflect stray laser energy toward the corner reflector 731 using an enlarged portion 714. The corner reflector 731 can be used to absorb and / or further reflect the laser energy.

[0070] In some examples, the corner reflector 731 can be formed by placing an insulating layer 732 between the distal surface of the spring plate 730 and the proximal surface of the top cap 770. The top cap 770 can form a surround that circumferentially surrounds the feedthrough pin 710, thereby forming a translucent ferrule 720 and an opening within which the feedthrough pin 710 is located. The inner top cap radius 759 measured from the vertical axis 756 can form an opening for inserting the translucent ferrule 720 and the feedthrough pin 710 before placing the insulating layer 732 and the spring plate 730. The corner reflector 731 can be formed by an opening in the insulating layer 732, where the opening has an opening radius 757 that is shorter than the inner top cap radius 759. The length difference between the opening radius 757 and the inner top cap radius 759 can expose the corner of the insulating layer 732, thereby forming the corner reflector 731.

[0071] In some examples, the top cap 770 can be cylindrical. In various examples, the top cap 770 can be formed of a metallic material (such as steel, aluminum, titanium, titanium alloy, niobium, platinum, platinum alloy). In some examples, the top cap 770 can be formed of a material including Grade 1 titanium. In some examples, the opening within the top cap 770 can be formed by milling a cylindrical core out of a cylindrical metallic stock.

[0072] In some examples, the stray laser energy can enter the cavity formed by the opening in the top cap through an annular window formed by a gap between the opening in the spring plate 730 and the outer axial surface of the feedthrough pin 710. In some examples, a first radius of the elongated portion of the feedthrough pin 710 measured from the vertical axis 756 can be shorter than both a second radius 752 of the enlarged portion 714 of the feedthrough pin 710 measured from the vertical axis 756 and a third radius 754 of the opening in the spring plate 730 measured from the vertical axis 756. The gap can be formed by the length difference between the first radius 750 of the elongated portion of the feedthrough pin 710 and the third radius 754 of the opening in the spring plate 730.

[0073] In some examples, the corner reflector 731 can be configured to absorb the reflected laser energy directed to the corner reflector 731 by the enlarged portion 714. The absorbed energy can be dissipated as heat above a surface that is separated from components that are vulnerable to high temperatures. Components located near the proximal surface of the battery 760 and distal to the translucent ferrule 720 can be shielded by dissipating the stray laser energy using the corner reflector 731.

[0074] Figure 8 is a flowchart illustrating an example of a technique 800 for manufacturing a feedthrough pin assembly according to one or more examples of the present disclosure. Although described with respect to Figure 2 the feedthrough pin assembly 200, one or more of the Figure 8 techniques may be used with other feedthrough pin assemblies described herein. A manufacturer may obtain a feedthrough pin having an elongated portion with a first radius and an enlarged portion with a second radius, where the first radius is less than the second radius (802). For example, a manufacturer may form, purchase, or otherwise obtain a feedthrough pin (e.g., feedthrough pin 210) having an elongated portion with a first radius (e.g., elongated portions 218A-218B) and an enlarged portion with a second radius (e.g., enlarged portion 214). In some examples, the feedthrough pin 210 may include a distal end configured to be electrically coupled to a battery. In some examples, forming the feedthrough pin (e.g., feedthrough pin 210) may include assembling, molding, or milling the feedthrough pin from raw metal. A manufacturer may mold the feedthrough pin 210 by milling the metal into the feedthrough pin 210. When milling the feedthrough pin 210, the raw metal may be used in conjunction with a milling machine to form the feedthrough pin 210.

[0075] The manufacturer may circumferentially orient a spring plate around the elongated portion, the spring plate having an opening with an opening radius less than the second radius (804). For example, the manufacturer may orient the opening in the spring plate (e.g., spring plate 230) to circumferentially surround a proximal portion (e.g., first elongated portion 218A) of the feedthrough pin (e.g., feedthrough pin 210).

[0076] The manufacturer may form an annular window from a circumferential gap between the spring plate and a first portion of the elongated portion (806). For example, the manufacturer may form an annular window (e.g., annular window 240) by orienting the spring plate (e.g., spring plate 230) around a proximal end (e.g., first elongated portion 218A) to create a gap between the feedthrough pin and the spring plate that is transparent to stray laser energy. In some examples, when centering the feedthrough pin 210 within the opening of the spring plate 230, the manufacturer may form the annular window 240 by creating a gap between a first portion (e.g., first elongated portion 218A) and the spring plate (e.g., spring plate 230). The annular window may be the result of an optically transparent gap between the feedthrough pin and the spring plate. In some examples, the air gap may not be a specific construct, but rather an optically transparent air gap providing a line of sight to the proximal surface of a translucent ferrule.

[0077] The manufacturer can position the translucent ferrule distally of the spring plate and circumferentially position (808) the translucent ferrule around a second portion of the elongate portion. For example, the manufacturer can position, dispose, or orient the translucent ferrule (e.g., translucent ferrule 220) distally of the spring plate (e.g., spring plate 230). By partially feeding the second elongate portion 218B through an opening within the translucent ferrule (e.g., translucent ferrule 220), the translucent ferrule (e.g., translucent ferrule 220) can be circumferentially positioned, disposed, or oriented around a second portion of the elongate portion (e.g., second elongate portion 218B). The translucent ferrule can be electrically insulating while being electromagnetically transparent to welding laser energy. In some examples, the feedthrough pin can be centered within the opening of the translucent ferrule.

[0078] Figure 9 is a flowchart illustrating an example of a technique 900 for laser welding a feedthrough pin assembly in accordance with one or more examples of the present disclosure. Although described with respect to the feedthrough pin assembly 300, one or more of the Figure 9 techniques can be used with other feedthrough pin assemblies described herein. In a laser welding technique for a feedthrough pin assembly, a user (e.g., a manufacturer or an assembler) can orient the feedthrough pin assembly toward a laser energy source, the feedthrough pin assembly including: a feedthrough pin including an elongate portion having a first radius and an enlarged portion having a second radius, wherein the first radius is less than the second radius; a spring plate including an opening having an opening radius less than the second radius, the spring plate being circumferentially oriented around a first portion of the elongate portion; an annular window formed by a circumferential gap between the spring plate and the first portion of the elongate portion; and a translucent ferrule positioned distally of the spring plate and circumferentially positioned (902) around a second portion of the elongate portion. In some examples, orienting the feedthrough pin assembly (e.g., feedthrough pin assembly 300) can include adjusting the orientation of the source to direct laser energy (e.g., laser energy 370) to a fixed-positioned feedthrough pin (e.g., feedthrough pin 310). In some examples, orienting the feedthrough pin assembly can include adjusting the orientation of the feedthrough assembly so as to direct laser energy from a fixed-positioned welding laser to the feedthrough pin. In some examples, directing laser energy to the feedthrough pin can include configuring the laser spot to irradiate a center of a proximal surface of the feedthrough pin. In some examples, off-center irradiation of the proximal surface by the laser spot can result in a greater amount and / or greater intensity of stray laser energy entering the annular window.

[0079] In a laser welding technique for a feedthrough pin assembly, a user (e.g., a manufacturer or an assembler) can activate a laser energy source to emit laser energy toward the feedthrough pin assembly, wherein an enlarged portion of the feedthrough pin assembly performs at least one of the following: attenuating or reflecting at least a portion of the emitted laser energy (904). Activating the laser energy source can include turning on an active welding laser. In some examples, the welding laser can include a fiber laser, a CO2 laser, a YAG laser, a gas laser, a solid-state laser, and a fiber laser. Different welding lasers can be used for different applications. Some applications include keyhole welding and seam welding. Activating the laser energy source can generate a laser, thereby generating a laser spot configured to irradiate a proximal surface of the feedthrough pin. Activating the laser can also include holding the laser for a period of time while melting and welding a proximal end of the feedthrough pin to an edge of an opening of a spring plate. Activating the laser can also include deactivating the laser when welding the feedthrough pin to the spring plate.

[0080] The present disclosure includes the following non-limiting embodiments.

[0081] Embodiment 1. A feedthrough pin assembly, the feedthrough pin assembly comprising: a feedthrough pin including an elongated portion having a first radius and an enlarged portion having a second radius, wherein the first radius is less than the second radius; a spring plate having an opening with an opening radius less than the second radius, the spring plate being circumferentially oriented around a first portion of the elongated portion; an annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion; and a translucent ferrule on a distal side of the spring plate and circumferentially positioned around a second portion of the elongated portion.

[0082] Embodiment 2. The feedthrough pin assembly according to Embodiment 1, wherein the feedthrough pin includes a distal end configured to be electrically coupled to a battery.

[0083] Embodiment 3. The feedthrough pin assembly according to Embodiments 1 to 2, wherein the enlarged portion is positioned distal to the translucent ferrule and proximal to the distal end of the feedthrough pin.

[0084] Embodiment 4. The feedthrough pin assembly according to Embodiments 1 to 3, wherein the enlarged portion is positioned distal to the annular window and proximal to the translucent ferrule.

[0085] Embodiment 5. The feedthrough pin assembly according to Embodiments 1 to 4, wherein at least a portion of the translucent ferrule is configured to perform at least one of the following: attenuating or reflecting at least a portion of the laser welding light.

[0086] Example 6. The feedthrough pin assembly according to any one of Examples 1 to 5, wherein the enlarged portion includes a first enlarged portion and a second enlarged portion, the first enlarged portion and the second enlarged portion being separated by an intermediate portion, wherein the radius of the first enlarged portion and the radius of the second enlarged portion are greater than the radius of the intermediate portion, and wherein the radius of the intermediate portion is less than the radius of the first enlarged portion and the radius of the second enlarged portion.

[0087] Example 7. The feedthrough pin assembly according to any one of Examples 1 to 6, wherein the feedthrough pin comprises a heat dissipating material.

[0088] Example 8. The feedthrough pin assembly according to Example 7, wherein the heat dissipating material comprises at least one of steel, silver, gold, or copper.

[0089] Example 9. The feedthrough pin assembly according to any one of Examples 1 to 8, wherein the first radius is less than the opening radius.

[0090] Example 10. The feedthrough pin assembly according to any one of Examples 1 to 9, wherein the first radius is half the length of the longest chord of the cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section, and wherein the second radius is half the length of the longest chord of the cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section.

[0091] Example 11. The feedthrough pin assembly according to any one of Examples 1 to 10, wherein a third radius can be defined as the distance of the longest radial straight line from the center of the feedthrough pin to a point on the inner edge of the spring plate defined by the annular window.

[0092] Example 12. A method of manufacturing a feedthrough pin assembly, the method comprising: obtaining a feedthrough pin having an elongated portion with a first radius and an enlarged portion with a second radius, wherein the first radius is less than the second radius; circumferentially orienting a spring plate around the elongated portion, the spring plate including an opening having an opening radius less than the second radius; forming an annular window from the circumferential gap between the spring plate and the first portion of the elongated portion; and positioning a translucent ferrule distally of the spring plate and circumferentially positioning the translucent ferrule around a second portion of the elongated portion.

[0093] Example 13. The method of manufacturing a feedthrough pin assembly according to Example 12, wherein the feedthrough pin includes a distal end configured to be electrically coupled to a battery.

[0094] Example 14. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 13, the method further comprising positioning the enlarged portion distally of the translucent ferrule and proximally of the distal end of the feedthrough pin.

[0095] Example 15. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 14, wherein the enlarged portion is positioned distally of the annular window and proximally of the translucent ferrule.

[0096] Example 16. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 15, wherein the translucent ferrule is configured to perform at least one of the following: attenuate or reflect at least a portion of the laser welding light.

[0097] Example 17. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 16, wherein the enlarged portion includes a first enlarged portion and a second enlarged portion separated by an intermediate portion, wherein the radius of the first enlarged portion and the radius of the second enlarged portion are greater than the radius of the intermediate portion, and wherein the radius of the intermediate portion is substantially the same as the first radius of the feedthrough pin.

[0098] Example 18. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 17, wherein the feedthrough pin comprises a heat dissipating material.

[0099] Example 19. The method of manufacturing a feedthrough pin assembly according to claim 18, wherein the heat dissipating material includes at least one of steel, silver, gold, or copper.

[0100] Example 20. The method of manufacturing a feedthrough pin assembly according to Examples 12 to 19, wherein the first radius is half the length of the longest chord of the cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section, and wherein the second radius is half the length of the longest chord of the cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section.

[0101] Example 21. The method of manufacturing a feedthrough pin according to Examples 12 to 20, wherein the third radius can be defined as the distance of the longest radial straight line from the center of the feedthrough pin to a point on the inner edge of the spring plate defined by the annular window.

[0102] Example 22. A method of laser welding a feedthrough pin, the method comprising: orienting a feedthrough pin assembly toward a laser energy source, the feedthrough pin assembly including: a feedthrough pin including an elongated portion having a first radius and an enlarged portion having a second radius, wherein the first radius is less than the second radius; a spring plate including an opening having an opening radius less than the second radius, the spring plate circumferentially oriented around a first portion of the elongated portion; an annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion; and a translucent ferrule positioned distally of the spring plate and circumferentially around a second portion of the elongated portion; and activating the laser energy source to emit laser energy toward the feedthrough pin assembly, wherein the enlarged portion of the feedthrough pin assembly performs at least one of: attenuating or reflecting at least a portion of the emitted laser energy.

[0103] Example 23. The method of laser welding a feedthrough pin according to Example 22, wherein the feedthrough pin includes a distal end configured to be electrically coupled to a battery.

[0104] Example 24. The method of laser welding a feedthrough pin according to Examples 22 to 23, wherein the enlarged portion is positioned distally of the translucent ferrule and proximally of the distal end of the feedthrough pin.

[0105] Example 25. The method of laser welding a feedthrough pin according to Examples 22 to 24, wherein the enlarged portion is positioned distally of the annular window and proximally of the translucent ferrule.

[0106] Example 26. The method of laser welding a feedthrough pin according to Examples 22 to 25, wherein at least a portion of the translucent ferrule is configured to perform at least one of: attenuating or reflecting at least a portion of the laser welding light.

[0107] Example 27. The method for laser welding of feedthrough pins according to Examples 22 to 26, wherein the enlarged portion includes a first enlarged portion and a second enlarged portion, the first enlarged portion and the second enlarged portion are separated by an intermediate portion, wherein the radius of the first enlarged portion and the radius of the second enlarged portion are greater than the radius of the intermediate portion, and wherein the radius of the intermediate portion is substantially the same as the first radius of the feedthrough pin.

[0108] Example 28. The method for laser welding of feedthrough pins according to Examples 22 to 27, wherein the feedthrough pin contains a heat dissipation material.

[0109] Example 29. The method for laser welding of feedthrough pins according to Examples 22 to 28, wherein the heat dissipation material includes at least one of steel, silver, gold, or copper.

[0110] Example 30. The method for laser welding of feedthrough pins according to Examples 22 to 29, wherein the first radius is smaller than the opening radius.

Claims

1. A feedthrough pin assembly, the feedthrough pin assembly comprising: A feedthrough pin, the feedthrough pin including an elongate portion having a first radius and an enlarged portion having a second radius, wherein the first radius is less than the second radius; A spring plate, the spring plate having an opening with an opening radius less than the second radius, the spring plate being circumferentially oriented around a first portion of the elongate portion; An annular window formed by a circumferential gap between the spring plate and the first portion of the elongate portion; And A translucent ferrule, the translucent ferrule being distal to the spring plate and circumferentially positioned around a second portion of the elongate portion.

2. The feedthrough pin assembly according to claim 1, wherein the feedthrough pin includes a distal end, wherein the distal end is configured to be electrically coupled to a battery.

3. The feedthrough pin assembly according to claims 1 to 2, wherein the enlarged portion is positioned distal to the translucent ferrule and proximal to the distal end of the feedthrough pin.

4. The feedthrough pin assembly according to claims 1 to 3, wherein the enlarged portion is positioned distal to the annular window and proximal to the translucent ferrule.

5. The feedthrough pin assembly according to claims 1 to 4, wherein at least a portion of the translucent ferrule is configured to perform at least one of: attenuating or reflecting at least a portion of a laser welding light.

6. The feedthrough pin assembly according to claims 1 to 5, wherein the enlarged portion includes a first enlarged portion and a second enlarged portion, the first enlarged portion and the second enlarged portion being separated by an intermediate portion, wherein the radius of the first enlarged portion and the radius of the second enlarged portion are greater than the radius of the intermediate portion, and wherein the radius of the intermediate portion is less than the radius of the first enlarged portion and the radius of the second enlarged portion.

7. The feedthrough pin assembly according to claims 1 to 6, wherein the feedthrough pin contains a heat dissipating material.

8. The feedthrough pin assembly according to claim 7, wherein the heat dissipating material includes at least one of steel, silver, gold, or copper.

9. The feedthrough pin assembly according to claims 1 to 8, wherein the first radius is less than the opening radius.

10. The feedthrough pin assembly according to claims 1 to 9, wherein the first radius is half the length of the longest chord of a cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section, and wherein the second radius is half the length of the longest chord of the cross-section, the longest chord extending linearly from a point on the outer edge of the shape formed by the cross-section to another point on the outer edge of the shape formed by the cross-section.

11. The feedthrough pin assembly according to claims 1 to 10, wherein a third radius can be defined as the distance of the longest radial straight line from the center of the feedthrough pin to a point on the inner edge of the spring plate defined by the annular window.

12. A method of manufacturing a feedthrough pin assembly according to any one of claims 1 to 11, the method comprising: Obtaining a feedthrough pin having an elongated portion with a first radius and an enlarged portion with a second radius, wherein the first radius is less than the second radius; Circumferentially orienting a spring plate around the elongated portion, the spring plate including an opening having an opening radius less than the second radius; Forming an annular window by a circumferential gap between the spring plate and the first portion of the elongated portion; And Positioning a translucent ferrule distally of the spring plate and circumferentially positioning the translucent ferrule around a second portion of the elongated portion.

13. The method of manufacturing a feedthrough pin assembly according to claim 12, wherein the feedthrough pin includes a distal end configured to be electrically coupled to a battery.

14. The method of manufacturing a feedthrough pin assembly according to claims 12 to 13, the method further comprising positioning the enlarged portion distally of the translucent ferrule and proximally of the distal end of the feedthrough pin.

15. A method of laser welding a feedthrough pin, the method comprising: Orienting a feedthrough pin assembly according to any one of claims 1 to 11 towards a laser energy source, the feedthrough pin assembly comprising: A feedthrough pin including an elongated portion with a first radius and an enlarged portion with a second radius, wherein the first radius is less than the second radius; A spring plate including an opening having an opening radius less than the second radius, the spring plate being circumferentially oriented around a first portion of the elongated portion; An annular window formed by a circumferential gap between the spring plate and the first portion of the elongated portion; and A translucent ferrule distally of the spring plate and circumferentially positioned around a second portion of the elongated portion; and Activating the laser energy source to emit laser energy towards the feedthrough pin assembly, wherein the enlarged portion of the feedthrough pin assembly performs at least one of attenuating or reflecting at least a portion of the emitted laser energy.

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