Hermetic Sensor Enclosure With Ceramic Cap for RF-Safe Implants

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Solution Overview

Problem

Implantable sensors containing non-biocompatible materials pose a challenge as they need to be isolated from contact with the body, and metal enclosures can disrupt radiofrequency communication, while glass and ceramic enclosures may compromise the mechanical properties of metallic implants during welding.

Innovation Solution

A hermetic sealing method using a ceramic cap laser-welded onto a metal rim of an anatomical implant to enclose sensing elements, absorbing welding heat and maintaining RF communication, with the rim supporting a sensor and other components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal enclosure is used to protect the sensor, then mechanical strength is improved, but RF communication is disrupted

Engineering Contradiction:

Improvemechanical strengthVSAvoidRF communication

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The enclosure is segmented into two distinct parts: a metal rim that provides mechanical strength and structural support, and a ceramic cap that enables RF communication while providing hermetic sealing. This segmentation allows each material to perform its optimal function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The enclosure uses a composite structure combining metal and ceramic materials. The metal rim provides mechanical strength, while the ceramic cap provides RF transparency and hermetic sealing. This composite approach resolves the contradiction by utilizing the complementary properties of different materials in a unified structure.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a ceramic cap is laser-welded to seal the sensor, then hermetic sealing is improved, but the implant's mechanical properties are compromised

Engineering Contradiction:

Improvehermetic sealingVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sealing function is separated from the load-bearing function. The ceramic cap provides hermetic sealing through laser welding, while the metal rim maintains the structural integrity and mechanical properties of the implant. This segmentation prevents the welding process from compromising the implant's mechanical properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal rim acts as an intermediary that absorbs the thermal stress and mechanical stress from the laser welding process. The welding is performed on the ceramic cap to the metal rim interface, and the rim's design allows it to withstand the thermal effects without compromising the overall mechanical properties of the implant.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If non-biocompatible materials are used in the sensor, then sensor functionality is improved, but biocompatibility is reduced

Engineering Contradiction:

Improvesensor functionalityVSAvoidbiocompatibility

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The non-biocompatible sensor components are extracted and isolated from direct contact with the biological environment. The hermetic seal created by the ceramic cap and metal rim enclosure separates the sensor's internal components (which may contain non-biocompatible materials) from the surrounding bodily fluids and tissues, allowing the sensor to maintain full functionality without compromising biocompatibility.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The hermetic enclosure acts as an intermediary barrier between the non-biocompatible sensor materials and the biocompatible biological environment. This barrier allows the sensor to perform its measurement functions while preventing any harmful interaction with the patient's body, effectively decoupling functionality from biocompatibility requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method ensures biocompatibility and effective RF communication while protecting the implant's mechanical integrity by absorbing welding heat, allowing for reliable tracking of patient health parameters.

Implementation Method 1

absorbing welding heat and maintaining RF communication

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

ceramic cap laser-welded onto a metal rim

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

ceramic cap laser-welded onto a metal rim

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 4

laser-welded

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 5

hermetically sealed within the pocket

Methodology Applied

Scientific EffectHermetic sealing: Physical Containment

Data Source

PatentUS12514505B2Hermetic enclosure for implantable sensors

Publication Date: 2026.01.06 DEPUY SYNTHES PROD INC

AI summary

In one example, an anatomical implant has an implant body and a rim. The implant body has an outer surface, and the rim extends from the implant body along an outward direction. The rim has an internal surface, and an external surface opposite the internal surface. The internal surface defines a pocket that can support a sensor therein. In another example, a system comprises the anatomical implant, the sensor, and a cap, where the cap is attached to the rim such that the sensor is hermetically sealed within the pocket.