Ceramic Header With Plated Traces for Implantable Device
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Solution Overview
Problem
Conventional implantable medical device (IMD) designs face challenges in reliably attaching the header, which houses an antenna and electrodes, due to the small size of the header and difficulties in achieving reliable adhesion to the IMD housing.
Innovation Solution
The IMD features a ceramic header with a main body that includes side walls, a distal end, and a proximal mounting end, with integrated electrode and antenna retention regions and platforms, and plated traces for electrical coupling, allowing for a secure and reliable attachment without the need for a feedthrough assembly, using a ceramic material with projecting and recessed features for enhanced reliability and biocompatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional epoxy cast or thermoplastic header is used, then the header can be formed and attached to the IMD housing, but the small size of the header makes attachment difficult and adhesion reliability is compromised
Solution Approach 1:
The patent employs a hybrid construction where a ceramic header body is combined with a metal shell. The ceramic provides biocompatibility and electrical insulation, while the metal shell provides mechanical strength and reliable attachment to the IMD housing. This composite approach resolves the contradiction by combining materials that individually address different requirements.
Solution Approach 2:
The header incorporates a curved or rounded geometry rather than sharp angles, which distributes stress more evenly during attachment and reduces stress concentration points. This curved design enhances both the reliability of attachment and the mechanical durability of the small header component.
2Reliability
If additional materials like epoxy or Tecothane are used for adhesion, then the header can be attached to the housing, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the header body and attachment structure into a single integrated ceramic component with the metal shell. The ceramic header is formed with integrated features that directly interface with the housing, eliminating the need for separate adhesive materials and reducing manufacturing steps while maintaining reliable attachment.
Solution Approach 2:
The ceramic header design incorporates self-aligning and self-securing features that allow the header to attach to the housing without requiring external adhesive materials. The integrated retention features and mechanical interlocking provide self-service attachment functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design provides a robust and reliable attachment method for the header to the IMD housing, improving manufacturing reliability and reducing the need for additional materials like epoxy or Tecothane, while maintaining a compact size and ensuring biocompatibility.
Implementation Method 1
The header may be formed by an epoxy cast in-place on an end of a case or housing of the IMD. Optionally, the header may be pre-molded using a thermoplastic polyurethane composition
Implementation Method 2
The main body includes a first plated trace formed through the ceramic material to be electrically coupled to the electronics module in the device housing. Between the antenna and the antenna connector, the main body includes a second plated trace formed through the ceramic material between the electrode and the electrode connector
Data Source
AI summary
Methods and devices are provided for implantable medical devices. The device comprises a device housing that has an electronics module, an electrode, an antenna, and a header that has a main body. The main body is formed of a ceramic material that includes side walls, a distal end and a proximal mounting end. The main body has an electrode retention region and an antenna retention platform. The antenna extends along the antenna retention platform. The electrode is provided at the electrode retention region. The mounting end includes electrode and antenna connectors. The main body includes a first plated trace formed through the ceramic material to be electrically coupled to the electronics module in the device housing. Between the antenna and the antenna connector, the main body includes a second plated trace formed through the ceramic material between the electrode and the electrode connector.