Electrode with Integrated Feedthrough Pin for Miniature Electrochemical Cells

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Solution Overview

Problem

Existing methods for manufacturing electrodes and electrochemical cells for implantable medical devices (IMDs) face challenges in creating compact designs that minimize patient discomfort and facilitate manufacturing, particularly in small anatomical spaces.

Innovation Solution

The method involves assembling an electrode assembly with a current collector attached to a feedthrough pin, forming a solid electrode from a first electrode material, and encapsulating it, along with a second electrode within a housing, to create a compact electrochemical cell that does not require separate attachment of electrodes to the feedthrough pin, using materials like platinum, titanium, and polymeric insulators, and employing a press assembly for material compaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If separate attachment of electrodes to feedthrough pin is used, then electrical connection is established, but device complexity and manufacturing steps increase

Engineering Contradiction:

Improveelectrode assembly structureVSAvoidelectrical connection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The current collector is integrated directly with the feedthrough pin to form a unified component, eliminating the need for separate attachment steps. This merging of components reduces device complexity and manufacturing steps while maintaining reliable electrical connection through the direct integration of conductive pathways.

Inventive Principle:

Principle #5Merging (Combining)

2Volume of moving object

If compact electrode design is implemented, then IMD size is reduced for small anatomical spaces, but manufacturing precision requirements increase

Engineering Contradiction:

ImproveIMD sizeVSAvoidelectrode formation

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The current collector is pre-formed and integrated with the feedthrough pin before electrode material is applied. This preliminary preparation of the conductive structure allows for precise positioning and reduces the precision requirements during subsequent electrode formation steps, enabling compact design while maintaining manufacturability.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If electrode material is directly formed on feedthrough pin, then separate attachment is eliminated, but electrical insulation requirements increase

Engineering Contradiction:

Improveelectrode assembly processVSAvoidelectrical insulation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

An insulating layer is introduced as an intermediary between the conductive feedthrough pin/current collector structure and the electrode material. This mediator enables direct formation of electrode material on the feedthrough pin while maintaining electrical insulation, simplifying manufacturing by eliminating separate attachment steps while ensuring proper electrical isolation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2633572B1Electrode with interconnection for miniature electrochemical cells and methods of making

Publication Date: 2017.04.05 MEDTRONIC INC

AI summary

Miniature electrodes and electrochemical cells are disclosed. Such electrodes are made from forming an electrode mixture onto a current collector and distal end of a feedthrough pin such that the current collector and distal end of the feedthrough pin is encapsulated. The methods and electrode assemblies disclosed herein allow such electrode assemblies to be made free from the step of directly attaching a formed electrode to a feedthrough pin and thus simplifying assembly and decreasing size.