Flex Circuit Sleeve Sealing for Implantable Power Connections

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Solution Overview

Problem

Existing implantable medical devices using glass-to-metal seals (GTMS) are not designed for exposure to bodily fluids, and there is a need for a flexible connection that adapts to various device sizes while maintaining hermeticity.

Innovation Solution

A flex circuit is used to connect the electrical energy power source to the medical device, sealed within a sleeve that protects it from bodily fluids, extending the path of moisture to the glass-to-metal seal and printed circuit board assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a coil spring is used to connect the terminal pin to the contact plate, then electrical connection is achieved, but the device size and flexibility are limited

Engineering Contradiction:

Improvedevice size adaptabilityVSAvoidconnection structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical coil spring connection with a flex circuit that provides electrical connection through a flexible printed circuit board. This substitution eliminates the need for mechanical compression and contact pressure, allowing for greater size adaptability and reduced structural complexity while maintaining reliable electrical connectivity between the terminal pin and contact plate

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a flex circuit composed of flexible insulative substrate with conductive traces, allowing the connection structure to adapt to different device sizes and configurations. The flexible nature of the circuit board enables size adaptability while the integrated trace design reduces overall connection structure complexity compared to discrete spring components

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of operation

If the glass-to-metal seal is exposed to body fluids, then the medical device can be implanted, but the hermeticity and reliability are compromised

Engineering Contradiction:

ImproveimplantabilityVSAvoidhermeticity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent introduces a hermetic seal assembly as an intermediary barrier between the glass-to-metal seal and the body fluid environment. This seal assembly, comprising a hermetic seal member with a barrier layer, acts as a protective mediator that allows the medical device to be implanted while preventing body fluids from contacting the GTMS, thereby maintaining both implantability and hermeticity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The hermetic seal member utilizes a barrier layer formed by depositing metal or metal alloy on the outer surface of the insulative material, creating a thin film protective barrier. This flexible yet hermetic barrier prevents fluid penetration while accommodating the implantable device configuration, ensuring both ease of implantation and long-term reliability

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the electrochemical cell is hermetically sealed inside the medical device, then the GTMS is protected from body fluids, but the device housing prevents flexibility in size adaptation

Engineering Contradiction:

Improveprotection from body fluidsVSAvoidsize adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent segments the protective function into separate components: the hermetic seal assembly is separated from the device housing, allowing the housing to be optimized for size adaptability while the seal assembly provides focused protection for the GTMS. This segmentation enables independent optimization of both reliability and adaptability characteristics

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hermetic seal assembly serves as an intermediary protective element that can be independently configured and positioned between the electrochemical cell and the external environment. This intermediary structure allows the device housing to maintain flexibility in size adaptation while the seal provides dedicated protection for the GTMS from body fluids

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12515060B1Electrical energy power source connected to an active medical device through a flex circuit

Publication Date: 2026.01.06 GREATBATCH LTD

AI summary

An active medical device comprises an electrical energy power source powering a medical device. The power source has an open-ended casing that is hermetically sealed with a glass-to-metal seal (GTMS) supported in a lid closing the casing. The medical device has an open-ended housing that houses a PCB assembly which is configured to control functions of the active medical device. A sleeve provides a sleeve lumen, and a flex circuit resides inside the sleeve lumen. The flex circuit inside the sleeve lumen is connected to the power source and to the PCB assembly to power the active medical device, and the sleeve is connected to the medical device housing at the housing open end and to the power source casing adjacent to the lid supporting the GTMS to hermetically seal the active medical device.