Laser Etched Bonding Surface for Implantable Medical Device Headers
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Solution Overview
Problem
Conventional methods for bonding polymeric headers to metallic housings in implantable medical devices, such as grit blasting, do not adequately increase the surface area and strength of the bond, particularly between dissimilar materials like titanium and polyurethane, leading to potential delamination due to thermal expansion differences.
Innovation Solution
Laser etching is used to create a textured surface on the metallic housing with a honeycomb pattern and spikes, increasing the surface area and improving bonding characteristics without embedding foreign materials, thus eliminating the need for additional anchors and enhancing mechanical locking with thermosetting polymers like epoxy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional grit blasting is used to roughen the bonding surface, then the surface area is increased, but foreign materials become embedded in the surface and bonding strength is insufficient for dissimilar materials
Solution Approach 1:
The patent replaces the mechanical grit blasting process with a laser-based process. The laser heats and melts the metal surface, creating a roughened texture through thermal processing rather than mechanical impact. This substitution eliminates the embedding of foreign grit particles while achieving the desired surface area increase and bonding characteristics.
Solution Approach 2:
The patent changes the physical state and properties of the bonding surface through controlled laser heating. By adjusting laser parameters (power, speed, pulse duration), the metal surface undergoes controlled melting and solidification, transforming from a smooth surface to a roughened surface with enhanced bonding properties without introducing foreign materials.
2Strength
If additional anchors are welded to strengthen the bond, then bonding strength is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent extracts and eliminates the additional anchor components from the device design. By sufficiently roughening the housing bonding surface through laser processing, the patent achieves adequate bonding strength without requiring separate anchor elements, thereby simplifying the overall device structure.
Solution Approach 2:
The laser-roughened housing surface performs multiple functions: it provides the primary bonding surface for the header, creates mechanical interlocking through surface texture, and eliminates the need for separate anchor components. This multi-functionality reduces device complexity while maintaining bonding strength.
3Reliability
If additional anchors and extended processing steps are used, then bonding reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent combines the surface roughening function and the bonding preparation function into a single laser processing step. The laser process simultaneously creates the roughened surface texture and prepares the surface for optimal polymer bonding, eliminating the need for separate anchor welding operations and reducing total manufacturing time.
Solution Approach 2:
The patent replaces the multi-step mechanical process (grit blasting followed by anchor welding) with a single laser-based process that achieves both surface roughening and bonding preparation in one operation, significantly reducing manufacturing time while maintaining or improving bonding reliability.
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 laser etched surface provides a strong, consistent, and reliable bond that meets mechanical and load requirements, reducing material and time costs while maintaining the integrity of electrical components, and is applicable to various medical devices.
Implementation Method 1
it has been found that by utilizing a laser process to heat and melt a metal surface in a controlled fashion, a roughened surface can be created that will promote bonding between dissimilar materials
Implementation Method 2
by utilizing a laser process to heat and melt a metal surface in a controlled fashion, a roughened surface can be created
Implementation Method 3
promote the adhesion and bonding of dissimilar materials
Data Source
AI summary
The present disclosure provides medical devices and methods of manufacturing medical devices wherein the medical device includes at least one bonding surface that has been roughed by laser etching to increase its surface area and improve its bonding characteristics. In many embodiments, the medical device is an implantable medical device that includes a hermetically sealed metallic housing that is bonded to a prefabricated non-metallic header. The hermetically sealed metallic housing includes at least one surface that has been subjected to a laser etching and roughening process to increase its surface area and improve its bonding characteristics. The laser etched surface may include spots created in a non-overlapping honeycomb-type pattern that may additionally include a series of spikes protruding therefrom to further improve bonding characteristics.