Low Surface Energy Layer for Hermetic Medical Implant Packaging
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Solution Overview
Problem
Current hermetic packaging technologies for implantable medical devices face challenges in achieving low permeability to bodily fluids, mechanical stability, and conformity with complex three-dimensional structures, particularly in reducing size and preventing corrosion or degradation from physiological environments.
Innovation Solution
A multi-layer packaging approach is introduced, featuring a low surface energy layer deposited over components and substrates, followed by a biocompatible hermetic coating. The low surface energy layer, made from materials like silicones or polyurethanes, conforms to the components, reduces surface energy, and minimizes stress, while the hermetic coating, composed of polymers and inorganic materials, enhances barrier properties and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hermetic packaging is used, then protection against bodily fluids is provided, but conformity with complex three-dimensional structures is poor
Solution Approach 1:
The patent applies parameter changes by transitioning the packaging material from a rigid state to a low-viscosity liquid state that can flow and conform to complex three-dimensional surfaces, then solidifying it to maintain the conformal shape. This parameter change enables the packaging to achieve both conformality with intricate device geometries and hermetic protection against bodily fluids.
2Volume of moving object
If packaging size is reduced for miniaturization, then device size is decreased, but mechanical stability is compromised
Solution Approach 1:
The patent employs composite materials by combining an elastomeric base material with reinforcing particles or fibers to create a composite packaging material. This composite structure provides both the flexibility needed for miniaturization and the mechanical strength required for stability, allowing the packaging to maintain integrity at reduced sizes.
3Reliability
If permeability to bodily fluids is reduced, then protection is improved, but material selection becomes more restrictive
Solution Approach 1:
The patent applies local quality by creating a multi-layer packaging structure where different layers serve different functions: one layer provides conformality and stress relief, while another layer provides the hermetic barrier against bodily fluids. This local differentiation of material properties allows each layer to be optimized for its specific function, achieving low permeability without overly restricting overall material selection.
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 solution provides improved conformity, mechanical stability, and reduced permeability to bodily fluids, ensuring the protection of both the patient and the device components, with enhanced handling and durability of the packaging.
Implementation Method 1
a low surface energy layer which is deposited as a liquid over at least a first surface of a first portion of the components and the substrate, the low surface energy layer becoming solidified after deposition
Data Source
AI summary
Implantable medical devices, and methods of coating same, including a plurality of components disposed on a substrate, and a low surface energy layer deposited as a liquid over at least a first portion of the components and the substrate, the low surface energy layer becoming solidified after deposition and conforming to at least the first portion of the components. The devices further include a biocompatible hermetic coating conforming to and sealingly covering at least a portion of the low surface energy layer.