Multi-layer Vapor Deposition Coating for Implantable Devices

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Solution Overview

Problem

Current packaging technologies for implantable medical devices are not cost-effective and fail to provide adequate protection against bodily fluids, leading to potential corrosion and degradation of components, while also requiring high application temperatures that may cause temperature defects.

Innovation Solution

A biocompatible multi-layer coating is applied using vapor deposition, comprising sets of layers formed by dissociation and deposition of polymeric precursors and biocompatible liquids, with each layer differing in diffusion properties to enhance the overall barrier effect, including the use of plasma-enhanced parylene and active agents for protection against bodily fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional packaging technologies are used, then components are protected to some extent, but the packaging is not cost-effective and requires high application temperatures that may cause temperature defects

Engineering Contradiction:

Improveprotection against bodily fluidsVSAvoidapplication temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the application temperature parameter from high temperatures to room temperature by using a multi-layer coating system with biocompatible materials that can be deposited at lower temperatures, thereby avoiding temperature defects while maintaining protection reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite multi-layer coating structure combining different biocompatible materials (such as parylene layers, liquid crystal polymers, and other biocompatible polymers) to achieve both protection against bodily fluids and compatibility with room temperature application processes

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional packaging technologies are used, then components are protected, but the packaging is not cost-effective for batch manufacturing

Engineering Contradiction:

Improveprotection against corrosion and degradationVSAvoidcost-effectiveness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the protective packaging into multiple functional layers, each providing specific protection properties (barrier, mechanical strength, biocompatibility), allowing for optimized material selection and batch manufacturing processes that reduce overall cost while maintaining reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-layer coating system provides multiple functions simultaneously (corrosion protection, biocompatibility, mechanical protection, and cost-effective batch manufacturing capability), making the packaging solution universally applicable to various implantable medical device components

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If single-layer packaging is used, then the structure is simple, but the permeability to bodily fluids is insufficient

Engineering Contradiction:

Improvepackaging structureVSAvoidhermetic seal quality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent uses composite multi-layer materials with different permeability characteristics to create a hermetic seal that blocks bodily fluids effectively, where each layer contributes specific barrier properties that complement each other to achieve superior protection

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements a nested multi-layer structure where successive layers are deposited over previous layers, with each layer providing an additional barrier against bodily fluid permeation, creating a deeply nested protective configuration that enhances hermetic seal quality

Inventive Principle:

Principle #7Nested doll (Nesting)

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 multi-layer coating provides a reliable, cost-effective, and hermetic seal that protects both the patient and the medical device components from bodily fluids, allowing for application at room temperature and reducing the risk of temperature defects, while incorporating active agents for enhanced protection.

Implementation Method 1

a biocompatible multi-layer coating applied at least in part by vapour deposition to conform to and sealingly cover at least a portion of the components

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition

Implementation Method 2

each set has at least one layer formed by dissociation of a polymeric precursor and then deposition of that dissociated precursor

Methodology Applied

Scientific EffectDissociation: Photodissociation

Implementation Method 3

at least one of the layers in each set is a plasma-enhanced parylene polymer

Methodology Applied

Scientific EffectPlasma enhancement: Plasma Enhanced Chemical Vapour Deposition

Data Source

PatentUS8361591B2Packaging with active protection layer

Publication Date: 2013.01.29 COAT X SA

AI summary

An implantable medical device including a plurality of components on a substrate, and a biocompatible multi-layer coating applied at least in part by vapor deposition to conform to and sealingly cover at least a portion of the components and/or the substrate. The coating is applied in at least two sets of layers, wherein each set has at least one layer formed by dissociation of a polymeric precursor and then deposition of that precursor, and another layer is a biocompatible liquid.