Leadless device with overmolded components

• US 10,029,107 B1
• Filed: 01/25/2018
• Issued: 07/24/2018
• Est. Priority Date: 01/26/2017
• Status: Active Grant

• Current Assignee: Cardiac Pacemakers Incorporated (Boston Scientific Corporation)
• Original Assignee: Cardiac Pacemakers Incorporated (Boston Scientific Corporation)
• Inventors: Webb, Erin Kristen, Williams, Thomas Lee, Sachs, Dana, Frankson, Danielle
• Primary Examiner(s): Nguyen, Phuong Chi T
• Application Number:
  US15/880,221
• Publication Number:
  US 20180207427A1
• Time in Patent Office: 180 Days
• Field of Search: 439 761, 439936, 439676, 439686, 361736, 36167901
• CPC Class Codes: A61N 1/365 controlled by a physiological parameter, e.g. heart potential evoked response A61N1/371
• CPC Class Codes: A61N 1/37276 characterised by means for reducing power consumption during telemetry
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/3756 Casings with electrodes thereon, e.g. leadless stimulators
• CPC Class Codes: A61N 1/3758 Packaging of the components within the casing

Abstract

An electronics module for use in an Implantable Medical Device (IMD) may include a plurality of electrical components connected to form a circuit that includes a terminal and a potting material that supports the plurality of electrical components. The plurality of electrical components and the potting material together form a circuit sub-module in which the terminal is accessible from outside of the circuit sub-module. A metallic layer that conforms to an outer surface of the circuit sub-module is provided thereon such that the terminal is accessible from outside of the metallic layer.

Claims

1. An electronics module in an Implantable Medical Device (IMD), the electronics module comprising:

a plurality of electrical components connected to form a circuit that includes a terminal;

a potting material supporting the plurality of electrical components, wherein

the plurality of electrical components and the potting material form a circuit sub-module, wherein the terminal is accessible from outside of the circuit sub-module; and

a metallic layer provided on an outer surface of the circuit sub-module, wherein the metallic layer conforms to the outer surface of the circuit sub-module, and the terminal is accessible from outside of the metallic layer;

wherein

the circuit includes a second terminal, and wherein the second terminal is accessible from outside of the circuit sub-module.

2. The electronics module of claim 1, wherein the potting material is molded over at least some of the plurality of electrical components.

3. The electronics module of claim 1, wherein the outer surface of the circuit sub-module is treated for receiving the metallic layer.

4. The electronics module of claim 1, further comprising an insulator between the terminal and the metallic layer.

5. The electronics module of claim 1, wherein the metallic layer comprises TiN.

6. The electronics module of claim 1, wherein the metallic layer includes a deposited layer.

7. The electronics module of claim 1, wherein the terminal is a feedthrough terminal.

8. The electronics module of claim 1, wherein the circuit is configured to sense cardiac electrical activity and to deliver pacing pulses.

9. A leadless cardiac pacemaker (LCP) configured to pace a patient'"'"'s heart, the LCP disposable within a chamber of the patient'"'"'s heart, the LCP comprising:

an electronics module comprising;

a plurality of electrical components connected to form a circuit that includes at least a first terminal, a second terminal and a third terminal;

a potting material supporting the plurality of electrical components, wherein the plurality of electrical components and the potting material form a circuit sub-module, wherein the first terminal, the second terminal and the third terminal are accessible from outside of the circuit sub-module; and

a metallic layer provided on an outer surface of the circuit sub-module, wherein the metallic layer conforms to the outer surface of the circuit sub-module, and the first terminal, the second terminal and the third terminal are accessible from outside of the metallic layer;

a plurality of electrodes, the first terminal of the electronics module is operatively coupled to one of the plurality of electrodes;

a power source having a first power terminal and a second power terminal, wherein the power source is secured relative to the electronics module with the first power terminal operatively coupled to the second terminal of the electronics module and the second power terminal operatively coupled to the third terminal of the electronics module.

10. The leadless cardiac pacemaker (LCP) of claim 9, further comprising a fixation mechanism secured relative to the electronics module for fixing the LCP to the patient'"'"'s heart.

11. The leadless cardiac pacemaker (LCP) of claim 9, wherein the potting material is molded over at least some of the plurality of electrical components.

12. The leadless cardiac pacemaker (LCP) of claim 9, wherein the plurality of electrical components comprise two or more stacked circuit boards operably coupled together via flexible interconnects, and wherein the potting material encapsulates at least a portion of the two or more stacked circuit boards.

13. The leadless cardiac pacemaker (LCP) of claim 9, wherein the circuit is configured to sense cardiac electrical activity via two or more of the plurality of electrodes and to deliver pacing pulses via two or more of the plurality of electrodes.

14. The leadless cardiac pacemaker (LCP) of claim 9, further comprising an over-molded layer over the electronics module.

15. The leadless cardiac pacemaker (LCP) of claim 14, further comprising a fixation mechanism secured relative to the electronics module via the over-molded layer, wherein the fixation mechanism is for fixing the LCP to the patient'"'"'s heart.

16. The leadless cardiac pacemaker (LCP) of claim 14, wherein the over-molded layer helps secure the power source relative to the electronics module.

17. A method of manufacturing a leadless implantable medical device (IMD), the method comprising:

potting a circuit in a potting material to at least partially encapsulate the circuit within the potting material;

applying a metal coating over the potted circuit to provide a moisture barrier to at least part of the potted circuit;

attaching the potted circuit to a battery and operatively connecting the circuit to the battery;

attaching a fixation mechanism for fixing the IMD to a patient'"'"'s heart;

operatively connecting a first electrode to the circuit; and

operatively connecting a second electrode to the circuit.

18. The method of claim 17, further comprising applying a parylene coating to the IMD subsequent to attaching the potted circuit to the battery.

19. The method of claim 17, wherein attaching the fixation mechanism comprises over-molding a layer over at least part of the fixation mechanism and over at least part of the potted circuit.