Circuit board mounted filtered feedthrough assembly having a composite conductive lead for an AIMD

• US 10,589,107 B2
• Filed: 03/04/2019
• Issued: 03/17/2020
• Est. Priority Date: 11/08/2016
• Status: Active Grant

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Inventors: Seitz, Keith W., Marzano, Thomas, Stevenson, Robert A., Frysz, Christine A., Woods, Jason, Brendel, Richard L., Martino, Marc Gregory
• Primary Examiner(s): Wehrheim, Lindsey G
• Application Number:
  US16/291,356
• Publication Number:
  US 20190192862A1
• Time in Patent Office: 379 Days
• CPC Class Codes: A61N 1/3754 Feedthroughs
• CPC Class Codes: H01G 4/012 Form of non-self-supporting electrodes
• CPC Class Codes: H01G 4/018 Dielectrics
• CPC Class Codes: H01G 4/224 Housing; Encapsulation
• CPC Class Codes: H01G 4/236 leading through the housing, i.e. lead-through
• CPC Class Codes: H01G 4/35 Feed-through capacitors or anti-noise capacitors
• CPC Class Codes: H01G 4/40 Structural combinations of fixed capacitors with other electric elements, the structure mainly consisting of a capacitor, e.g. RC combinations
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/10015 Non-printed capacitor

Abstract

A feedthrough separates a body fluid side from a device side. A passageway is disposed through the feedthrough. A body fluid side leadwire extends from a first end disposed inside the passageway to a second end on the body fluid side. A device side leadwire extends from a first end disposed inside the passageway to a second end on the device side. The body fluid side leadwire is hermetically sealed to the feedthrough body and is not of the same material as the device side leadwire. A circuit board has an active via hole with a second end of the second leadwire residing therein. The circuit board has an active circuit trace that is electrically connectable to electronic circuits housed in an AIMD, and a circuit board ground metallization. An active electrical path extends from the first leadwire to the second leadwire to an MLCC chip capacitor mounted on the circuit board and to the circuit board active circuit trace, and a ground electrical path extends from the MLCC chip capacitor to the circuit board ground metallization and then to the ferrule.

Claims

1. A circuit board mounted filtered feedthrough assembly having a composite conductive lead for an active implantable medical device (AIMD), the circuit board mounted filtered feedthrough assembly comprising:

a) a ferrule comprising a ferrule opening, wherein the ferrule is configured to be attachable to an opening in a housing of an AIMD;

b) an insulator at least partially residing in the ferrule opening where a first gold braze hermetically seals the insulator to the ferrule, wherein at least one insulator passageway extends through the insulator to an insulator first end surface and an insulator second end surface, and wherein an internal metallization is disposed on an inner surface of the at least one insulator passageway;

c) a first leadwire comprising a first leadwire first end spaced from a first leadwire second end, wherein the first leadwire first end resides in the at least one insulator passageway;

d) a second leadwire which is not of the same material as the first leadwire, the second leadwire comprising a second leadwire first end spaced from a second leadwire second end, wherein the second leadwire first end resides in the at least one insulator passageway and is positioned at or adjacent to the first leadwire first end, and wherein the second leadwire second end extends outwardly beyond the insulator second end surface;

e) a second gold braze contacting the first leadwire first end, the second leadwire first end and the internal metallization in the at least one insulator passageway, the first braze forming a hermetic seal separating the insulator first end surface from the insulator second end surface in the at least one insulator passageway; and

f) a circuit board comprising spaced apart circuit board first and second sides, wherein the circuit board first side is adjacent to the insulator second end surface;

g) a circuit board active via hole extending through the circuit board, wherein at least a portion of the second leadwire second end extending outwardly beyond the insulator second end surface resides in the circuit board active via hole, and wherein the circuit board comprises at least one circuit board active circuit trace that is electrically connectable to electronic circuits housed in the AIMD, and wherein the circuit board comprises a circuit board ground metallization that is spaced from the at least one active circuit trace; and

h) at least one two-terminal MLCC chip capacitor comprising a chip capacitor dielectric supporting at least one active electrode plate interleaved in a capacitive relationship with at least one ground electrode plate, wherein an active metallization is electrically connected to the at least one active electrode plate, and a ground metallization is electrically connected to the at least one ground electrode plate of the at least one two-terminal MLCC chip capacitor,

i) wherein an active electrical path extends from the first leadwire to the second leadwire and then to the active metallization of the at least one two-terminal MLCC chip capacitor and to the circuit board active circuit trace, and

j) wherein a ground electrical path extends from the ground metallization of the at least one two-terminal MLCC chip capacitor to the circuit board ground metallization and then to the ferrule.

2. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the circuit board ground metallization extends from a circuit board ground metallization first portion that is electrically connected to the ground metallization of the at least one two-terminal MLCC chip capacitor to a circuit board ground metallization second portion that is electrically connected to the ferrule or to the first gold braze hermetically sealing the insulator to the ferrule.

3. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the circuit board active via hole extending through the circuit board is electrically isolated from the at least one circuit board ground metallization.

4. The circuit board mounted filtered feedthrough assembly of claim 3, wherein the active electrical path comprises a first electrically conductive material that electrically connects the capacitor active metallization to the second leadwire and to the circuit board active circuit trace, and wherein the ground electrical path comprises a second electrically conductive material that electrically connects the capacitor ground metallization to at least one of the ferrule and the first gold braze.

5. The circuit board mounted filtered feedthrough assembly of claim 4, wherein the first and second electrically conductive materials are selected from the group consisting of a solder, a solder BGA, a solder paste, an epoxy, and a polyimide.

6. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the at least one two-terminal MLCC chip capacitor is attached to the circuit board, and wherein the circuit board is attached to the insulator.

7. The circuit board mounted filtered feedthrough assembly of claim 1, further including an oxide-resistant metal addition, wherein:

a) a second electrically conductive material electrically connects the ground metallization of the at least one two-terminal MLCC chip capacitor to the oxide resistant metal addition, and

b) a third electrically conductive material electrically connects the oxide-resistant metal addition to the ferrule, wherein the second and third electrically conductive materials and the oxide-resistant metal addition comprise the ground electrical path, or

c) the oxide-resistant metal addition is welded to the ferrule, and wherein a fourth electrically conductive material electrically connects the oxide-resistant metal addition to the ground metallization of the at least one two-terminal MLCC chip capacitor, the fourth electrically conductive material and the oxide-resistant metal addition comprising the ground electrical path.

8. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the second leadwire comprises platinum or palladium.

9. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the first leadwire is not biocompatible.

10. The circuit board mounted filtered feedthrough assembly of claim 9, wherein the first leadwire comprises niobium or tantalum.

11. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the first gold braze hermetically sealing the insulator to the ferrule is disposed at or adjacent to the insulator second end surface but does not extend to the insulator first end surface.

12. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the first and second hermetic seals each have a leak rate that is not greater than 1×

10<sup>−

7</sup> std cc He/sec.

13. The circuit board mounted filtered feedthrough assembly of claim 1, wherein an adhesion metallization is disposed at least partially on an outer surface of the insulator and a wetting metallization is disposed on the adhesion metallization, and wherein the first gold braze hermetically seals the ferrule to the wetting metallization.

14. The circuit board mounted filtered feedthrough assembly of claim 1, wherein an insulative washer is disposed between the insulator and the circuit board.

15. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the ferrule is configured to be joined to a housing for the AIMD by a laser weld or braze.

16. The circuit board mounted filtered feedthrough assembly of claim 1, wherein, when the filtered feedthrough assembly is attached to a housing of an AIMD, the insulator first end surface is a body fluid side that resides outside the AIMD and the insulator second end surface is a device side that resides inside the AIMD.

17. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the second leadwire second end extends outwardly beyond the circuit board.

18. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the second leadwire second end is recessed inwardly from the circuit board second side opposite the insulator second end surface.

19. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the first leadwire first end is soldered or welded to the second leadwire first end.

20. The circuit board mounted filtered feedthrough assembly of claim 1, wherein the circuit board active circuit trace is embedded in the circuit board.

21. The circuit board mounted filtered feedthrough assembly of claim 1, wherein a ground pin is conductively and mechanically connected to the ferrule, and wherein there is at least one internal circuit board ground circuit trace that is electrically connected to the ground pin and to the ground metallization of the at least one two-terminal MLCC chip capacitor.

22. The circuit board mounted filtered feedthrough assembly of claim 21, wherein there are at least two internal circuit board ground circuit traces and an external circuit board ground circuit trace disposed adjacent to either the ferrule, the insulator, or both, and wherein the at least two internal circuit board ground circuit traces and the external circuit board ground trace are electrically connected to the ground pin and to the ground metallization of the at least one two-terminal MLCC chip capacitor.

23. The circuit board mounted filtered feedthrough assembly of claim 21, wherein the ground pin is conductively and mechanically connected to the ferrule by one of the group consisting of a third gold braze, a laser weld, and being integral with the ferrule.

24. The circuit board mounted filtered feedthrough assembly of claim 21, wherein the ground pin resides in a countersink in the ferrule.

25. The circuit board mounted filtered feedthrough assembly of claim 21, wherein the ground pin extends through a ferrule via hole extending to a ferrule first side and a ferrule second side.

26. The circuit board mounted filtered feedthrough assembly of claim 1, the first leadwire second end extends outwardly beyond the insulator first end surface.

27. A circuit board mounted filtered feedthrough assembly having a composite conductive lead for an active implantable medical device (AIMD), the circuit board mounted filtered feedthrough assembly comprising:

a) a ferrule comprising a ferrule opening, wherein the ferrule is configured to be attachable to an opening in a housing of an AIMD;

b) an insulator at least partially residing in the ferrule opening where a first gold braze hermetically seals the insulator to the ferrule, wherein a plurality of insulator passageways extend through the insulator to an insulator first end surface and an insulator second end surface, and wherein an internal metallization is disposed on an inner surface of each of the plurality of insulator passageways;

c) a plurality of first leadwires, each comprising a first leadwire first end spaced from a first leadwire second end, wherein a first leadwire first end resides in each of the plurality of insulator passageways;

d) a plurality of second leadwires which are not of the same material as the first leadwires, the plurality of second leadwires each comprising a second leadwire first end spaced from a second leadwire second end, wherein a second leadwire first end resides in each of the plurality of insulator passageways and is positioned at or adjacent to a respective first leadwire first end, and wherein the plurality of second leadwire second ends extend outwardly beyond the insulator second end surface;

e) a plurality of second gold brazes, a respective second gold braze contacting the first leadwire first end, the second leadwire first end and the internal metallization to thereby form a hermetic seal separating the insulator first end surface from the insulator second end surface in each of the plurality of insulator passageways; and

f) a circuit board comprising spaced apart circuit board first and second sides, wherein the circuit board first side is adjacent to the insulator second end surface;

g) a plurality of circuit board active via holes extending through the circuit board, wherein at least a portion of a respective one of the plurality of second leadwire second ends extending outwardly beyond the insulator second end surface resides in one of the circuit board active via holes, and wherein the circuit board comprises a plurality of circuit board active circuit traces that are electrically connectable to electronic circuits housed in the AIMD; and

h) a plurality of two-terminal MLCC chip capacitors, each comprising a chip capacitor dielectric supporting at least one active electrode plate interleaved in a capacitive relationship with at least one ground electrode plate, wherein an active metallization is electrically connected to the at least one active electrode plate, and a ground metallization is electrically connected to the at least one ground electrode plate of each of the plurality of two-terminal MLCC chip capacitors,

i) wherein an active electrical path extends from each of the first leadwires to a respective one the second leadwires and then to the active metallization of a respective one of the plurality of two-terminal MLCC chip capacitors and to a respective one of the circuit board active circuit traces, and

j) wherein a ground electrical path extends from the ground metallization of a respective one of the plurality of two-terminal MLCC chip capacitors to the circuit board ground metallization and then to the ferrule.

28. The circuit board mounted filtered feedthrough assembly of claim 27, wherein the plurality of first leadwire second ends extend outwardly beyond the insulator first end surface.

29. A circuit board mounted filtered feedthrough assembly having a composite conductive lead for an active implantable medical device (AIMD), the circuit board mounted filtered feedthrough assembly comprising:

a) a ferrule comprising a ferrule opening, wherein the ferrule is configured to be attachable to an opening in a housing of an AIMD, and wherein a ground pin is conductively and mechanically connected to the ferrule;

b) an insulator at least partially residing in the ferrule opening where a first gold braze hermetically seals the insulator to the ferrule, wherein a plurality of insulator passageways extend through the insulator to an insulator first end surface and an insulator second end surface, and wherein an internal metallization is disposed on an inner surface of each of the plurality of insulator passageways;

c) a plurality of first leadwires, each comprising a first leadwire first end spaced from a first leadwire second end, wherein a first leadwire first end resides in each of the plurality of insulator passageways;

d) a plurality of second leadwires which are not of the same material as the first leadwires, the plurality of second leadwires each comprising a second leadwire first end spaced from a second leadwire second end, wherein a second leadwire first end resides in each of the plurality of insulator passageways and is positioned at or adjacent to a respective first leadwire first end, and wherein the plurality of second leadwire second ends extend outwardly beyond the insulator second end surface;

e) a plurality of second gold brazes, a respective second gold braze contacting the first leadwire first end, the second leadwire first end and the internal metallization to thereby form a hermetic seal separating the insulator first end surface from the insulator second end surface in each of the plurality of insulator passageways;

f) a plurality of two-terminal MLCC chip capacitors, each comprising a chip capacitor dielectric supporting at least one active electrode plate interleaved in a capacitive relationship with at least one ground electrode plate, wherein an active metallization is electrically connected to the at least one active electrode plate, and a ground metallization is electrically connected to the at least one ground electrode plate of each of the plurality of two-terminal MLCC chip capacitors;

g) a circuit board comprising spaced apart circuit board first and second sides, wherein the circuit board first side is adjacent to the insulator second end surface, and wherein there is at least one internal circuit board ground circuit trace;

h) a plurality of circuit board active via holes extending through the circuit board, wherein at least a portion of a respective one of the second leadwire second ends extending outwardly beyond the insulator second end surface resides in one of the circuit board active via holes, and wherein the circuit board comprises a plurality of circuit board active circuit traces that are electrically connectable to electronic circuits housed in the AIMD; and

i) a plurality of circuit board ground via holes extending through the circuit board, wherein a ground metallization resides on an inner surface of each of the plurality ground via holes in the circuit board, and wherein the at least one internal circuit board ground circuit trace is electrically connected to the ground pin and to the plurality of circuit board ground metallizations,

j) wherein an active electrical path extends from each of the first leadwires to a respective one the second leadwires and then to the active metallization of a respective one of the plurality of two-terminal MLCC chip capacitors and to a respective one of the circuit board active circuit traces, and

k) wherein a ground electrical path extends from the ground metallization of a respective one of the plurality of two-terminal MLCC chip capacitors to the ground metallization residing in a respective one of the plurality of ground via holes in the circuit board, the ground metallization being electrically connected to the internal circuit board ground circuit trace electrically connected to the ground pin and to the ferrule.

30. The circuit board mounted filtered feedthrough assembly of claim 29, wherein at least two ground pins are conductively and mechanically connected to the ferrule, and wherein the plurality of two-terminal MLCC chip capacitors reside between the two ground pins.

31. The circuit board mounted filtered feedthrough assembly of claim 29, wherein there are at least two internal circuit board ground circuit traces and an external circuit board ground circuit trace disposed adjacent to either the ferrule, the insulator, or both, and wherein the at least two internal circuit board ground circuit traces and the external circuit board ground trace are electrically connected to the ground pin and to the ground metallizations of each of the plurality of two-terminal MLCC chip capacitors.

32. The circuit board mounted filtered feedthrough assembly of claim 29, wherein the plurality of first leadwire second ends extend outwardly beyond the insulator first end surface.