Complex connector in component footprint of implantable medical device

• US 20040068302A1
• Filed: 10/07/2002
• Published: 04/08/2004
• Est. Priority Date: 10/07/2002
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Bomstad, Timothy T., Norton, John D., Robinson, Scott J., Ries, Andrew J., Breyen, Mark D., Casby, Kurt J., Rodgers, Angela, Ross, Brian J., Clarke, Michael E., Kehn, Jeffrey L., Appleseth, Wayne L., Erklouts, Dan D.
• Granted Patent: US 8,249,710 B2
• Time in Patent Office: Days
• US Class Current: 607/36
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/37512 Pacemakers
• CPC Class Codes: H01G 9/008 Terminals
• CPC Class Codes: H01G 9/08 Housing; Encapsulation
• CPC Class Codes: H01R 2201/12 for medicine and surgery

Abstract

A complex connector and component within an implantable medical device in which the complex connector is positioned within the spacing footprint of the component to optimize packaging within the device.

Claims

1. An implantable medical device having at least one capacitor for storing and delivering electrical energy on demand and in which the capacitor includes a related connector for electrically connecting the capacitor with at least one other component within the device, wherein the capacitor is shaped to connect with an embedded complex electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of the capacitor.

2. The device of claim 1 in which the capacitor is a flat capacitor.

3. The device of claim 1 in which the embedded electrical connector comprises a substantially flat injection molded component.

4. The device of claim 3 in which the embedded electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least one wire-way shaped to receive and protect a bare metal wire connector from an associated capacitor.

5. The device of claim 1 in which the embedded electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least four wire-ways each shaped to receive and protect a bare metal wire connector from an associated capacitor.

6. The device of claim 1 in which the embedded electrical connector is sized so as to fit within the space formed within the zone so that a wall to wall battery may be positioned in abutting relation to the capacitor without the connector creating any margin between the capacitor and the battery.

7. The device of claim 1 in which the connector comprises exposed metal pads for dedicated test points that are separate from wire connect points.

8. The device of claim 5 in which the connector wire ways are arranged so that two wire ways connect to a common electrical connector on the stamped metal piece and each of the two additional wires are split among the positive and negative voltage electrical connectors on the stamped metal piece.

9. The device of claim 1 in which the at least one capacitor for storing and delivering electrical energy on demand has at least a 30 Joule capacity, a volume of less than about 36.5 cubic centimeters and a thickness of less than about 14 millimeters.

10. An implantable medical device having at least one capacitor for storing and delivering electrical energy on demand and in which the capacitor has a related connector for electrically connecting the capacitor with at least one other component within the device, wherein the capacitor is shaped to connect with an embedded electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of the capacitor and by at least one additional perimeter surface of the capacitor which forms a notched area.

11. The device of claim 10 in which the capacitors are each a flat capacitor.

12. The device of claim 10 in which the embedded electrical connector comprises a substantially flat injection molded component.

13. The device of claim 12 in which the embedded electrical connector comprises a stamped metal piece and an injection molded resinous piece forming a connector with at least one wire-way shaped to receive and protect a bare metal wire connector from an associated capacitor.

14. The device of claim 10 in which the embedded electrical connector comprises a stamped metal piece and an injection molded resinous piece forming a connector with at least four wire-ways each shaped to receive and protect a bare metal wire connector from an associated capacitor.

15. The device of claim 10 in which the embedded electrical connector is sized so as to fit within the space formed within the zone so that a wall to wall battery may be positioned in abutting relation to the capacitor without the connector creating any margin between the capacitor and the battery.

16. The device of claim 10 in which the connector comprises exposed metal pads for dedicated test points that are separate from wire connect points.

17. The device of claim 14 in which the connector wire ways are arranged so that two wire ways connect to a common electrical connector on the stamped metal piece and each of the two additional wires are split among the positive and negative voltage electrical connectors on the stamped metal piece.

18. The device of claim 14 in which each wire way comprises a resilient restriction shaped to allow a centered press fit of a wire into the wire way.

19. The device of claim 10 in which the at least one capacitor for storing and delivering electrical energy on demand has at least a 30 Joule capacity, a volume of less than about 33 cubic centimeters and a thickness of less than about 13.5 millimeters.

20. An implantable medical device having at least one capacitor for storing and delivering electrical energy on demand and in which the capacitor has a related connector for electrically connecting the capacitor with at least one other component within the device, wherein the capacitor is shaped to connect with an injection molded thermoplastic or cast thermoset embedded complex electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of the capacitor.

21. The device of claim 20 in which the capacitor is a flat capacitor.

22. The device of claim 20 in which the embedded electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least four wire-ways each shaped to receive and protect a bare metal wire connector from an associated capacitor.

23. The device of claim 20 in which the embedded electrical connector is sized to fit within the space formed within the zone so that a wall to wall battery may be positioned in abutting relation to the capacitor without the connector creating any margin between the capacitor and the battery.

24. The device of claim 22 in which the connector wire ways are arranged so that two wire ways connect to a common electrical connector on the stamped metal piece and each of the two additional wires are split among the positive and negative voltage electrical connectors on the stamped metal piece.

25. The device of claim 22 in which each wire way comprises a resilient restriction shaped to allow a centered press fit of a wire into the wire way.

26. An implantable cardiac medical device comprising:

a. at least one flat capacitor for storing and delivering electrical energy on demand, the capacitor having at least a 30 Joule capacity;

the device having a volume of less than about 36 cubic centimeters and a thickness of less than about 15 millimeters; and

b. said capacitor has a related connector for electrically connecting the capacitor with at least one other component within the device, wherein the capacitor is shaped to connect with an embedded complex electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of a housing of the capacitor.

27. The device of claim 26 in which the embedded electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least four wire-ways each shaped to receive and protect a bare metal wire connector from an associated capacitor.

28. The device of claim 26 in which the embedded electrical connector is sized to fit within the space formed within the zone so that a wall to wall component may be positioned adjacent to the capacitor without the connector creating any margin area between the capacitor and the battery.

29. The device of claim 27 in which the connector wire ways are arranged so that two wire ways connect to a common electrical connector on the stamped metal piece and each of the two additional wires are split among the positive and negative voltage electrical connectors on the stamped metal piece, and wherein each wire way is bounded by finger elements of the thermoplastic or thermoset material raised above the height of the wire in each wire way.

30. An implantable medical device having at least one storage component for storing and delivering electrical energy when needed and in which the storage component has an associated connector for electrically connecting the storage component with at least one other component within the device, wherein the storage component is shaped to connect with the associated connector as an embedded complex electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of the storage component and at least one third surface of a perimeter portion of the storage component.

31. The implantable medical device of claim 30 in which the storage component is at least one capacitor or at least one battery.

32. An implantable cardiac defibrillator medical device comprising:

a. at least one internal component for energy storage and delivery of a defibrillation shock to a user, said internal component having a first energy storage and delivery capacity and a first volume, and said internal component is shaped to connect with an embedded electrical connector that is sized to fit within a space formed within a zone defined by linear extensions of two perimeter surfaces of the internal component; and

b. said first storage and delivery capacity is at least as great as any other known energy storage and delivery internal component less than about 40 Joules, and the first volume is less than the volume of said any other known energy storage and delivery internal component having the identical energy storage and delivery capacity.

33. The device of claim 32 in which the at least one internal component is a flat capacitor.

34. The device of claim 32 in which the embedded electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least one wire-way shaped to receive and protect a bare metal wire connector from an associated capacitor.

35. The device of claim 32 in which the embedded electrical connector is sized to fit within the space formed within the zone so that a wall to wall component may be positioned adjacent to the capacitor without the connector creating any margin area between the capacitor and the battery.

36. The device of claim 32 in which the at least one capacitor for storing and delivering electrical energy on demand has at least a 30 Joule capacity, and a volume of less than about 35 cubic centimeters.

37. An implantable medical device complex electrical connector for connecting at least one energy storage and delivery component to at least one other component within the device, wherein the complex connector comprises:

a. a stamped metallic portion for providing electrical connection between electrical connectors of an energy storage and delivery component and another component within the implantable medical device; and

b. an injection molded thermoplastic or cast thermoset complex connector portion formed in contact with the stamped metallic portion to provide a plurality of wire pathways shaped to receive electrical connectors from at least one energy storage and delivery component and to guide said energy storage and delivery component electrical connectors into selective electrical contact with portions of said stamped metallic portion.

38. The device of claim 37 in which the stamped metallic portion is selected from a list of metals including nickel, titanium, copper, aluminum, tantalum, niobium, platinum, platinum family or alloys, stainless steel, palladium, rhodium, and any other compatible conductive metal.

39. The device of claim 37 in which the embedded complex electrical connector comprises a substantially flat injection molded component.

40. The device of claim 37 in which the embedded electrical complex connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least one wire-way shaped to receive and protect a wire connector from an associated capacitor.

41. The device of claim 37 in which the embedded complex electrical connector thermoplastic or thermoset portion is selected from a list of materials including polyetheramide, polyurethane, and nylon.

42. The device of claim 37 in which the embedded complex electrical connector thermoplastic or cast thermoset material is a moldable high temperature dimensionally stable high dielectric constant electrical insulator having a high flashpoint threshold and a high flow rate

43. The device of claim 37 in which the embedded complex electrical connector comprises a stamped metal piece and an injection molded thermoplastic or cast thermoset piece forming a connector with at least four wire-ways each shaped to receive and protect a metal wire connector from extending from an associated capacitor.

44. The device of claim 37 in which the embedded complex electrical connector is sized and shaped to fit within a space defined by linear extensions of two perimeter surfaces of a housing of the capacitor and by at least one additional perimeter surface of the energy storage and delivery component which forms a notched area so that another component which extends from one internal wall of the device housing to an opposing internal wall of the housing may be positioned in abutting relation to the energy storage and delivery component with the connector integrated between the two components without creating any margin area between the wall to wall component and the energy storage and delivery component.

45. The device of claim 37 in which the connector comprises exposed metal pads for dedicated test points that are separate from wire connect points.

46. The device of claim 43 in which the connector wire ways are arranged so that two wire ways connect to a common electrical connector on the stamped metal piece and each of the two additional wires are split among the positive and negative voltage electrical connectors on the stamped metal piece.

47. The device of claim 43 in which each wire way comprises a wall portion resilient restriction shaped to allow a centered press fit of a wire into the wire way.

49. The device of claim 37 in which the embedded electrical connector is sized and shaped to fit within a space defined by linear extensions of two perimeter surfaces of the capacitor and by at least one additional perimeter surface of the energy storage and delivery component which forms a notched area so that another component within the device may be positioned in abutting relation to the energy storage and delivery component with the connector integrated between the two components without creating any margin between the wall to wall component and the energy storage and delivery component;

wherein the injection molded thermoplastic or cast thermoset material connector portion has an upper and a lower surface, and said lower surface has a curved portion shaped to conform to the said at least one additional perimeter surface of the energy storage and delivery component.

50. The device of claim 40 in which the stamped metallic portion comprises a common lead frame and a plurality of conductive stamping legs.

51. The device of claim 37 in which the stamped metallic portion comprises a breakaway groove in a lower surface portion between the common lead frame and the stamping legs;

the groove having wall portions shaped to allow reliable separation of the common lead frame from the stamping legs to eliminate any post-molding trim of the injection molded thermoplastic or cast thermoset material connector.

52. The device of claim 51 in which the shape of the groove wall portions directs the separation of the common lead frame from the stamping legs to ensure proper separation at a location inside an outer periphery of the connector to provide a flash free shutoff at the breakaway groove location.

53. The device of claim 37 in which the metallic portion has upper and lower surfaces, and said upper surface has a directional burr to ensure proper shutoffs during the injection molding process.

54. The device of claim 50 in which the common lead frame comprises keying structure for positioning during the assembly processes.

55. The device of claim 50 in which the plurality of conductive stamping legs each comprise at a plurality of conductive pads.

56. The device of claim 55 in which at least two of the plurality of conductive pads are configured at different heights from a lower surface plan of the conductive stamping legs.

57. The device of claim 55 in which the plurality of conductive pads comprise dedicated testing pads for testing a component attached to the connector, pads for connecting a component to the connector, and pads for connecting the connector to another component or assembly within the device.

58. The device of claim 55 in which the conductive pads have anchor tab structures which extend into the conductive stamping legs and fix the location of the pads to facilitate automated assembly processes.

59. The device of claim 56 in which the connector wire ways are arranged to provide an optimized polarity scheme for connecting two components each with a positive and negative wire lead connector to the connector in a manner so that the connector will then connect to another component or assembly within the device using only three conductive pads, wherein the wire ways of the injection molded thermoplastic or cast thermoset material piece are configured to intersect and cross over each of the conductive stamping legs so that two wire ways allow wire connections to pads on a common stamping leg and each of the two additional wires are split between positive and negative voltage conductive pads on each of the other two conductive stamping legs on the stamped metal piece.

48. The device of 47 in which each wall portion resilient restriction comprises a protrusion extending into each wire way from a wire way wall portion, and with each protrusion opposing another protrusion so that the pair of opposing protrusions create a restriction in the wire way which has upper surfaces angled to receive and guide a wire toward the centerline of the wire way as the wire is press fit in a downward manner against the upper surfaces of the restriction.

60. An implantable medical device complex electrical connector for connecting at least one internal component or assembly to at least one other component or assembly within the device, wherein the connector comprises:

a. a stamped metallic portion for providing electrical connection between electrical connectors of one internal component or assembly and another component or assembly within the implantable medical device; and

b. an injection molded thermoplastic or cast thermoset material connector portion formed in contact with the stamped metallic portion to provide a plurality of wire pathways shaped to receive electrical connectors from at least one internal component or assembly and to guide said internal component or assembly electrical connectors into selective electrical contact with conductive pads of said stamped metallic portion.

61. A method of manufacturing an electrical connector for use in an implantable medical device comprising the steps of:

a. stamping a metallic insert out of raw sheet stock;

b. metal plating the metallic insert with a conductive plating material; and

c. injection or cast molding a thermoplastic or thermoset connector portion with the metallic insert to form an integrated electrical connector for use in an implantable medical device wherein the thermoplastic or thermoset material connector portion comprises upper and a lower surfaces which are shaped for integrated and conformal fit within a zone of the peripheral footprint of an associated component, the zone being defined by linear extensions of two perimeter surfaces of the associated component and by at least one additional perimeter surface of the associated component that is within the implantable medical device.

62. A method of assembling a complex electrical connector to an energy storage and delivery device for use within an implanted medical device, comprising the steps of:

a. stamping a metallic insert out of raw sheet stock;

b. metal plating the metal insert with a conductive plating material;

c. loading the metallic insert into a mold and molding a thermoplastic or thermoset material connector portion with the metallic insert and forming an integrated electrical connector for use in an implantable medical device, with said forming comprising creation of channel shaped wire-ways each sized to receive an electrical wire connector from an energy storage and delivery device component of the medical device; and

wherein said forming also comprising providing a mold which shapes the thermoplastic or thermoset material connector portion with upper and a lower surfaces which are further shaped for integrated and conformal fit within a zone of the peripheral footprint of an associated energy storage and delivery device within the medical device, the zone being defined by linear extensions of two perimeter surfaces of the associated energy storage and delivery device and by at least one additional perimeter surface of the associated energy storage and delivery device;

d. removing and inspecting the connector from the mold; and

e. placing an electrical wire connection into a wire-way in the complex connector.

63. A method of assembling a complex electrical connector to an energy storage and delivery component for use within an implanted medical device, comprising the steps of:

a. providing an energy storage and delivery component that is shaped to connect with an embedded complex electrical connector that is sized to fit within a space formed within a notched zone defined by linear extensions of two perimeter surfaces of the energy storage and delivery component;

b. stamping a metallic insert out of raw sheet stock;

c. metal plating the metallic insert with a conductive plating material;

d. molding a thermoplastic or thermoset material connector portion with the metallic insert and forming an integrated electrical connector for use in the implantable medical device, with said forming comprising creation of channel shaped wire-ways each sized to receive an electrical wire connector from the energy storage and delivery device component;

e. positioning the electrical connector into the notched zone on the energy storage and delivery device; and

f. placing an electrical wire connection into a wire-way.

64. The method of claim 63 further including the step of electrically connecting the electrical wire in the wire-way with a metallic stamping leg.