WRAP-AROUND CONTAINER FOR CONTROL MODULE OF ELECTRICAL STIMULATION SYSTEMS AND METHODS OF MAKING AND USING

• US 20160220826A1
• Filed: 01/26/2016
• Published: 08/04/2016
• Est. Priority Date: 01/30/2015
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Funderburk, Jeffery Van
• Granted Patent: US 10,413,739 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/3754 Feedthroughs
• CPC Class Codes: A61N 1/3758 Packaging of the components within the casing
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: H05K 5/0086 portable, e.g. battery operated apparatus casings for switching devices H01H9/02
• CPC Class Codes: H05K 5/0247 Electrical details of casings, e.g. terminals, passages for cables or wiring
• CPC Class Codes: H05K 5/04 Metal casings
• CPC Class Codes: H05K 5/06 Hermetically-sealed casings specially adapted for small components H05K5/0095

Abstract

An implantable control module for an electrical stimulation system includes a connector housing including a connector having one or more ports and connector contacts disposed within the connector; a metal electronics housing coupled to the connector housing; an electronic subassembly disposed within the metal electronics housing; and a feedthrough assembly disposed between the connector housing and the metal electronics housing and including at least one non-conductive block and conductive feedthroughs extending through the at least one non-conductive block and electrically coupling the electronic subassembly to the connector contacts. The metal electronics housing includes a metal sheet bent to form at least a portion of the first major surface and at least a portion of the second major surface. The first major surface has a length and includes a first sealed seam extending along an entirety of the length of the first major surface.

Claims

1. An implantable control module for an electrical stimulation system, the control module comprising:

a connector housing comprising a connector having one or more ports each configured and arranged to receive a proximal end of a lead or lead extension and a plurality of connector contacts disposed within the connector and configured and arranged for making contact with terminals disposed on the proximal end portion of the lead or lead extension;

a metal electronics housing coupled to the connector housing and having a first major surface and a second major surface opposite the first major surface, wherein the metal electronics housing comprises a metal sheet bent to form at least a portion of the first major surface and at least a portion of the second major surface, wherein the first major surface has a length and comprises a first sealed seam extending along an entirety of the length of the first major surface;

an electronic subassembly disposed within the metal electronics housing; and

a feedthrough assembly disposed between the connector housing and the metal electronics housing and comprising at least one non-conductive block and a plurality of conductive feedthroughs extending through the at least one non-conductive block and electrically coupling the electronic subassembly to the connector contacts.

2. The control module of claim 1, wherein the metal electronic housing further comprises a second metal sheet bent to form at least a portion of the first major surface and at least a portion of the second major surface, the metal electronic housing further comprises a second sealed seam extending along an entirety of the length of the second major surface.

3. The control module of claim 2, wherein the first sealed seam and the second sealed seam both join the first bent metal sheet to the second bent metal sheet.

4. The control module of claim 1, wherein the first bent metal sheet comprises a first edge and a second edge, wherein the first sealed seam joins the first edge to the second edge.

5. The control module of claim 1, wherein the metal electronics housing further comprises a bottom plate attached to the first bent metal sheet.

6. The control module of claim 1, wherein the feedthrough assembly comprises a metal flange disposed around the at least one non-conductive block and attached to the metal electronics housing.

7. The control module of claim 1, wherein the first bent metal sheet consists of grade 23 titanium alloy.

8. The control module of claim 1, wherein the first bent metal sheet comprises at least one interlocking feature along the first sealed seam.

9. The control module of claim 8, wherein the at least one interlocking feature is a dovetailed feature.

10. An electrical stimulation system, comprising:

the control module of claim 1; and

a lead coupleable to the control module comprising a proximal end portion, a distal end portion, a plurality of electrodes disposed along the distal end portion, and a plurality of terminals disposed along the proximal end portion and electrically coupled to the plurality of electrodes.

11. An implantable control module for an electrical stimulation system, the control module comprising:

a connector housing comprising a connector having one or more ports each configured and arranged to receive a proximal end of a lead or lead extension and a plurality of connector contacts disposed within the connector and configured and arranged for making contact with terminals disposed on the proximal end of the lead or lead extension;

a metal electronics housing coupled to the connector housing and consisting essentially of a single metal sheet bent to produce at least a first major surface, wherein the first major surface has a length and comprises a sealed seam extending along an entirety of the length of the first major surface;

an electronic subassembly disposed within the metal electronics housing; and

a feedthrough assembly disposed between the connector housing and the metal electronics housing and comprising at least one non-conductive block and a plurality of conductive feedthroughs extending through the at least one non-conductive block and electrically coupling the electronic subassembly to the connector contacts.

12. The control module of claim 11, wherein the single metal sheet comprises a first edge and a second edge, wherein the first sealed seam joins the first edge to the second edge.

13. The control module of claim 11, wherein the metal sheet forms a second major surface opposite the first major surface, at least two side surfaces coupling the first and second major surfaces, and a bottom piece coupling the first major surface to the second major surface and coupling two of the at least two side surfaces.

14. The control module of claim 11, wherein the feedthrough assembly comprises a metal flange disposed around the at least one non-conductive block and attached to the metal electronics housing.

15. The control module of claim 11, wherein the single metal sheet consists of grade 23 titanium alloy.

16. The control module of claim 11, wherein the single metal sheet comprises at least one interlocking feature formed along each of at least two edges of the single metal sheet.

17. The control module of claim 11, wherein the at least one interlocking feature is a dovetailed feature.

18. An electrical stimulation system, comprising:

the control module of claim 11; and

a lead coupleable to the control module comprising proximal end portion, a distal end portion, a plurality of electrodes disposed along the distal end portion, and a plurality of terminals disposed along the proximal end portion and electrically coupled to the plurality of electrodes.

19. A method of making an implantable control module of an electrical stimulation system, the method comprising:

providing a single flat metal sheet;

bending the single flat metal sheet to form an electronics housing with a seam along a length of the first major surface of the electronics housing;

sealing the seam;

disposing an electronics subassembly within the electronics housing; and

coupling a feedthrough assembly and a connector housing to the electronics housing.

20. The method of claim 19, wherein the single flat metal sheet comprises at least one interlocking feature formed along each of at least two edges of the single flat metal sheet, wherein bending the single flat metal sheet comprises interlocking the at least one interlocking feature of the at least two edges.