Feedthrough for electrical connectors

• US 7,988,507 B2
• Filed: 02/04/2008
• Issued: 08/02/2011
• Est. Priority Date: 09/30/2002
• Status: Expired due to Fees

• Current Assignee: Cochlear Limited
• Original Assignee: Cochlear Limited
• Inventors: McCusker, Desmond A., Parker, John L., Milojevicrg, Dusan, Darley, Derek Ian
• Primary Examiner(s): Nguyen; Truc T
• Application Number:
  US12/025,145
• Publication Number:
  US 20080208289A1
• Time in Patent Office: 1,275 Days
• Field of Search: 439/668, 439/909, 607/37, 607/119
• US Class Current: N/A
• 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 1/0541 Cochlear electrodes
• CPC Class Codes: H01R 13/5224 for medical use
• CPC Class Codes: H01R 2201/12 for medicine and surgery
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10S 439/909 Medical use or attached to human body
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/5149 to sever electric terminal from supply strip

Abstract

A method (10) of forming an electrically conducting feedthrough. The method (10) comprises a first step (11) of forming an electrically conductive structure (21) comprising a sacrificial component and a non-sacrificial component. At least a portion of the non-sacrificial component can then be coated with a relatively electrically insulating material (35) prior to removal of at least a portion of the sacrificial component from the electrically conductive structure. The structure of the feedthrough provides electrical connection through the wall of a housing of an implantable component while preventing unwanted transfer of materials between the interior of the component and the surrounding environment.

Claims

1. A feedthrough for an implantable medical device comprising:

an electrically insulating body including a first surface and a second surface; and

one or more electrically conductive structures configured to contiguously extend through and be embedded within said electrically insulating body, such that each of said one or more electrically conductive structures are circumferentially covered by said electrically insulating body, such that opposing ends of said at least one electrically conductive structures are exposed, and such that said at least one electrically conductive structures extend beyond at least the first or second surface,

wherein the one or more electrically conductive structures comprise an electrically conductive metal or metal alloy and have a thickness of a film of the same electrically conductive metal or metal alloy.

2. The feedthrough of claim 1 wherein the electrically insulating body is formed of a ceramic.

3. The electrically conducting feedthrough of claim 1, wherein respective configurations of first ends and second opposite ends of the one or more electrically conductive structures are such that the spacing between the first ends of the electrically conductive structures at or adjacent the first surface of the insulating body is different from the spacing between the second ends of the electrically conductive structures at or adjacent the second face of the insulating body.

4. The electrically conducting feedthrough of claim 3, wherein the dimension and/or shape of the first ends of said conductive structures are different from the dimension and/or shape of the second ends of the conductive structures.

5. The feedthrough of claim 1, wherein the electrically insulating body has a first face into which one of said one or more electrically conductive structures enter the electrically insulating body and a second face out of which the one of said one or more electrically conductive structures exit the electrically insulating body, wherein at least a portion of the outer surface of said conductive structures defines an interface path between the one of said one or more electrically conductive structures and the insulating material that is equal in length to the shortest distance between said first face and said second face when the faces are parallel to each other.

6. The feedthrough of claim 1, wherein the electrically insulating body has a location of entry into which one of said one or more electrically conductive structures enter the electrically insulating body and a location of exit out of which the one of said one or more electrically conductive structures exits the electrically insulating body, wherein the one of said one or more electrically conductive structures have a length between said location of entry and said location of exit that is equal to the shortest distance between the location of entry and the location of exit.

7. The feedthrough of claim 1, comprising a plurality of electrically conductive structures, wherein said electrically conductive structures are circumferentially covered by said electrically insulating body such that a hermetic seal is formed between the electrically conductive structures and the electrically insulating body.

8. The implantable medical apparatus of claim 1, wherein the one or more electrically conductive structures are formed from a film or shim of the electrically conductive metal or metal alloy.

9. The implantable medical apparatus of claim 1, wherein the one or more electrically conductive structures comprise shims of the electrically conductive metal or metal alloy.

10. The feedthrough of claim 1, wherein:

the one or more electrically conductive structures are in direct contact with the electrically insulating body; and

the electrically insulating body is a monolithic body.

11. The feedthrough of claim 7, wherein the hermetic seal is located at least an interface between the embedded electrically conductive members and the surrounding insulating member.

12. The feedthrough of claim 7, wherein the hermetic seal is adapted to prevent transfer of fluids from a first side of the feedthrough into which the one or more electrically conductive structures enter the electrically insulating body to a second side of the feedthrough out of which the one or more electrically conductive structure exit the electrically insulating body.

13. The feedthrough of claim 7, wherein the hermetic seal is adapted to prevent transfer of fluids from a first side of the feedthrough into which the one or more electrically conductive structures enter the electrically insulating body, along one or more of the electrically conductive structures, to a second side of the feedthrough out of which the one or more electrically conductive structure exit the electrically insulating body.

14. A feedthrough for an implantable medical device comprising:

an electrically insulating body including a first surface and a second surface; and

a plurality of electrically conductive structures contiguously extending through and embedded within said electrically insulating body, such that said plurality of electrically conductive structures are circumferentially covered by said electrically insulating body, such that opposing ends of said one or more electrically conductive structures are exposed, and such that said at least one electrically conductive structures extend beyond at least the first or second surface,

wherein said electrically conductive structures comprise an electrically conductive metal or metal alloy having a thickness of about 70 microns.

15. The feedthrough of claim 14, wherein said electrically conductive structures have a thickness of between about 40 microns and about 70 microns.

16. The feedthrough of claim 14, wherein said electrically conductive structures have an overall elongate length of at least 7 mm.

17. The feedthrough of claim 14, wherein:

the one or more electrically conductive structures are in direct contact with the electrically insulating body; and

the electrically insulating body is a monolithic body.

18. The feedthrough of claim 15, wherein said electrically conductive structures have a thickness of about 50 microns.

19. A feedthrough for an implantable medical device comprising:

an electrically insulating body including a first surface and a second surface; and

a plurality of electrically conductive structures contiguously extending through and embedded within said electrically insulating body, such that said electrically conductive structures are circumferentially covered by said electrically insulating body such that a hermetic seal is formed between the electrically conductive structures and the electrically insulating body, such that opposing ends of said electrically conductive structures are exposed, and such that said at least one electrically conductive structures extend beyond at least the first or second surface,

wherein said conductive structures comprise an electrically conductive metal or metal alloy.

20. The feedthrough of claim 19, wherein the hermetic seal is located at least an interface between the embedded conductive members and the surrounding insulating member.

21. The feedthrough of claim 19, wherein the hermetic seal is adapted to prevent transfer of fluids from a first side of the feedthrough into which the one or more electrically conductive structures enter the electrically insulating body to a second side of the feedthrough out of which the one or more electrically conductive structure exit the electrically insulating body.

22. The feedthrough of claim 19, wherein the hermetic seal is adapted to prevent transfer of fluids from a first side of the feedthrough into which the one or more electrically conductive structures enter the electrically insulating body, along one or more of the electrically conductive structures, to a second side of the feedthrough out of which the one or more electrically conductive structure exit the electrically insulating body.

23. The feedthrough of claim 19, wherein:

the plurality of electrically conductive structures are in direct contact with the electrically insulating body; and

the electrically insulating body is a monolithic body.

25. The feedthrough of claim 22, wherein the hermetic seal is adapted to prevent transfer of fluids from the second side of the feedthrough, along one or more of the electrically conductive structures, to the first side of the feedthrough.

24. An implantable medical apparatus, comprising:

a medical device adapted to be implanted in a human, the medical device including a housing having a housing wall; and

a feedthrough adapted to be implanted in a human, wherein the feedthrough is attached to the housing wall of the medical device, the feedthrough including;

an electrically insulating body; and

a plurality of conductive structures contiguously extending through and embedded within said electrically insulating body, such that said electrically conductive structures are circumferentially covered by said electrically insulating body, and such that opposing ends of said at least one electrically conductive structures are exposed,

wherein the one or more electrically conductive structures comprise an electrically conductive metal or metal alloy,

wherein the feedthrough provides electrical communication from an outside of the housing through the housing wall to an inside of the housing.

26. The feedthrough of claim 24, wherein:

the plurality of electrically conductive structures are in direct contact with the electrically insulating body; and

the electrically insulating body is a monolithic body.

27. The implantable medical apparatus of claim 24, wherein said electrically conductive structures comprise an electrically conductive metal or metal alloy having a thickness of about 70 microns.

28. The implantable medical apparatus of claim 24, wherein said electrically conductive structures are circumferentially covered by said electrically insulating body such that a hermetic seal is formed between the electrically conductive structures and the electrically insulating body.

29. The implantable medical apparatus of claim 24, wherein the feedthrough is adapted to limit transfer of fluids from a exterior of the housing to an interior of the housing by preventing the transfer of fluids through the feedthrough along one or more of the electrically conductive structures.

30. The implantable medical apparatus of claim 24, wherein the implantable medical apparatus is a cochlear implant hearing prosthesis and the feedthrough provides electrical conduction between the circuitry within an implantable stimulator unit of said prosthesis and one or more intracochlear or extracochlear electrodes and/or an implantable receiver coil.