Medical device communication and charging assemblies for use with implantable signal generators, and associated systems and methods

• US 9,776,002 B2
• Filed: 12/22/2014
• Issued: 10/03/2017
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Nevro Corporation
• Original Assignee: Nevro Corporation
• Inventors: Parker, Jon, Chitre, Yougandh, Walker, Andre B.
• Primary Examiner(s): Lee, Erica
• Application Number:
  US14/579,957
• Publication Number:
  US 20150174409A1
• Time in Patent Office: 1,016 Days
• Field of Search: None
• CPC Class Codes: A61N 1/36071 Pain
• CPC Class Codes: A61N 1/37229 Shape or location of the implanted or external antenna
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/3787 from an external energy source
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01Q 7/00 Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
• CPC Class Codes: H02J 2310/23 The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 50/05 using capacitive coupling
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/402 the two or more transmitting or the two or more receiving devices being integrated in the same unit, e.g. power mats with several coils or antennas with several sub-antennas
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

Communication and charging assemblies for medical devices are disclosed herein. A communication and charging assembly in accordance with a particular embodiment includes a support element, with a communication antenna and a charging coil coupled to the support element. The charging coil can include wire loops having a plurality of wires and the support element can include a mounting surface shaped to match the charging coil and the communication antenna. In one embodiment, the communication and charging assembly are mounted in a header of an implantable signal generator.

Claims

1. An implantable signal generator, comprising:

a can having a shell, a lid, a controller and a battery, wherein the lid encloses an open end of the shell, and wherein the battery is electrically coupled to the controller; and

a header portion adjacent the lid, wherein the header portion includes a communication antenna, a charging coil, a receiving element having an output terminal, and a feed-through wire extending from the output terminal, through the lid, and into the can, and wherein—

the receiving element is at least partially physically secured by the feed-through wire and positioned to provide an electrical connection to a signal delivery device,

the output terminal and the communication antenna are electrically coupled to the controller,

the charging coil is electrically coupled to the battery,

the charging coil is positioned to receive electromagnetic energy and direct electrical current to charge the battery, and

the communication antenna is positioned to receive external control signals and direct the external control signals to the controller.

2. The implantable signal generator of claim 1, further comprising a support element carrying the charging coil and the communication antenna.

3. The implantable signal generator of claim 1 wherein the charging coil includes a first wire loop positioned in a first plane and a second wire loop positioned in a second plane, the first plane disposed at a non-zero angle with respect to the second plane.

4. The implantable signal generator of claim 1 wherein the header includes a header cap encasing the charging coil and the communication antenna.

5. The implantable signal generator of claim 4 wherein the header cap includes a curved surface, and wherein the charging coil is shaped to at least partially match the curved surface.

6. An implantable signal generator, comprising:

a can having a shell, a lid, a controller and a battery, wherein the lid encloses an open end of the shell, and wherein the battery is electrically coupled to the controller; and

a header portion adjacent the lid, wherein the header portion includes an output terminal, a communication antenna, a charging coil, a support element carrying the charging coil and the communication antenna, and a plurality of feed-through wires extending from the shell, through the lid, and at least partially physically securing the support element via the communication antenna and the charging coil, and wherein—

the output terminal and the communication antenna are electrically coupled to the controller,

the charging coil is electrically coupled to the battery,

the charging coil is positioned to receive electromagnetic energy and direct electrical current to charge the battery, and

the communication antenna is positioned to receive external control signals and direct the external control signals to the controller.

7. An implantable medical device for delivering electrical therapy signals, comprising:

a can having a shell and a lid;

a header carried by the can and positioned adjacent to the lid;

an output terminal positioned within the header and operably coupleable to a signal delivery device;

a controller operably coupled to the output terminal to control the delivery of the electrical therapy signals;

a battery operably coupled to the controller to provide electrical power;

a charging coil positioned within the header to receive electromagnetic energy, wherein the charging coil is configured to generate electrical current via the electromagnetic energy and direct the electrical current to the battery;

a communication antenna positioned within the header to receive data transmitted via an electromagnetic signal and direct the data to the controller;

a support element positioned within the header, wherein the support element carries the charging coil and the communication antenna; and

a first feed-through wire, and a second feed-through wire, wherein the first feed-through wire and the second feed-through wire extend through the lid and electrically couple the communication antenna to the controller, and wherein the first feed-through wire and the second feed-through wire at least partially secure the support element in a fixed position via the communication antenna.

8. The medical device of claim 7 wherein the header comprises an epoxy volume in which the support element, the charging coil, and the communication antenna are positioned.

9. The medical device of claim 7 wherein the charging coil includes a first wire loop positioned in a first plane and a second wire loop positioned in a second plane, the first plane disposed at a non-zero angle relative to the second plane.

10. The medical device of claim 7 wherein the header includes a molded header cap having a cutout positioned to support the output terminal.

11. The medical device of claim 7 wherein the implantable signal generator further comprises a third feed-through wire and a fourth feed-through wire, and wherein the third feed-through wire and the fourth feed-through wire are positioned to extend from the shell, through the lid, and to the charging coil.

12. An implantable signal generator, comprising:

a shell having a rounded rectangular shape and an open end;

a battery positioned within the shell to provide electrical power;

a controller positioned within the shell and electrically coupled to the battery;

a lid fixedly attached to the open end of the shell;

a support element attached to the lid, external to the shell;

a charging coil mounted to the support element and electrically coupled to the battery, wherein the charging coil is positioned to receive electromagnetic energy to charge the battery;

a communication antenna mounted to the support element and electrically coupled to the controller, wherein the communication antenna is positioned to receive data for control of the implantable signal generator; and

an output terminal electrically coupled to the controller via a feed-through wire, wherein the feed-through wire extends through the lid and at least partially maintains a position of the output terminal.

13. The implantable signal generator of claim 12, further comprising a receiving element external to the shell and attached to the lid via the feed-through wire, wherein the receiving element includes the output terminal to provide an electrical connection to a signal delivery device.

14. The implantable signal generator of claim 12, further comprising a molded header supporting the charging coil and the communication antenna.

15. The implantable signal generator of claim 12 wherein the charging coil includes a plurality of wires, and wherein individual wires are wound into loops.

16. The implantable signal generator of claim 12 wherein the support element includes a receiving surface extending around a perimeter of the support element, and wherein the receiving surface engages the communication antenna.