Patent Description:
In some instances, high voltage capacitors are used for implantable medical device applications. Capacitors paired with batteries can provide high-energy power solutions for various devices, such as, for instance, tachycardia devices. In some instances, the energy is delivered in the form of electrical current by a lead wire that originates at the anode in the capacitor and reaches out of the capacitor into the device. For the proper transfer of energy a seal is needed through which the lead wire can reach to the outside of the component. There are two primary functions of the seal: (<NUM>) to inhibit electrical conduction between the case and the wire; and (<NUM>) to inhibit material transfer from inside the capacitor into the device.

Typically, a feedthrough seal includes glass, which is melted and solidified between the inside of a ferrule and a concentrically placed tantalum wire. Such an assembly is known as a glass-to-metal seal (GTMS). The GTMS is prepared separately around the tantalum wire. A second tantalum wire from a formed anode assembly is cut to size, bead blasted to remove oxide layer, and then welded onto the tantalum wire coming from the GTMS. The anode and GTMS assembly then undergo a reforming step by heating. The ferrule of the GTMS is then laser welded to the capacitor case. Thus, the entire sealing procedure involves a number of steps making it a complex, expensive, and time-consuming process.

<CIT>, cited under Article <NUM>(<NUM>) EPC, describes a wet tantalum capacitor of a dual anode design. The capacitor may include an insulative seal and a feedthrough lead.

<CIT>, cited under Article <NUM>(<NUM>) EPC, describes a capacitor having at least two side-by-side anodes with a cathode current collector disposed between the anodes and housed inside a casing. The capacitor may include an insulative seal and a feedthrough lead.

<CIT>, cited under Article <NUM>(<NUM>) EPC, describes a wet tantalum capacitor of either a single anode design or of multiple anode configurations having cathode active material supported on the casing and sealed in its own separator material. The capacitor may include an insulative seal and a feedthrough lead.

<CIT> describes a seal structure for an encased electrical device with a lead projecting through a compressed insulative plug disposed within a closure disk integrally sealed to the casing.

<CIT> describes a miniature insulative feedthrough which receives an electrical lead therethrough and includes a ferrule having first and second open ends and an interior surface. At least a first insulating ring is positioned within the ferrule and has an aperture therethrough for receiving the electrical lead. At least one compression ring is positioned within the ferrule for sealingly engaging the interior surface, the compression ring also having an aperture therethrough for receiving the electrical lead. First and second retaining portions are provided for maintaining the insulating ring and the compression ring in position within the ferrule.

<CIT> describes hermetically sealed capacitors, and a process for forming such capacitors utilizing glass-to-metal end seals.

<CIT> describes an apparatus for forming a seal within a ferrule having a compression ring disposed therein. The apparatus comprises a frame assembly for crimping a portion of the ferrule, and a push rod assembly coupled to the frame assembly. The push rod assembly is capable of independent articulation with respect to the frame assembly and is configured to compress the compression ring within the ferrule.

The present invention relates to a device including a case and a feedthrough seal apparatus according to claim <NUM>.

The invention also relates to a method of making a feedthrough seal apparatus configured to seal an opening in a device according to claim <NUM>.

The present subject matter relates to a feedthrough seal system, apparatus, and method. In some examples, the feedthrough seal system, apparatus, and method of the present patent application can be used for a feedthrough seal of a component, such as, for instance, a capacitor. The present subject matter can be used for a feedthrough seal for a component of a medical device in such a way as to reduce overall cost compared to current manufacturing methods In the device according to the present invention, as recited in claim <NUM>, the feedthrough seal apparatus comprises a plug disposed within the opening of the case, wherein the plug is formed from a polymeric material and optionally an adhesive material; a ferrule attached to the case and disposed within the opening, wherein the plug is affixed within the ferrule; and a lead wire including a first end and a second end, the lead wire extending through the plug, such that the first end of the lead wire is disposed within the interior space of the case and the second end extends from the plug to the exterior of the case, wherein the lead wire is configured to allow electrical communication between the interior space of the case and the exterior of the case, and wherein the feedthrough seal apparatus is configured to seal the opening in the case, the plug being configured to electrically insulate the lead wire from the case; wherein the polymeric material of the plug includes a thermoplastic polymeric material configured to be thermally joined to the lead wire with heating of the thermoplastic polymeric material, thereby affixing the plug to the lead wire; and wherein the lead wire includes an adhesion feature configured to enhance adhesion between the lead wire and the plug, wherein the adhesion feature includes one or more of a bent portion of the lead wire, a textured surface, and a porous surface.

According to the present invention, the method of making a feedthrough seal apparatus, as recited in claim <NUM>, comprises:.

The present inventors have recognized, among other things, that the present subject matter can be used for a feedthrough seal of a component of a medical device. In some examples, the present inventors have recognized that the present subject matter can be used to produce seals that are substantially functionally equivalent to, relatively simpler to manufacture than, and relatively less expensive than GTMS. For instance, compared to current seals (such as GTMS, for instance), the present subject matter, in various examples, can reduce manufacturing time, manufacturing difficulty, and material cost while achieving a seal that can withstand voltages of the component, inhibit current leakages between the wire and case, physically inhibit the wire and case from contacting one another, and inhibit movement of electrolyte molecules outside of the component.

In various examples, the feedthrough seal apparatuses described herein are configured to meet various performance and property requirements. Such requirements can include one or more of the following:.

In some examples, the feedthrough seal apparatuses described herein are hermetic in that the feedthrough seal apparatuses are configured to meet a helium leak test with <NUM> × <NUM>-<NUM> atm. cc/s being the threshold for pass or fail. In some examples, the feedthrough seal apparatuses described herein are configured to meet a helium leak test for hermeticity for a device feedthrough, in which <NUM> × <NUM>-<NUM> atm. cc/s is the threshold for pass or fail.

In some examples, the feedthrough seal apparatuses can include one or more polymeric materials, including polysulfones, polyetherketones, and polyolefins such as polyethylene and polypropylene. In some examples, the polymeric materials can be in the unfilled form. In other examples, the polymeric materials can be in the filled form, incorporating one or more fillers, such as glass, ceramic, or clay particles or a combination thereof. In some examples, the feedthrough seal apparatuses include one or more bonding agents or adhesives, such as, but not limited to epoxy. In various examples, the feedthrough seal apparatuses can include one or more epoxies including, but not limited to, Loctite <NUM> epoxy, Masterbond EP3HTMed epoxy, Cyberpoxy <NUM> epoxy, and/or Epo-Tek 353ND epoxy.

Referring to <FIG>, a component <NUM> of a device is shown. In some examples, the component <NUM> is a capacitor <NUM>. In other examples, the component <NUM> can be a component other than a capacitor, such as, but not limited to, a battery. In some examples, the device within which the component <NUM> is disposed is a medical device. In further examples, the device is an implantable medical device. In other examples, the component <NUM> can be disposed within a device other than a medical device. For the sake of simplifying description, the examples herein refer to the component <NUM> as a capacitor <NUM>; however, it should be understood that the component <NUM> is not limited to a capacitor <NUM> and can include any component, such as a battery, for instance.

In some examples, the capacitor <NUM> includes a case <NUM> surrounding an interior space <NUM> of the capacitor. In some examples, the case <NUM> can be formed from a metallic material, such as, but not limited to titanium, stainless steel, or the like. In some examples, the case <NUM> includes an opening <NUM> therein to allow access to the interior space <NUM> from an exterior <NUM> of the case <NUM>. In some examples, the capacitor <NUM> includes an anode <NUM> and an electrolyte material within the interior space <NUM> of the case <NUM>.

In some examples, the capacitor <NUM> includes a feedthrough seal apparatus <NUM> in order to fluidly seal the opening <NUM> of the case <NUM> while still allowing electrical communication between the exterior <NUM> and the interior space <NUM> of the case <NUM> but electrically insulating the interior space <NUM> from the exterior <NUM> of the case <NUM>. In various examples, the feedthrough seal apparatus <NUM> aids in inhibiting electrolyte material (and other materials) from escaping from the interior space <NUM> and outside materials and/or contaminants from entering the interior space <NUM> of the case <NUM>. In some examples, the feedthrough seal apparatus <NUM> includes a plug <NUM> disposed within the opening <NUM> of the case <NUM> and a lead wire <NUM> extending through the plug <NUM>. In various examples, some of which are described below, the plug <NUM> can be formed from various materials, including one or more polymeric materials, one or more adhesive materials, one or more glass materials, and one or more ceramic materials or various combinations thereof. The plug <NUM>, in some examples, is configured to be electrically insulative, among other things. In this way, in some examples, the plug <NUM> is configured to insulate the interior space <NUM> of the case <NUM> and the contents thereof from the exterior <NUM> of the case <NUM>. In further examples, the plug <NUM> is configured to electrically insulate the lead wire <NUM> from the case <NUM> and/or other components of the capacitor <NUM> and/or device.

In some examples, the lead wire <NUM> includes a first end 134A and a second end 134B. In some examples, the lead wire <NUM> extends through the plug <NUM>, such that the first end 134A of the lead wire <NUM> is disposed within the interior space <NUM> of the case <NUM> and the second end 134B extends from the plug <NUM> to the exterior <NUM> of the case <NUM>. In some examples, the first end 134A of the lead wire <NUM> is configured to electrically couple to the anode <NUM>. In further examples, the second end 134B of the lead wire <NUM> is configured to electrically couple to circuitry within the device but outside of the case <NUM> of the capacitor <NUM>. In various examples, the lead wire <NUM> is configured to allow electrical communication between the interior space <NUM> of the case <NUM> (and/or one or more components therein) and the exterior <NUM> of the case <NUM>. In some examples, the lead wire <NUM> is formed from a metallic material, such as, but not limited to, tantalum. In this way, in some examples, the feedthrough seal apparatus <NUM> is configured to seal the opening <NUM> in the case <NUM>. In some examples, the feedthrough seal apparatus <NUM> is configured to hermetically seal the opening <NUM> in the case <NUM>.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> can be used within a device, such as a medical device. In further examples, the feedthrough seal apparatus <NUM> can be used in a component of the device, such as the capacitor <NUM> described above. In some examples, the feedthrough seal apparatus <NUM> is configured to seal an opening <NUM> in a case <NUM>. In some examples, the feedthrough seal apparatus <NUM> includes a lead wire <NUM> disposed within a plug <NUM> for sealing the opening <NUM> of the case <NUM> while, at the same time, allowing electrical communication (through the lead wire <NUM>) between an interior space <NUM> of the case <NUM> and an exterior <NUM> of the case <NUM>.

In some examples, the feedthrough seal apparatus <NUM> includes a ferrule <NUM>. In some examples, the ferrule <NUM> is formed, at least in part, from a metallic material. The ferrule <NUM>, in some examples, can be disposed within the opening <NUM> of the case <NUM> and attached to the case <NUM>. In some examples, the ferrule <NUM> includes a flange 236B or other structure to facilitate attachment to the case <NUM>. In some examples, the flange 236B is welded to the case <NUM>. In some examples, other ways of attachment are used, such as press-fitting, adhesive, or the like. Although shown with a flange 236B in <FIG>, it should be understood that the ferrule <NUM> does not require the flange 236B in order to be attached to the case <NUM> and can be welded, press-fit, adhered, or otherwise attached to the case <NUM> even without the flange 236B. In some examples, the ferrule <NUM> is substantially cylindrical in shape such that the ferrule is substantially circular when viewed from an end (see <FIG>). However, in other examples, the ferrule can include other shapes when viewed from an end, such as, but not limited to ovular, elliptical, or polygonal. In various examples, the ferrule <NUM> is formed from a metallic material, such as, but not limited to, titanium, stainless steel, or the like.

In some examples, the plug <NUM> is disposed within the ferrule <NUM>. In some examples, the plug <NUM> is affixed within and/or to the ferrule <NUM>. In further examples, the plug <NUM> is affixed to the lead wire <NUM>, in addition to or instead of the ferrule <NUM>. In some examples, the plug <NUM> includes a polymeric material, which can be affixed to the ferrule <NUM> and/or the lead wire <NUM> using an adhesive. In further examples, the plug <NUM> includes a thermoplastic polymeric material, which can be thermally joined to the ferrule <NUM> and/or the lead wire <NUM> with heating of the thermoplastic polymeric material. In some examples, the plug <NUM> can be bulk heated (in an oven, for instance), which causes the entire plug <NUM> to heat up, thereby allowing the plug <NUM> to become at least partially flowable to adhere the plug <NUM> to the ferrule <NUM> and/or the lead wire <NUM>. In other examples, the plug <NUM> can be locally heated (for instance, using laser or electrical energy) to heat portions of the plug <NUM> abutting the ferrule <NUM> and/or the lead wire <NUM>, thereby allowing portions of the plug <NUM> abutting the ferrule <NUM> and/or the lead wire <NUM> to become at least partially flowable to adhere the plug <NUM> to the ferrule <NUM> and/or the lead wire <NUM>. In some examples, the plug <NUM> can include a polymeric material that is sized and shaped to correspond to an interior of the ferrule <NUM>, such that the plug <NUM> can be press-fit into the ferrule <NUM> to affix the plug <NUM> at least partially within the ferrule <NUM>. In some examples, the plug <NUM> can include a passage therethough sized and shaped to allow sealing, press-fit engagement with the lead wire <NUM>.

In some examples, the plug <NUM> is formed from an adhesive, such that the adhesive, in a flowable state, can be poured, injected, or otherwise placed within the ferrule <NUM> to solidify, cure, or otherwise harden, thereby taking the shape of the interior of the ferrule <NUM>. In this way, the adhesive forms the plug <NUM> and adheres the plug <NUM> to the ferrule <NUM> and/or the lead wire <NUM>. In some examples, the plug <NUM> is formed from epoxy.

In some examples, the ferrule <NUM> includes an inwardly-extending portion 236A. In some examples, the inwardly-extending portion 236A reduces the size of a ferrule opening 236C than would otherwise be present if there were no inwardly-extending portion. In some examples, the inwardly-extending portion 236A is disposed at an end of the ferrule <NUM>. In other examples, the inwardly-extending portion can be disposed at a location intermediate ends of the ferrule.

In some examples, with the plug <NUM> formed from an adhesive, the inwardly-extending portion 236A decreases the size of the ferrule opening 236C, and, in turn, aids in retaining the adhesive within the ferrule <NUM> after insertion of the adhesive into the ferrule <NUM> and before the adhesive solidifies, cures, or otherwise hardens. That is, the decreased size of the ferrule opening 236C lessens the likelihood of adhesive escaping or otherwise leaking through the ferrule opening 236C. Additionally, in some examples, viscosity of the adhesive can also aid in retaining the adhesive within the ferrule <NUM> after insertion of the adhesive into the ferrule <NUM> and before the adhesive solidifies, cures, or otherwise hardens. The more viscous the adhesive, the less likely it is that the adhesive escapes or otherwise leaks through the ferrule opening 236C. However, it is noted that the more viscous the adhesive, the less easily it will flow and fill up the ferrule <NUM>. Therefore, in some examples, a viscosity of the adhesive can be achieved such that the adhesive will flow into the ferrule <NUM> but not leak through the ferrule opening 236C.

In some examples, with the plug <NUM> formed from a polymeric material, the inwardly-extending portion 236A provides for a surface on which the plug <NUM> can rest to facilitate proper placement within the ferrule <NUM> and/or inhibit migration of the plug <NUM> outside of the ferrule <NUM> and toward the interior space <NUM> of the case <NUM>. For instance, in some examples, the plug <NUM> can rest on the inwardly-extending portion 236A during affixation of the plug <NUM> to the ferrule <NUM> and/or the lead wire <NUM>, thereby maintaining the plug <NUM> in position within the ferrule <NUM> during thermal joining, application and curing of adhesive, or other affixation techniques.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a ferrule <NUM> that includes an inwardly-extending portion 336A, which decreases the size of a ferrule opening 336C (for instance, the space between the ferrule <NUM> and a lead wire <NUM>). In some examples, the inwardly-extending portion 336A includes a stepped feature 336A. In some examples, the stepped feature 336A extends inwardly from a sidewall 336D of the ferrule <NUM> at an angle of substantially ninety degrees with respect to the sidewall 336D. In other examples, the stepped feature 336A can extend from the sidewall 336D at angles other than substantially ninety degrees, such as, for instance, less than ninety degrees, such that the stepped feature 336A extends in an inward and upward direction (with respect to <FIG>) within an interior of the ferrule <NUM>. In various examples, the stepped feature 336A can provide for a surface on which a plug <NUM> can rest to facilitate proper placement within the ferrule <NUM> and/or inhibit migration of the plug <NUM> outside of the ferrule <NUM> and toward the interior space of the case and/or can aid in retaining the plug <NUM> (if formed from an adhesive) within the ferrule <NUM> after insertion of the adhesive into the ferrule <NUM> and before the adhesive solidifies, cures, or otherwise hardens due to the decreased size of the ferrule opening 336C.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a ferrule <NUM> that includes an inwardly-extending portion 436A, which decreases the size of a ferrule opening 436C (for instance, the space between the ferrule <NUM> and a lead wire <NUM>). In some examples, the inwardly-extending portion 436A includes a tapered feature 436A. In some examples, the tapered feature 436A extends inwardly from a sidewall 436D of the ferrule <NUM> at an angle of greater than ninety degrees with respect to the sidewall 436D, such that the tapered feature 436A extends in an inward and downward direction (with respect to <FIG>) from the sidewall 436D of the ferrule <NUM>. In various examples, the tapered feature 436A can provide for a surface on which a plug <NUM> can rest to facilitate proper placement within the ferrule <NUM> and/or inhibit migration of the plug <NUM> outside of the ferrule <NUM> and toward the interior space of the case and/or can aid in retaining the plug <NUM> (if formed from an adhesive) within the ferrule <NUM> after insertion of the adhesive into the ferrule <NUM> and before the adhesive solidifies, cures, or otherwise hardens due to the decreased size of the ferrule opening 436C.

Referring to <FIG>, in some examples, a ferrule <NUM> can include a flange 536B that is longer than the flange 236B described above. The longer flange 536B, in some examples, allows for one or more welds <NUM> to be spaced at a greater distance from a sidewall 536D of the ferrule <NUM> than if the flange were shorter. In this way, welding the flange 536D to a case <NUM> can be accomplished with less risk of harming the lead wire, the plug, or any other component due to the heat generated during the welding process. For instance, in some examples, heat from welding can decompose adhesive used with respect to the plug, so keeping the location of the weld <NUM> at a greater distance from the adhesive allows for greater dissipation of heat within the ferrule <NUM> and lessens the chances of the heat decomposing, breaking down, or otherwise adversely affecting the plug and/or the adhesive.

Referring to <FIG>, in some examples, a ferrule <NUM> includes an adhesion feature <NUM> configured to enhance adhesion between the ferrule <NUM> and a plug. In some examples, an interior surface of a sidewall 636D of the ferrule <NUM> includes the adhesion feature <NUM>, which includes one or more bumps, roughness, pegs, dimples, ridges, ribs, holes, pores, or the like or a combination thereof. In this way, the adhesion feature <NUM> is configured to increase surface area and provide texture to enhance affixation of the plug thereto and provide a mechanical bond between the plug and the ferrule <NUM>, whether the plug is formed from an adhesive (such as, but not limited to, epoxy) inserted into the ferrule <NUM> and allowed to set, cure, or otherwise harden or a polymeric material which is heated to thermally join the plug to the ferrule <NUM> (using either bulk heating or local heating, for instance) or is affixed to the ferrule <NUM> using adhesive.

Referring to <FIG>, in some examples, a ferrule <NUM> includes an adhesion feature <NUM> configured to enhance adhesion between the ferrule <NUM> and a plug. In some examples, a sidewall 736D of the ferrule <NUM> includes the adhesion feature <NUM>, which includes one or more holes, pores, openings, channels, voids, or the like or a combination thereof through the sidewall 736D from an interior surface of the sidewall 736D to an exterior surface of the sidewall 736D. In this way, the adhesion feature <NUM> is configured to allow the plug to flow at least partially into the adhesion feature <NUM> to enhance affixation of the plug thereto and provide a mechanical bond between the plug and the ferrule <NUM>, whether the plug is formed from an adhesive (such as, but not limited to, epoxy) inserted into the ferrule <NUM> and allowed to set, cure, or otherwise harden or a polymeric material which is heated to thermally join the plug to the ferrule <NUM> (using either bulk heating or local heating, for instance) or is affixed to the ferrule <NUM> using adhesive.

Referring to <FIG>, in some examples, a ferrule <NUM> includes a non-cylindrical shape. In some examples, the ferrule <NUM> includes an angled sidewall 836D such that the ferrule <NUM> essentially forms a frustoconical shape. In this way, the angled sidewall 836D is similar to the inwardly-extending portion 436A of the example ferrule <NUM> shown in <FIG> except that the angled sidewall 836D extends for substantially the entire length of the ferrule <NUM> and not just a portion of it. In this way, the shape of the ferrule <NUM> allows for a ferrule opening 836C to be decreased in size than if the ferrule were to include straight sidewalls and be more cylindrical in shape. In various examples, the angled sidewall 836D can provide for a surface on which a plug can rest to facilitate proper placement within the ferrule <NUM> and/or inhibit migration of the plug outside of the ferrule <NUM> and toward the interior space of the case and/or can aid in retaining the plug (if formed from an adhesive) within the ferrule <NUM> after insertion of the adhesive into the ferrule <NUM> and before the adhesive solidifies, cures, or otherwise hardens due to the decreased size of the ferrule opening 836C. Although the example ferrule <NUM> shown in <FIG> includes a substantially uniformly angled sidewall 836D, in other examples, other non-cylindrical ferrule shapes are contemplated, such as, for instance, a curved sidewall (inwardly curving to provide for a decreased ferrule opening), an angled sidewall having at least a first portion angled at a first angle (with respect to a longitudinal axis) and a second portion angled at a second angle (with respect to the longitudinal axis), a stepped sidewall, or one or more other substantially non-cylindrically-shaped sidewalls.

Referring to <FIG>, in some examples, a lead wire <NUM>, <NUM>, <NUM> can include an adhesion feature <NUM>, <NUM>, <NUM> configured to enhance adhesion between the lead wire <NUM>, <NUM>, <NUM> and a plug <NUM>, <NUM>, <NUM>. In various examples, the adhesion feature <NUM>, <NUM>, <NUM> can include various structures or features to increase surface area and provide texture to enhance affixation of the lead wire <NUM>, <NUM>, <NUM> to the plug <NUM>, <NUM>, <NUM> and provide a mechanical bond between the plug <NUM>, <NUM>, <NUM> and the lead wire <NUM>, <NUM>, <NUM>, whether the plug <NUM>, <NUM>, <NUM> is formed from an adhesive (such as, but not limited to, epoxy) inserted into a ferrule <NUM>, <NUM>, <NUM> and allowed to set, cure, or otherwise harden or a polymeric material which is heated to thermally join the plug <NUM>, <NUM>, <NUM> to the lead wire <NUM>, <NUM>, <NUM> or is affixed to the lead wire <NUM>, <NUM>, <NUM> using adhesive. In various examples, the adhesion feature <NUM>, <NUM>, <NUM> of the lead wire <NUM>, <NUM>, <NUM> can be used instead of or in addition to an adhesion feature of the ferrule <NUM>, <NUM>, <NUM> (such as an adhesion feature similar to the adhesion feature <NUM> described above, for instance). It is contemplated in various examples that various adhesion features <NUM>, <NUM>, <NUM> can be used with the lead wire <NUM>, <NUM>, <NUM>, including, but not limited to, one or more bumps, roughness, pegs, dimples, ridges, ribs, or the like or a combination thereof.

For instance, with respect to <FIG>, the adhesion feature <NUM> of the lead wire <NUM> includes a bent portion <NUM> of the lead wire <NUM>. In some examples, the bent portion <NUM> can be substantially helical. In other examples, the bent portion <NUM> can include a substantially wavy portion, a substantially saw-tooth portion, or portions include various other bend patterns. In some examples, the lead wire <NUM> can include a bent portion including a single bend. In other examples, the lead wire <NUM> can include a bent portion including multiple bends. In some examples, the lead wire <NUM> can include a bent portion including two or more different bend patterns.

With respect to <FIG>, the adhesion feature <NUM> of the lead wire <NUM> includes a textured surface <NUM> of the lead wire <NUM>. In some examples, the textured surface <NUM> of the lead wire <NUM> includes bumps <NUM> along a portion of the lead wire <NUM> to provide increased surface area and/or texture around and within which adhesive or polymeric material of the plug <NUM> forms to enhance affixation of the lead wire <NUM> to the plug <NUM>. In other examples, the textured surface <NUM> can include ridges, dimples, channels, or other patterns or textures or a combination of patterns or textures.

With respect to <FIG>, the adhesion feature <NUM> of the lead wire <NUM> includes a porous surface <NUM> of the lead wire <NUM>. In some examples, the porous surface <NUM> of the lead wire <NUM> includes holes <NUM> along a portion of the lead wire <NUM> to provide increased surface area and/or texture around and within which adhesive or polymeric material of the plug <NUM> forms to enhance affixation of the lead wire <NUM> to the plug <NUM>. In other examples, the porous surface <NUM> can include dimples, channels, or other patterns or textures or a combination of patterns or textures.

Referring again to <FIG>, it is noted that in various examples, a lead wire can include a combination of two or more of the adhesion features <NUM>, <NUM>, <NUM>. For instance, in some examples, a lead wire can include a bent portion <NUM> in combination with a porous surface <NUM>. In other examples, a lead wire can include a textured surface <NUM> in combination with a porous surface <NUM>. In other examples, a lead wire can include a bent portion <NUM> in combination with a textured surface <NUM>. And, in further examples, a lead wire can include a bent portion <NUM> in combination with a textured surface <NUM> and a porous surface <NUM>. In this way, affixation of the various lead wire examples with a plug is enhanced by increasing the surface area and/or texture around and/or within which adhesive or polymeric material of a plug interacts.

In various examples, referring still to <FIG>, the lead wire <NUM>, <NUM>, <NUM> can include various cross sections. In some examples, the lead wire <NUM>, <NUM>, <NUM> includes a substantially circular cross section. However, in other examples, the lead wire <NUM>, <NUM>, <NUM> can include a non-circular cross section, potentially providing for increased affixation between the lead wire <NUM>, <NUM>, <NUM> and the plug <NUM>, <NUM>, <NUM>. For instance, in some examples, a non-circular cross section can inhibit twisting between the lead wire <NUM>, <NUM>, <NUM> and the plug <NUM>, <NUM>, <NUM>. Some examples of non-circular cross sections that can be employed along at least a portion of the lead wire <NUM>, <NUM>, <NUM> include, but are not limited to, cross sections that are square, quadrilateral, triangular, ovular, elliptical, star-shaped, flat, polygonal, lobed, or the like. In some examples, the lead wire <NUM>, <NUM>, <NUM> can include two or more different cross-sectional shapes, such as the various cross-sectional shape examples above, over at least a portion of the length of the lead wire <NUM>, <NUM>, <NUM>. One or more of such non-circular cross sections can be employed, in some examples, in addition to one or more of the adhesion features <NUM>, <NUM>, <NUM> described above, to further enhance affixation between the lead wire and the plug. However, in other examples, a lead wire can include one or more a non-circular cross sections along at least a portion of the length of the lead wire without employing one or more of the adhesion features <NUM>, <NUM>, <NUM> described above, depending upon the desired characteristics of adhesion and/or interaction between the lead wire and the plug.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a ferrule <NUM>, the ferrule <NUM> being attached within an opening of a case or other device or component, as described herein. In some examples, the feedthrough seal apparatus <NUM> includes a lead wire <NUM> extending from an interior of the case to an exterior of the case. In some examples, a plug <NUM> can include a polymeric material and can be inserted into the ferrule <NUM> by sliding it in the direction of arrow X along the lead wire <NUM> and into the ferrule <NUM>. In some examples, the plug <NUM> is sized and shaped to correspond to an interior of the ferrule <NUM> to allow the plug <NUM> to be press-fit into the ferrule <NUM> to affix the plug <NUM> at least partially within the ferrule <NUM>. In some examples, the plug <NUM> is formed from a thermoplastic polymeric material and is sized and shaped to fit snugly within the ferrule <NUM> and around the lead wire <NUM>, thereby allowing for heating (for instance, either bulk or local heating) of the plug <NUM> to thermally join the plug <NUM> to the ferrule <NUM> and the lead wire <NUM>. In further examples, the plug <NUM> can be designed to match an inner geometry of the ferrule <NUM>. In other examples, the plug <NUM> is sized and shaped to allow for space between the plug <NUM> and the ferrule <NUM> and between the plug <NUM> and the lead wire <NUM> to allow for placement of adhesive within the space to affix the plug <NUM> to the ferrule <NUM> and the lead wire <NUM>. In some examples, one or both of the ferrule <NUM> and the lead wire <NUM> include an adhesion feature, as described herein.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM>, <NUM>', <NUM>" includes a ferrule <NUM>, <NUM>', <NUM>", the ferrule <NUM>, <NUM>', <NUM>" being attached within an opening of a case or other device or component, as described herein. In some examples, the feedthrough seal apparatus <NUM>, <NUM>', <NUM>" includes a lead wire <NUM>, <NUM>', <NUM>" extending from an interior of the case to an exterior of the case. In some examples, one or both of the ferrule <NUM>, <NUM>', <NUM>" and the lead wire <NUM>, <NUM>', <NUM>" include an adhesion feature, as described herein. In some examples, a plug <NUM>, <NUM>', <NUM>" can include a polymeric portion 1332A, 1332A', 1332A" and an adhesive portion 1332B, 1332B', 1332B". In some examples, the polymeric portion 1332A, 1332A', 1332A" can be inserted into the ferrule <NUM>, <NUM>', <NUM>" by sliding it in the direction along the lead wire <NUM>, <NUM>', <NUM>" and into the ferrule <NUM>, <NUM>', <NUM>". In some examples, the polymeric portion 1332A, 1332A', 1332A" is sized and shaped to correspond to an interior of the ferrule <NUM>, <NUM>', <NUM>" to allow the polymeric portion 1332A, 1332A', 1332A" to be press-fit into the ferrule <NUM>, <NUM>', <NUM>" to affix the polymeric portion 1332A, 1332A', 1332A" at least partially within the ferrule <NUM>, <NUM>', <NUM>". In some examples, the polymeric portion <NUM>, <NUM>', <NUM>" is formed from a thermoplastic polymeric material and is sized and shaped to fit snugly within the ferrule <NUM>, <NUM>', <NUM>" and around the lead wire <NUM>, <NUM>', <NUM>", thereby allowing for heating (either bulk or local heating, for instance) of the polymeric portion <NUM>, <NUM>', <NUM>" to thermally join the polymeric portion <NUM>, <NUM>', <NUM>" to the ferrule <NUM>, <NUM>', <NUM>" and the lead wire <NUM>, <NUM>', <NUM>". In further examples, the plug <NUM>, <NUM>', <NUM>" can be designed to match an inner geometry of the ferrule <NUM>, <NUM>', <NUM>". In other examples, the polymeric portion 1332A, 1332A', 1332A" is sized and shaped to allow for space between the polymeric portion 1332A, 1332A', 1332A" and the ferrule <NUM>, <NUM>', <NUM>" and between the polymeric portion 1332A, 1332A', 1332A" and the lead wire <NUM>, <NUM>', <NUM>" to allow for placement of adhesive within the space to affix the polymeric portion 1332A, 1332A', 1332A" to the ferrule <NUM>, <NUM>', <NUM>" and the lead wire <NUM>, <NUM>', <NUM>". In some examples, the polymeric portion 1332A, 1332A', 1332A" can aid in positioning of the lead wire <NUM>, <NUM>', <NUM>" with respect to the ferrule <NUM>, <NUM>', <NUM>". In some examples, the polymeric portion 1332A, 1332A', 1332A" can help center the lead wire <NUM>, <NUM>', <NUM>" with respect to the ferrule <NUM>, <NUM>', <NUM>". That is, in some examples, formation of a hole within the polymeric portion 1332A, 1332A', 1332A" for the lead wire <NUM>, <NUM>', <NUM>" (for instance, substantially centered within the polymeric portion 1332A, 1332A', 1332A") with respect to an outer perimeter of the polymeric portion 1332A, 1332A', 1332A" can allow for proper spacing between the lead wire <NUM>, <NUM>', <NUM>" and the ferrule <NUM>, <NUM>', <NUM>", thereby making it less likely for the lead wire <NUM>, <NUM>', <NUM>" to come into contact with the ferrule <NUM>, <NUM>', <NUM>" once the plug <NUM>, <NUM>', <NUM>" is positioned within the ferrule <NUM>, <NUM>', <NUM>". Once the polymeric portion 1332A, 1332A', 1332A" is in position within the ferrule <NUM>, <NUM>', <NUM>", in some examples, adhesive can be inserted within the ferrule <NUM>, <NUM>', <NUM>" to form the adhesive portion 1332B, 1332B', 1332B" of the plug <NUM>, <NUM>', <NUM>" and fill at least a portion of the ferrule <NUM>, <NUM>', <NUM>" on top of the polymeric portion 1332A, 1332A', 1332A". In some examples, the use of the polymeric portion 1332A, 1332A', 1332A" aids in closing off a ferrule opening 1336C, 1336C', 1336C", such that adhesive with a lower viscosity can be used (as compared to an adhesive used without a polymeric portion and, in turn, a larger ferrule opening, as described above). That is, because the ferrule opening 1336C, 1336C', 1336C" is largely (if not completely) closed off by the polymeric portion 1332A, 1332A', 1332A", there is not as large of a gap to span with the adhesive (as there is in examples above), and, therefore, a less viscous adhesive would be less likely to leak from the ferrule opening 1336C, 1336C', 1336C" than if the ferrule opening 1336C, 1336C', 1336C" were not largely closed off by the polymeric portion 1332A, 1332A', 1332A".

In various examples, different configurations of the ferrule <NUM>, <NUM>', <NUM>" can be used. For instance, referring to <FIG>, in some examples, a sidewall 1336D of the ferrule <NUM> includes an inwardly-extending portion 1336A. In some examples, the inwardly-extending portion 1336A reduces the size of the ferrule opening 1336C than would otherwise be present if there were no inwardly-extending portion. In some examples, the inwardly-extending portion 1336A is disposed at an end of the ferrule <NUM>. In other examples, the inwardly-extending portion can be disposed at a location intermediate ends of the ferrule. In some examples, the inwardly-extending portion 1336A can be configured to support the polymeric portion 1332A and retain the polymeric portion 1332A within the ferrule <NUM>. In this way, the polymeric portion 1332A is inhibited from passing through and/or out of the ferrule <NUM>.

Referring to <FIG>, in some examples, a sidewall 1336D' of the ferrule <NUM>' includes an inwardly-extending portion 1336A', which decreases the size of the ferrule opening 1336C' (for instance, the space between the ferrule <NUM>' and a lead wire <NUM>'). In some examples, the inwardly-extending portion 1336A' includes a tapered feature 1336A'. In some examples, the tapered feature 1336A' extends inwardly from the sidewall 1336D' of the ferrule <NUM>' at an angle of greater than ninety degrees with respect to the sidewall 1336D', such that the tapered feature 1336A' extends in an inward and downward direction (with respect to <FIG>) from the sidewall 1336D' of the ferrule <NUM>'. In some examples, the tapered feature 1336A' can be configured to support the polymeric portion 1332A' and retain the polymeric portion 1332A' within the ferrule <NUM>'. In this way, the polymeric portion 1332A' is inhibited from passing through and/or out of the ferrule <NUM>'.

Referring to <FIG>, in some examples, a sidewall 1336D" of the ferrule <NUM>" is substantially straight, such that the ferrule <NUM>" is substantially cylindrical in shape. In this way, in some examples, a frictional fit between the polymeric portion 1332A" and the ferrule <NUM>" and/or between the polymeric portion 1332A" and the lead wire <NUM>" is used to retain the polymeric portion 1332A" within the ferrule <NUM>" and inhibit the polymeric portion 1332A" from passing through and/or out of the ferrule <NUM>".

Referring to <FIG>, in some examples, a case <NUM> (for instance, of a medical device or a component of a medical device) includes an opening <NUM> with a lead wire <NUM> extending from within an interior space <NUM> of the case <NUM> to an exterior <NUM> of the case <NUM>. In various examples, a feedthrough seal apparatus <NUM>', <NUM>" can be used to seal the opening <NUM> of the case while still allowing electrical communication between the interior space <NUM> of the case <NUM> and the exterior <NUM> of the case <NUM>. In some examples, the feedthrough seal apparatus <NUM>', <NUM>" can be used to hermetically seal the opening <NUM> of the case.

In some examples, referring specifically to <FIG>, the feedthrough seal apparatus <NUM>' includes a ferrule <NUM>' and a plug <NUM>' disposed at least partially within the ferrule <NUM>'. In various examples, in manners similar to those described herein, the plug <NUM>' can include a polymeric material, which can be affixed within the ferrule <NUM>' (for instance, with thermal joining, press-fitting, an adhesive, or the like or a combination thereof). The plug <NUM>' and the affixed ferrule <NUM>' can then be slid along the lead wire <NUM> in the direction of arrow X' and into place within the opening <NUM> of the case <NUM>. In some examples, the ferrule <NUM>' can then be engaged to the case <NUM> within the opening <NUM>, for instance by welding or another engagement means. With the ferrule <NUM>' and the plug <NUM>' in place with respect to the lead wire <NUM>, in some examples, the plug <NUM>' can be affixed to the lead wire <NUM> (for instance, with thermal joining, press-fitting, an adhesive, or the like or a combination thereof). In this way, the plug <NUM>' can be hermetically bonded to the ferrule <NUM>' and the lead wire <NUM>. In some examples, the feedthrough seal apparatus <NUM>' includes one or more of the following advantages:.

In some examples, referring specifically to <FIG>, the feedthrough seal apparatus <NUM>" includes a plug <NUM>". That is, the feedthrough seal apparatus <NUM>" does not include a ferrule. In various examples, in manners similar to those described herein, the plug <NUM>" can include a polymeric material. The plug <NUM>" can be slid along the lead wire <NUM> in the direction of arrow X" and into place within the opening <NUM> of the case <NUM>. In some examples, the plug <NUM>" can then be engaged to the case <NUM> within the opening <NUM>, for instance by thermal joining, an adhesive, or another engagement means. With the plug <NUM>" in place with respect to the lead wire <NUM>, in some examples, the plug <NUM>" can be affixed to the lead wire <NUM> (for instance, with thermal joining, an adhesive, or the like or a combination thereof). In this way, in some examples, a one-component feedthrough seal apparatus <NUM>" can be used to seal the opening <NUM> of the case <NUM>, thereby reducing, if not eliminating, the need for a ferrule. Furthermore, in some examples, the plug <NUM>" is hermetically bonded directly to the case <NUM> and the lead wire <NUM>. In some examples, the feedthrough seal apparatus <NUM>" includes one or more of the following advantages:.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a ferrule <NUM> engaged within an opening <NUM> of a case <NUM>. As with previous examples, the ferrule <NUM> can be engaged to the case <NUM> by welding or another engagement means. In some examples, a plug <NUM> is included at least partially within the ferrule <NUM>, the plug <NUM> being affixed to the ferrule <NUM>. In some examples, the plug <NUM> can include a thermoplastic polymeric material, such that, when heated (either bulk or locally, for instance), at least a portion <NUM> of the plug <NUM> abutting the ferrule <NUM> melts or otherwise becomes flowable to interact with the ferrule <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the ferrule <NUM>. In like manner, in some examples, the plug <NUM> can be heated (either bulk or locally, for instance) to melt at least a portion <NUM> of the plug <NUM> abutting a lead wire <NUM> to interact with the lead wire <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the lead wire <NUM>. Although the ferrule <NUM> is shown with straight walls in the present example, it should be understood that the ferrule <NUM> can include a stepped portion or a tapered portion at an inner end, as described with respect to other examples herein, and/or a flange at an outer end, as is also described with respect to other examples herein.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a ferrule <NUM> engaged within an opening <NUM> of a case <NUM>. As with previous examples, the ferrule <NUM> can be engaged to the case <NUM> by welding or another engagement means. In some examples, a plug <NUM> is included at least partially within the ferrule <NUM>, the plug <NUM> being affixed to the ferrule <NUM>. In some examples, the plug <NUM> can be affixed to the ferrule <NUM> using adhesive <NUM> between the plug <NUM> and the ferrule <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the plug <NUM> to the ferrule <NUM>. In like manner, in some examples, the plug <NUM> can be affixed to a lead wire <NUM> using adhesive <NUM> between the plug <NUM> and the lead wire <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the plug <NUM> to the lead wire <NUM>. Although the ferrule <NUM> is shown with a stepped portion at an inner end in the present example, it should be understood that the ferrule <NUM> can include straight walls or a tapered portion at an inner end, as described with respect to other examples herein, and/or a flange at an outer end, as is also described with respect to other examples herein. In some examples, the shape of the ferrule <NUM> allows for relatively efficient seal formation. In some examples, the shape of the ferrule <NUM> facilitates the accurate positioning of the plug <NUM> and inhibits the plug <NUM> from sliding toward the interior of the case <NUM> within the ferrule <NUM>.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM>, <NUM>' includes a ferrule <NUM>, <NUM>' engaged within an opening <NUM>, <NUM>' of a case <NUM>, <NUM>'. As with previous examples, the ferrule <NUM>, <NUM>' can be engaged to the case <NUM>, <NUM>' by welding or another engagement means. In some examples, a plug <NUM>, <NUM>' is included at least partially within the ferrule <NUM>, <NUM>', the plug <NUM>, <NUM>' being affixed to the ferrule <NUM>, <NUM>'.

In some examples, referring to <FIG>, the plug <NUM> can include a thermoplastic polymeric material, such that, when heated (either bulk or locally, for instance), at least a portion <NUM> of the plug <NUM> abutting the ferrule <NUM> and/or case <NUM> melts or otherwise becomes flowable to interact with the ferrule <NUM> and/or the case <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the ferrule <NUM> and/or the case <NUM>. In like manner, in some examples, the plug <NUM> can be heated (either bulk or locally, for instance) to melt at least a portion <NUM> of a longitudinal passage 1732C of the plug <NUM> abutting a lead wire <NUM> to interact with the lead wire <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the lead wire <NUM>. Although the ferrule <NUM> is shown with straight walls in the present example, it should be understood that the ferrule <NUM> can include a stepped portion or a tapered portion at an inner end, as described with respect to other examples herein, and/or a flange at an outer end, as is also described with respect to other examples herein.

Referring to <FIG>, in some examples, the plug <NUM>' can be affixed to the ferrule <NUM>' using adhesive <NUM>' between the plug <NUM>' and the ferrule <NUM>' and/or the case <NUM>', which, with solidifying, curing, or hardening of the adhesive <NUM>', affixes the plug <NUM>' to the ferrule <NUM>' and/or the case <NUM>'. In like manner, in some examples, the plug <NUM>' can be affixed to a lead wire <NUM>' using adhesive <NUM>' between a longitudinal passage 1732C' of the plug <NUM>' and the lead wire <NUM>', which, with solidifying, curing, or hardening of the adhesive <NUM>', affixes the plug <NUM>' to the lead wire <NUM>'. Although the ferrule <NUM>' is shown with straight walls in the present example, it should be understood that the ferrule <NUM>' can include a stepped portion or a tapered portion at an inner end, as described with respect to other examples herein, and/or a flange at an outer end, as is also described with respect to other examples herein.

Referring to <FIG>, the plug <NUM>, <NUM>', in some examples, includes a body portion 1732A, 1732A' configured to be inserted within the ferrule <NUM>, <NUM>' and a flange portion 1732B, 1732B' configured to remain outside the ferrule <NUM>, <NUM>' to abut a top of the ferrule <NUM>, <NUM>' and/or the case <NUM>, <NUM>'. The flange portion 1732B, 1732B' allows for increased contact area between the plug <NUM>, <NUM>' and the ferrule <NUM>, <NUM>' and/or the case <NUM>, <NUM>' than a plug having only the body portion to allow for increased affixation between the plug <NUM>, <NUM>' and the ferrule <NUM>, <NUM>' and/or the case <NUM>, <NUM>' either through thermal joining of the portion <NUM> of the plug <NUM> or by solidifying, curing, or hardening of the adhesive <NUM>'.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a plug <NUM> engaged within an opening <NUM> of a case <NUM>. In this way, in some examples, a one-component feedthrough seal apparatus <NUM> can be used to seal the opening <NUM> of the case <NUM>, thereby reducing, if not eliminating, the need for a ferrule. In some examples, the plug <NUM> can include a thermoplastic polymeric material, such that, when heated (for instance, either bulk or locally), at least a portion <NUM> of the plug <NUM> abutting the case <NUM> melts or otherwise becomes flowable to interact with the case <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the case <NUM>. In like manner, in some examples, the plug <NUM> can be heated (for instance, either bulk or locally) to melt a portion <NUM> of the plug <NUM> abutting a lead wire <NUM> to interact with the lead wire <NUM> and, with solidifying or hardening of the portion <NUM>, thermally join or otherwise affix the plug <NUM> to the lead wire <NUM>. In the example of <FIG>, the feedthrough seal apparatus <NUM> is substantially disk-shaped and is relatively thin. Depending upon the application, the environment, and other factors of the feedthrough seal apparatus <NUM>, other shapes of the feedthrough seal apparatus <NUM> can be used in other examples, including, but not limited to, the shapes of the feedthrough seal apparatus examples described herein.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a plug <NUM> engaged within an opening <NUM> of a case <NUM>. In this way, in some examples, a one-component feedthrough seal apparatus <NUM> can be used to seal the opening <NUM> of the case <NUM>, thereby reducing, if not eliminating, the need for a ferrule. In some examples, the plug <NUM> can include a polymeric material, which is then affixed within the opening <NUM> of the case <NUM>. In some examples, the plug <NUM> can be affixed to the case <NUM> using adhesive <NUM> between the plug <NUM> and the case <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the plug <NUM> to the case <NUM>. In like manner, in some examples, the plug <NUM> can be affixed to a lead wire <NUM> using adhesive <NUM> between the plug <NUM> and the lead wire <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the plug <NUM> to the lead wire <NUM>. In the example of <FIG>, the feedthrough seal apparatus <NUM> is substantially frustoconically-shaped to increase contact area between the plug <NUM> and at least one of the case <NUM> and the lead wire <NUM> than other differently-shaped feedthrough seal apparatuses, such as, for instance, the substantially disk-shaped plug <NUM> of the feedthrough seal apparatus <NUM> described above. In some examples, the plug <NUM> is designed to maximize the area of contact with the case <NUM> and the lead wire <NUM>. Depending upon the application, the environment, and other factors of the feedthrough seal apparatus <NUM>, other shapes of the feedthrough seal apparatus <NUM> can be used in other examples, including, but not limited to, the shapes of the feedthrough seal apparatus examples described herein. In some examples, the shape of the plug <NUM> allows for efficient seal formation. In some examples, the shape of the plug <NUM> results in increased area of contact between the metal of the case <NUM> and/or the lead wire <NUM> and the polymeric material of the plug <NUM>.

Referring to <FIG>, in some examples, a feedthrough seal apparatus <NUM> includes a plug <NUM> engaged within an opening <NUM> of a case <NUM>. In some examples, the plug <NUM> includes a first portion 2032A and a second portion 2032E. In this way, in some examples, a two-component feedthrough seal apparatus <NUM> can be used to seal the opening <NUM> of the case <NUM>, thereby reducing, if not eliminating, the need for a ferrule. In some examples, the first and second portions 2032A, 2032E of the plug <NUM> can include a polymeric material.

In some examples, the first portion 2032A of the plug <NUM> includes a body portion 2032B configured to be inserted within the opening <NUM> of the case <NUM> and a flange portion 2032C configured to remain outside the opening <NUM> to abut a top of the case <NUM>. The second portion 2032E, in some examples, includes an opening 2032F through the second portion 2032E, such that the second portion 2032E forms a substantially annular shape. In some examples, the opening 2032F of the second portion 2032E is sized to accept the body portion 2032B within the opening 2032F to enable the first portion 2032A and the second portion 2032E to be fitted together to form the plug <NUM>. In some examples, the second portion 2032E is configured to engage with the first portion 2032A. For instance, in some examples, the second portion 2032E is sized to frictionally engage with the first portion 2032A. In other examples, the second portion 2032E is configured to be threadably engaged with the first portion 2032A. In still other examples, the first portion 2032A and the second portion 2032E are configured to be fastened together, for instance, using adhesive.

In some examples, the first and second portions 2032A, 2032E of the plug <NUM> are affixed within and around the opening <NUM> of the case <NUM>. In some examples, the first portion 2032A of the plug <NUM> is affixed to the case <NUM> and within the opening <NUM> using adhesive <NUM> between the first portion 2032A of the plug <NUM> and the case <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the first portion 2032A of the plug <NUM> to the case <NUM> within the opening <NUM>. The second portion 2032E of the plug <NUM> can then be engaged with the first portion 2032A of the plug <NUM> to essentially sandwich a portion of the case <NUM> around the opening <NUM> between the flange portion 2032C of the first portion 2032A and the second portion 2032E. In some examples, the second portion 2032E of the plug <NUM> is affixed to the case <NUM> using adhesive <NUM> between the second portion 2032E of the plug <NUM> and the case <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the second portion 2032E of the plug <NUM> to the case <NUM>. In like manner, in some examples, the first portion 2032A of the plug <NUM> can be affixed to a lead wire <NUM> using adhesive <NUM> between a longitudinal passage 2032D of the first portion 2032A of the plug <NUM> and the lead wire <NUM>, which, with solidifying, curing, or hardening of the adhesive <NUM>, affixes the first portion 2032A of the plug <NUM> to the lead wire <NUM>. Although described as being affixed to the case <NUM> with adhesive <NUM>, in other examples, the plug <NUM> can include a thermoplastic polymeric material, such that, when heated (for instance, either bulk or locally), at least a portion of the plug <NUM> abutting the case <NUM> melts or otherwise becomes flowable to interact with the case <NUM> and, with solidifying or hardening of the portion, thermally join or otherwise affix the plug <NUM> to the case <NUM> and the lead wire <NUM>.

Referring to <FIG>, in some examples, the case <NUM>, <NUM>, <NUM> (for instance, proximate the opening <NUM>, <NUM>, <NUM>) can include one or more adhesion features to improve bonding, adhesion, and/or interaction between the case <NUM>, <NUM>, <NUM> and the plug <NUM>, <NUM>, <NUM>. In some examples, such adhesion features can include, but are not limited to, surface roughness, bumps, ridges, dimples, channels, or other patterns or textures or a combination of patterns or textures. In similar manner to the various adhesion features described above with respect to the various ferrule examples and/or the various lead wire examples, employing one or more of such adhesion features with respect to the case <NUM>, <NUM>, <NUM> can provide increased surface area and/or texture around and within which adhesive or polymeric material of the plug <NUM>, <NUM>, <NUM> can form in order to enhance affixation of the plug <NUM>, <NUM>, <NUM> to the case <NUM>, <NUM>, <NUM>. Although mentioned specifically with respect to the examples in <FIG>, in various examples, it is noted that one or more of such adhesion features can be employed with respect to any of the examples of cases described herein in order to enhance adhesion, bonding, or interaction between the various plug examples and the various case examples described herein.

Various examples of feedthrough seal apparatuses are summarized in Table <NUM>, below.

In various examples, with reference to <FIG> and the description herein, a method is included for making a feedthrough seal apparatus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>. In some examples, the feedthrough seal apparatus <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> is configured to seal an opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> in a device <NUM>, the device <NUM> including a case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> surrounding an interior space <NUM>, <NUM>, <NUM>. In some examples, the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> includes the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> therein to allow access to the interior space <NUM>, <NUM>, <NUM> from an exterior <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>. The method, in some examples, includes positioning a plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> within the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>. In some examples, a lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> is positioned within the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>. In some examples, the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> includes a first end 134A and a second end 134B. In some examples, the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> extends through the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, such that the first end 134A of the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> is disposed within the interior space <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> and the second end 134B extends from the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> to the exterior <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, wherein the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> is configured to allow electrical communication between the interior space <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> and the exterior <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>.

In some examples, the method further includes positioning a ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' within the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, wherein the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' is positioned within the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>, <NUM>, <NUM>'. In some examples, positioning the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' includes inserting adhesive within the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' and around the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. In this way, the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' is formed at least partially, if not entirely, from adhesive.

In some examples, the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' is formed at least partially, if not entirely, from one or more polymeric materials. In some examples, the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>' is affixed to the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>' and the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM>' using adhesive. In other examples, the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM> includes a thermoplastic polymeric material, wherein the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM> is thermally joined to the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM> and the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>, <NUM>, <NUM> by heating the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>', <NUM>, <NUM>. In some examples, the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' is affixed within the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' and/or to the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM> by press-fitting the plug <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' at least partially within the ferrule <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>' and/or around the lead wire <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>", <NUM>. In some examples, the ferrule <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' is affixed within the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>' by welding the ferrule <NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, <NUM>' to the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>'.

In some examples, the plug <NUM>, <NUM>", <NUM>, <NUM>, <NUM> is affixed within the opening <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. That is, the feedthrough seal apparatus <NUM>, <NUM>", <NUM>, <NUM>, <NUM> includes no ferrule and the plug <NUM>, <NUM>", <NUM>, <NUM>, <NUM> is bonded directly to the case <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. In some examples, the plug <NUM>, <NUM>", <NUM>, <NUM>, <NUM> includes a polymeric material. In some examples, the plug <NUM>, <NUM>", <NUM>, <NUM> is affixed within the opening <NUM>, <NUM>, <NUM>, <NUM> of the case <NUM>, <NUM>, <NUM>, <NUM> and to the lead wire <NUM>, <NUM>, <NUM>, <NUM> using an adhesive. In some examples, the plug <NUM>, <NUM>", <NUM>, <NUM> includes a thermoplastic polymeric material, wherein the plug <NUM>, <NUM>", <NUM>, <NUM> is thermally joined to the case <NUM>, <NUM>, <NUM>, <NUM> and the lead wire <NUM>, <NUM>, <NUM>, <NUM> by heating the plug <NUM>, <NUM>", <NUM>, <NUM>.

The present inventors have recognized various advantages of the subject matter described herein. For instance, in some examples, the present subject matter is advantageous for use in a feedthrough seal of a component of a medical device. In some examples, the present inventors have recognized that the present subject matter can be advantageous for use in feedthrough seals that are substantially functionally equivalent to, relatively simpler to manufacture than, and relatively less expensive than GTMS. For instance, compared to current seals (such as GTMS, for instance), the present subject matter, in various examples, can reduce manufacturing time, manufacturing difficulty, and material cost while achieving a seal that can withstand voltages of the component, inhibit current leakages between the wire and case, physically inhibit the wire and case from contacting one another, and inhibit movement of electrolyte molecules outside of the component. While various advantages of the example apparatuses, systems, and methods are listed herein, this list is not considered to be complete, as further advantages may become apparent from the description and figures presented herein.

Although the subject matter of the present patent application has been described with reference to various examples, workers skilled in the art will recognize that changes can be made in form and detail without departing from the scope of the subject matter recited in the below claims.

The above Detailed Description includes references to the accompanying drawings, which form a part of the Detailed Description. The drawings show, by way of illustration, specific examples in which the present apparatuses, systems, and methods can be practiced.

The above Detailed Description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more elements thereof) can be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, various features or elements can be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter can lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the invention should be determined with reference to the appended claims.

In this document, the terms "a" or "an" are used to include one or more than one, independent of any other instances or usages of "at least one" or "one or more. In this document, the terms "about" and "approximately" or similar are used to refer to an amount that is nearly, almost, or in the vicinity of being equal to a stated amount.

Claim 1:
A device including a case (<NUM>, <NUM>) and a feedthrough seal apparatus (<NUM>), the case (<NUM>) surrounding an interior space (<NUM>) and including an opening (<NUM>, <NUM>) therein to allow access to the interior space (<NUM>) from an exterior (<NUM>) of the case (<NUM>), the feedthrough seal apparatus (<NUM>) comprising:
a plug (<NUM>, <NUM>) disposed within the opening (<NUM>) of the case (<NUM>), wherein the plug (<NUM>) is formed from a polymeric material and optionally an adhesive material;
a ferrule (<NUM>) attached to the case (<NUM>) and disposed within the opening (<NUM>), wherein the plug (<NUM>) is affixed within the ferrule (<NUM>); and
a lead wire (<NUM>) including a first end (134A) and a second end (134B), the lead wire (<NUM>) extending through the plug (<NUM>), such that the first end (134A) of the lead wire (<NUM>) is disposed within the interior space (<NUM>) of the case (<NUM>) and the second end (134B) extends from the plug (<NUM>) to the exterior (<NUM>) of the case (<NUM>), wherein the lead wire (<NUM>) is configured to allow electrical communication between the interior space (<NUM>) of the case (<NUM>) and the exterior (<NUM>) of the case (<NUM>), and wherein the feedthrough seal apparatus (<NUM>) is configured to seal the opening (<NUM>) in the case (<NUM>), the plug (<NUM>) being configured to electrically insulate the lead wire (<NUM>) from the case (<NUM>);
characterised in that
the polymeric material of the plug (<NUM>) includes a thermoplastic polymeric material configured to be thermally joined to the lead wire (<NUM>) with heating of the thermoplastic polymeric material, thereby affixing the plug (<NUM>) to the lead wire (<NUM>); and
in that the lead wire (<NUM>, <NUM>, <NUM>) includes an adhesion feature (<NUM>, <NUM>, <NUM>) configured to enhance adhesion between the lead wire (<NUM>, <NUM>, <NUM>) and the plug (<NUM>, <NUM>, <NUM>), wherein the adhesion feature (<NUM>, <NUM>, <NUM>) includes one or more of a bent portion (<NUM>) of the lead wire (<NUM>), a textured surface (<NUM>), and a porous surface (<NUM>).