Patent Description:
<CIT>, <CIT>, <CIT>, and <CIT> disclose techniques for enclosing implantable medical device components in containers.

This disclosure provides design, material, and use alternatives for medical devices, including delivery systems. The invention provides an implantable medical device according to claim <NUM> and a method of manufacturing of such device, according to claim <NUM>. For better understanding of the invention the present disclosure provides also further examples, not falling under the scope of the claims. The invention refers to an implantable medical device comprising operational circuitry for the implantable medical device including a first plurality of electrical components, a metal canister shaped for housing the operational circuitry, and a dampening layer selectively molded onto and attached to the first plurality of electrical components, the dampening layer providing electrical isolation to the first plurality of electrical components and configured to reduce susceptibility to vibration of the first plurality of electrical components. The operational circuitry includes at least one second electrical component, and the dampening layer is not disposed over the at least one second electrical component. The operational circuitry includes a printed circuit board assembly (PCBA), and the dampening layer provides mechanical fixation of one or more of batteries, capacitors, dump shields, speakers, telemetry components, and recharging coils to the PCBA.

Alternatively or additionally to the above example, the dampening layer is in direct contact with the canister.

Alternatively or additionally to any of the above examples, the dampening layer comprises a thermoplastic, an elastomer, or a thermoplastic elastomer.

Alternatively or additionally to any of the above examples, the dampening layer omits epoxy. Alternatively or additionally to any of the above examples, the dampening layer is a hot melt polymer configured to be molded under low pressure.

Alternatively or additionally to any of the above examples, the dampening layer is impregnated with a desiccant.

Alternatively or additionally to any of the above examples, the dampening layer is impregnated with a hydrogen getter material.

Alternatively or additionally to any of the above examples, the dampening layer provides a positive fixation of the operational circuitry to the canister by adhesion to the canister.

Alternatively or additionally to any of the above examples, the dampening layer provides mechanical fixation of the operational circuitry to the canister.

Alternatively or additionally to any of the above examples, the dampening layer forms one or more cavities containing a desiccant and/or hydrogen getter material.

Alternatively or additionally to any of the above examples, the dampening layer forms one or more cavities containing an X-Ray identification marker.

Alternatively or additionally to any of the above examples, the dampening layer is impregnated with an activated carbon or charcoal to absorb certain organic and/or inorganic compounds from surfaces of the operational circuitry.

Alternatively or additionally to any of the above examples, the dampening layer is impregnated with a composite desiccant selected to achieve pre-determined moisture uptake properties.

Alternatively or additionally to any of the above examples, the dampening layer is a composite including two or more polymeric materials.

Alternatively or additionally to any of the above examples, the at least one second electrical component includes at least one of a battery, an accelerometer, a piezo speaker, an analog timing crystal, and a Bluetooth module.

Alternatively or additionally to any of the above examples, the dampening layer includes a plurality of projections configured to provide an interference fit with the inner surface of the canister.

Alternatively or additionally to any of the above examples, the medical device is devoid of any metallic layer between the dampening layer and the canister.

Alternatively or additionally to any of the above examples, the medical device is devoid of any insulating layer between the dampening layer and the canister.

Alternatively or additionally to any of the above examples, the operational circuitry is configured to sense biological activity, and/or to deliver electrical therapy.

According to the present invention, a method of manufacturing an implantable medical device, comprises molding a dampening layer onto at least a portion of a printed circuit board assembly (PCBA) having a circuit board carrying a plurality of first electrical components, thereby creating a covered operational circuit, and placing the covered operational circuit into a canister for the medical device, wherein the dampening layer is configured to reduce internal motion of the PCBA and/or components thereon. The implantable medical device includes at least one second electrical component, and the dampening layer is not disposed over the at least one second electrical component. The operational circuit includes a printed circuit board assembly (PCBA), and the dampening layer provides mechanical fixation of one or more of batteries, capacitors, dump shields, speakers, telemetry components, and recharging coils to the PCBA.

Alternatively or additionally to any of the above examples, the PCBA carries at least one second electrical component, and the dampening layer does not cover the at least one second electrical component.

Alternatively or additionally to any of the above examples, the step of molding the dampening layer comprises molding a hot melt polymer configured to be molded under low pressure. Alternatively or additionally to any of the above examples, the dampening layer provides a positive fixation of the operational circuitry to the canister by adhesion to the canister. Alternatively or additionally to any of the above examples, the dampening layer provides mechanical fixation of the operational circuitry to the canister.

Alternatively or additionally to any of the above examples, the method further comprises hermetically sealing the canister without the addition of a separate desiccant inside the canister.

Alternatively or additionally to any of the above examples, the method further comprises hermetically sealing the canister without the addition of a separate getter inside the canister. Alternatively or additionally to any of the above examples, the moldable material is not an epoxy.

Alternatively or additionally to any of the above examples, the moldable material provides a positive fixation of the operational circuitry to the canister by adhesion to the canister.

Alternatively or additionally to any of the above examples, the moldable material provides mechanical fixation of the operational circuitry to the canister.

In another example, a method of manufacturing an implantable medical device, comprises molding a dampening layer onto at least a portion of a printed circuit board assembly (PCBA) having a circuit board carrying a plurality of first electrical components, thereby creating a covered operational circuit, and placing the covered operational circuit into a canister for the medical device, wherein the dampening layer is configured to reduce internal motion of the PCBA and/or components thereon.

Alternatively or additionally to any of the above examples, the step of molding the dampening layer comprises molding a hot melt polymer configured to be molded under low pressure.

Alternatively or additionally to any of the above examples, the method further comprises hermetically sealing the canister without the addition of a separate getter inside the canister.

Alternatively or additionally to any of the above examples, the moldable material is not an epoxy.

The Figures, and Detailed Description, which follow, more particularly exemplify some of these embodiments.

For simplicity and clarity purposes, not all elements of the disclosure are necessarily shown in each figure or discussed in detail below.

The term "monolithic" shall generally refer to an element or elements made from or consisting of a single structure or base unit/element. A monolithic and/or unitary element shall exclude structure and/or features made by assembling or otherwise joining multiple discrete elements together.

The following description should be read with reference to the drawings, which are not necessarily to scale, wherein similar elements in different drawings are numbered the same. The detailed description and drawings are intended to illustrate but not limit the claimed invention. Those skilled in the art will recognize that the various elements described and/or shown may be arranged in various combinations and configurations without departing from the scope of the disclosure. The detailed description and drawings illustrate example embodiments of the claimed invention. However, in the interest of clarity and ease of understanding, while every feature and/or element may not be shown in each drawing, the feature(s) and/or element(s) may be understood to be present regardless, unless otherwise specified.

Many implantable medical devices (defibrillators, pacemakers, monitors, neuro-stimulators or modulators, drug pumps, etc.) comprise a printed circuit board assembly (PCBA), and a battery. The PCBA may typically comprise a circuit board and a plurality of components placed on the circuit board with electrical connections between the components. More than one PCBA may be included, for example an implantable defibrillator may comprise each of high power and low power PCBA builds or "hybrids. " The electrical components may include a wide variety of elements, including resistors, capacitors, transistors, discrete logic devices, logic arrays, memory of various types, amplifiers, chips carrying such components (or other components), oscillators, inductors, accelerometers such as in the form of micro-electromechanical systems (MEMS), microcontrollers, etc., without intending limitation to these named items. High power systems such as defibrillators may include specially designed high-power capacitors, transformers, and dump resistors.

Pre-molded liners have previously been the primary means of constraining the PCBA relative to the other components within the housing or canister. The canister, which may be conductive, may in some cases be used as an electrode for signal sensing or therapy delivery. The canister is typically hermetically sealed. The hermetically sealed canister typically also contains one or more desiccant elements, for removing residual or encroaching moisture, and a hydrogen getter may be included to capture hydrogen that may be released by device components after hermetic sealing.

Design requirements typically require a variety of validation tests including, for example and without limitation, aging, thermal and mechanical testing, including flex and drop tests, for example. Component variation as well as tolerances amongst components in the canister and on the PCBA can create stresses that may have deleterious effects on, for example, the conductive interconnects between components, and/or on the components themselves, such as relatively sensitive optical isolators (when included). Moreover, relatively larger components, such as batteries and (particularly for defibrillators) high power capacitors have higher mass than other components and may place greater strain on interconnects and PCBA itself. New and alternative approaches to controlling motion and/or vibration in the device are desired.

The innovations described below may be used in conjunction with many types of implantable medical devices (IMD) and/or wearable medical devices. In some examples, the medical device may be, but is not limited to, an implantable cardiac monitor (ICM), an implantable cardioverter-defibrillator (ICD), an implantable pacemaker, leadless cardiac pacemaker (LCP) or other implantable electrophysiology device configured to be implanted in the body, including near or in the heart. Other implantable devices may include neurostimulation devices, such as those for deep brain stimulation, spinal cord stimulation, vagus nerve stimulation, sacral nerve stimulation, and other brain, heart, or peripheral neural stimulation, implantable pumps and/or sensors for use in, for example and without limitation, diabetes management, drug delivery, etc., and any other implantable medical device, particularly active medical devices having electronics therein for one or more of delivering therapy, sensing biological conditions, and/or communicating with other implanted or external devices.

<FIG> is an exploded view of an example IMD. The canister as illustrated includes a first canister component <NUM> and a second canister component <NUM>. The first and second canister components <NUM>, <NUM> may be made of any suitable biocompatible material. Titanium is an illustrative material, although other materials, such as medical grade stainless steel, may be used in place of or in combination with titanium. Portions of the outside of the first and second canister components <NUM>, <NUM> may be coated, shaped, or treated in any suitable fashion. In some embodiments, the first and second canister components <NUM>, <NUM> may be configured to matingly fit together, for example, in a snap fit or an overlapping fit. Typically, the completed device will have a weld seam joining the first canister component <NUM> to the second canister component <NUM>, although additional intermediate members may also be included on the inside or outside of the device, and welding need not be used for some embodiments using, for example, adhesive or snap-fit.

Internal parts shown in the exploded view include the operational circuitry of the device. In the illustrative embodiment shown, the operational circuitry is shown in a highly simplified fashion, and includes capacitors <NUM>, <NUM>, a battery <NUM>, and PCBA <NUM>. Also illustrated is an electro-magnetic interference (EMI) shield <NUM>, which may include a dump resistor as disclosed in <CIT>, the disclosure of which is incorporated herein by reference. The operational circuitry shown is for an ICD (having relatively large capacitors <NUM>, <NUM>), but may take a variety of other forms as noted above. The precise details of the components and/or the operational circuitry generally may vary widely depending upon the desired functionality of the device.

The operational circuitry contained within the IMD is highly sensitive, and relative motion between the PCBA and other elements within the canister may result in interconnect issues. In some cases, vibration or device flexure may lead to cracked traces, cracked solder joints, and other failures. In order to prevent relative motion between the PCBA <NUM> and other internal components, a dampening layer may be molded over the PCBA <NUM>. The dampening layer may be a moldable material <NUM> such as, but not limited to, a thermoplastic, elastomer, thermoplastic elastomer (TPE), or hot melt polymer. In some examples, the dampening layer may be a composite or blend including two or more polymeric materials.

The moldable material <NUM> may provide a positive fixation of the operational circuitry to the canister by adhering to the canister. In some example, the moldable material achieves such adhesive fixation in the molding process, where the canister or a part thereof is in the mold fixture and, for example, at least partly defines the mold cavity. The moldable material may also or instead provide mechanical fixation to the canister by friction, interlock, or compression fit with the canister, as for example if the canister or a portion thereof is added after molding is completed. In some examples, the moldable material <NUM> may provide mechanical fixation to hold components such as one or more batteries, capacitors, dump shields, speakers, telemetry components, and recharging coils in relation to the PCBA. The moldable material <NUM> also reduces connector relative motion within the IMD and provides electrical isolation of sensitive and/or high voltage components.

In some examples, PCBA <NUM> may be placed in a mold cavity generally matching the internal geometry of the electronic assembly, and the moldable material is molded over the PCBA at low pressure. By generally matching, the preceding sentence may be understood to mean that a mold cavity may be defined using a more or less flat surface spaced from the PCBA board (as placed in the mold cavity fixture) by an appropriate distance allowing all components on the PCBA to be covered by the mold material. For example, if the maximum height of components on the PCBA is, for example and without limitation, <NUM> millimeters (mm), the mold design may allow for <NUM> of space between the PCBA board and the mold surface, providing at least <NUM> of moldable material at its thinnest point. The design may use, for example and without limitation, a distance of <NUM> to <NUM>, or more or less, as desired, of spacing between the maximum component height and the mold cavity wall. A thicker molded layer may require more time to cool/solidify, while a thinner molded layer may present manufacturing difficulties if voids occur at the desired temperature and pressure. It is not necessary for the mold to be a flat offset from the PCBA. It can be any geometry and does not have to cover every component.

In some examples, the moldable material <NUM> is not an epoxy and/or does not require heat curing. For example, the moldable material <NUM> may exclude or omit epoxy entirely. Other examples may include epoxy for select uses within the IMD, but the material used to cover a plurality of components on the PCBA <NUM> as "moldable material <NUM>" omits epoxy.

One example of material that may be suitable for moldable material <NUM> is the thermoplastic elastomer, styrene-ethylene-butylene-styrene (SEBS). Other examples include high performance polyamide (PA) hotmelt adhesives, such as Henkel® Macromelt® <NUM> and Henkel® Macromelt® <NUM>. These are moldable under low pressure (between <NUM> and <NUM> bar), are solvent free, have short cycle time (<NUM>-<NUM> seconds), do not require a heat curing process, and adhere to polar plastics such as polyamide, acrylonitrile butadiene styrene (ABS), and polyvinyl chloride (PVC). Henkel® Macromelt® <NUM> has a Shore A hardness of <NUM>. Henkel® Macromelt® <NUM> has a Shore A hardness of <NUM>. In some examples, polyamide hotmelt molding can achieve enhanced sealing and improved protection of electrical components as compared to conventional <NUM>-part casting materials (epoxy) or potting resins or silicones. The polyamide hotmelt molding material is a single component material that provides water-tight encapsulation and electrical insulation. Other hotmelts may be used, such as the copolymers Henkel® Technomelt® AS4226, or Henkel® Technomelt® AS8998 (a polyolefin).

Further examples include Dymax® Speedmask® maskants including Dymax® Speedmask® <NUM>-SC and Dymax® Speedmask® <NUM>-G. These moldable acrylated urethanes have a fast cure time (<NUM>-<NUM> seconds) under UV or visible light, and have a Shore D hardness of <NUM>-<NUM>. Another example of a suitable moldable material is Robnor ResinLab® EL227CL, a two-part low viscosity polyurethane resin with a Shore A hardness of <NUM>. Other acrylated urethanes may be used, such as Dymax® Speedmask® <NUM>-<NUM> or Dymax® Speedmask® <NUM>-<NUM>-B-REV-A. A further example of a moldable material is polycaprolactone.

In some examples, the moldable material <NUM> is molded over just the PCBA <NUM>, omitting the moldable material <NUM> over other electrical components such as the battery and/or capacitor. In other examples, the moldable material <NUM> is molded over the PCBA <NUM> and at least one additional component of the operational circuitry such as, but not limited to, the battery, high voltage capacitors, and interconnects between the battery, high voltage capacitors, and the PCBA. The moldable material <NUM>, in some examples, covers both high voltage and low voltage circuitry. In some examples the moldable material <NUM> only covers high voltage circuitry. In still other examples, the moldable material <NUM> covers only low voltage circuitry.

Additional components of the operational circuitry may include, but are not limited to, capacitors and batteries. In the example illustrated in <FIG>, the moldable material <NUM> is disposed over a majority of the PCBA <NUM> and completely encapsulates the battery but the majority of the capacitors <NUM>, <NUM> are uncovered. The moldable material <NUM>, once molded, defines a plurality of projections <NUM> on the outer surface of the moldable material <NUM>. In the example illustrated in <FIG>, the projections <NUM> are a series of concentric ridges that extend from the moldable material <NUM> and onto the outer surface of the capacitor <NUM> and battery <NUM>. The projections <NUM> may provide an enhanced friction fit with the inner surface of the canister when the device is assembled. In other examples, the moldable material <NUM> may encapsulate the capacitors <NUM>, <NUM>. The moldable material <NUM> dampens any internal motion within the device once assembled. Additionally, the moldable material <NUM> provides electrical isolation for the components of the PCBA <NUM>, and minimizes the risk of tolerance stack issues. In some examples, the moldable material <NUM> may minimize or completely eliminate the need for liner and/or insulator components. In some examples, the presence of the moldable material <NUM> does not result in any visible or tactile changes to the end user, including the surgeon and patient, and the mass increase is minimal.

In this example, the moldable material <NUM> is in direct contact with the inner surface of the canister, and the IMD is devoid of any intervening layer between the moldable material <NUM> and the canister. In particular, the device is devoid of any intervening metallic, conducting layer or, in the alternative, insulating dielectric layer, between the moldable material <NUM> and the canister. In other examples, one or more additional layers or components may be provided, such as an electro-magnetic interference (EMI) shield as disclosed in <CIT> and/or <NUM>,<NUM>,<NUM>. The EMI shield can block or absorb external interference as well as preventing internal arcing events. An EMI shield may wrap around the majority of the inner device electronics and the moldable material, if desired. For example, an EMI shield may have first and second sides, connected at an edge, corresponding to the larger faces of the canister, as shown in the <NUM>,<NUM>,<NUM> and <NUM>,<NUM>,<NUM> patents. A dump resistor may also be provided, for dumping stored energy on the high-power capacitors when needed (such as when a patient having a defibrillator has a non-sustained episode of tachyarrhythmia, in which case the capacitors may charge to a high voltage but therapy is not delivered due to spontaneous termination of the identified arrhythmia). Because a dump resistor may need to dissipate a relatively large amount of energy quickly, a larger area resistor may be used, such as one printed on a flexible circuit and placed outside the moldable material and positioned between the moldable material and the canister. The dump resistor can be integrated into an EMI shield, as shown in <CIT>. Some examples, such as lower power therapy devices or monitoring devices may omit a dump resistor and/or EMI shield, if desired. In the example shown, the EMI shield and dump resistor is included at <NUM> (see <FIG>).

<FIG> highlights an area at <NUM> which is configured for coupling to feedthrough pins to a header. As is common in the art, a header is provided in association with a canister for coupling to a lead that attaches mechanically to the header/canister, as well as electrically to the circuitry inside the IMD. For manufacturing purposes, the region of the PCBA that will attach to the feedthrough may be blocked from receiving the moldable material <NUM>. In some examples, certain components of the IMD may be integrated into the header, rather than appearing on the PCBA. For example, an MRI filtering sub circuit may be provided in a header or attached directly to a header, or may be integrated into the feedthrough structure associated with a header. If that is the case, the moldable material <NUM> may cover internal components but not those associated with the header and feedthrough, if desired.

In an example, the moldable material <NUM> can be applied over a partial assembly, with the feedthrough wires extending out in the area of the header, and also leaving exposed wires or interconnects for coupling to one or more additional components such as the battery or capacitors. For example, a partial electronic assembly may omit the battery/power source during the application of the moldable material, to avoid stressing the battery cell as well as ensuring that the electronic assembly is not powered and therefore inactive during the molding step. In another example, the moldable material may be added with the aid of a fixture that mates with one half of the canister after the electronic assembly is completed, with battery and header attached, as a final step before the canister is hermetically sealed.

In addition, other components that may be present in the IMD may or may not be covered with the moldable material <NUM>. For example, the anti-motion characteristics of a moldable material <NUM> may generate a concern about reduced functionality of an accelerometer, or piezo speaker. Such components may be shielded from receiving the moldable layer <NUM>, if desired, during the molding process, or may be omitted from the subassembly during molding with a place for receiving the component shielded from receiving the moldable layer <NUM> or with an interconnect or wire provided uncovered by the moldable layer <NUM> after molding. In other example, specific sub-circuits, such as a crystal oscillator, and/or a Bluetooth module may be treated separately and provided without covering from the moldable material.

Some IMD devices have rechargeable batteries (common for neuromodulation systems, for example), and may have associated therewith a charging coil. Other devices may omit a battery and instead rely on received energy, such as magnetic, electrical or mechanical (i.e. sonic or ultrasonic) energy received at a coil or transducer. If desired, the charging coil or other transducer may be provided outside of the moldable material <NUM>, though in some examples the charging coil can be provided such that the moldable material <NUM> covers it, or it may be provided outside of the canister entirely such as on the side of the canister or in the header. For example, the charging coil may be capable of warming during its operation as it receives incident electrical or magnetic fields from an external device, and this may present a risk of reflow of the moldable material <NUM>.

<FIG> illustrates the back of the IMD shown in <FIG>, showing the moldable material <NUM> covering the battery, a majority of the PCBA <NUM>, but not the capacitor <NUM>. As shown, the EMI shield <NUM> and/or dump resistor has been placed over the moldable material <NUM> and in contact with a portion <NUM> of the PCBA <NUM> that is also not covered by the moldable material <NUM>. In another illustration, the EMI shield <NUM> may also carry a piezoelectric speaker used to issue audible alerts to the user, or a vibrating actuator used to issue a vibration alert to the user. In some examples, items like speakers, vibrating actuators, and some sensors (such as an accelerometer) may be placed outside of the moldable material <NUM> to prevent the vibration dampening characteristics of the moldable material <NUM> from impairing functionality of such components.

<FIG> and <FIG> show front and back sides, respectively, of an example of the operational circuitry of an IMD before adding the moldable material. The PCBA <NUM>, battery <NUM>, and two (high voltage) capacitors <NUM>, <NUM> are the parts of the operational circuitry to be at least partly covered with the moldable material. The molding process may be carried out outside of the canister, with the molded assembly inserted into the canister during a later stage of manufacturing. In other examples, the operational circuitry may be disposed in a first part of the canister and the moldable material may be disposed over the circuitry in place, following by welding the second part of the canister to the first part.

A method of manufacturing an IMD using the moldable material begins with selecting the components of the operational circuitry that will be at least partially covered with the moldable material. A mold cavity is then defined by placing a mold cavity, which may be a monolithic part or may have plural pieces that function together, relative to the PCBA and/or other components. The mold itself may also be referred to as a fixture; the mold may include separately moveable parts as for example if a mandrel is provided that can be moved relative to the rest of the mold, with the mandrel used, for example, by pressing it against the PCBA board (or other component) at a location where a void is desired. For example, a mandrel having a hollowed end may be placed over a component that is not to receive the moldable material <NUM>.

<FIG> illustrate various examples of moldable material <NUM>, <NUM>, <NUM>, <NUM> with different designs for the projection <NUM>, <NUM>, <NUM>, <NUM>. <FIG> illustrates the moldable material <NUM> with projections <NUM> forming concentric rings that will extend over the capacitor. <FIG> illustrates the moldable material <NUM> with projections <NUM> forming domes, some of which will be disposed on the capacitor. <FIG> illustrates the moldable material <NUM> with projections <NUM> forming lines, some of which will extend onto the capacitor. <FIG> illustrates the moldable material <NUM> with projections <NUM> forming separate outlines, one of which will be disposed on the capacitor. In addition to the projections <NUM>, <NUM>, <NUM>, <NUM> illustrated in <FIG>, the projections <NUM> may include dimples, ribs, wave patterns, or any other structure that provides an interference or friction fit with the inside of the canister. The projections <NUM> control stack-up, assembly compression force, and/or system vibration response.

In some examples, moldable material <NUM>, <NUM>, <NUM>, <NUM> will cover the majority of the PCBA <NUM>, the battery will be completely encapsulated, and one of the capacitors <NUM> will only have projections <NUM> deposited on the top surface, but otherwise remain uncovered by moldable material <NUM> as shown in <FIG>. In some examples of moldable material <NUM>, <NUM>, <NUM>, <NUM>, the second capacitor <NUM> will generally remain completely uncovered by moldable material <NUM>, as shown in the back view in <FIG>. On the rear of the device, the moldable material <NUM> may cover some parts of the PCBA <NUM> while leaving others uncovered. As shown in the cross-section of <FIG>, the moldable material <NUM> may completely encapsulate the battery <NUM> and a majority of the components on the PCBA <NUM>, with the projections <NUM> extending above the level of the moldable material <NUM>.

In some examples, intentional voids are left between the encapsulated battery and the canister. This may allow for the battery to swell, as batteries of certain chemistries (such as LiMnO2 and others) often do during use/aging as the chemical reactions inside the battery create changes in thickness. For this reason, in some examples, the moldable material is applied in a mold separate from the canister and then placed in the canister. In other example the battery may not be covered by the moldable material <NUM>.

After the moldable material <NUM> has been molded onto the desired electrical components to form a submodule, the submodule may be assembled with additional components in the canister to form the IMD. As shown in <FIG> and <FIG>, an EMI shield <NUM> may be added over the moldable material <NUM> on the back of the device, with a portion <NUM> of the EMI shield <NUM> contacting a portion <NUM> (allowing electrical connection thereto, as the EMI shield <NUM> may be electrically grounded) of the PCBA <NUM> remaining uncovered by the moldable material <NUM>.

The method of manufacturing the IMD including the moldable material <NUM> may be achieved by using the moldable material either to fill large regions or to be selectively placed onto critical locations. The moldable material may be omitted over selected components such as an accelerometer, piezo speaker, analog timing crystal, and Bluetooth module. In one example, the components of operational circuitry to be covered are placed into a mold designed to hold the components and provide an outer shape for the moldable material. The liquefied moldable material is then poured or injected into the mold and allowed to harden. In some examples, the PCBA may have one or more holes to allow the moldable material to flow through, creating internal features that receive desiccant and/or hydrogen getter material.

In one example, the moldable material may form one or more cavities, such as a defined void, for the later placement of desiccant and/or hydrogen getter material. In another example, the moldable material may form a cavity configured to receive an X-Ray identification marker. Post processing, such as a removal process, may be performed to create a cavity or void for placement of a desiccant, hydrogen getter, or X-Ray identification marker. The desiccant, hydrogen getter material, and/or X-Ray identification marker may be added during assembly. In another example, the liquefied moldable material may be selectively deposited onto certain electrical components using a nozzle connected to a reservoir of liquefied moldable material. The projections <NUM> may be formed either by molding or selective deposition. Elements that are not to be covered with the moldable material may be masked. Examples of masking materials include a polysulfene liner, polymer with a higher melting temperature than the moldable material <NUM>, and/or a metalized shield on a polyetheretherketone (PEEK) liner.

Several devices were made, and in some examples, PCBA resonance was eliminated. In other examples, the first resonance frequency of the electronic assembly was changed from about <NUM> to about <NUM>. This change in resonance results in sensitive components being less likely to resonate and be damaged during vibration exposure (such as during shipping, MRI, daily use, etc.). Lower frequencies may be more damaging and more likely to occur, so a higher resonance helps avoid damage and typically indicates a greater level of mechanical robustness. Additionally, selective encapsulation of the moldable material on the electronic assembly exhibits a linear vibration response of the electronic assembly as subject to random vibration as compared to conventional devices which may not. A linear vibration response typically indicates mechanical robustness (i.e. no rattling of components within the housing). A non-linear vibration response may exhibit itself in vibration failure or failure upon exposure to other loading conditions, such as mechanical shock, forces applied by ribs, muscles, and skin when implanted.

The moldable material reduces internal motion of the PCBA relative to other internal components. Laser scanning vibrometer testing may be used to analyze the vibration response of IMDs including moldable material <NUM> covering one or more internal components. The test examines the magnitude of relative motion at the associated resonance frequencies for moldable material <NUM> filled devices.

Prior subcutaneous implantable cardioverter defibrillators S-ICD devices built using existing, standard frame and shield techniques were tested to find a resonance frequency of approximately <NUM> when tested with a <NUM> V burst chirp from <NUM> to <NUM>. Transmissibility is a measure of relative motion that is calculated as the output acceleration divided by the input acceleration of device. A design goal is to reduce the amplitude of the transmissibility, meaning that the internal components are moving similarly to the edge of the pulse generator (PG) can, and also to make the resonance frequency as high as possible.

Two test S-ICD devices were created using functional internal components, but with a moldable material in place of the top liner. The cans were tack welded for closure. These devices were subjected to vibration testing, and <FIG> and <FIG> show graphs of Magnitude [m/s<NUM> / (m/s<NUM>)] on the x axis related to Frequency [Hz] on the y axis, and <FIG> and <FIG> show graphs of Phase on the x axis related to Frequency [Hz] on the y axis, each using ambient temperature for the testing. Additional testing of the same devices was performed at <NUM> to mimic the device implant environment, as shown in <FIG> and <FIG>. There was no PCBA bending mode on these devices; the resonance corresponds with the bending mode of the pulse generator can. The testing did indicate a spike in transmissibility at <NUM>, which was determined to be caused by the fixturing itself rather than the device under test. Since the vibration response of the devices with moldable material <NUM> (Macromelt®) is linear, random vibration testing (<NUM> GRMS) was performed at <NUM>. Graphs of results are shown in <FIG>. Again, there was no PCBA bending mode, and the observed the resonance corresponds with the bending mode of the pulse generator can.

The inclusion of a moldable material <NUM>, such as the Macromelt® fill improves device vibration performance by increasing the resonance frequency significantly in a burst chirp excitation by eliminating the first bending mode of the PCBA. In these tests, the resonance frequency increased from <NUM> with prior build processes to <NUM> using the moldable material <NUM>. The first PCBA bending mode was eliminated with the addition of the moldable material. The assembly also responded linearly and showed elevated resonance in random vibration excitation. Thus, the testing performed demonstrates the capability of the invention to reduce vibration under the tested conditions, including eliminating the PCBA bending mode.

In some examples, a desiccant may be added to the moldable material when in liquid form and mixed prior to depositing the moldable material onto the selected electronics components. The desiccant may be added in powder or pellet form. Because the moldable material is impregnated with the desiccant, the desiccant provides for a slow uptake of moisture in the first <NUM> hours, then a rapid uptake after around <NUM> hours. This slow initial uptake of moisture may allow for the remainder of the assembly steps to be performed out of a glove box, which may reduce manufacturing costs. One example of a desiccant that may be added to the moldable material is a type 3A molecular sieve powder desiccant. Another example is an alkali metal aluminosilicate, the potassium form of the type A crystal structure. Molecular sieves are generally crystalline metal aluminosilicates having a three-dimensional interconnecting network of silica and alumina tetrahedra. Another example of desiccant that may be added to the moldable material includes silica.

In one test, Henkel® Macromelt®<NUM> loaded with desiccant powder was found to saturate after about <NUM> hours in <NUM> and <NUM>% relative humidity, which is longer than the <NUM>-<NUM> hours for conventional sheet desiccants to become saturated. Adding the desiccant to the polymer extends the saturation time because the polymer slows transmission of the water to the desiccant. The saturation time may depend in part on the permeability of the polymer.

In addition, the typical manufacture would allow for smaller amounts of desiccant to be placed in the device. Blending the desiccant material into the moldable material makes it relatively easy to increase the total amount of desiccant that may be placed. Desiccant uptake for the S-ICD manufactured using prior methods with a sheet desiccant is <NUM> of water vapor. In contrast, manufacturing using the blended moldable material and desiccant allows a larger amount of desiccant to be placed, increasing the total uptake capacity; one test example achieved more than <NUM>% increase (to <NUM> of water vapor). In this example, the desiccant and Macromelt® was mixed in a <NUM>:<NUM> ratio. In other examples, the desiccant may be added to the moldable material (whether Macromelt® or other material) in a mix ratio of, for example, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>.

The liquefied moldable material may also be impregnated with a hydrogen getter material prior to molding. In some examples, both the desiccant and hydrogen getter may be added. In other examples, only one of the desiccant or hydrogen getter may be added to the moldable material. Some examples may use hydrogen getters made of polyisoprene, polybutadiene, polyvinyl propargyl ether, polyacetylene, and polyvinyl acetylene. Use of such getter materials is described in <CIT>, titled IMPLANTABLE MEDICAL DEVICE WITH A HYDROGEN GETTER.

The incorporation of a desiccant and/or hydrogen getter directly into the moldable material may eliminate the need for a separate liner or insulation and/or the placement of separate sheets, dots, gobs, etc. of desiccant and/or getter material. This reduces the steps in manufacturing as well as the overall component count. If additional desiccant and/or hydrogen getter materials are desired, the moldable material may be formed with a cavity to hold the additional materials. In some examples, the manufacturing process may be completed without the addition of a hydrogen getter material other than that provided in the moldable material. In some examples, the manufacturing process may be completed without the addition of a desiccant material other than that provided in the moldable material. Finally, in some examples, the manufacturing process may be completed with both hydrogen getter material and desiccant material omitted except to the extent one, the other, or both are provided in the moldable material.

Incorporation into the moldable material may slow absorption during manufacturing, allowing more of the assembly to take place outside of a glove box. The incorporation of desiccant and/or hydrogen getter directly into the moldable material may also reduce the amount of desiccant and hydrogen getter material needed because there is less air volume in the canister and a reduced moisture envelope due to the volume of moldable material. The elimination of liner and/or insulation may result in a minimal increase in mass gain from the moldable material. Additionally, the molded manufacturing steps may allow for faster and easier design changes, as the moldable material can easily adjust to the addition/subtraction, swapping out, or rearrangement of electronic components.

In some examples, the dampening layer may be impregnated with a composite desiccant that is selected to tailor moisture uptake properties. For example, first and second desiccants having different properties may be used, with a first desiccant that is faster acting and a second desiccant that is slower acing, or other combination. The type and amounts of various desiccants may be selected and combined to achieve specific, pre-determined moisture uptake properties. The composite desiccant may control the uptake rate of moisture as the water vapor levels change inside the canister. For example, the profile of amount of moisture absorbed over various time periods may be achieved with a particular composite of desiccants. For example, silica gel is highly effective at high water vapor levels but poor in low water vapor levels. A molecular sieve is effective at low water vapor levels, but plateaus in its percent moisture uptake as water vapor level increases. Calcium oxide is highly effective in low water vapor levels and has a high capacity uptake when compared to a molecular sieve in a higher water vapor percent environment, but the uptake is very slow. Therefore, the composite mixture achieves a balance between the manufacturing process, design requirement, and long-term capture of moisture generated from potential reactions inside the canister.

In other examples, the dampening layer may be impregnated with an activated carbon or charcoal. As the dampening layer is in direct contact with the PCBA and/or battery, the inclusion of carbon or charcoal may allow the dampening layer to absorb certain organic and/or inorganic compounds, such as sulfur or electrolytes, from surfaces of the operational circuitry (PCBA) and/or battery.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may 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. The Abstract is provided to allow the reader to quickly ascertain the nature of the technical disclosure, and shall not be used to interpret or limit the scope or meaning of the claims.

Claim 1:
An implantable medical device comprising:
operational circuitry for the implantable medical device including a first plurality of electrical components; and
a metal canister (<NUM>, <NUM>) shaped for housing the operational circuitry,
wherein a dampening layer (<NUM>) is selectively molded onto and attached to the first plurality of electrical components, the dampening layer providing electrical isolation to the first plurality of electrical components and configured to reduce susceptibility to vibration of the first plurality of electrical components wherein the operational circuitry includes at least one second electrical component, and the dampening layer is not disposed over the at least one second electrical component,
wherein the operational circuitry includes a printed circuit board assembly, and the dampening layer provides mechanical fixation of one or more of batteries, capacitors,
dump shields, speakers, telemetry components, and recharging coils to the printed circuit board assembly.