LEADLESS DEVICE WITH OVERMOLDED COMPONENTS

Abstract

An electronics module for use in an Implantable Medical Device (IMD) may include a plurality of electrical components connected to form a circuit that includes a terminal and a potting material that supports the plurality of electrical components. The plurality of electrical components and the potting material together form a circuit sub-module in which the terminal is accessible from outside of the circuit sub-module. A metallic layer that conforms to an outer surface of the circuit sub-module is provided thereon such that the terminal is accessible from outside of the metallic layer.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/450,850 filed on Jan. 26, 2017, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The disclosure is directed to implantable devices such as leadless implantable devices and more particularly to leadless implantable devices with over-molded components.

BACKGROUND

Implantable medical devices are commonly used today to monitor physiological or other parameters of a patient and/or deliver therapy to a patient. For example, to help patients with heart related conditions, various medical devices (e.g., pacemakers, defibrillators, etc.) can be implanted in a patient's body. Such devices may monitor and in some cases provide electrical stimulation (e.g. pacing, defibrillation, etc.) to the heart to help the heart operate in a more normal, efficient and/or safe manner. In another example, neuro stimulators can be used to stimulate tissue of a patient to help alleviate pain and/or other condition. In yet another example, an implantable medical device may simply be an implantable monitor that monitors one or more physiological or other parameters of the patient, and communicates the sensed parameters to another device such as another implanted medical device or an external device. In some cases, there may be a desire to make an implantable medical device more compact.

SUMMARY

The disclosure describes implantable medical devices (IMD), such as but not limited to leadless cardiac pacemakers (LCP), neuro-stimulators (NS), and/or implantable monitors (IM), that are configured to be implanted within the body, including in or near the heart. In some cases, an IMD may include an electronics module that is at least partially hermetically sealed prior to assembly of the electronics module into the IMD. In some instances, the electronics module is hermetically sealed prior to assembly of the IMD. In some cases, the electronics module may be hermetically sealed by a metallic sealing layer that is deposited on the electronics module and may conform to the outer surface of the electronics module. The sealed electronics module may then be assembled with other components to form the IMD.

In one example, an electronics module for use in an Implantable Medical Device (IMD) may include a plurality of electrical components that are connected to form a circuit that includes a terminal and a potting material supporting the plurality of electrical components, wherein the plurality of electrical components and the potting material form a circuit sub-module, wherein the terminal is accessible from outside of the circuit sub-module. The electronics module may include a metallic layer that is provided on an outer surface of the circuit sub-module that conforms to the outer surface of the circuit sub-module. The terminal may be accessible from outside of the metallic layer.

Alternatively or additionally, the potting material may be molded over at least some of the plurality of electrical components.

Alternatively or additionally, the outer surface of the circuit sub-module may be treated for receiving the metallic layer.

Alternatively or additionally, the electronics module may further include an insulator between the terminal and the metallic layer so that the terminal is not shorted to the metallic layer.

Alternatively or additionally, the metallic layer may include TiN.

Alternatively or additionally, the metallic layer may include a deposited layer.

Alternatively or additionally, the terminal may be a feedthrough terminal.

Alternatively or additionally, the circuit may include a second terminal, and the second terminal may be accessible from outside of the circuit sub-module.

Alternatively or additionally, the circuit may be configured to sense cardiac electrical activity and to deliver pacing pulses.

In another example, a leadless cardiac pacemaker (LCP) may be configured to pace a patient's heart and be disposable within a chamber of the patient's heart. The illustrative LCP may include an electronics module, a plurality of electrodes and a power source. The electronics module may include a plurality of electrical components connected to form a circuit that includes at least a first terminal, a second terminal and a third terminal. A potting material supports the plurality of electrical components, and the plurality of electrical components and the potting material together form a circuit sub-module in which the first terminal, the second terminal and the third terminal are accessible from outside of the circuit sub-module. A metallic layer is provided on an outer surface of the circuit sub-module and conforms to the outer surface of the circuit sub-module such that the first terminal, the second terminal and the third terminal are accessible from outside of the metallic layer. The first terminal of the electronics module is operatively coupled to one of the plurality of electrodes. The power source has a first power terminal and a second power terminal and is secured relative to the electronics module with the first power terminal operatively coupled to the second terminal of the electronics module and the second power terminal operatively coupled to the third terminal of the electronics module.

Alternatively or additionally, the LCP may further include an over-molded layer over the electronics module.

Alternatively or additionally, the LCP may further include a fixation mechanism secured relative to the electronics module via the over-molded layer for fixing the LCP to the patient's heart.

Alternatively or additionally, the over-molded layer may help secure the power source relative to the electronics module.

Alternatively or additionally, the LCP may further include a fixation mechanism that is secured relative to the electronics module for fixing the LCP to the patient's heart.

Alternatively or additionally, the potting material may be molded over at least some of the plurality of electrical components before the metallic layer is provided.

Alternatively or additionally, the plurality of electrical components include two or more stacked circuit boards operably coupled together via flexible interconnects and the potting material encapsulates at least a portion of the two or more stacked circuit boards.

Alternatively or additionally, the circuit may be configured to sense cardiac electrical activity via two or more of the plurality of electrodes and to deliver pacing pulses via two or more of the plurality of electrodes.

In another example, a method of manufacturing a leadless implantable medical device (IMD) may include potting a circuit in a potting material to at least partially encapsulate the circuit within the potting material. A metal coating is applied over the potted circuit to provide a moisture barrier to at least part of the potted circuit. The potted circuit may be attached to a battery and the circuit may be operatively connected to the battery. A fixation mechanism for fixing the IMD to a patient's heart may also be attached. A first electrode may be operably connected to the circuit and a second electrode may be operably coupled to the circuit.

Alternatively or additionally, the method may further include applying a parylene coating to the IMD subsequent to attaching the potted circuit to the battery.

Alternatively or additionally, attaching the fixation mechanism may include over-molding a layer over at least part of the fixation mechanism and over at least part of the potted circuit.

The above summary of some embodiments is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The Figures, and Detailed Description, which follow, more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE FIGURES

The disclosure may be more completely understood in consideration of the following description of in connection with the accompanying drawings, in which:

FIG. 1 is a side of an example electronics circuit usable in an implantable medical device (IMD) in accordance with the disclosure;

FIG. 2 is a perspective view of an example electronics package in which the electronics circuit of FIG. 1 has been potted in accordance with the disclosure;

FIG. 3 is a cross-sectional view of the example electronics package of FIG. 2, taken along line 3-3 of FIG. 2;

FIG. 4 is a perspective view of the example electronics package of FIG. 2, shown attached to a power source such as a battery;

FIG. 5 is a perspective view of a portion of the assembly of FIG. 4, showing the addition of a fixation assembly and an optional X-ray ID tag;

FIG. 6 is a perspective view of the completed IMD;

FIG. 7 is a schematic block diagram of an illustrative LCP in accordance with the disclosure;

FIG. 8 is a schematic block diagram of an illustrative LCP in accordance with the disclosure;

FIG. 9 is a side view of an IMD in accordance with the disclosure;

FIG. 10 is a schematic block diagram of the IMD of FIG. 9;

FIG. 11 is a side view of an IMD in accordance with the disclosure;

FIG. 12 is a schematic block diagram of the IMD of FIG. 11;

FIG. 13 is a schematic block diagram of another IMD in accordance with the disclosure;

FIG. 14 is a diagram of an example electrical circuit in accordance with an example of the disclosure;

FIG. 15 is a diagram of an example electrical circuit in accordance with an example of the disclosure;

FIG. 16 is a diagram of an example electrical circuit in accordance with an example of the disclosure; and

FIG. 17 is a diagram of an example electrical circuit in accordance with an example of the disclosure.

While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

DESCRIPTION

For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification.

All numeric values are herein assumed to be modified by the term “about”, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may be indicative as including numbers that are rounded to the nearest significant figure.

The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

Although some suitable dimensions, ranges and/or values pertaining to various components, features and/or specifications are disclosed, one of skill in the art, incited by the present disclosure, would understand desired dimensions, ranges and/or values may deviate from those expressly disclosed.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include or otherwise refer to singular as well as plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed to include “and/or,” unless the content clearly dictates otherwise.

The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The detailed description and the drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure. The illustrative embodiments depicted are intended only as exemplary. Selected features of any illustrative embodiment may be incorporated into an additional embodiment unless clearly stated to the contrary.

In some cases, an electronics circuit may be potted in a potting material to form an electronics package that may be used in forming an implantable medical device (IMD). In some instances, potting the electronics circuit in a potting material, and optionally covering the potted electronics circuit in a metallic layer may provide at least a partial hermetic seal protecting the electronic components of the electronics circuit at least long enough to finish the assembly process for building the IMD. In some cases, the addition of the metallic layer provides a hermetic seal for the electronics circuit. In some cases, for example, this provides an ability to create a smaller IMD by not requiring that the entire IMD be encased in a pre-formed metallic housing that would otherwise provide the hermetic seal for the IMD. In some cases, one or more components, such as a pre-formed outer metallic housing, an internal desiccant, and other components, may not be needed, thereby potentially making the IMD more compact. In some cases, instead of making the IMD more compact, the possible exclusion of particular components may provide more battery space in order to provide a longer-lasting battery, or perhaps more circuitry space in order to provide the IMD with greater processing power. These are just examples.

FIG. 1 is a side view of an electronics circuit 10. In some cases, the electronics circuit 10 may be configured to sense cardiac electrical activity and to deliver pacing pulses. In some cases, the electronics circuit 10 may have a stacked configuration. In some instances, the electronics circuit 10 may have other configurations such as a planar circuit board arranged in an axial direction, for example. As shown, the electronics circuit 10 has a stacked configuration, with a first island section 12, a second island section 14 and a third island section 16, with the third island section 16 secured to a proximal feedthrough 18. In some cases, the inclusion of feedthroughs such as the proximal feedthrough 18 may facilitate metal coating (as will be discussed) and attachment to other elements such as an electrode, for example. A first ribbon section 20 extends between the first island section 12 and the third island section 16, and electrically couples the first island section 12 to the third island section 16. A second ribbon section 22 extends between the second island section 14 and the third island section 16, and electrically couples the second island section 14 to the third island section 16. As a result, all three island sections 12, 14, 16 are electrically coupled to each other.

As can be seen, the first island section 12 includes a terminal 24 extending upward from the first island section 12 as well as one or more electronics components 26 shown mounted to an underside of the first island section 12. In some cases, the terminal 24 may be considered as being a feedthrough terminal. The second island section 14 includes electronics components 28 and 32 mounted on either side of the second island section 14. In some cases, the terminal 24 extends from the electronics component 28. The third island section 16 includes electronics components 34 and 36 mounted to the third island section 16. It will be appreciated that this is merely illustrative. FIGS. 14 through 17, as will be discussed subsequently, provide additional examples of what the electronics circuit 10 may look like prior to potting.

FIG. 2 is a perspective view of an electronics package 38, in which the electronics circuit 10 (FIG. 1) has been potted with a potting material 40. FIG. 3 provides a cross-sectional view in order to show internal components. In some cases, the potting material 40 may provide structural stability to the electronics package 38. The potting material 40 may, for example, provide short term hermetic sealing until a subsequent metal layer can be applied. In some instances, the potting material 40 may be an electrically insulating material so that the potting material 40 itself does not short circuit the internal components. The proximal feedthrough 18 can be seen, as can the terminal 24. As shown, a ceramic feedthrough 39 electrically isolates the terminal 24. In some cases, the potting material 40 may have ridges 42 formed in an exterior of the potting material 40. In some instances, the ridges 42 prove beneficial in helping to provide mechanical locking of a subsequent over-molding.

The potting material 40 may include a variety of electrically-insulating materials. Illustrative but non-limiting examples of suitable polymeric materials include epoxy, thinned medical adhesives, liquid crystal polymers as well as thermoplastic materials. In some cases, polymeric materials may be selected having melting points and/or other thermal processing parameters that render the polymeric materials safe to use with the various components of the electronics circuit 10.

In some cases, the electronics circuit 10 may undergo a baking step in which the electronics circuit 10 is subjected to heat in order to remove any residual moisture and/or gasses that may be present within or on the electronics circuit 10. In some cases, this is not required. This may be performed within a hood or other controlled-atmosphere environment. In some cases, the potting material 40 may be applied to the electronics circuit 10 while the electronics circuit 10 remains within the hood or other controlled-atmosphere environment. In some cases, a mold may be used to shape the potting material 40 into a particular shape, such as to include the ridges 42. Some areas such as the terminal 24, for example, may be masked off prior to application of the potting material 40

In some case, the potting material 40 may be molded over at least some of the plurality of electronics components. In some cases, as can be seen in FIG. 3, the potting material 40 has essentially filled in the available space between the island sections 12, 14, 16 as well as between the electronics components 26, 28, 32, 34, 36. In some cases, the potting material 40 helps to mechanically strengthen the electronics circuit 10 against vibration and other mechanical stresses. In some cases, it is contemplated that the potting material 40 may also help seal the electronics circuit 10 against external moisture that could otherwise damage the electronics circuit 10.

In some cases, as shown, the electronics package 38 also includes a metal layer 44 that has been applied over the potting material 40. The metal layer 44 provides and/or improves a hermetic seal of the electronics package 38. In some cases, prior to applying the metal layer 44, an outer surface 46 of the potting material 40 may be processed to provide a better adhesion between the potting material 40 and the metal layer 44. Illustrative but non-limiting examples of surface preparations include etching, such as chemical etching, laser etching and the like. In some cases, an intermediate material may be applied to the potting material 40 in order to improve adhesion of the metal layer 44. In some cases, an insulating layer 47 may be disposed between the potting material 40 and the metal layer 44. In some cases, the layer 47 may represent an optional layer of intermediate material.

There are a variety of techniques by which the metal layer 44 may be applied. In a particular example, the metal layer 44 may include titanium nitride and may be applied via magnetron sputtering. Other suitable application techniques include, but are not limited to, sputter deposition, electron beam evaporation, plasma laser deposition, cathodic arc deposition, electrohydrodynamic deposition, dipping, plating and/or any other suitable technique. In some cases, it is contemplated that the metal layer 44 may be a metal foil that is wrapped around the potting material 40. In some cases, the metal layer 444 may be a composite of a wrapped metal and a deposited metal. In some cases, the metal layer 44 may have seams or edges that may be sealed using brazing, welding, or any other suitable technique.

Once the electronics package 38 has been formed, the electronics package 38 may be used in assembling an implantable medical device (IMD). FIGS. 4 through 6 provide an illustrative but non-limiting example of using the electronics package 38 in forming a leadless cardiac pacemaker (LCP). As can be seen in FIG. 4, the electronics package 38 may be secured onto a battery 50. In some cases, the electronics package 38 may be welded to the battery 50, although other methods of securing the electronics package 38 to the battery 50 are contemplated (e.g. adhesive bonding, soldering, etc.). In some cases, an outer housing 52 of the battery 50 may be electrically active, and a proximal electrode 54 may be formed by masking off the rest of the outer housing 52 of the battery 50. In some cases, for example, a Parylene coating 55 may be applied to the outer housing 52 of the battery 50 except at the proximal electrode 54. In other cases, another process, technique or material may be used to electrically isolate the rest of the outer housing 52 of the battery 50. A retrieval feature 56 may be secured to the battery 50.

FIG. 5 shows a portion of the assembly including the electronics package 38 and the battery 50. An outline 58 provides an indication of a subsequent epoxy overmolding. In some cases, a fixation assembly 60 may be disposed relative to a top of the electronics package 38 and may be secured in place via epoxy overmolding. In some cases, the fixation assembly 60 may include a plurality (four are shown) of fixation tines 62 extending from the fixation assembly 60. In some cases, the plurality of fixation tines 62 extend from a ring (not shown) that helps to secure the fixation assembly 60 within the epoxy overmolding. If desired, an x-ray ID tag 64 may be secured in place to the electronics package 38 prior to the epoxy overmolding or may be overmolded within the epoxy.

FIG. 6 shows an assembled LCP 70. An epoxy overmolding 72 covers the electronics package 38, securing the fixation assembly 60 to the LCP 70. In some cases, finishing the assembly may include welding a distal electrode 74 to the terminal 24. In some cases, a drug collar 76 may be secured in place relative to the distal electrode 74. It will be appreciated that in assembling some implantable devices that are not LCPs, for example, there may not be a distal electrode 74 and there may not be a drug collar 76. In some cases, by eliminating an outer metal housing, a battery insulator and a desiccant, the overall volume of the LCP 70 may represent a 10 or 15 percent reduction or more.

FIG. 7 is a schematic block diagram of an illustrative leadless cardiac pacemaker (LCP) that may be implanted into a patient and may operate to deliver appropriate therapy to the heart, such as to deliver anti-tachycardia pacing (ATP) therapy, cardiac resynchronization therapy (CRT), bradycardia therapy, and/or the like. As can be seen in FIG. 7, the LCP 100 may be a compact device with all components housed within or directly on a housing 120. In some cases, the LCP 100 may be considered as being an example of the LCP 70 (FIG. 6) or the LCP 200 (FIG. 8) to be discussed subsequently.

In the example shown in FIG. 7, the LCP 100 may include a communication module 102, a pulse generator module 104, an electrical sensing module 106, a mechanical sensing module 108, a processing module 110, a battery 112, and an electrode arrangement 114. The LCP 100 may include more or less modules, depending on the application.

The communication module 102 may be configured to communicate with devices such as sensors, other medical devices such as an SICD, and/or the like, that are located externally to the LCP 100. Such devices may be located either external or internal to the patient's body. Irrespective of the location, external devices (i.e. external to the LCP 100 but not necessarily external to the patient's body) can communicate with the LCP 100 via communication module 102 to accomplish one or more desired functions. For example, the LCP 100 may communicate information, such as sensed electrical signals, data, instructions, messages, R-wave detection markers, etc., to an external medical device (e.g. SICD and/or programmer) through the communication module 102. The external medical device may use the communicated signals, data, instructions, messages, R-wave detection markers, etc., to perform various functions, such as determining occurrences of arrhythmias, delivering electrical stimulation therapy, storing received data, and/or performing any other suitable function. The LCP 100 may additionally receive information such as signals, data, instructions and/or messages from the external medical device through the communication module 102, and the LCP 100 may use the received signals, data, instructions and/or messages to perform various functions, such as determining occurrences of arrhythmias, delivering electrical stimulation therapy, storing received data, and/or performing any other suitable function. The communication module 102 may be configured to use one or more methods for communicating with external devices. For example, the communication module 102 may communicate via radiofrequency (RF) signals, inductive coupling, optical signals, acoustic signals, conducted communication signals, and/or any other signals suitable for communication.

In the example shown in FIG. 7, the pulse generator module 104 may be electrically connected to the electrodes 114. In some examples, the LCP 100 may additionally include electrodes 114′. In such examples, the pulse generator 104 may also be electrically connected to the electrodes 114′. The pulse generator module 104 may be configured to generate electrical stimulation signals. For example, the pulse generator module 104 may generate and deliver electrical stimulation signals by using energy stored in the battery 112 within the LCP 100 and deliver the generated electrical stimulation signals via the electrodes 114 and/or 114′. Alternatively, or additionally, the pulse generator 104 may include one or more capacitors, and the pulse generator 104 may charge the one or more capacitors by drawing energy from the battery 112. The pulse generator 104 may then use the energy of the one or more capacitors to deliver the generated electrical stimulation signals via the electrodes 114 and/or 114′. In at least some examples, the pulse generator 104 of the LCP 100 may include switching circuitry to selectively connect one or more of the electrodes 114 and/or 114′ to the pulse generator 104 in order to select which of the electrodes 114/114′ (and/or other electrodes) the pulse generator 104 delivers the electrical stimulation therapy. The pulse generator module 104 may generate and deliver electrical stimulation signals with particular features or in particular sequences in order to provide one or multiple of a number of different stimulation therapies. For example, the pulse generator module 104 may be configured to generate electrical stimulation signals to provide electrical stimulation therapy to combat bradycardia, tachycardia, cardiac synchronization, bradycardia arrhythmias, tachycardia arrhythmias, fibrillation arrhythmias, cardiac synchronization arrhythmias and/or to produce any other suitable electrical stimulation therapy. Some more common electrical stimulation therapies include anti-tachycardia pacing (ATP) therapy, cardiac resynchronization therapy (CRT), and cardioversion/defibrillation therapy. In some cases, the pulse generator 104 may provide a controllable pulse energy. In some cases, the pulse generator 104 may allow the controller to control the pulse voltage, pulse width, pulse shape or morphology, and/or any other suitable pulse characteristic.

In some examples, the LCP 100 may include an electrical sensing module 106, and in some cases, a mechanical sensing module 108. The electrical sensing module 106 may be configured to sense the cardiac electrical activity of the heart. For example, the electrical sensing module 106 may be connected to the electrodes 114/114′, and the electrical sensing module 106 may be configured to receive cardiac electrical signals conducted through the electrodes 114/114′. The cardiac electrical signals may represent local information from the chamber in which the LCP 100 is implanted. For instance, if the LCP 100 is implanted within a ventricle of the heart (e.g. RV, LV), cardiac electrical signals sensed by the LCP 100 through the electrodes 114/114′ may represent ventricular cardiac electrical signals. In some cases, the LCP 100 may be configured to detect cardiac electrical signals from other chambers (e.g. far field), such as the P-wave from the atrium.

The mechanical sensing module 108 may include one or more sensors, such as an accelerometer, a pressure sensor, a heart sound sensor, a blood-oxygen sensor, a chemical sensor, a temperature sensor, a flow sensor and/or any other suitable sensors that are configured to measure one or more mechanical/chemical parameters of the patient. Both the electrical sensing module 106 and the mechanical sensing module 108 may be connected to a processing module 110, which may provide signals representative of the sensed mechanical parameters. Although described with respect to FIG. 7 as separate sensing modules, in some cases, the electrical sensing module 106 and the mechanical sensing module 108 may be combined into a single sensing module, as desired.

The electrodes 114/114′ can be secured relative to the housing 120 but exposed to the tissue and/or blood surrounding the LCP 100. In some cases, the electrodes 114 may be generally disposed on either end of the LCP 100 and may be in electrical communication with one or more of the modules 102, 104, 106, 108, and 110. The electrodes 114/114′ may be supported by the housing 120, although in some examples, the electrodes 114/114′ may be connected to the housing 120 through short connecting wires such that the electrodes 114/114′ are not directly secured relative to the housing 120. In examples where the LCP 100 includes one or more electrodes 114′, the electrodes 114′ may in some cases be disposed on the sides of the LCP 100, which may increase the number of electrodes by which the LCP 100 may sense cardiac electrical activity, deliver electrical stimulation and/or communicate with an external medical device. The electrodes 114/114′ can be made up of one or more biocompatible conductive materials such as various metals or alloys that are known to be safe for implantation within a human body. In some instances, the electrodes 114/114′ connected to the LCP 100 may have an insulative portion that electrically isolates the electrodes 114/114′ from adjacent electrodes, the housing 120, and/or other parts of the LCP 100. In some cases, one or more of the electrodes 114/114′ may be provided on a tail (not shown) that extends away from the housing 120.

The processing module 110 can be configured to control the operation of the LCP 100. For example, the processing module 110 may be configured to receive electrical signals from the electrical sensing module 106 and/or the mechanical sensing module 108. Based on the received signals, the processing module 110 may determine, for example, abnormalities in the operation of the heart H. Based on any determined abnormalities, the processing module 110 may control the pulse generator module 104 to generate and deliver electrical stimulation in accordance with one or more therapies to treat the determined abnormalities. The processing module 110 may further receive information from the communication module 102. In some examples, the processing module 110 may use such received information to help determine whether an abnormality is occurring, determine a type of abnormality, and/or to take particular action in response to the information. The processing module 110 may additionally control the communication module 102 to send/receive information to/from other devices.

In some examples, the processing module 110 may include a pre-programmed chip, such as a very-large-scale integration (VLSI) chip and/or an application specific integrated circuit (ASIC). In such embodiments, the chip may be pre-programmed with control logic in order to control the operation of the LCP 100. By using a pre-programmed chip, the processing module 110 may use less power than other programmable circuits (e.g. general purpose programmable microprocessors) while still being able to maintain basic functionality, thereby potentially increasing the battery life of the LCP 100. In other examples, the processing module 110 may include a programmable microprocessor. Such a programmable microprocessor may allow a user to modify the control logic of the LCP 100 even after implantation, thereby allowing for greater flexibility of the LCP 100 than when using a pre-programmed ASIC. In some examples, the processing module 110 may further include a memory, and the processing module 110 may store information on and read information from the memory. In other examples, the LCP 100 may include a separate memory (not shown) that is in communication with the processing module 110, such that the processing module 110 may read and write information to and from the separate memory.

The battery 112 may provide power to the LCP 100 for its operations. In some examples, the battery 112 may be a non-rechargeable lithium-based battery. In other examples, a non-rechargeable battery may be made from other suitable materials, as desired. Because the LCP 100 is an implantable device, access to the LCP 100 may be limited after implantation. Accordingly, it is desirable to have sufficient battery capacity to deliver therapy over a period of treatment such as days, weeks, months, years or even decades. In some instances, the battery 112 may a rechargeable battery, which may help increase the useable lifespan of the LCP 100. In still other examples, the battery 112 may be some other type of power source, as desired.

To implant the LCP 100 inside a patient's body, an operator (e.g., a physician, clinician, etc.), may fix the LCP 100 to the cardiac tissue of the patient's heart. To facilitate fixation, the LCP 100 may include one or more anchors 116. The anchor 116 may include any one of a number of fixation or anchoring mechanisms. For example, the anchor 116 may include one or more pins, staples, threads, screws, helix, tines, and/or the like. In some examples, although not shown, the anchor 116 may include threads on its external surface that may run along at least a partial length of the anchor 116. The threads may provide friction between the cardiac tissue and the anchor to help fix the anchor 116 within the cardiac tissue. In other examples, the anchor 116 may include other structures such as barbs, spikes, or the like to facilitate engagement with the surrounding cardiac tissue.

The potted electronics packages described herein may be used in a variety of different implantable medical devices. FIGS. 8 through 13 provide illustrative but non-limiting examples of implantable medical devices employing potted electronics packages. FIG. 8 is a schematic diagram of a leadless cardiac pacemaker (LCP) 200 that is configured to sense cardiac electrical activity of a patient′ heart as well as to generate and deliver pacing pulses to the patient's heart when appropriate. The LCP 200 includes an electronics module 202 that includes a plurality of electrical components that are connected to form a circuit 204. FIGS. 1 and 14-17 provide examples of circuits having a plurality of electrical components, so the individual electrical components are not shown in FIG. 8 for clarity.

In some cases, as shown, the circuit 204 includes at least a first terminal 206, a second terminal 208 and a third terminal 210. A potting material 212 supports the plurality of electrical components and in combination with the circuit 204 (including the plurality of electrical components) forms a circuit sub-module 214. In some cases, the circuit 204 may include two or more stacked circuit boards that are operably coupled together via flexible interconnects (such as shown in FIG. 3), and the potting material 212 may encapsulate at least a portion of the two or more stacked circuit boards. The first terminal 206, the second terminal 208 and the third terminal 210 are accessible from outside of the circuit sub-module 214. A metallic layer 216 may be provided on an outer surface 218 of the circuit sub-module 214. In some cases, a feedthrough feature, such as an insulating feedthrough feature 206a,b, may be provided around the first terminal 206 to isolate the first terminal 206 from the metallic layer 216. The second terminal 208 and the third terminal 210 may have similar insulating feedthrough features. The first terminal 206, the second terminal 208 and the third terminal 210 are shown to be accessible from outside of the metallic layer 216. In some cases, the metallic layer 216 conforms to the outer surface 218 of the circuit sub-module 214.

The illustrative LCP 200 includes a power source 220 having a first power terminal 222 and a second power terminal 224. In some cases, the power source 220 may be secured relative to the electronics module 202 with the first power terminal 222 operably coupled to the second terminal 208 of the electronics module 202 and the second power terminal 224 operably coupled to the third terminal 210 of the electronics module 202.

In some cases, the LCP 200 includes an over-molded layer 226 that extends over at least the electronics module 202 and optionally over the power source 220 as well. In some cases, the over-molded layer 226 helps to secure the electronics module 202 to the power source 220. In some cases, the over-molded layer 226 may help to secure a fixation mechanism 228 relative to the electronics module 202. In some cases, for example, the fixation mechanism 228 may be configured to fix the LCP 200 relative to the patient's heart.

In some cases, the LCP 200 includes a plurality of electrodes and the first terminal 206 may be operably coupled to one of the plurality of electrodes. As illustrated, the LCP 200 includes a distal electrode 230 that is operably coupled to the first terminal 206. The LCP 200 also includes one or more proximal electrodes 232. In some cases, for example, there is a single proximal electrode 232 that extends radially around the LCP 200. Although not explicitly shown, the single proximal electrode 232 may be coupled to one of the terminals of the power source 220 and/or to another terminal of the circuit 204. In some cases, the circuit 204 is configured to sense cardiac electrical activity via two or more of the plurality of electrodes, such as for example the distal electrode 230 and the proximal electrode 232 and to deliver pacing pulses via two or more of the plurality of electrodes.

FIG. 9 is a side view of an IMD 240 that includes an electronics module 242 and a power module 244 while FIG. 10 is a schematic block diagram of the IMD 240. The electronics module 242 may, for example, include an electronics package 248 such as the electronics package 38 (FIG. 2), and may, for example, be considered as being an example of the electronics module 202 (FIG. 8). The IMD 240 includes a distal feedthrough 246. The power module 244 may include a first battery connection 243 and a second battery connection 245 that are operably and electrically coupled to a battery 247 within the power module 244. While not expressly illustrated, it will be appreciated that the first battery connection 243 and the second battery connection 245 are both directly or indirectly operably coupled to the electronics package 248. The battery 247 may have a metal battery housing 249. The electronics module 242 may include a thin film metal outer layer 251. In some cases, the IMD 240 includes a metal distal end 252 and a ceramic feedthrough 254 accommodating and electrically isolating an electrical connector 256 from the metal distal end 252. In some cases, there may be a braze joint 271 between the ceramic feedthrough material and the adjoining metal.

FIG. 11 is a side view of an assembly 260 while FIG. 12 is a schematic block diagram of the assembly 260. The assembly 260 includes an electronics module 262, a metal distal end 264 and a metal proximal end 267. In some cases, the assembly 260 may be completely assembled, and can subsequently be secured to a separate battery or other power source. The electronics module 262 includes the electronics package 248, as referenced in FIG. 10. The electronics module 262 may include conductors 266, 268 and 270, extending from the electronics module 262 through ceramic passthroughs 272, 274 and 276, respectively. In some cases, there may be a braze joint 271 between the ceramic material and the adjoining metal to form a hermetic seal. The illustrative electronics module 262 may include a thin film metal layer 278, a metal distal end 264 and a metal proximal end 267 to form a hermitic seal about the electronics package 248.

FIG. 13 is a schematic view of a biocompatible device 280. An interior 282 of the biocompatible device 280 includes both a power supply and an electronics package such as the electronics package 248. The biocompatible device 280 includes a thin metal layer 284 that encloses the power supply and the electronics package, and that is formed into a biocompatible shape for implantation into a desired body location. In some cases, the electronics package, or at least the potting material disposed about the electronics package, may be formed into any desired shape, size or configuration. The electronics package may include a conformal metal layer. As a result, the biocompatible device 280 may be formed into any desired shape that may be beneficial for the intended use of the biocompatible device 280.

The biocompatible device 280 includes a metal plate 286 and a ceramic feedthrough 288 inserted into the metal plate 286. A first conductor 290, a second conductor 292 and a third conductor 294 each extend through the ceramic feedthrough 288 as shown. In some cases, there may be a braze joint 271 between the ceramic material and the adjoining metal to form a hermetic seal. In some cases, the conductors 290, 292, 294 may, for example, be configured to be connected to one or electrodes. In some cases, the conductors 290, 292, 294 may be configured to be connected via one or more wires or other conductors to another implantable device.

FIGS. 14 through 17 provide additional illustrative but non-limiting examples of stacked circuit board configurations that may, for example, be used as part of the electronics package shown in FIG. 2. Further details regarding the composition and construction of these stacked circuit boards may be found in U.S. Patent Application Publication No. 2016/0151621, the contents of which are hereby incorporated by reference.

In FIG. 14, an electrical circuit 300 includes an island section 302 and an island section 304 that are joined together via a ribbon section 306. A processing module 310 is shown as being fixed to the island section 304 and circuit elements 308A and 308B are shown as being fixed to the island section 302. In one example, the processing module 310 and circuit elements 308A and 308B may represent circuit elements that implement the functions of communication module 102, pulse generator module 104, electrical sensing module 106, mechanical sensing module 108, and/or processing module 110. The processing module 110 may include any circuit elements or components, such as a pre-programmed logic chip or a programmable microprocessor. The circuit elements 308A and 308B may represent capacitors, resistors, diodes, or other circuit elements.

In some examples, each island section 302, 304 may be circular in shape, but this is not required. Each island section 302, 304 may have a diameter that is slightly less than an inner diameter of a cross section of an implantable medical device housing (e.g. LCP 100) so that the island sections 302, 304 may fit within the device when stacked. Some example diameters include 3.8 millimeters to 12.7 millimeters. However, in other examples, the islands 302, 304 may be triangular, square, ovoid, or any other suitable shape. In at least some examples, the specific shape of the islands sections 302, 304 may generally match a cross section shape of an implantable medical device housing. Some example ranges for the length of the ribbon section 306 include 3.8 millimeters to 12.7 millimeters.

The island sections 302, 304 may include rigid printed circuit boards (PCBs). In such cases, the island sections 302, 304 may include metal or other traces electrically connecting each of the components on each of the island sections 302, 304. The ribbon section 306, on the other hand, may include a flexible substrate, for example a polymer including polyamide or any other suitable flexible substrate. Trace(s) 322 may be embedded within the polymer of the ribbon section 306 and may be electrically insulated from the environment external to the electrical circuit 300. Generally, the ribbon section 306 may be relatively more flexible than the island sections 302, 304. Accordingly, when disposed within an implantable medical device, such as LCP 100, the ribbon section 306 may be folded or bent to allow island sections 302, 304 to be stacked relative to one another without bending the island sections 302, 304 to a significant degree (e.g. less than a 15 degree deflection between two tangent lines, where each tangent line is tangent to the upper surface of the island section at a corresponding edge of the island section).

FIG. 15 depicts another example configuration of islands 302, 304. In the example of FIG. 15, second major opposing surfaces 312B, 314B are facing each other. With the processing module 310 and the circuit elements 308A-308C in the configuration as depicted in FIG. 15, this means that the processing module 310 and the circuit elements 308A-308C are disposed on the outside of the stacked circuit.

FIGS. 16 and 17 provide example configurations of an electrical circuit 400 that may be used as part of the electronics package of FIG. 2. In FIG. 6, island sections 401, 403, and 405 are stacked with first major opposing surfaces 412A and 414A of the island sections 401 and 403 facing each other and with a second major opposing surface of the island section 401 and a first major opposing surface 416A facing each other. In FIG. 17, the island sections 401, 403, and 405 are stacked with a first major opposing surface 412A and a second major opposing surface 416B of island sections 401 and 405, respectively, facing each other and with first major opposing surfaces 416A, 412A of the island sections 403, 405 facing each other. In this configuration, the first ribbon section 406 may be longer than the second ribbon section 407.

Of course, these are only a few examples of stacked configurations that island sections 401, 403, and 405 may take. In other examples, the island section 403 may be in the middle of the stack with the island section 401 on top and the island section 405 on bottom. In still further examples, the locations of the processing module 410 and the circuit elements 408A-H may differ, or the island sections may include additional or different components, e.g. various mechanical/physiological/biological sensors such as an accelerometer, a posture sensor, heart sounds sensor, or the like. Accordingly, the stacked configuration of these different examples may look different than depicted in FIGS. 14 through 17, or the dimensions of the stacked configurations may differ to accommodate the various different components.

It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the disclosure. This may include, to the extent that it is appropriate, the use of any of the features of one example embodiment being used in other embodiments.

Claims

1. An electronics module for use in an Implantable Medical Device (IMD), the electronics module comprising:

a plurality of electrical components connected to form a circuit that includes a terminal;

a potting material supporting the plurality of electrical components, wherein the plurality of electrical components and the potting material form a circuit sub-module, wherein the terminal is accessible from outside of the circuit sub-module; and

a metallic layer provided on an outer surface of the circuit sub-module, wherein the metallic layer conforms to the outer surface of the circuit sub-module, and the terminal is accessible from outside of the metallic layer.

2. The electronics module of claim 1, wherein the potting material is molded over at least some of the plurality of electrical components.

3. The electronics module of claim 1, wherein the outer surface of the circuit sub-module is treated for receiving the metallic layer.

4. The electronics module of claim 1, further comprising an insulator between the terminal and the metallic layer.

5. The electronics module of claim 1, wherein the metallic layer comprises TiN.

6. The electronics module of claim 1, wherein the metallic layer includes a deposited layer.

7. The electronics module of claim 1, wherein the terminal is a feedthrough terminal.

8. The electronics module of claim 1, wherein the circuit includes a second terminal, and wherein the second terminal is accessible from outside of the circuit sub-module.

9. The electronics module of claim 1, wherein the circuit is configured to sense cardiac electrical activity and to deliver pacing pulses.

10. A leadless cardiac pacemaker (LCP) configured to pace a patient's heart, the LCP disposable within a chamber of the patient's heart, the LCP comprising:

an electronics module comprising: a plurality of electrical components connected to form a circuit that includes at least a first terminal, a second terminal and a third terminal; a potting material supporting the plurality of electrical components, wherein the plurality of electrical components and the potting material form a circuit sub-module, wherein the first terminal, the second terminal and the third terminal are accessible from outside of the circuit sub-module; and a metallic layer provided on an outer surface of the circuit sub-module, wherein the metallic layer conforms to the outer surface of the circuit sub-module, and the first terminal, the second terminal and the third terminal are accessible from outside of the metallic layer;

a plurality of electrodes, the first terminal of the electronics module is operatively coupled to one of the plurality of electrodes;

a power source having a first power terminal and a second power terminal, wherein the power source is secured relative to the electronics module with the first power terminal operatively coupled to the second terminal of the electronics module and the second power terminal operatively coupled to the third terminal of the electronics module.

11. The leadless cardiac pacemaker (LCP) of claim 10, further comprising an over-molded layer over the electronics module.

12. The leadless cardiac pacemaker (LCP) of claim 11, further comprising a fixation mechanism secured relative to the electronics module via the over-molded layer, wherein the fixation mechanism is for fixing the LCP to the patient's heart.

13. The leadless cardiac pacemaker (LCP) of claim 11, wherein the over-molded layer helps secure the power source relative to the electronics module.

14. The leadless cardiac pacemaker (LCP) of claim 10, further comprising a fixation mechanism secured relative to the electronics module for fixing the LCP to the patient's heart.

15. The leadless cardiac pacemaker (LCP) of claim 10, wherein the potting material is molded over at least some of the plurality of electrical components.

16. The leadless cardiac pacemaker (LCP) of claim 10, wherein the plurality of electrical components comprise two or more stacked circuit boards operably coupled together via flexible interconnects, and wherein the potting material encapsulates at least a portion of the two or more stacked circuit boards.

17. The leadless cardiac pacemaker (LCP) of claim 10, wherein the circuit is configured to sense cardiac electrical activity via two or more of the plurality of electrodes and to deliver pacing pulses via two or more of the plurality of electrodes.

18. A method of manufacturing a leadless implantable medical device (IMD), the method comprising:

potting a circuit in a potting material to at least partially encapsulate the circuit within the potting material;

applying a metal coating over the potted circuit to provide a moisture barrier to at least part of the potted circuit;

attaching the potted circuit to a battery and operatively connecting the circuit to the battery;

attaching a fixation mechanism for fixing the IMD to a patient's heart;

operatively connecting a first electrode to the circuit; and

operatively connecting a second electrode to the circuit.

19. The method of claim 18, further comprising applying a parylene coating to the IMD subsequent to attaching the potted circuit to the battery.

20. The method of claim 18, wherein attaching the fixation mechanism comprises over-molding a layer over at least part of the fixation mechanism and over at least part of the potted circuit.