Connector cavity assembly for a medical device and manufacturing method

Abstract

A connector cavity assembly for a medical device, comprising at least one connector cavity comprising a plurality of electrically conductive electrode contacts spaced apart from each other and a plurality of electrically insulating insulation elements, wherein the electrode contacts and the insulation elements are arranged alternatingly; and a connector cavity housing. The connector cavity assembly is characterized in that the at least one connector cavity is removably arranged within the connector cavity housing, wherein the connector cavity housing exerts a pretension on the at least one connector cavity leading to a liquid-tight sealing between the insulation elements and the electrode contacts.

Claims

1. A connector cavity assembly for a medical device, comprising: at least one connector cavity comprising a plurality of electrically conductive electrode contacts spaced apart from each other and a plurality of electrically insulating insulation elements, wherein the electrode contacts and the insulation elements are arranged alternatingly along a longitudinal axis, and a connector cavity housing, wherein the at least one connector cavity is removably arranged within the connector cavity housing, wherein the connector cavity housing is dimensioned so that it exerts a pretension directed along the longitudinal axis on the at least one connector cavity leading to a liquid-tight sealing between the insulation elements and the electrode contacts.

2. The connector cavity assembly according to claim 1, wherein the at least one connector cavity extends in a longitudinal direction from a proximal end to a distal end and comprises a proximal end element positioned at the proximal end and a distal end element positioned at the distal end.

3. The connector cavity assembly according to claim 2, wherein the connector cavity housing is in contact with the connector cavity solely via the distal end element and the proximal end element.

4. The connector cavity assembly according to claim 1, wherein the connector cavity assembly further comprises at least two connector cavities that are offset to each other in a longitudinal direction and/or in a transversal direction of the connector cavity housing.

5. The connector cavity assembly according to claim 1, wherein the connector cavity housing comprises at least one receiving portion for receiving a further component of a medical device.

6. The connector cavity assembly according to claim 5, wherein the at least one receiving portion enables an attachment of a further component of a medical device by a latching connection.

7. The connector cavity assembly according to claim 1, wherein the connector cavity assembly further comprises at least one of an antenna, a coil, and guideways for an external wiring.

8. The connector cavity assembly according to claim 1, wherein the connector cavity housing comprises at least one spacer on its lower side that is intended to face a body portion of a medical device when the connector cavity housing is part of a medical device.

9. A medical device comprising a connector cavity assembly according to claim 1.

10. The medical device according to claim 9, wherein the connector cavity assembly is embedded into a resin, wherein a connecting port is formed in the resin so that an interior of the at least one connector cavity of the connector cavity assembly is accessible from outside the medical device.

11. The medical device according to claim 9, wherein the medical device is an implantable cardiac pacemaker, an implantable cardioverter defibrillator, or an implantable neurostimulator.

12. A method for manufacturing a connector cavity assembly, comprising the following steps: a) providing a connector cavity housing, b1) assembling a connector cavity by alternatingly placing electrically conductive electrode contacts and electrically insulating insulation elements into a tensioning device or tool, or b2) placing a pre-assembled connector cavity comprising alternatingly positioned electrically conductive electrode contacts and electrically insulating insulation elements into a tensioning device or tool, c) exerting a pretension on the connector cavity with the tensioning device or tool, d) transferring the pretensioned connector cavity into the connector cavity housing, e) releasing or removing the tensioning device, and f) allowing the connector cavity housing to exert a pretension on the connector cavity.

13. The method according to claim 12, wherein the step of assembling the connector cavity or of placing a pre-assembled connector cavity into the pretensioning device is performed without any mandrel being present in an interior space of the connector cavity.

14. The method according to claim 12, wherein the connector cavity housing is a plastic component made by injection molding.

15. A method for manufacturing a medical device, comprising the following steps: a) providing a connector cavity assembly comprising: at least one connector cavity comprising a plurality of electrically conductive electrode contacts spaced apart from each other and a plurality of electrically insulating insulation elements, wherein the electrode contacts and the insulation elements are arranged alternatingly along a longitudinal axis, and a connector cavity housing, wherein the at least one connector cavity is removably arranged within the connector cavity housing, wherein the connector cavity housing is dimensioned so that it exerts a pretension directed along the longitudinal axis on the at least one connector cavity leading to a liquid-tight sealing between the insulation elements and the electrode contacts, b) placing the connector cavity assembly on a body of a medical device, c) establishing an electrical contact between at least one electrically conductive electrode contact of the connector cavity assembly and an electronics housed in the body of the medical device, and d) casting a hardenable resin around the connector cavity assembly.

Description

DESCRIPTION OF THE DRAWINGS

(1) In the Figures:

(2) FIG. 1 shows an embodiment of a connector cavity;

(3) FIG. 2 shows a longitudinal section through the connector cavity of FIG. 1;

(4) FIG. 3A shows a first view on an embodiment of the connector cavity assembly with two connector cavities;

(5) FIG. 3B shows a second view on the connector cavity assembly of FIG. 3A;

(6) FIG. 4 shows a third embodiment of a connector cavity assembly;

(7) FIG. 5 shows a second embodiment of a connector cavity assembly;

(8) FIG. 6 shows a fourth embodiment of a connector cavity assembly;

(9) FIG. 7 shows a fifth embodiment of a connector cavity assembly; and

(10) FIG. 8 shows an embodiment of a medical device.

DETAILED DESCRIPTION

(11) FIG. 1 shows an embodiment of a connector cavity 1 comprising a distal end element 2 at its distal end and a proximal end element 3 at its proximal end. Between the distal end element 2 the proximal end element 3, a plurality of ring-shaped insulation elements 4 made from silicone and alternating metal rings 5 each comprising a metal spring in their interior are positioned. The insulating elements 4 act as spacer between the metal rings 5 and for electrically insulating two adjacent metal rings 5. The metal rings 5 act as electrode contacts.

(12) The insulating elements 4 are compressible. The distal end element 2 and the proximal end element 3 are non-elastic. If a pressure is exerted onto the distal end element 2 and/or the proximal end element 3, the insulating elements 4 are (slightly) compressed and sealingly about the adjacent metal rings 5.

(13) The connector cavity 1 is intended to receive a connector of at least one electrode or lead that is to be inserted into an interior space of the connector cavity 1.

(14) This can be seen from FIG. 2 representing a longitudinal section through the connector cavity 1 of FIG. 1. In FIG. 2 and in the following Figures the same numeral references are used for the same or similar elements.

(15) It is apparent, that an interior space 6 of the connector cavity 1 has sufficient space for housing a connector comprising up to eight electrical contacts (each contact contacting a metal spring 50 of the respective metal ring 5). Thus, the connector cavity 1 is suited to receive a connector of a lead having up to eight electrodes.

(16) It is apparent from the depiction of FIG. 2 that the insulation elements 4 electrically insulate two adjacent metal rings 5, whereas each metal ring 5 is in electrical contact with a metal spring 50 centrally arranged surrounding a longitudinal axis L of the connector cavity 1. An electrical contact can be inserted along this longitudinal axis L into the interior space 6 of the connector cavity 1 since each insulating element 4 as well as each metal spring 50 comprises a central opening.

(17) FIG. 3A shows an embodiment of the connector cavity assembly 7 comprising two constructively identical connector cavities 1 and a connector cavity housing 8 housing both connector cavities 1. For better overview only some of the components of the connector cavities 1 are marked with the respective numeral reference. Reference is made to the explanations given with respect to FIGS. 1 and 2 for explaining the structural details of the connector cavities 1.

(18) The connector cavity housing 8 comprises two connector cavity receiving portions into which the connector cavities 1 are inserted. Thereby, the connector cavity housing 8 directly contacts the respective distal end elements 2 and proximal end element 3 of the connector cavities 1. In doing so, it exerts a pressure onto the distal end elements 2 and the proximal end elements 3 resulting in a pretension of the insulation elements 4 between the conductive metal rings 5. The exerted pressure and thus the resulting pretension is defined by the spatial dimensions of the connector cavity receiving portion, i.e., the distance between a first end portion contacting the distal end element 2 and a second end portion contacting the proximal end element 3 of the respective connector cavity 1. Since this distance is always the same due to a highly standardized manufacturing method (preferably by injection molding) the exerted pressure and the resulting pretension of the connector cavities 1 is also always the same. Even if a high number of connector cavity assemblies 7 is manufactured, the variance between individual connector cavity assemblies 7 is thus very small.

(19) FIG. 3B shows the connector cavity assembly 7 of FIG. 3A from the backside. Regarding the individual elements of the connector cavity assembly 7, in particular the connector cavity housing 8 and the inserted connector cavities 1, reference is made to the explanations given with respect to FIG. 3A and the preceding Figures. Like in FIG. 3A and also like in the following Figures, only some of the individual elements of the connector cavity assembly 7 are marked with the respective numeral reference to allow a better overview.

(20) In the depictions of FIG. 3A and FIG. 3B, two spacers 9 can be seen that are provided at a lower side of the connector cavity housing 8. These spacers 9 serve for guaranteeing a defined distance between the connector cavity housing 8 and a body portion of a medical device onto which the connector cavity housing 8 or the connector cavity assembly 7, respectively, is to be applied. FIGS. 4 to 7 particularly illustrates the function of the aforementioned spacers 9. Preferably, the spacers 9 comprise a protruding portion, which is meant to be received by a matching opening or recess on a portion of the above mentioned body portion of the medical device.

(21) FIG. 4 shows an embodiment of the connector cavity assembly 7, wherein the connector housing 8 comprises a holding element 10 that holds an antenna 11. Thereby, the antenna 11 is clipped onto the holding element 10. It can further be seen from FIG. 4 how the connector cavity assembly 7 is to be placed a body portion 12 of a medical device. Thereby, electrical connectors 13 of the body portion 12, particularly pins 13 extending through the feedthrough 20 of the housing 12 of a medical device, face the mounted connector cavity assembly 7 and enable an electrical connection of individual components of the connector cavity assembly 7 to the body portion 12 of the medical device. Advantageously, the electrical connectors 13 (pins) of the body portion 12 (housing) are fixed to the respective wiring ribbons of the connector cavity assembly 7 by soldering, brazing or welding.

(22) The holding element 10 enables a pre-assembly of the antenna 11 on the connector cavity housing 8 so as to form part of the connector cavity assembly 7. This facilitates a later assembly of the final medical device since the antenna 11 needs no longer be placed into a resin mold upon embedding the antenna 11 and the connector cavities 1 as well as optionally further electrical elements in a resin.

(23) FIG. 5 shows another embodiment of a connector cavity assembly 7 already mounted to the body portion 12 or housing of a medical device. Like the embodiments described with respect to FIG. 4, also the embodiment shown in FIG. 5 comprises an antenna 11 held by a holding element 10 of the connector cavity housing 8 of the connector cavity assembly 7. Furthermore, two connector cavities 1 are inserted into respective connector cavity receiving portions of the connector cavity housing 8. Additionally, a plurality of first wiring ribbons 14 guided in guideways formed on the connector cavity housing 8 is provided. These first wiring ribbons 14 contact the metal rings 5 of the upper connector cavity 1 and thus establish an electric contact between electronics housed in the body portion 12 of the medical device and the metallic springs 50 arranged inside the metal rings 5, particularly via the pins 13 of the feedthrough 20. Since the upper connector cavity 1 is arranged closer to that side oriented towards the front in FIG. 5, the first wiring ribbons 14 do not come into contact with any parts of the lower connector cavity 1, in particular not with any electrically conductive part of the lower connector cavity 1.

(24) FIG. 6 shows another embodiment of the connector cavity assembly 7 with a connector cavity housing 8 and two inserted connector cavities 1. Thereby, the view on this exemplary embodiment of the connector cavity assembly 7 is from the opposite side than the view onto the connector cavity assembly 7 of FIG. 5.

(25) In the embodiment shown in FIG. 6, a plurality of second wiring ribbons 15 is shown guided in guideways formed on the connector cavity housing 8. Since the lower connector cavity 1 is closer to that side of the connector cavity housing 8 that faces to the front in FIG. 6, the second wiring ribbons 15 can easily get in contact with the lower connector cavity 1 and thus establish an electric contact between electronics housed in the body portion 12 or housing of the medical device and the metallic springs 50 arranged inside the metal rings 5.

(26) FIG. 7 shows another embodiment of the connector cavity assembly 7 with a connector cavity housing 8 and two inserted connector cavities 1. Besides the antenna 11 and the first wiring ribbons 14 already known from the preceding embodiments, this embodiment also comprises an inductive coil 16 for charging a medical device, the connector cavity assembly 7 forms part of. Thereby, the connector cavity housing 8 comprises four guiding pins 17 for guiding the inductive coil 16 as well as four holding clips 18 for holding the conductive coil 16.

(27) By providing these guiding pins 17 it is particularly easy to bring the inductive coil 16 into the correct position on the connector cavity housing 8. Furthermore, the holding clips 18 serve for a tight connection of the inductive coil 16 on the connector cavity housing 8.

(28) It would also be possible to provide holding pins 17 and holding clips 18 without additionally providing a holding element 10 for the antenna 11 and/or without providing guideways for the first wiring ribbons 14 that are all present in the embodiment of FIG. 7. But a combination of these individual elements, i.e., a combination of the precedingly explained embodiments of the connector cavity assembly 7 makes it particularly simple to combine different functionalities into the single connector cavity assembly 7 so as to further facilitate the manufacturing process of a medical device of which the connector cavity 7 forms part of.

(29) It is furthermore easily apparent that the embodiment shown in FIG. 6, i.e., a connector cavity assembly 7 making use of guideways for second wiring ribbons 15 can also be combined with some or all of the other embodiments. Then, both the upper connector cavity 1 and the lower connector cavity 1 can be easily contacted by first and second wiring ribbons 14, 15 guided over respective guideways.

(30) FIG. 8 shows a neurostimulator 19 serving as medical device. It comprises a body portion 12 and a header portion 20. The header portion 20 comprises a resin into which a connector cavity assembly 7, e.g., the embodiment shown in FIG. 7, with an inductive coil 16 is embedded. The resin of the header portion 20 serves for sealing all embedded components with respect to an environment, i.e., with the respect to a body of the patient who carries the neurostimulator 19 as implantable device.

(31) The header portion 20 comprises two connecting ports 21 through each of which a connector of an electrode can be inserted so as to reach the interior of the respective connector cavity 1. In doing so, an electrical contact between the neurostimulator 19 and a connected electrode (not shown in FIG. 8) can be established.

(32) It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teachings of the disclosure. The disclosed examples and embodiments may include some or all of the features disclosed herein. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention, which is to be given the full breadth thereof. Additionally, the disclosure of a range of values is a disclosure of every numerical value within that range, including the end points.