US 6,141,205 A · Implantable medical device having flat electrolytic capacitor with consolidated electrode tabs and corresponding feedthroughs · patentgrep

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Abstract

An implantable medical device such as a defibrillator is described. The device includes an hermetically sealed housing containing a flat electrolytic capacitor and an energy source such as a battery. The battery is connected to the capacitor and provides charge thereto. The capacitor stores the charge at a relatively high voltage. The charge stored in the capacitor is discharged through a defibrillation lead to a site on or in the heart when fibrillation of the heart is detected by the implantable medical device. Methods of making and using the implantable medical device, the capacitor, and their various components are disclosed.

Claims38

Dependent claims

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least two of the plurality of anode layers each being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving at least two of the second tabs and an anode feedthrough pin extending from the second coiled basal portion;
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, and the at least two second tabs are aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of each of the at least two second tabs therewithin and being connected thereto, the cover being sealingly disposed over the open end of the case.

5 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) at least two anode sub-assemblies, each of said anode sub-assemblies comprising a plurality of flat anode layers formed of anode foil, each of the plurality of anode layers having top and bottom surfaces, at least one of the plurality of anode layers of each anode sub-assembly being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location;
(c) at least two separator layers formed of separator material, each of the separator layers defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
and
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second tabs of the at least two anode sub-assemblies therewithin and an anode feedthrough pin extending from the second coiled basal portion;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that a first one of the at least two separator layers is disposed between the at least one cathode layer and one of the at least two anode sub-assemblies, the first tab is aligned with a first predetermined registration position in the electrode assembly, a second one of the at least two separator layers is disposed between the first one and a second one of the at least two anode sub-assemblies, the second tabs of first and second ones of the at least two anode sub-assemblies are aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tabs of the first and the second of the at least two anode sub-assemblies and being connected thereto.

4 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least one of the plurality of anode layers being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin, a cathode feedthrough pin extending from the first coiled basal portion, and an intermediate strain relief component disposed between a proximal end of the first cathode feedthrough means and the cathode feedthrough pin;
and
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second width therewithin and an anode feedthrough pin extending from the second coiled basal portion;
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, and the second tab is aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tab therewithin and being connected thereto, the cover being sealingly disposed over the open end of the case.

6 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least one of the plurality of anode layers being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second width therewithin, an anode feedthrough pin extending from the second coiled basal portion, and an intermediate strain relief component disposed between a proximal end of the first anode feedthrough means and the anode feedthrough pin;
and
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, and the second tab is aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tab therewithin and being connected thereto, the cover being sealingly disposed over the open end of the case.

6 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, at least one of the anode layers being a notched anode layer and more than one of the anode layers being non-notched anode layers, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least one of the plurality of anode layers being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second width therewithin and an anode feedthrough pin extending from the second coiled basal portion;
and
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, and the second tab is aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tab therewithin and being connected thereto, the cover being sealingly disposed over the open end of the case.

6 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least onc of the plurality of anode layers being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second width therewithin and an anode feedthrough pin extending from the second coiled basal portion;
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
and
(h) means for securing the at least one cathode layer, the plurality of anode layers and the first separator layer to prevent movement or shifting, the means for securing comprising an electrode wrap and corresponding adhesive strip;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, and the second tab is aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tab therewithin and being connected thereto, and the cover being sealingly disposed over the open end of the case.

7 more elements

A substantially flat electrolytic capacitor suitable for use in an hermetically sealed implantable medical device, comprising:

(a) at least one flat cathode layer being formed of cathode foil and having a first perimeter of a first overall length, the cathode layer having top and bottom surfaces and at least a first tab projecting from the first perimeter at a first predetermined perimeter location, the first tab having a first width;
(b) a plurality of flat anode layers formed of anode foil, the plurality of anode layers forming an anode sub-assembly having top and bottom surfaces, at least one of the plurality of anode layers being a first anode layer having a second perimeter of a second overall length and at least a second tab projecting from the second perimeter at a second predetermined perimeter location, the second tab having a second width;
(c) at least a first separator layer formed of separator material, the first separator layer defining a third perimeter having a third physical dimension;
(d) a first cathode feedthrough means comprising a first coiled basal portion having a first inside diameter for receiving the first width therewithin and a cathode feedthrough pin extending from the first coiled basal portion;
(e) a first anode feedthrough means comprising a second coiled basal portion having a second inside diameter for receiving the second width therewithin and an anode feedthrough pin extending from the second coiled basal portion;
and
(f) a case having sidewalls extending upwardly from a flat planar base to form an open end;
(g) a cover for sealing the open end of the case;
wherein the at least one cathode layer, the plurality of anode layers and the first separator layer are vertically stacked in the case to form an electrode assembly such that the first separator layer is disposed between the at least one cathode layer and the anode sub-assembly, the first tab is aligned with a first predetermined registration position in the electrode assembly, wherein at least portions of the first separator layer are secured at the periphery thereof to corresponding portions of a second separator layer by at least one of crimping, stitching, adhesive bonding, ultrasonic paper welding and direct pressure bonding, and the second tab is aligned with a second predetermined registration position in the electrode assembly, the first coiled basal portion receiving the first width of the first tab therewithin and being connected thereto, the second coiled basal portion receiving the second width of the second tab therewithin and being connected thereto, the cover being sealingly disposed over the open end of the case.

6 more elements

Dependencies are inferred from the claim text.