DE102017208625B3 - CONNECTOR ELEMENTS, SOCKET ELEMENT AND IMPLANTABLE ELECTRICAL CONNECTOR AND MANUFACTURING METHOD - Google Patents

Abstract

The present invention relates to a plug element and a socket element for electrically contacting the plug element, in particular for use in implantable components. The present invention further relates to corresponding manufacturing methods for manufacturing the male member and the female member and to an implantable miniaturized electrical connector. A plug element comprises an electrically insulating connector base body (110), at least one contact pin (106) which is arranged on a contact surface (112) of the connector base body (110) such that the contact pin (106) is connectable to a socket contact (108), and a connection element (120), which is electrically conductively connected to the contact pin (106). The contact pin (106) has a columnar projection (114) which is integrally formed on the electrically insulating connector base body (110), a conductor track (118) running inside the projection (114), which is connected to the connection element (120), and a contact layer (116) disposed on an outer surface of the protrusion (114) and connected to the trace (118) and connectable to the female contact (108).

Description

The present invention relates to a plug element and a socket element for electrically contacting the plug element, in particular for use in implantable components. The present invention further relates to corresponding manufacturing methods for manufacturing the male member and the female member and to an implantable miniaturized electrical connector.

Implantable connectors play an important role in the field of Active Implantable Medical Devices (AIMD). Such devices typically include an electronic component that includes the battery and control electronics for the implant, and a lead, usually a cable with an electrode at the end thereof. In order to facilitate the implantation and also to allow the replacement of defective, repairable or used parts, such as the batteries of a cardiac pacemaker, these two components are usually connected to each other by means of an electrical connector. For example, in RG Hauser, BJ Maron, "Lessons from the Failure and Recall of an Implantable Cardioverter-Defibrillator", Circulation 112 , 2040 (2005), such batteries have a life of 3 to 7 years.

For applications such as pacemakers, brain stimulators, spinal cord stimulators or nerve stimulators implantable connectors have been used for several years. Such conventional connectors are described, for example, in the article PEK Donaldson, "The Craggs Connector; a Termination for Copper Cable "Med Biol Eng Comput, vol. 23, pp. 195-196, 1985, dissertation by M. Schuettler, "Three-Dimensional Shaping of Planar Microelectrodes for Neuroprosthetics for Optimized Derivation and Stimulation on the Peripheral Nerve," Dissertation at the University of Saarland, 2002. Chapter 10.3. and the Bal Seal Engineering Inc. Datasheet, "SYGNUS Implantable Contact System Integrated Seal / contact system for active medical implants, TMB-10-APG-2.5C-09/12," http://www.balseal.com/ sites / default / files / SYGNUS TMB10_091712.pdf (17.06.2015). Other conventional implantable connectors are described in the articles of M. Cocco, P. Dario, M. Torot, P. Pastacaldi, R. Sacchetti, "An Implantable Neural Connector Incorporating Microfabricated Components", Journal of Micromechanical Microengineering 3, pp. 2 19-221, 1993 and JE Letechipia, PH Peckham, M. Gazdik, The Patent US 5 199 879 A discloses an electrical assembly including a first circuit element, e.g. A thermal conduction module having at least one conductive pin projecting from the TCM to be frictionally and electrically engaged with a flexible portion of a circuit device of a second circuit element (eg, a PCB). An opening is provided within the PCB with respect to the flexible portions such that portions thereof at least partially protrude beyond the opening and frictionally engage corresponding conductive portions of the pin as they are inserted into the opening. Each of these flexible sections is in turn part of a circuit layer which may be connected to respective conductive planes or the like within the PCB while the respective conductive sections of the pin are in turn electrically connected to various conductive layers within or on the TCM.

The patent US Pat. No. 8,465,328 B2 refers to an electrical connector assembly having a male and a female connector. On the male connector, first guide protrusions are arranged, which are higher than columnar protrusions forming the male terminals. On the female side, openings are provided which allow easy movement of the guide projections, while the columnar projections engage in cross-shaped slots of the female connector.

The patent US 8 267 700 B2 refers to a connector assembly intended to achieve a reduction in height and also to prevent the male and female connectors from disengaging during mechanical loading. For this purpose, the columnar pin has a bulged end portion which is in the mated state with an elastically deformed contact pad of the female connector in engagement.

However, the known connectors have a variety of disadvantages. For example, none of the conventional connectors in complex systems with a large number of electrical channels can be used in a confined space, because the distances between the individual contacts are too large. For example, although there are 232 channel electrode systems for retinal implants, there are no correspondingly miniaturized implantable connectors.

Furthermore, in known connectors often from the outside after the mating of the male and female part an adhesive mass must be added to the required isolation to the outside to reach. In addition, often too high insertion forces are required, so that the connector can be easily damaged.

Implantable connectors must meet a variety of requirements. On the one hand, they must meet the general requirements of every type of electrical connection: low contact resistance, electrical insulation between the individual contacts and the environment, reliability and mechanical stability. In addition, implantable connectors must be biocompatible and biostable in a wet, aggressive environment. An implantable connector must continue to be isolated from any type of fluid and electrolyte in the body and to withstand the cleaning and disinfecting procedures before and during implantation.

The object on which the present invention is based, therefore, is to provide improved plug and socket elements for an implantable electrical connector, which overcome the disadvantages of the known solutions and are thereby produced efficiently and inexpensively.

Furthermore, it is the object of the invention to provide related manufacturing methods and an electrical connector assembly.

These objects are achieved by the subject matter of the independent claims. Advantageous developments of the present invention are the subject of several dependent claims.

The present invention is based on the idea of producing a plug element with a preferably laser-structured main body of, for example, a HTCC (high-temperature cofired ceramic) material, which can be plugged together with an elastic bush element.

In particular, a plug element according to the present invention comprises an electrically insulating plug main body, at least one contact pin, which is arranged on a contact surface of the plug main body so that the contact pin is connectable to a female contact, and a connection element, which is electrically conductively connected to the contact pin on , The at least one contact pin has a columnar projection which is integrally formed on the electrically insulating connector base body, a conductor extending in the interior of the projection which is connected to the connection element, and a contact layer arranged on an outer surface of the connector base body which is connected to the conductor path and with can be connected to the socket contact.

As a result, a dimensionally stable contact pin can be generated in a simple manner, which is in particular also suitable for forming contact arrays with a very small size and close distances. The contact pin itself is made of an insulating material, so that the required creepage and insulation distances can be maintained even for tighter contact pin grid.

According to an advantageous embodiment of the present invention, the connector body is made of a ceramic material. Ceramic is mechanically resilient and biostable.

For example, a so-called ceramic green body, for. As a multi-layer, glass-containing alumina green sheet, structured and then solidified by heat (so-called. Cofiring process). The processing of such green bodies can be carried out in an advantageous manner by means of laser structuring. As a result, very fine structures can be produced with low tolerances. Of course, cutting and punching methods can also be used. Furthermore, by laminating a plurality of green film layers approximately any desired layer thicknesses can be produced. Through the sintering process, the green sheets solidify to the final ceramic material, while the organic fillers responsible for the flexibility of the green sheet escape. It must be taken into account that, depending on the system used, the sintering process involves a significant volume shrinkage of the material.

According to an advantageous development of the present invention, furthermore, at least one elastic insulating layer is arranged on the contact surface of the connector base body such that the insulating layer surrounds the contact pin. This insulating layer has the advantage that it electrically isolates the contacts with each other, on the other hand enables a seal against external influences when the male member and the female member are plugged together. The elastic insulating layer can be made, for example, from a silicone material, for example based on polydimethylsiloxane (PDMS). Due to its elasticity, this insulating layer forms a sealing element between the two parts of the electrical connector out. Additional adhesive layers are no longer necessary. As a result, the manufacturing process is simplified while ensuring the solubility of the connection between the male member and the female member.

Advantageously, the connection element can be connected to a multiplicity of electrode shapes and device feed lines, for example with insulated wire or a flexible flat conductor with an insulating sheath of polyimide (PI) or polydimethylsiloxane (PDMS). This can be achieved by arranging the at least one connection element on the rear side of the base body opposite the contact surface.

According to an advantageous embodiment of the present invention, the contact layer is made of gold, platinum or an alloy thereof. The advantages of such precious metals or precious metal alloys are u. a. their corrosion resistance, high electrical conductivity and good processability. Of course, the connector elements according to the present invention can also be made with other metals or electrically conductive materials.

The present invention further relates to a female member for electrically contacting a male member. The socket element has an electrically insulating bushing base body and at least one socket contact element which can be connected to a contact pin of the plug element. The electrically insulating bushing main body has a recess, wherein a socket contact element is arranged on the recess, that the socket contact element during mating plug element and socket element by the contact pin is deflected into the recess inside. Such a resilient contact element has the advantage that a uniform mechanical and electrical contact between the socket contact element and an associated contact pin can be ensured without having to provide additional resilient locking devices. As a result, the distance between the individual contact elements in an array can be kept low.

According to an advantageous embodiment of the present invention, the socket main body is at least partially made of a ceramic material or of a silicone material, for example polydimethylsiloxane (PDMS). The use of a silicone material has the advantage that the base body of the sleeve element is elastic and can be applied sealingly against a rigid plug element. As a result, a sufficient insulation of the connector can be ensured to the outside in an aggressive and humid environment.

In a particularly simple manner, the resilient socket contact element can be formed by at least one self-supporting, electrically conductive contact lug. For example, a ring arranged symmetrically around the depression may be provided by a plurality of circular segment-shaped contact lugs. Of course, differently shaped flags or tongues can be provided, which can be deflected by the inserted pin into the recess.

Furthermore, the socket element has at least one elastic insulating layer, which is arranged on the socket base body such that the insulating layer surrounds the recess and the socket contact element is exposed. In this way it can be ensured that all further electrically conductive tracks are protected and the individual socket contact elements are electrically separated from each other.

The present invention also provides manufacturing methods for the male and female elements of the invention.

• Herstellen eines elektrisch isolierenden Steckergrundkörpers mit mindestens einem daran angeformten säulenförmigen Vorsprung, wobei der Vorsprung mit einem durch ihn hindurchgehenden Kanal versehen wird;
• Aufbringen einer elektrisch leitfähigen Beschichtung zum Ausbilden eines Kontaktstifts, wobei die elektrisch leitfähige Beschichtung die äußere Oberfläche des mindestens einen säulenförmigen Vorsprungs wenigstens teilweise bedeckt und der Kanal wenigstens teilweise mit der leitfähigen Beschichtung gefüllt ist;
• Anbringen eines Anschlusselements, das mit dem Kontaktstift elektrisch leitend verbunden ist.

A method for manufacturing a plug element comprises the following steps:

• Producing an electrically insulating connector base body having at least one columnar projection formed thereon, wherein the projection is provided with a channel passing therethrough;
• Applying an electrically conductive coating to form a contact pin, wherein the electrically conductive coating at least partially covers the outer surface of the at least one columnar protrusion and the channel is at least partially filled with the conductive coating;
• Attaching a connection element which is electrically conductively connected to the contact pin.

Such a manufacturing method is compatible with the established methods of packaging and assembly technology and allows in a simple way the production of a connector that is implantable and also suitable for large quantities of electrical channels.

The plug base body is produced in a particularly efficient manner by structuring a ceramic green body and then sintering it. As already mentioned, the ceramic material has the advantage that it is biocompatible and stable. In addition to the already mentioned HTCC green bodies, LTCC (low temperature cofired ceramic) green bodies can also be used. The ceramic material may also be glass filled. The three-dimensional structuring of these green bodies, which is required to produce the columnar projections for the contact pins and the electrical conductors passing through the projections, preferably takes place by means of a three-dimensional laser machining of the green body (also called green body).

Generally, there is little adhesion between the individual components of a green body. The ceramic bond and thus the high strength is obtained only by firing at high temperatures. The fire allows sintering and thus only the actual ceramic material is created. As a result of the processes during firing, a solidification and densification of structured basic body takes place, which is also expressed in a decrease in porosity. This process causes a total volume decrease, the so-called burning shrinkage. This can be very different for different ceramic materials and must be taken into account in the geometric design accordingly.

• Anordnen des elektrisch isolierenden Steckergrundkörpers in einer Maskenstruktur, so dass der mindestens eine säulenförmige Vorsprung in einer zugehörigen Maskenausnehmung aufgenommen ist, wobei zwischen der äußeren Oberfläche des säulenförmigen Vorsprungs und der inneren Wandung der Maskenausnehmung ein Freiraum verbleibt,
• Verteilen einer elektrisch leitfähigen Siebdruckpaste, so dass der Freiraum zwischen der äußeren Oberfläche des mindestens einen säulenförmigen Vorsprungs und der inneren Wandung der Maskenausnehmung sowie der Kanal des mindestens einen säulenförmigen Vorsprungs mit der Siebdruckpaste gefüllt sind,
• Aushärten der elektrisch leitfähigen Siebdruckpaste.

The sintered ceramic base body is subsequently provided with the required electrical connections, wherein the step of applying an electrically conductive coating preferably comprises the following partial steps:

• Arranging the electrically insulating plug base body in a mask structure so that the at least one columnar projection is accommodated in an associated mask recess, wherein a clearance remains between the outer surface of the columnar projection and the inner wall of the mask recess,
• Distributing an electrically conductive screen printing paste such that the space between the outer surface of the at least one columnar projection and the inner wall of the mask recess and the channel of the at least one columnar projection are filled with the screen printing paste,
• Curing the electrically conductive screen printing paste.

With the aid of such a mask process and using screen-printing pastes, the coating of the three-dimensional column structures can take place both inside and outside in a particularly cost-effective manner. Of course, however, other metallization can find application, such as sputtering, vapor deposition or electroless plating. In particular, sputtering of the metallization leads to high-quality layers. Alternatively, the columnar projection can also be metallized by means of a sputtering or vapor deposition process with the aid of the same masking.

In a next step, an elastic insulating layer can be structured and attached to the connector body such that the insulating layer surrounds the at least one contact pin. In this way, an even better electrical insulation of the pins to one another and a liquid-tight encapsulation of the mated contacts can be achieved to the outside.

The insulating layer is preferably made of a silicone rubber film, wherein corresponding recesses for the contact pins are produced by means of a laser processing of the film. So that the silicone film securely adheres to the ceramic material of the base body, the surface of the connector base body to which the insulating layer is attached, be activated by a plasma treatment. Advantageously, further adhesives or adhesion promoters are then dispensable.

• Herstellen eines elektrisch isolierenden Buchsengrundkörpers mit mindestens einer Vertiefung,
• Herstellen einer elektrisch isolierenden Kontaktfolie, die mindestens ein freigelegtes Buchsenkontaktelement trägt,
• Verbinden des Buchsengrundkörpers mit der Kontaktfolie, wobei das Buchsenkontaktelement so an der Vertiefung angeordnet ist, dass das Buchsenkontaktelement beim Zusammenstecken eines Steckerelements mit dem Buchsenelement durch den Kontaktstift in die Vertiefung hinein auslenkbar ist, und wobei weiterhin mindestens eine elastische Isolierlage so an dem Buchsengrundkörper angeordnet wird, dass die Isolierlage die Vertiefung umgibt und das Buchsenkontaktelement freigelegt ist.

A method of manufacturing a female member according to the present invention comprises the following steps:

• Producing an electrically insulating socket main body having at least one recess,
• Producing an electrically insulating contact foil which carries at least one exposed socket contact element,
• Connecting the socket base body with the contact foil, wherein the socket contact element is arranged on the recess, that the socket contact element during mating of a plug element with the socket element by the contact pin is deflected into the recess, and further wherein at least one elastic insulating layer is arranged on the socket main body in that the insulating layer surrounds the recess and the socket contact element is exposed.

The method according to the invention makes it possible in a particularly simple manner to produce a socket element which is suitable for an implantable electrical connector. The recesses are preferably designed as blind holes, so that an optimal electrical insulation and sealing can be achieved.

In this case, the socket main body, as described above with respect to the connector element, can be made of a HTCC or LTCC green compact, wherein the recesses are introduced by means of a laser processing method. Alternatively, it can also be provided that the bushing body is made partly or wholly from a flexible material such as silicone rubber.

So that the socket contact element can be connected to external components, a connection element is advantageously provided, and at least one electrically conductive connection is formed, which extends from the socket contact element through at least part of the socket main body to the connection element. Such an electrically conductive connection can be produced particularly efficiently if first a channel is formed in the socket main body, then an electrically conductive screen printing paste is distributed, so that the channel is at least partially filled with the screen printing paste, and finally the electrically conductive screen printing paste is cured. Any missing contacts can be bridged by a sputtering or vapor deposition process.

According to an advantageous embodiment of the present invention, it is provided that the contact foil comprises at least two layers of a silicone material, between which a structured metallization layer is arranged, wherein the at least one socket contact element is produced by laser structuring of the metallization layer. In order for the contact film to adhere to the socket main body without further adhesives and adhesion promoters, the surface of the socket main body to which the contact film is applied can be activated by a plasma treatment.

The principles of the present invention allow for the provision of an implantable electrical connector having a male member, a female member and a terminal unit connected to the male member for connecting an electrode assembly or an electronic component. For example, the termination unit can connect to one or more insulated wires or to a flexible flat conductor with a polyimide (PI) or polydimethylsiloxane (PDMS) insulating sheath.

• 1 eine schematische Schnittdarstellung einer erfindungsgemäßen elektrischen Verbinderanordnung gemäß einem ersten Ausführungsbeispiel vor dem Zusammenstecken;
• 2 eine schematische Schnittdarstellung der Verbinderanordnung aus 1 im zusammengesteckten Zustand;
• 3 ein Layout einer Metallschicht mit einem Buchsenkontaktelement;
• 4 eine schematische Schnittdarstellung einer erfindungsgemäßen elektrischen Verbinderanordnung gemäß einem zweiten Ausführungsbeispiel vor dem Zusammenstecken;
• 5 eine schematische Schnittdarstellung der Verbinderanordnung aus 3 im zusammengesteckten Zustand;
• 6 eine schematische Schnittdarstellung des Steckerelements aus 1 mit angebrachter Lötverbindung;
• 7 eine schematische Schnittdarstellung des Buchsenelements aus 2 mit angebrachter Lötverbindung;
• 8 eine schematische Schnittdarstellung eines Steckerelements mit einer Anschlusseinheit gemäß einer vorteilhaften Ausführungsform der vorliegenden Erfindung;
• 9 eine schematische Schnittdarstellung eines Steckerelements mit einer Anschlusseinheit gemäß einer weiteren vorteilhaften Ausführungsform der vorliegenden Erfindung;
• 10 eine schematische Schnittdarstellung eines Steckerelements mit einer Anschlusseinheit gemäß einer weiteren vorteilhaften Ausführungsform der vorliegenden Erfindung.

For a better understanding of the present invention, this will be explained in more detail with reference to the embodiments illustrated in the following figures. The same parts are provided with the same reference numerals and the same component names. Furthermore, some features or combinations of features from the various embodiments shown and described may represent separate, inventive or inventive solutions. Show it:

• 1 a schematic sectional view of an electrical connector assembly according to a first embodiment according to the invention before mating;
• 2 a schematic sectional view of the connector assembly 1 in the assembled state;
• 3 a layout of a metal layer with a female contact element;
• 4 a schematic sectional view of an electrical connector assembly according to a second embodiment of the invention before mating;
• 5 a schematic sectional view of the connector assembly 3 in the assembled state;
• 6 a schematic sectional view of the plug element 1 with attached solder joint;
• 7 a schematic sectional view of the socket element 2 with attached solder joint;
• 8th a schematic sectional view of a plug element with a connection unit according to an advantageous embodiment of the present invention;
• 9 a schematic sectional view of a plug element with a connection unit according to a further advantageous embodiment of the present invention;
• 10 a schematic sectional view of a plug element with a connection unit according to a further advantageous embodiment of the present invention.

With reference to the 1 will initially be the principle of the connector assembly 100 be explained in more detail according to a first advantageous embodiment of the present invention.

The connector assembly 100 includes a plug element 102 and a socket element 104 , The plug element 102 has at least one contact pin 106 on that with a socket contact 108 can be put together. It is noted at this point that in the 1 to 6 only one contact pin at a time 106 with the associated socket contact 108 are shown. Of course, the plug element 102 and the socket element 104 also a variety of contact pins 106 or socket contacts 108 exhibit. The specific advantages of the present invention, in particular allowing very small pitches, are particularly significant when each corresponding array of contact pins 106 and socket contacts 108 are provided.

According to a first embodiment of the present invention, the plug element 102 an electrically insulating connector body 110 on. The connector body 110 is for example made of a glass-filled ceramic material, for. As a HTCC material. The contact pin 106 is at a contact surface 112 arranged when plugged together the socket contact 108 is facing. According to the present invention, the contact pin 106 through a columnar projection 114 formed, which is integrally made of the same material as the rest of the connector body 110 , According to the embodiment shown, the projection 114 a circular cylindrical shape. Of course, however, other than circular cross sections, for example polygonal or elliptical cross sections may be provided.

So that the contact pin 106 has the required electrical conductivity, it is on its outer surface with a contact layer 116 Mistake. The contact layer 116 For example, it can be made of gold, platinum or an alloy of these two metals. Of course, however, other electrically conductive materials can be used.

A trace 118 is inside the projection 114 arranged and connects the contact layer 116 with a connection element 120 , In the embodiment shown, the connecting element 120 through a connection patch 122 and a solder layer deposited thereon 124 educated. According to the invention, the connection element 120 on the back surface 126 of the connector body 110 arranged, the contact surface 112 opposite. This allows the connection element 120 be easily connected to a variety of terminal units for connection of an electrode assembly or electronic component, such as a pacemaker.

Furthermore, the plug element 102 an elastic insulating layer 128 on that so at the contact surface 112 of the connector body 110 arranged is that the insulating layer 128 the contact pin 106 surrounds. This elastic insulating layer can be made of silicone rubber, for example, and serves in the mated state of the connector assembly 100 an electrical and mechanical sealing of the contact. The insulating layer 128 For example, as a prefabricated film with corresponding recesses for the contact pins 106 getting produced. For adhesion between the ceramic connector body 110 and the insulating layer 128 can be provided that the contact surface 112 of the connector body 110 is activated by means of a plasma treatment.

To establish the electrical connection, the plug element 102 in the direction of the arrow 130 so with the socket element 104 put together that all pins 106 with the associated socket contacts 108 interact.

The socket element 104 has an electrically insulating socket body 132 on. In the embodiment shown, the socket body is 132 through a ceramic layer 134 and a silicone layer disposed thereon 136 educated. The socket body 132 points according to the contact pins 106 wells 138 on, in each of which a contact pin 106 is pluggable. The wells 138 are formed for example by openings in the silicone layer 136 are continuous and through the ceramic layer 134 be closed, leaving the wells 138 Blind holes are.

At the recess 138 is a socket contact element 140 arranged, which makes the electrical contact to the contact layer 116 of the contact pin 106 manufactures. According to the invention, the socket contact element 140 formed by electrically conductive cantilevered contact lugs, which occur when inserting the contact pin 106 into the depression 138 let it deflect into it. Advantageously, the socket contact element takes 140 its original position again when the connection between the plug element 102 and the socket element 104 is disconnected. However, it is not necessarily required for the functioning of the present invention that the contact lugs are elastic spring arms.

According to the embodiment shown, the female contact element 140 Part of a structured metallization layer, with the exception of the exposed areas of a protective second insulating layer 142 is covered. Preferably, the second insulating layer is also a silicone material. At least one track 144 connects the socket contact element 140 with a contact patch 146 which allows connection to another electrical component or trace (not shown in the figures).

The almost completely mated condition of the connector assembly 100 is in 2 shown. The contact pin 106 is so far in the depression 138 pushed in that the spring arms that the socket contact element 140 form, are deflected downwards and with the contact layer 116 of the contact pin 106 are in electrically conductive plant. Will the plug element 102 even further in the direction 130 on the socket element 104 moved, come the surfaces of the insulating layer 128 and the insulating layer 142 in sealing contact. For a person skilled in the art it is clear that the dimensions of the contact pin 106 and the depression 138 must be chosen so that the contact pin 106 not through the bottom surface of the recess 138 is blocked before the two insulating layers 128 . 142 are in contact with each other.

3 shows a layout of the metallization layer for a female contact 108 out 1 , The socket contact element 140 is by four symmetrically arranged contact lugs 150 with a circle segment-shaped boundary 148 educated. A circular cylindrical contact pin comes with these contact lugs 150 with four flat contacts in plant. However, it will be clear to one skilled in the art that other geometries can be used.

The 4 and 5 show a connector assembly 100 according to a second advantageous embodiment of the present invention. The plug element 102 again has a plug made of ceramic plug body 110 on. A columnar projection 114 forms the contact pin 106 , Unlike the embodiment of the 1 and 2 In this embodiment, the contact layer 116 not to the contact surface 112 of the connector body 110 drawn. The insulating lead 114 runs through a conductor track 118 which the contact layer 116 with the connection element 120 combines. An elastic insulating layer 128 covers the contact surface 112 except for the areas where the contact pins 106 are arranged.

The associated bushing element 104 has a bushing body 132 on, which consists entirely of a ceramic material. The depression 138 is worked out, for example, by means of a laser structuring of the ceramic material. Unlike the embodiment of the 1 and 2 is the socket contact element 140 by a double layer of an electrically conductive metal foil 152 and an electrically insulating film 154 educated.

Furthermore, according to the second embodiment, a via 156 provided that the contact marks 146 to a rear connection element 158 leads. The connection between the metal foil 152 and the contact patch 146 can, for example, via a so-called microflex connection 160 respectively.

In this method, a flexible contact carrier is provided with metallized vias and positioned over the mating contact pads of a mating contact carrier such that the mating contact pads are accessible through the vias. Then, by means of a bonding device, for example, a conventional Thermosonicdrahtbonders (ultrasound with temperature support), each bonded a bonding ball of gold through the vias on the underlying mating contact pad and torn off. The thinner flexible contact carrier is thus riveted as it were on the rigid mating contact carrier and at the same time the electrical connection between the vias and the underlying Gegenkontaktpads made. Alternatively, instead of gold bonding balls, drops of suitable solder can also be introduced through the vias onto the underlying mating contact pad. A detailed description of the microflex connections used for the connection between a flexible contact carrier and an associated rigid mating contact carrier is given, for example, in the publication Stieglitz, T., Beutel, H., Meyer, JU: "Microflex" - A new assembling technique for interconnects , J. Intelligent Material Systems and Structures 11 . 417 - 425 . 2000 , refer to.

An elastic insulating layer 142 covers the microflex connection 160 from. In contrast to the first embodiment, the elastic insulating layer is sufficient 142 also so far about the depression 138 in that in the mated condition of the connector assembly 100 (please refer 5 ) the contact pin 106 like a sealing lip encloses. As material for the elastic insulating layer 142 For example, a silicone film is considered.

According to the second embodiment, the recess 138 no simple cylindrical inner contour, but has a circumferential shoulder 162 on which the socket contact element 140 in the mated condition of the connector 100 supported.

As an alternative to the microflex connection, a solder connection to a conductor wire can also be provided. This embodiment is in the 6 and 7 shown. How out 6 can be seen, the male element 102 a connecting patch 122 on that with a wire 164 via a solder joint 124 connected is. As in 7 The socket element can also be shown 104 have a solder joint that the contact pads 146 with a wire 166 combines.

The 8th to 10 illustrate the plug element according to the invention 102 in combination with various terminal units for connecting an electrode assembly or an electronic component. It shows 8th a first connection unit 168 for connecting a plurality of insulated wires 170 , 9 shows the coupling of the plug element according to the invention 102 via a connection unit 172 to a flexible conductor carrier with an insulating sheath made of silicone (PDMS). Such track carriers are also commonly referred to as Flexible Printed Circuit (FPC) or Flexible Flat Cable (FFC). 10 Finally, shows a plug element 102 with a connection unit 146 suitable for connection with polyimide-insulated electrodes 180 suitable is. In any case, the plug element 102 through the rear side arranged on a flat surface connection elements 120 Contactable in a particularly simple manner.

The following are with reference to the 1 to 7 exemplary methods for making the implantable connector assembly of the invention 100 explained in detail.

For the plug element 102 a green body of alumina and glass is patterned using a laser. First, the outer contours and the channels for the later conductor track 118 passing through the contact pin 106 leads, manufactured. Subsequently, the material is structured so that the projections 114 be formed.

Subsequently, the base body thus formed 110 subjected to a temperature treatment so that it is sintered. Shrinkage rates of 15% to 20% occur depending on the material.

For applying the metallization, so the contact layer 116 and the track 118 , becomes the sintered body 110 in a mask, for example, made of HTCC green film, placed around the protrusions 114 there is sufficient space for the penetration of a conductive paste. In a screen printing process, conductive paste is applied so that it covers the outsides of the contact pins 106 and the channel inside the contact pins 106 fills. For example, a gold conductive paste can be used. Then the paste is dried and the mask removed.

The conductive coating of the connection element 120 is applied in a next step from the back. For these contacts, for example, a platinum / gold conductive paste can be used. This paste is then thermally cured.

Finally, the elastic insulating layer 128 in the form of a silicone film with openings for the passage of the contact pins 106 appropriate. For this purpose, the surface is advantageously 112 of the metallized body 110 activated by a plasma treatment.

The socket element 104 is also prepared using a glass filled green ceramic body. The bush elements of the 1 and 2 such as 7 of which the 4 and 5 ,

As in 1 is shown, only a part of the socket body 132 made of ceramic. The part of the socket body 132 that the depressions 138 is made of silicone. The sintered ceramic layer 134 is subjected to a plasma treatment and with a prefabricated silicone layer 136 together. The silicone layer 136 can also already with the metallization 152 and the elastic insulating layer 142 be connected. The structuring of the metal foil 152 takes place for example by etching or laser structuring.

A somewhat modified embodiment of the female element 104 is in the 4 and 5 shown. Here must the socket body 132 be patterned before sintering using a laser structuring step so that the wells 138 including the shoulders 162 are formed in the solid material. In addition, channels for the vias 156 brought in.

A conductive paste, such as a gold conductive paste, is, as in the manufacture of the male member 102 , for the formation of the via 156 applied and cured.

In an independent step, this becomes a metal foil 152 between two silicone films 154 arranged and laminated. This multilayer construction is electrically connected to the via by means of a microflex connection 156 connected.

Subsequently, the elastic insulating layer 142 , which may also be made of silicone, attached.

In summary, the present invention provides a male member that preferably uses laser-structured HTCC materials as the insulating base material. By using HTCC material with a planar silicone rubber and metal foil to make a female member having an array of female contacts having resilient contact elements, improved electrical contact between the contact pin and the female contact can be achieved. Planar silicone layers are used to provide good insulation and moisture impermeability. The mechanical stability of the connector is ensured by the ceramic material, while the separated soft and mechanically resilient structures of the socket member allow easy insertion of the contact pin, without having to deform the overall structure of the connector.

The mating takes place in a direction along the longitudinal axis of the contact pin, while the forces for mechanical and electrical contact during operation act transversely to the longitudinal axis of the contact pin. As a result, the contact resistance is independent of the insertion force.

An essential advantage of the solution according to the invention is the modular producibility of the electrodes and electronic components, as in the case of a cardiac pacemaker. Therefore, damaged individual components can be replaced. With the connector assembly according to the invention, miniaturized contact arrays can be connected to a stabilizing mechanical support which simultaneously constitutes a connector to an electronic component, a cable, or an additional extension cable. For example, a different electrode array may be combined with a thin film-based flat extension cable, each compatible with the same type of implantable connector.

The use of biocompatible materials increases acceptance and reduces barriers to approval. Finally, the use of laser machining to make the ceramic bodies allows a simple modification of the design without having to purchase additional tools.

LIST OF REFERENCE NUMBERS

numeral description 100 connector assembly 102 male member 104 female member 106 pin 108 female contact 110 Plug body 112 contact area 114 head Start 116 contact layer 118 conductor path 120 connecting element 122 pads 124 solder layer 126 Back surface 128 Elastic insulating layer 130 plug-in direction 132 Book Seng round body 134 ceramic layer 136 silicone layer 138 deepening 140 Female contact element 142 Elastic insulating layer 144 conductor path 146 pads 148 limit 150 contact tag 152 metal foil 154 Electrically insulating film 156 via 158 connecting element 160 Microflex connection 162 shoulder 164 wire 166 wire 168 Connection unit for insulated wires 170 Insulated wires 172 Connection unit for flexible conductor carrier made of silicone 174 Conductor carrier 176 Connection unit for PI-isolated electrodes 180 Conductor carrier

Claims (20)

Plug element (102) having an electrically insulating connector base body (110), at least one contact pin (106) which is arranged on a contact surface (112) of the connector base body (110) so that the contact pin (106) with a socket contact (108) is connectable . and a terminal member (120) electrically connected to the contact pin (106), the at least one contact pin (106) forming a columnar projection (114) formed on the electrically-insulating connector main body (110) inside Projection (114) extending trace (118) connected to the terminal (120) and a contact layer (116) disposed on an outer surface of the projection (114) connected to the trace (118) and connected to the female contact (108 ) is connectable. Plug element (102) after Claim 1 wherein the plug base body (110) is made of a ceramic material. Plug element (102) after Claim 1 or 2 wherein at least one elastic insulating layer (128) is further disposed on the contact surface (112) of the connector base (110) such that the insulating layer (128) surrounds the contact pin (106). Plug element (102) according to one of the preceding claims, wherein the connection element (120) has a contact patch (122) which is arranged on a contact surface (112) opposite rear side (126) of the connector base body (110). A male member (102) according to any one of the preceding claims, wherein the contact layer (116) is made of gold, platinum or an alloy thereof. Socket element (104) for electrically contacting a plug element (102) with an electrically insulating bushing body (132), at least one socket contact element (140) connectable to a contact pin (106) of the plug element (102), wherein the electrically insulating female body (132) has a recess (138), and wherein the female contact member (140) is disposed on the recess such that the female contact member (140) upon mating male member (102) and female member (104) by the contact pin (106) is deflectable into the depression (138), further comprising at least one resilient insulating layer (142) disposed on the female body (132) such that the insulating layer (142) surrounds the depression (138) and the female contact element (140) is exposed. Bushing element (104) after Claim 6 wherein the socket body (132) is at least partially made of a ceramic material or polydimethylsiloxane (PDMS). Bushing element (104) after Claim 6 or 7 wherein the socket contact element (140) is formed by at least one self-supporting, electrically conductive contact lug (150). A method of making a male member (102), the method comprising the steps of: Producing an electrically insulating connector base body (110) with at least one columnar projection (114) formed thereon, wherein the projection (114) is provided with a channel passing therethrough, Applying an electrically conductive coating to form a contact pin (106), the electrically conductive coating at least partially covering the outer surface of the at least one columnar protrusion (114), and at least partially filling the channel with the conductive coating, Attaching a connection element (120) which is electrically conductively connected to the contact pin (106). Method according to Claim 9 in that the connector base body (110) is produced by structuring a ceramic green body and then sintering it. Method according to Claim 10 wherein structuring of the green body is performed by a laser patterning method. Method according to one of Claims 9 to 11 wherein the step of applying an electrically conductive coating (112) comprises disposing the electrically insulating plug body (110) in a mask structure such that the at least one columnar protrusion (114) is received within an associated mask cavity leaving a space between the outer surface of the columnar protrusion (114) and the inner wall of the mask recess, distributing an electrically conductive screen printing paste so that the clearance between the outer surface of the at least one columnar protrusion (114) and the inner wall of the mask recess and the Channel of the at least one columnar projection (114) are filled with the screen printing paste, and curing the electrically conductive screen printing paste, or metallization of the columnar projection (114) by means of a sputtering or vapor deposition process and distributing an electrically conductive screen printing paste, so that the channel of the at least one columnar projection (114) is filled with the screen printing paste, and curing the electrically conductive screen printing paste. Method according to one of Claims 9 to 12 further comprising the step of patterning and attaching an elastic insulating layer (128) to the male body (110) such that the insulating layer (128) surrounds the at least one contact pin (106). Method according to Claim 13 in which the surface of the plug main body (110) to which the insulating layer (128) is attached is activated by a plasma treatment. A method of making a female member (104), the method comprising the steps of: Producing an electrically insulating socket main body (132) having at least one depression (138), Producing an electrically insulating contact foil (154) carrying at least one exposed socket contact element (140), Connecting the socket base body (132) to the contact foil, wherein the socket contact element (140) is arranged on the recess (138) such that the socket contact element (140) is pushed together with the socket element (104) by the contact pin (106) when a plug element (102) is plugged together ) is deflectable into the recess (138) and further wherein at least one elastic insulating layer (142) is disposed on the socket body (132) such that the insulating layer (142) surrounds the recess (138) and exposes the socket contact element (132) is. Method according to Claim 15 and further comprising the step of forming at least one electrically conductive connection extending from the socket contact element (140) through at least a portion of the socket body (132) to a terminal (158). Method according to Claim 16 wherein the step of forming at least one electrically conductive connection comprises the steps of: forming a channel in the socket body (132), distributing an electrically conductive screen printing paste such that the channel is at least partially filled with the screen printing paste, curing the electrically conductive screen printing paste. Method according to one of Claims 15 to 17 in that the contact foil (154) comprises at least two layers of a silicone material, between which a structured metallization layer (152) is arranged, and wherein the at least one socket contact element (140) is produced by laser structuring of the metallization layer (152). Method according to Claim 18 wherein the surface of the socket body (132) to which the contact foil (154) is attached is activated by a plasma treatment. An implantable electrical connector (100) comprising: a plug member (102) according to any one of Claims 1 to 5 , a socket element (104) according to one of Claims 6 to 8th , and a connector unit (168, 172, 176) connected to the male member (102) for connecting an electrode assembly or an electronic component.

Images