Implantable hearing aid with improved sealing

Abstract

An improved implantable hearing aid apparatus and related method of manufacture are disclosed. The inventive apparatus and method utilize electrodeposition techniques to yield enhanced sealing of implanted componentry. In one embodiment an inventive apparatus comprises at least first and second implantable hearing aid component housing members having at least one electrodeposited layer overlapping adjacent portions of the housing members to provide a hermetic seal therebetween. In another embodiment an inventive apparatus comprises an implantable hearing aid component housing member formed via electrodeposition having a plurality of electrodeposited layers, wherein at least two adjacent ones of the layers comprise differing materials (e.g. to yield enhanced functional characteristics). By way of primary example, a hollow bellows of any implantable middle ear actuator may be formed via the sequential electrodeposition of multiple layers on a shaped mandrel which is then selectively removed (e.g., via a removal fluid).

What is claimed is:  
     
         1 . A method for use in the manufacture of an implantable hearing aid apparatus, comprising: 
 positioning first and second implantable hearing aid component housing members in adjacent relation; and,    electrodepositing a first layer of a first material on adjacent portions of said first and second housing members to establish an interconnection and hermetic seal therebetween.    
     
     
         2 . A method as recited in  claim 1 , wherein said first material is a biocompatible metal selected from a group consisting of gold, titanium and platinum.  
     
     
         3 . A method as recited in  claim 1 , wherein said adjacent portions of said first and second housing members are configured to define a substantially flush interface region therebetween.  
     
     
         4 . A method as recited in  claim 3 , wherein said adjacent portions of said first and second housing members are disposed in abutting relation.  
     
     
         5 . A method as recited in  claim 3 , wherein first layer is at least one of substantially continuously arcuate and substantially planar.  
     
     
         6 . A method as recited in  claim 3 , said positioning step further comprising: 
 locating an end of one of said first and second housing members within an end of the other of said first and second housing members.    
     
     
         7 . A method as recited in  claim 3 , said electrodepositing step comprising: 
 covering an outer surface portion of at least one of said first and second implantable hearing aid component housing members.    
     
     
         8 . A method as recited in  claim 7 , wherein said outer surface portion comprises a second material different than said first material.  
     
     
         9 . A method as recited in  claim 1 , further comprising: 
 supporting said first and second housing members on a mandrel during said electrodeposition step; and    removing said mandrel from within said first and second housing member via contact with a removal fluid.    
     
     
         10 . A method as recited in  claim 1 , further comprising: 
 positioning a third implantable hearing aid component housing member in adjacent relation to one of said first and second housing members; and,    electrodepositing a first layer of said first material on adjacent portions of said third housing member and said one of said first and second housing members to establish an interconnection and hermetic seal therebetween.    
     
     
         11 . A method as recited in  claim 10 , wherein said electrodepositing steps of  claim 1  and  claim 10  are carried out simultaneously.  
     
     
         12 . A method as recited in  claim 1 , wherein said first layer is of a thickness between about 5 microns and 50 microns.  
     
     
         13 . A method as recited in  claim 1 , further comprising: 
 electrodepositing a second layer of a second material on said first layer, wherein said first and second materials are different.    
     
     
         14 . A method as recited in  claim 13 , wherein said first layer has at least one of a modulus of elasticity, tensile strength and yield strength that is at least two times greater than that of said second layer.  
     
     
         15 . A method as recited in  claim 13 , wherein said first material is a metal selected from a group consisting of: nickel, iron, chromium, iridium, copper and aluminum; and wherein said second material is a metal selected from a group consisting of: gold, titanium and platinum.  
     
     
         16 . A method as recited in  claim 13 , wherein said second layer substantially covers said first layer.  
     
     
         17 . A method for use in the manufacture of an implantable hearing apparatus, comprising: 
 electrodepositing at least a first layer of a first material on a shaped mandrel to form a first implantable hearing aid component housing member; and,    removing said shaped mandrel from within said implantable hearing aid component member.    
     
     
         18 . A method as recited in  claim 17 , wherein said removing step includes: 
 contacting said shaped mandrel with a removal fluid.    
     
     
         19 . A method as recited in  claim 18 , wherein said contacting step includes one of: 
 leaching said shaped mandrel with a reagent fluid;    dissolving said shaped mandrel with a solvent; and    melting said shaped mandrel with application of heat.    
     
     
         20 . A method as recited in  claim 18 , wherein said first material is substantially, chemically inert in relation to said removal fluid.  
     
     
         21 . A method as recited in  claim 18 , wherein said shaped mandrel comprises a material selected from a group consisting of aluminum, iron or magnesium.  
     
     
         22 . A method as recited in  claim 21 , wherein said fluid comprises a reagent selected from a group consisting of sodium hydroxide, sulfuric acid or nitric acid.  
     
     
         23 . A method as recited in  claim 17 , further comprising: 
 electrodepositing a second layer of a second material on to said first layer, wherein said first material and said second material are different.    
     
     
         24 . A method as recited in  claim 23 , further comprising: 
 electrodepositing a third layer of a third material on to said second layer, wherein said third material and said second material are different.    
     
     
         25 . A method as recited in  claim 24 , wherein said first material and said third material are biocompatible and substantially cover opposing sides of said second layer to provide a hermetic seal thereupon.  
     
     
         26 . A method as recited in  claim 25 , wherein said first material is selected from a group consisting of gold, titanium and platinum, wherein said second material is selected from a group consisting of nickel, iron, chromium, iridium, copper and aluminum, and wherein said third material is selected from a group consisting of gold, titanium and platinum.  
     
     
         27 . A method as recited in  claim 25 , wherein said second layer has at least one of a modulus of elasticity, tensile strength and yield strength that is at least two times greater than that of the first and third layers.  
     
     
         28 . A method as recited in  claim 23 , wherein said first layer has at least one of a modulus of elasticity, tensile strength and yield strength that is at least two times greater than that of the second layer.  
     
     
         29 . A method as recited in  claim 28 , wherein said first material is a metal selected from a group consisting of nickel, iron, chromium, iridium, copper and aluminum, and wherein said second material is a metal selected from a group consisting of gold, titanium and platinum.  
     
     
         30 . A method as recited in  claim 17 , further comprising: 
 hot isostatic pressing of said implantable hearing aid component housing member.    
     
     
         31 . A method as recited in  claim 17 , further comprising: 
 positioning a second implantable hearing aid component housing member in adjacent relation to said housing member; and    electrodepositing a first layer of a first material on adjacent portions of said first and second housing members to establish an interconnection and hermetic seal therebetween.    
     
     
         32 . A method for use in the manufacture of an implantable hearing aid apparatus, comprising: 
 electrodepositing a plurality of layers on a shaped mandrel to form a bellows, said bellows having an undulating configuration between proximal and distal ends thereof, wherein said adjacent ones of said plurality of layers comprise a different material;    interconnecting said proximal end of said bellows to a transducer housing, and said distal end of said bellows to a vibratory member extending away from said transducer housing.    
     
     
         33 . A method as recited in  claim 32 , said interconnecting step comprising: 
 electrodepositing an overlapping layer on adjacent portions of said bellows and at least one of a proximal sleeve and distal sleeve.    
     
     
         34 . A method as recited in  claim 33 , further comprising: 
 flowably removing said shaped mandrel from within said bellows via contact with a removal fluid.    
     
     
         35 . A method as recited in  claim 33 , wherein said overlapping layer and an inner and outer layer of said plurality of layers comprise at least one material selected from a group consisting of platinum, gold and titanium, and wherein an intermediate layer at said plurality of layers comprises at least one material selected from a group consisting of chromium, iridium, nickel, iron, copper and aluminum.