Hermetic feedthrough assembly for ceramic body

1. A feedthrough assembly formed from a method comprising:

providing a green ceramic body;

forming a through-hole in the green ceramic body having a first diameter;

inserting a corrosion-resistant solid wire through the hole, the wire comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium, and the wire having a second diameter;

firing the green ceramic body to sinter it thereby forming a sintered ceramic body; and

the first and second diameters being selected such that cracking of the sintered ceramic body adjacent the wire as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and the wire,

wherein the green ceramic body has a thickness of at least 0.050 inches thick.

2. The feedthrough assembly of claim 1 , further comprising an electrode connected to a first end of the wire.

3. The feedthrough assembly of claim 2 , wherein the electrode is substantially coplanar with a surface of the sintered ceramic body.

4. The feedthrough assembly of claim 1 , wherein the hermetic seal is a diffusion bond between the metal wire and the sintered ceramic body.

5. The feedthrough assembly of claim 1 , wherein the wire has a diameter of less than about 0.020 inches.

6. The feedthrough assembly of claim 1 , wherein the ceramic body comprises primarily compounds selected from the group consisting of oxides, carbides, borides, nitrides, and silicides of aluminum, zirconium, beryllium, silicon, titanium, hafnium, magnesium, zinc and yttrium.

7. The feedthrough assembly of claim 1 , wherein the green ceramic body has a thickness of less than about 0.10 inches.

8. The feedthrough assembly of claim 1 , wherein the wire has a diameter of less than about 0.020 inches and the green ceramic body has a thickness of less than about 0.10 inches.

9. The feedthrough assembly of claim 1 , wherein the metal wire has a substantially round cross-section or a substantially conical shape.

10. The feedthrough assembly of claim 1 , wherein the segment of wire contacting the ceramic body has a substantially spherical shape.

11. The feedthrough assembly of claim 1 , further comprising a contact pad connected to a second end of the wire.

12. A feedthrough assembly formed from a method comprising:

providing a green ceramic body that surrounds a corrosion-resistant solid wire extending through the green ceramic body, the wire comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium; and

firing the green ceramic body to sinter it, thereby forming a sintered ceramic body;

whereby cracking of the sintered ceramic body adjacent the wire as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and the wire, and

wherein the green ceramic body has a thickness of at least 0.050 inches thick.

13. The feedthrough assembly of claim 12 , further comprising an electrode connected to a first end of the wire.

14. The feedthrough assembly of claim 13 , wherein the electrode is substantially coplanar with a surface of the sintered ceramic body.

15. The feedthrough assembly of claim 12 , wherein the hermetic seal is a diffusion bond between the metal wire and the sintered ceramic body.

16. The feedthrough assembly of claim 12 , wherein the wire has a diameter of less than about 0.020 inches.

17. The feedthrough assembly of claim 12 , wherein the ceramic body comprises primarily compounds selected from the group consisting of oxides, carbides, borides, nitrides and silicides of aluminum, zirconium, beryllium, silicon, titanium, hafnium, magnesium, zinc and yttrium.

18. The feedthrough assembly of claim 12 , wherein the green ceramic body has a thickness of less than about 0.10 inches.

19. The feedthrough assembly of claim 12 , wherein the wire has a diameter of less than about 0.020 inches and the green ceramic body has a thickness of less than about 0.10 inches.

20. The feedthrough assembly of claim 12 , wherein the wire has a substantially round cross-section or a substantially conical shape.

21. The feedthrough assembly of claim 12 , wherein the segment of wire contacting the ceramic body has a substantially spherical shape.

22. The feedthrough assembly of claim 12 , further comprising a contact pad connected to a second end of the wire.

23. A multi-conductor feedthrough assembly formed from a method comprising:

providing a green ceramic body;

forming at least two through-holes in the green ceramic body, each through-hole having a first or second diameter;

inserting a corrosion-resistant solid wire through each through-hole, each wire comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium, and each wire having a third or fourth diameter;

firing the green ceramic body to sinter it, thereby forming a sintered ceramic body; and

the first, second, third and fourth diameters being selected such that cracking of the sintered ceramic body adjacent each wire as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and each wire,

wherein the green ceramic body has a thickness of at least 0.050 inches thick.

24. A multi-conductor feedthrough assembly formed from a method comprising:

providing a green ceramic body that surrounds a plurality of corrosion-resistant solid wires extending through the green ceramic body, the wires each comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium; and

firing the green ceramic body to sinter it, thereby forming a sintered ceramic body;

whereby cracking of the sintered ceramic body adjacent each of the plurality of wires as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and each of the plurality of wires, and

wherein the green ceramic body has a thickness of at least 0.050 inches thick.

25. An implantable glucose-level sensing device, comprising a feedthrough assembly formed from a method comprising:

providing a green ceramic body;

forming a through-hole in the green ceramic body having a first diameter;

inserting a corrosion-resistant solid wire through the hole, the wire comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium, and the wire having a second diameter;

firing the green ceramic body to sinter it, thereby forming a sintered ceramic body; and

the first and second diameters being selected such that cracking of the sintered ceramic body adjacent the wire as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and the wire,

wherein the green ceramic body has a thickness of at least 0.050 inches thick.

26. An implantable glucose-level sensing device, comprising a feedthrough assembly formed from a method comprising:

providing a green ceramic body that surrounds at least a portion of a corrosion-resistant solid wire extending through the green ceramic body, the wire comprising a material selected from the group consisting of platinum, palladium, rhodium, iridium, osmium and alloys of platinum, palladium, rhodium, iridium, and osmium; and

firing the green ceramic body to sinter it, thereby providing a sintered ceramic body;

whereby cracking of the sintered ceramic body adjacent the wire as a result of dimensional changes of the green ceramic body during firing is avoided and a substantially hermetic seal is formed between the sintered ceramic body and the wire,

wherein the green ceramic body has a thickness of at least 0.050 inches thick.