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Pre-molded header with universal tip-to-tip feedthru adaptor

  • US 7,489,968 B1
  • Filed: 04/07/2006
  • Issued: 02/10/2009
  • Est. Priority Date: 04/07/2006
  • Status: Active Grant
First Claim
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1. A method of making a pre-molded header assembly for an implantable medical device which includes a casing containing electronic circuitry and having a mounting surface and at least one feedthru wire connected to the electronic circuitry and projecting out of the mounting surface, the method comprising the steps of:

  • (a) providing an electrically conductive connector block having a bore with a longitudinal axis for engageably receiving a proximal end portion of a lead carrying at least one electrical connector;

    (b) attaching one end of a bore contact wire to the connector block;

    (c) keying a length of the bore contact wire distant from the one end with a guiding channel formed on an upper region of a feedthru adapter and through a transverse channel extending through the feedthru adapter from the upper region to an undersurface thereof;

    (d) continuing to key the bore contact wire by bending an end portion thereof extending to a tip end into conformance with an orientation channel formed on the undersurface of the feedthru adapter and having a predetermined azimuthal direction;

    (e) molding a header encapsulating the feedthru adapter, the connector block, and the bore contact wire which, when solidified, has an undersurface for mounting engagement on the mounting surface of the casing and an elongated receptacle with a longitudinal axis aligned with the longitudinal axis of the bore of the connector block, the receptacle positioned to receive the proximal end portion of the lead as it engages the connector block;

    (f) attaching the molded header to the casing so the undersurface thereof is in engagement with the mounting surface of the casing;

    (g) immediately prior to step (f), bending an end portion of the feedthru wire extending to a tip end in a direction generally aligned with the predetermined azimuthal direction of an associated orientation channel formed on the underside of the feedthru adapter so that the tip end of the feedthru wire and the tip end of the bore contact wire terminate facing in the same direction and lie in the same plane;

    (h) welding together the end portions of the feedthru wire and the bore contact wire; and

    (i) backfilling with sealant material the interface between the header and the casing.

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