Connector assemblies for implantable medical electrical systems

• US 8,412,330 B2
• Filed: 09/22/2008
• Issued: 04/02/2013
• Est. Priority Date: 10/03/2007
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Kast, John E., Peters, Charles E., Baade, Michael J., Alexander, James A., Ries, Andrew J.
• Primary Examiner(s): Schaetzle, Kennedy
• Application Number:
  US12/680,580
• Publication Number:
  US 20100240253A1
• Time in Patent Office: 1,653 Days
• Field of Search: 607/37, 607/38
• US Class Current: 607/37
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/3752 Details of casing-lead connections
• CPC Class Codes: A61N 1/3754 Feedthroughs
• CPC Class Codes: H01R 13/5224 for medical use
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

Abstract

A device connector assembly includes a plurality of electrical contacts and a sealing member including a corresponding plurality of apertures; each electrical contact extends within a corresponding aperture of the plurality of apertures such that each contact is accessible for coupling with a corresponding connector element of a lead connector. The lead connector elements protrude from a first side of an insulative substrate of the lead connector, and may be coupled to the contacts of the device connector assembly by aligning each connector element with the corresponding aperture of the sealing member, and applying a force to a second side of the insulative substrate, opposite the first side, in order to press each connector element into engagement with the corresponding contact.

Claims

1. A medical electrical system comprising:

a medical electrical lead including a lead body, a plurality of conductors extending within the lead body, and a connector coupled to a proximal end of the lead body, the connector comprising;

an insulative substrate including first side and a second side; and

a plurality of connector elements protruding from the first side of the insulative substrate, each connector element of the plurality of connector elements coupled to a corresponding conductor of the plurality of conductors; and

a medical electrical device including a housing, electronic circuitry enclosed within the housing, and a connector assembly, the connector assembly comprising;

a feedthrough mount joined to the housing and including a cavity;

an insulative base mounted within the cavity of the feedthrough mount;

a sealing member including a first surface, a second surface, opposite the first surface, and a plurality of apertures extending front the first surface to the second surface, the first surface being joined to the insulative base;

a plurality of electrical contacts, each contact of the plurality of electrical contacts being supported by the insulative base and extending within a corresponding aperture of the plurality of apertures of the sealing member to be accessible for coupling with a corresponding connector element of the plurality of connector elements of the lead connector, each contact being recessed within the corresponding aperture with respect to the second surface of the sealing member;

a plurality of feedthrough members, each feedthrough member of the plurality of feedthrough members being coupled to a corresponding contact of the plurality of electrical contacts and extending into the housing, through the insulative base and the feedthrough mount, to couple with the electronic circuitry; and

a lid including a top seal member, the top seal member configured to mate with the second surface of the sealing member and with the second side of the insulative substrate of the lead connector, when the plurality of connector elements are coupled to the plurality of electrical contacts.

2. The system of claim 1, wherein the feedthrough mount of the device connector assembly includes a rigid sidewall surrounding the cavity, and a connector insertion port extending through a portion of the sidewall, from an exterior to an interior of the cavity.

3. The system of claim 2, wherein the lid of the device connector assembly is pivotably attached to the portion of the sidewall of the feedthrough mount through which the connector insertion port extends.

4. The system of claim 2, wherein:

the insulative substrate of the lead connector is deformable; and

a cross-sectional area of the connector insertion port of the device connector assembly is sized such that the insulative substrate must be deformed for insertion therethrough.

5. The system of claim 1, wherein:

the lead connector further includes an aperture extending through the insulative substrate, from the first side to the second side; and

the device connector assembly further includes a feature for mating with the aperture of the lead connector.

6. The system of claim 1, wherein:

the lead connector further includes an aperture extending through the insulative substrate, from the first side to the second side;

the device connector assembly further includes a feature for mating with the aperture of the lead connector;

the lid of the device connector assembly further includes a securing feature; and

the feature of the device connector assembly, for mating with the aperture of the lead connector, is further adapted to mate with the securing feature of the lid, when the top seal member of the connector assembly mates with the sealing member of the connector assembly.

7. The system of claim 1, wherein:

the lead connector further includes an aperture extending through the insulative substrate, from the first side to the second side; and

the device connector assembly further includes a post extending away from the insulative base of the connector assembly for mating with the aperture of the lead connector.

8. The system of claim 7, wherein the post includes threads for mating with a fastener to secure the lid of the connector assembly over the sealing member of the connector assembly.

9. The system of claim 1, wherein the device connector assembly further comprises a post extending away from the insulative base thereof, the post including threads for mating with a fastener to secure the lid of the connector assembly over the sealing member of the connector assembly.

10. The system of claim 1, wherein at least one feedthrough member of the plurality of feedthrough members of the device connector assembly includes a first part coupled to the corresponding contact of the plurality of contacts, a second part extending through the insulative base, and a bend extending between the first part and the second part.

11. The system of claim 1, wherein:

at least one connector element of the plurality of connector elements of the lead includes an approximately cylindrical portion having a longitudinal axis extending in a direction approximately orthogonal to the first side of the insulative substrate; and

at least one electrical contact of the plurality of the electrical contacts corresponding to the at least one connector element includes a first pair of opposing contact surfaces and a second pair of opposing contact surfaces, the first and second pairs of opposing contact surfaces adapted to couple the at least one connector element to the at least one electrical contact, and the first pair of opposing contact surfaces being offset from the second pair of opposing contact surfaces in a direction approximately orthogonal to the longitudinal axis of the at least one connector element when the at least one connector element is coupled to the at least one electrical contact.

12. A medical electrical system comprising:

a first medical electrical lead and a second medical electrical lead, each of the first and second leads including a lead body, a plurality of conductors extending within the lead body, and a connector coupled to a proximal end of the lead body, each of the connectors comprising;

an insulative substrate including first side and a second side;

an aperture extending through the insulative substrate, from the first side to the second side; and

a plurality of connector elements protruding from the first side of the insulative substrate, each connector element of the plurality of connector elements coupled to a corresponding conductor of the plurality of conductors; and

a medical electrical device including a housing, electronic circuitry enclosed within the housing, and a connector assembly, the connector assembly comprising;

a feedthrough mount joined to the housing and including a cavity;

an insulative base mounted within the cavity of the feedthrough mount;

a sealing member including a first surface, a second surface, opposite the first surface, and a plurality of apertures extending from the first surface to the second surface, the first surface being joined to the insulative base;

a plurality of electrical contacts, each contact of the plurality of electrical contacts being supported by the insulative base and extending within a corresponding aperture of the plurality of apertures of the sealing member to be accessible for coupling with a corresponding connector element of the plurality of connector elements of the first and second lead connectors, each contact being recessed within the corresponding aperture with respect to the second surface of the sealing member, and the plurality of electrical contacts being divided into a first group and a second group, the contacts of the first group being arranged for coupling with the connector elements of first lead connector, and the contacts of the second group being arranged for coupling with the connector elements of the second lead connector;

a plurality of feedthrough members, each feedthrough member of the plurality of feedthrough members being coupled to a corresponding contact of the plurality of electrical contacts and extending into the housing, through the insulative base and the feedthrough mount, to couple with the electronic circuitry;

a first feature for mating with the aperture of the first lead connector and second feature for mating with the aperture of the second lead connector, the first and second features being located in between the first and second groups of the plurality of electrical contacts; and

a lid including a top seal member, the top seal member configured to mate with the second surface of the sealing member and with the second side of the insulative substrate of each of the first and second lead connectors, when the plurality of connector elements of each of the first and second lead connectors are coupled to the plurality of electrical contacts.

13. The system of claim 12, wherein:

the lid of the device connector assembly further includes a securing feature; and

the first and second features of the device connector assembly, for mating with the apertures of the first and second lead connectors, are further adapted to mate with the securing feature of the lid, when the top seal member of the connector assembly mates with the sealing member of the connector assembly.

14. The system of claim 12, wherein each of the first and second features of the device connector assembly, for mating with the apertures of the first and second lead connectors, comprises a post extending away from the insulative base of the connector assembly.

15. The system of claim 14, wherein each post includes threads for mating with a fastener to secure the lid of the connector assembly over the sealing member of the connector assembly.

16. The system of claim 12, wherein:

each of the first and second lead connectors further includes a proximal end; and

the aperture of each of the first and second lead connectors is located in proximity to the proximal end.

17. A method for coupling a medical electrical lead connector to a medical electrical device connector assembly, the method comprising:

orienting a first side of an insulative substrate of the lead connector such that a plurality of connector elements, which protrude from the first side of the substrate, face a corresponding plurality of apertures of a sealing member of the device connector assembly;

aligning each connector element of the plurality of connector elements with a corresponding aperture of the plurality of apertures, after orienting the first side of lead connector;

inserting the lead connector through an insertion port of the device connector assembly prior to aligning the plurality of connector elements;

applying a force from a second side of the insulative substrate to press each aligned connector element of the plurality of connector elements into the corresponding aperture and into engagement with an electrical contact coupling receptacle that extends within the corresponding aperture; and

securing a top seal member over the lead connector, after applying the force to press each connector element into engagement, such that the top seal member engages the second side of the insulative substrate of the lead connector and the sealing member of the device connector assembly.

18. The method of claim 17, further comprising deforming the insulative substrate of the lead connector prior to inserting the lead connector.

19. The method of claim 17, wherein inserting the lead connector comprises pulling a proximal end of the insulative substrate of the lead connector through the insertion port.

20. The method of claim 17, wherein aligning the plurality of connector elements comprises coupling an alignment feature formed in the insulative substrate of the lead connector with a mating feature of the device connector assembly.

21. The method of claim 20, wherein coupling the alignment feature of the lead connector comprises inserting a post of the device connector assembly through an aperture formed through the insulative substrate of the lead connector.

22. A method for coupling a medical electrical lead connector to a medical electrical device connector assembly, the method comprising:

orienting a first side of an insulative substrate of the lead connector such that a plurality of connector elements, which protrude from the first side of the substrate, face a corresponding plurality of apertures of a sealing member of the device connector assembly;

aligning each connector element of the plurality of connector elements with a corresponding aperture of the plurality of apertures, after orienting the first side of lead connector;

applying a force from a second side of the insulative substrate to press each aligned connector element of the plurality of connector elements into the corresponding aperture and into engagement with an electrical contact coupling receptacle that extends within the corresponding aperture; and

securing a top seal member over the lead connector, after applying the force to press each connector element into engagement, such that the top seal member engages the second side of the insulative substrate of the lead connector and the sealing member of the device connector assembly;

wherein aligning the plurality of connector elements comprises coupling an alignment feature formed in the insulative substrate of the lead connector with a mating feature of the device connector assembly; and

coupling the alignment feature of the lead connector comprises inserting a post of the device connector assembly through an aperture formed through the insulative substrate of the lead connector.

23. The method of claim 22, further comprising:

inserting the lead connector through an insertion port of the device connector assembly prior to aligning the plurality of connector elements; and

deforming the insulative substrate of the lead connector prior to inserting the lead connector.

24. The method of claim 22, further comprising inserting the lead connector through an insertion port of the device connector assembly prior to aligning the plurality of connector elements;

wherein inserting the lead connector comprises pulling a proximal end of the insulative substrate of the lead connector through the insertion port.

25. A method for coupling a medical electrical lead connector to a medical electrical device connector assembly, the method comprising:

orienting a first side of an insulative substrate of the lead connector such that a plurality of connector elements, which protrude from the first side of the substrate, face a corresponding plurality of apertures of a sealing member of the device connector assembly;

aligning each connector element of the plurality of connector elements with a corresponding aperture of the plurality of apertures, after orienting the first side of lead connector;

applying a force from a second side of the insulative substrate to press each aligned connector element of the plurality of connector elements into the corresponding aperture and into engagement with an electrical contact coupling receptacle that extends within the corresponding aperture; and

securing a top seal member over the lead connector, after applying the force to press each connector element into engagement, such that the top seal member engages the second side of the insulative substrate of the lead connector and the sealing member of the device connector assembly;

wherein securing a top seal member over the lead connector comprises closing a lid over the lead connector, the top seal member being attached to the lid.

26. The method of claim 25, wherein:

aligning the plurality of connector elements comprises coupling an alignment feature formed in the insulative substrate of the lead connector to a mating feature of the device connector assembly; and

further comprising securing the lid to the mating feature.

27. The method of claim 25, further comprising:

inserting the lead connector through an insertion port of the device connector assembly prior to aligning the plurality of connector elements;

wherein the lid is attached to the device connector assembly in proximity to the insertion port.

28. The method of claim 25, further comprising inserting the lead connector through an insertion port of the device connector assembly prior to aligning the plurality of connector elements.

29. The method of claim 28, further comprising deforming the insulative substrate of the lead connector prior to inserting the lead connector.

30. The method of claim 28, wherein inserting the lead connector comprises pulling a proximal end of the insulative substrate of the lead connector through the insertion port.

31. The method of claim 25, wherein aligning the plurality of connector elements comprises coupling an alignment feature formed in the insulative substrate of the lead connector with a mating feature of the device connector assembly.

32. The method of claim 31, wherein coupling the alignment feature of the lead connector comprises inserting a post of the device connector assembly through an aperture formed through the insulative substrate of the lead connector.