Connector and methods of fabrication

• US 7,244,150 B1
• Filed: 01/09/2006
• Issued: 07/17/2007
• Est. Priority Date: 01/09/2006
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Advanced Bionics Corporation (Sonova Holding AG)
• Inventors: Tong, Robert Randall, Brase, Randall Lee
• Primary Examiner(s): Paumen; Gary F.
• Application Number:
  US11/327,880
• Publication Number:
  US 20070161294A1
• Time in Patent Office: 554 Days
• Field of Search: 439/668, 439/669, 439/909, 439 23- 26, 439/28, 607/37, 607/46
• US Class Current: 439/668
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/36017 with leads or electrodes penetrating the skin
• CPC Class Codes: A61N 1/3752 Details of casing-lead connections
• CPC Class Codes: Y10S 439/909 Medical use or attached to human body

Abstract

A connector includes a unitary body defining a hollow center region configured and arranged to receive a proximal contact portion of a lead. The unitary body may define connector pockets and seal features within the hollow center region. The connector pockets can be spaced-apart and may define openings through the unitary body. The seal features may be disposed between the connector pockets.

Claims

1. A connector comprising:

a unitary body defining a hollow center region configured and arranged to receive a proximal contact portion of a lead, the unitary body further defining within the hollow center region a plurality of spaced-apart connector pockets, wherein each connector pocket defines an opening through the unitary body, and the unitary body further defining within the hollow center region a plurality of seal features disposed between the connector pockets, the connector pockets adapted to receive a plurality of conductive contacts entirely therein except for a part, if any, of the contacts which protrude through the openings.

2. The connector of claim 1, wherein the openings through the unitary body are disposed on one side of the unitary body.

3. The connector of claim 1, wherein the connector pockets are spaced-apart at substantially uniform intervals.

4. The connector of claim 1, wherein the unitary body further defines a stop pocket at an end of the hollow center region.

5. The connector of claim 1, further comprising a connector block coupled to the unitary body.

6. The connector of claim 1, further comprising the plurality of conductive contacts disposed in the openings through the unitary body.

7. The connector of claim 6, further comprising a plurality of conductors coupled to the conductive contacts.

8. The connector of claim 1, wherein the unitary body comprises polysilicone.

9. The connector of claim 1, wherein at least four conductive contacts are disposed in the openings through the unitary body.

10. A stimulation device comprising:

a lead with a proximal contact portion comprising a plurality of contacts;

an electronic subassembly;

a connector that receives the proximal contact portion of the lead, wherein the connector comprises a unitary body that defines a hollow center region configured and arranged to receive the proximal contact portion of the lead, wherein the unitary body further defines within the hollow center region a plurality of spaced-apart connector pockets, wherein each connector pocket defines an opening through the connector, and the unitary body further defining within the hollow center region a plurality of seal features disposed between the connector pockets and entirely in the connector pockets except for a part, if any, of the contacts which protrude through the openings; and

a plurality of conductive contacts disposed in the openings of the connector and configured and arranged to couple the contacts of the lead to the electronic subassembly.

11. The stimulation device of claim 10, wherein the unitary body further defines a stop pocket at an end of the hollow region.

12. The stimulation device of claim 10, wherein the connector pockets are spaced-apart at substantially uniform intervals.

13. The stimulation device of claim 10, further comprising a connector block coupled to the unitary body.

14. The stimulation device of claim 10, further comprising a plurality of conductors that couple the electronic subassembly to the conductive contacts.

15. A method of making a stimulation device that provides electrical pulses to a tissue comprising:

forming a connector comprising a unitary body defining a hollow center region configured and arranged to receive a proximal contact portion of a lead, wherein the unitary body further defines within the hollow center region a plurality of spaced-apart connector pockets, wherein each connector pocket defines an opening through the unitary body, and the unitary body further defining within the hollow center region a plurality of seal features disposed between the connector pockets;

disposing a plurality of conductive contacts in the openings through the unitary body and entirely in the connector pockets except for a part, if any, of the contacts which protrude through the openings; and

coupling contacts on a lead to an electronic subassembly through the connector and conductive contacts.

16. The method of claim 15, wherein the connector is formed by molding, and wherein forming a connector comprises:

disposing mold insert pieces in a mold frame;

forming a unitary body around the mold insert pieces; and

removing the mold insert pieces from the unitary body formed around the mold insert pieces.

17. The method of claim 16, wherein disposing told insert pieces in a mold frame comprises disposing mold insert pieces in a mold frame using a locating feature.

18. The method of claim 15, wherein disposing a plurality of the conductive contacts in the openings through the unitary body comprises swelling the material used to form the unitary body.

19. The method of claim 15, further comprising coupling a connector block to the unitary body.

20. The method of claim 15, wherein coupling a lead to an electronic subassembly comprises coupling the lead to the electronic subassembly via a plurality of conductors.