Neurodiagnostic needle electrode pair assembly and method of manufacture

1 . A neurodiagnostic needle electrode pair assembly comprising:

a pair of needle electrodes connected to a pair of leadwires by respective electrical connections between proximal ends of the needle electrodes and distal ends of the leadwires;

a needle spacer including parallel holes in a spaced apart relationship, the needle electrodes extending into and through the parallel holes that define a spacing between the needle electrodes;

a recovered heat shrink tube covering the needle spacer, the respective electrical connections and the distal ends of the leadwires and

a leadwire spacer adjacent to and abutting the needle spacer, and that includes second parallel holes in a spaced apart relationship, the respective electrical connections and the distal ends of the leadwires extending into the second holes that define a spacing between the leadwires, and

wherein the recovered heat shrink tube covers the needle spacer, and the leadwire spacer including the second parallel holes into which the respective electrical connections and the distal ends of the leadwires extend.

2 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the needle spacer is an extrusion having a fixed cross-sectional profile.

3 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the respective electrical connections include mechanical crimps, and the mechanical crimps and the second parallel holes of the leadwire spacer have matching, non-circular cross sections.

4 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the leadwire spacer includes a pair of adjacent, recovered heat shrink tubes that include respective ones of the second parallel holes.

5 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the leadwire spacer is an extrusion having a fixed cross-sectional profile.

6 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the needle spacer and the leadwire spacer are extrusions having a common, fixed cross-sectional profile.

7 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the recovered heat shrink tube includes an inner adhesive lining that adheres the recovered heat shrink tube to the needle spacer and the leadwire spacer.

8 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the parallel holes of the needle spacer have a non-circular cross section.

9 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the needle electrodes are bent near the proximal ends to form bent needle ends near the respective electrical connections, and

wherein the needle spacer further includes slots into which the bent needle ends extend.

10 . The neurodiagnostic needle electrode pair assembly of claim 1 , wherein the recovered heat shrink tube includes an inner adhesive lining that adheres the recovered heat shrink tube to the needle spacer, the respective electrical connections and the distal ends of the leadwires.

11 . A method of manufacturing a neurodiagnostic needle electrode pair assembly, the method comprising:

connecting a pair of needle electrodes to a pair of leadwires by forming respective electrical connections between proximal ends of the needle electrodes and distal ends of the leadwires;

extending the needle electrodes into and through parallel holes of a needle spacer, the parallel holes defining a spacing between the needle electrodes;

positioning a heat shrink tube over the needle spacer, the respective electrical connections and the distal ends of the leadwires;

applying heat to recover the heat shrink tube covering the needle spacer, the respective electrical connections, and the distal ends of the leadwires and

wherein before the pair of needle electrodes are extended into and through the parallel holes of the needle spacer, the method further comprises: extending the needle electrodes into and through second parallel holes of a leadwire spacer, and the respective electrical connections and the distal ends of the leadwires into the second holes that define a spacing between the leadwires.

12 . The method of claim 11 , wherein the needle spacer is an extrusion having a fixed cross-sectional profile.

13 . The method of claim 11 , wherein the pair of needle electrodes are extended into and through the parallel holes of the needle spacer to position the needle spacer adjacent to and abutting the leadwire spacer, and

wherein the heat shrink tube is positioned over the needle spacer and the leadwire spacer, and the heat is applied to recover the heat shrink tube covering the needle spacer, and the leadwire spacer including the second parallel holes into which the respective electrical connections and the distal ends of the leadwires extend.

14 . The method of claim 11 , wherein the respective electrical connections include mechanical crimps, and the mechanical crimps and the second parallel holes of the leadwire spacer have matching, non-circular cross sections.

15 . The method of claim 11 , wherein the leadwire spacer includes a pair of adjacent, recovered heat shrink tubes that include respective ones of the second parallel holes.

16 . The method of claim 11 , wherein the needle spacer and the leadwire spacer are extrusions having a common, fixed cross-sectional profile.

17 . The method of claim 11 , wherein the needle electrodes are bent near the proximal ends to form bent needle ends near the respective electrical connections, and the needle spacer further includes slots, and

wherein extending the needle electrodes into and through parallel holes of the needle spacer includes extending the bent needle ends into the slots of the needle spacer.

18 . The method of claim 17 , wherein the heat shrink tube is positioned over the needle spacer and the leadwire spacer, and includes an inner adhesive lining that adheres the recovered heat shrink tube to the needle spacer and the leadwire spacer.