Molded headers for implantable signal generators, and associated systems and methods
Molded headers, implantable signal generators having molded headers, and associated systems and methods are disclosed herein. An implantable signal generator in accordance with a particular embodiment includes a can having a shell and a battery positioned at least partially within the shell. An output terminal can be operably coupled to the battery and positioned to provide electrical power to a signal delivery device. A pre-molded header having a plurality of openings can be coupled to the can, and the output terminal can be positioned at least partially within an individual opening.
1. An implantable signal generator, comprising:
a can having a shell and a battery positioned at least partially within the shell;
a pre-molded header coupled to the can and having a first opening, a second opening, and a third opening;
an output terminal operably coupled to the battery and positioned to provide electrical power to a signal delivery device, wherein the output terminal is positioned at least partially within the first opening;
a charging coil positioned at least partially within the second opening and operably coupled to the battery; and
a communication antenna positioned at least partially within the third opening to receive control signals.
2. The implantable signal generator of claim 1 wherein the pre-molded header comprises a polymer.
3. The implantable signal generator of claim 1 , further comprising a first cover positioned over the second opening, and a second cover positional over the third opening, wherein the first cover and the second cover at least partially seal the pre-molded header.
4. The implantable signal generator of claim 1 wherein the pre-molded header comprises a first header portion and a second header portion, and wherein the first and second header portions are coupleable to form the pre-molded header.
5. The implantable signal generator of claim 1 , wherein the pre-molded header includes a curved surface, and wherein the charging coil is shaped to at least partially match the curved surface.
6. The implantable signal generator of claim 1 , further comprising a set screw block positioned at least partially within the header, the set screw block including a receiving passage having a funnel shaped sidewall.
7. The implantable signal generator of claim 6 wherein the pre-molded header includes an access seal positioned to provide access to the set screw block.
8. The implantable signal generator of claim 1 wherein the pre-molded header includes a curved shape, wherein the charging coil and the communication antenna are shaped to at least partially match the curved shape of the pre-molded header, wherein the implantable signal generator further comprises a plurality of covers, and wherein individual covers are affixed to the pre-molded header to seal the first opening, the second opening, and the third opening.
9. An implantable signal generator, comprising:
a shell;
a pre-molded header including a body having a rounded upper surface and a base shaped to align with the shell, wherein the body includes an opening; and
a charging coil positioned at least partially in the opening.
10. The pre-molded header of claim 9 wherein the body comprises a polymer.
11. The pre-molded header of claim 9 , further comprising a cover affixed to the body, the cover positioned over the opening.
12. The pre-molded header of claim 9 wherein the charging coil is shaped to match the rounded upper surface.
13. The pre-molded header of claim 9 wherein the opening is a first opening, the pre-molded header further having a second opening shaped to receive a communication antenna.
14. A method for forming an implantable signal generator, the method comprising:
inserting a charging coil at least partially within a pre-formed opening in a pre-molded header; and
attaching the pre-molded header to a can having a shell and a lid.
15. The method of claim 14 wherein inserting a charging coil at least partially within the pre-formed opening includes inserting the charging coil prior to attaching the pre-molded header to the can, the method further comprising positioning a battery within the can, and wherein attaching the pre-molded header to the can includes aligning the header with the can and establishing an electrical connection between the charging coil and the battery.
16. The method of claim 14 , further comprising attaching a cover to the pre-molded header to seal the pre-formed opening.
17. The method of claim 14 wherein the pre-formed opening is a first pre-formed opening, the method further comprising inserting a communication antenna at least partially within a second pre-formed opening of the pre-molded header, prior to attaching the pre-molded header to the can.
18. The method of claim 14 wherein the charging coil is shaped to at least partially match a rounded upper surface of the pre-molded header.
19. A method for forming an implantable signal generator, the method comprising:
inserting an electronic component at least partially within a pre-formed opening in a pre-molded header;
attaching the pre-molded header to a can having a shell and a lid; and
positioning a set screw block at least partially within the pre-molded header to receive an electrical connector, wherein the set screw block includes a receiving passage for the electrical connector, and wherein the receiving passage includes a tapered sidewall.
20. A method for forming a pre-molded header for an implantable signal generator having a can, the method comprising:
forming a body having a plurality of opening positioned to receive electronic components and a base shaped to at least partially match a shape of the can, wherein forming the body includes forming an external shape of the body using a molding process and forming the plurality of openings after the molding process.
21. The method of claim 20 wherein forming the pre-molded header further includes forming the body to include a rounded upper surface.
22. The method of claim 21 wherein forming a body having a plurality of openings includes forming the body to include an opening shaped to receive a charging coil having a shape that at least partially matches the rounded upper surface.
23. The method of claim 20 , further comprising providing a cover shaped to affix to the body and seal an individual opening.
24. An implantable signal generator, comprising:
a can;
a battery positioned within the can;
a pre-molded header attached to the can and having a plurality of openings, wherein the pre-molded header includes a rounded upper surface;
a receiving element having a plurality of output terminals, wherein the receiving element is positioned at least partially within a first individual opening, wherein the plurality of output terminals are electrically coupled to the battery and positioned to be electrically coupled to a signal delivery device;
a charging coil positioned within a second individual opening and having a shape that at least partially matches the rounded upper surface of the pre-molded header, wherein the charging coil is electrically coupled to the battery;
an antenna positioned within a third individual opening and having a shape that at least partially matches the rounded upper surface of the pre-molded header;
a set screw block positioned at least partially within the header, the set screw block including a receiving passage having a funnel shaped sidewall;
a first cover attached to the pre-molded header and sealing the charging coil in the second individual opening; and
a second cover attached to the pre-molded header and sealing the antenna in the third individual opening.