Granted Patent B2

US 12,377,271 · App. 17/149,454 · Granted Aug 5, 2025

Inventors: Jon Parker (San Jose, CA); Yougandh Chitre (Santa Clara, CA); Andre B. Walker (Monte Sereno, CA)

Assignee: Nevro Corp.

A61N1/36071A61N1/37229A61N1/375A61N1/3787H01Q7/00H02J7/0042H02J50/05H02J50/10H02J50/402H02J50/70H01F38/14Y10T29/49204

Abstract

Claims (50)

1. A medical device for delivering electrical therapy signals to a patient's spinal region to alleviate pain, comprising:

a controller; and

a header including a molded material and containing multiple header components encased within the molded material, the encased header components including:

a communication antenna positioned to receive external control signals;

a support element including a backing and a first receiving surface extending away from the backing to define a corresponding perimeter of the support element;

a charging coil disposed around the perimeter defined by the first receiving surface; and

at least one output terminal operably coupled to the controller to provide electrical power to a signal delivery device.

2. The medical device of claim 1 wherein the communication antenna is disposed on the support element.

3. The medical device of claim 2 , wherein the perimeter is a first perimeter, wherein the support element includes a second receiving surface that defines a corresponding second perimeter of the support element, and wherein the communication antenna is positioned around the second receiving surface.

4. The medical device of claim 1 , wherein the molded material comprises a polymer.

5. The medical device of claim 1 , further comprising a can including a lid and wherein the support element is coupled to the lid.

6. The medical device of claim 5 , wherein the charging coil is arranged such that the can does not impede any electromagnetic energy transmitted by an external power source configured and arranged to induce a current in the charging coil by way of electromagnetic induction.

7. The medical device of claim 1 , wherein the charging coil includes a plurality of wire loops, and wherein a first wire loop is offset from a second wire loop along both a first axis and a second axis orthogonal to the first axis.

8. The medical device of claim 1 , wherein the charging coil includes a plurality of wire loops, and wherein a first wire loop is positioned in a first plane and a second wire loop is positioned in a second plane, the first plane disposed at a non-zero angle relative to the second plane.

9. A medical device for delivering electrical therapy signals to a patient's spinal region to alleviate pain, the medical device comprising:

a controller; and

a header including a molded material and containing multiple header components encased within the molded material, the encased header components including:

a support element including a backing and a first receiving surface extending away from the backing to define a corresponding perimeter of the support element;

a charging coil disposed around the perimeter defined by the first receiving surface;

at least one output terminal operably coupled to the controller to provide electrical power to a signal delivery device; and

a communication antenna disposed on the support element,

wherein the molded material includes a curved shape, and wherein the charging coil and the communication antenna are shaped to at least partially match the curved shape.

10. A signal generator, comprising:

a battery; and

a header including a molded material and containing multiple header components encased within the molded material, the encased header components including:

a communication antenna positioned to receive external control signals;

a charging coil electrically coupled to the battery via at least one individual wire, wherein the charging coil is positioned to receive electromagnetic energy and direct electrical current to charge the battery; and

a support element including a backing and a receiving surface extending away from the backing to define a corresponding perimeter of the support element, wherein at least the charging coil is positioned around the receiving surface and the support element is supported in position at least in part by the at least one individual wire.

11. The signal generator of claim 10 , wherein the charging coil includes a plurality of wire loops.

12. The signal generator of claim 11 , wherein a first wire loop is positioned in a first plane and a second wire loop is positioned in a second plane, and wherein the second plane is different from the first plane.

13. The signal generator of claim 11 , wherein a first wire loop is positioned in a first plane and a second wire loop is positioned in a second plane, the first plane disposed at a non-zero angle with respect to the second plane.

14. The signal generator of claim 10 , wherein the molded material includes a curved surface, and wherein the charging coil is shaped to at least partially match the curved surface.

15. The signal generator of claim 10 , further comprising a can including a lid and the lid includes a plurality of feed-throughs, and wherein the implantable signal generator further comprises:

a controller positioned within the can and configured to direct electrical signals to at least one output terminal; and

a plurality of wires positioned to extend through the feed-throughs and operably couple the controller to the communication antenna and the battery to the charging coil.

16. A method for forming a signal generator, the method comprising:

forming a support element, wherein the support element includes a backing and a receiving surface extending away from the backing to define a corresponding perimeter of the support element;

forming a communication antenna;

forming a charging coil having at least one individual wire extending therefrom;

positioning the charging coil around the perimeter;

supporting the support element in position relative to a molding cavity using at least the at least one individual wire of the charging coil;

positioning the communication antenna in the molding cavity; and

disposing a quantity of liquid material into the molding cavity to thereby encase the support element, the charging coil, and the communication antenna within the liquid material and form a header.

17. The method of claim 16 , further comprising:

providing a battery and a controller;

electrically coupling the charging coil to the battery; and

electrically coupling the communication antenna to the controller.

18. The method of claim 16 , further comprising positioning the communication antenna on the support element.

19. The method of claim 16 , wherein the liquid material comprises a polymer.

20. The method of claim 16 , wherein the support element, the charging coil, and the communication antenna are encased and molded into a shape substantially simultaneously, wherein the shape includes a rounded rectangular portion.

Assignments (3)

Continuity (5)

References Cited (326)