Method of making a pin with multiple in-line contacts

Abstract

A tool-less connector with multiple contacts and a compact design is provided. Therefore, a connector that is normally tunneled through body tissue will now require only a minimally invasive subcutaneous tunnel, which should reduce tissue healing time, patient discomfort, and risk of infection. In addition, providing additional contacts allows enhanced stimulation protocols. One embodiment of the present invention provides a connector pin containing multiple in-line contacts. Each “line” consists of a row of independent contacts arranged in a linear array running along the long axis of the pin. In other embodiments of the invention, the mating receptacle of the connector allows for multiple contacts while minimizing the space required for the increased number of contacts. Additional embodiments provide features that, for instance, prevent the contacts on the connector pin to touch the contacts in the receptacle until all contacts are appropriately aligned.

What is claimed is:  
     
         1 . A method of making a connector pin, comprising: 
 providing a pin-shaped mold;    positioning a plurality of electrical contacts in the pin-shaped mold;    arranging the plurality of electrical contacts in at least two rows;    providing a plurality of conducting wires, each having an end;    electrically connecting the end of at least one conducting wire to each of the electrical contacts; and    introducing insulating material into the mold to form a pin with electrical contacts positioned in at least two rows along the pin.    
     
     
         2 . The method of  claim 1  further comprising providing a printed circuit board for electrically connecting the end of at least one conducting wire to each of the electrical contacts.  
     
     
         3 . The method of  claim 1  wherein electrically connecting the end of at least one conducting wire to each of the electrical contacts comprises providing a printed circuit board for electrically connecting the end of at least one conducting wire to each of the electrical contacts, and wherein positioning the plurality of electrical contacts in the pin-shaped mold comprises positioning at least a printed circuit board in a mold.  
     
     
         4 . The method of  claim 1  wherein the plurality of electrical contacts are temporarily held together in an array with bridging sections between the contacts, and the method further comprises cutting the bridging sections.  
     
     
         5 . The method of  claim 1  wherein the contacts comprise stainless steel, nickel-plated stainless steel, gold-plated beryllium copper, titanium, tantalum, platinum, or platinum/iridium.  
     
     
         6 . The method of  claim 1  wherein the at least two rows are not straight.  
     
     
         7 . The method of  claim 1  further comprising forming at least one groove in the pin.  
     
     
         8 . The method of  claim 1  further comprising forming at least one notch in the pin.  
     
     
         9 . The method of  claim 1  wherein the connector pin is configured to provide electrical connection between any two selected from the group consisting of an implantable pulse generator, a trial stimulator, and external lead cable, a percutaneous lead extension, an implantable lead extension, and a lead containing an electrode array.  
     
     
         10 . The method of  claim 1  wherein the connector pin includes a proximal portion and a distal portion and the method further comprises forming at the proximal portion a means for securely holding the pin.  
     
     
         11 . The method of  claim 1  wherein the connector pin includes a proximal portion and a distal portion and the method further comprises forming a strain relief at the proximal portion.  
     
     
         12 . The method of  claim 1  further comprising providing means for maintaining alignment of the pin during use.  
     
     
         13 . The method of  claim 1  further comprising providing means for assuring proper orientation of the pin during use.  
     
     
         14 . The method of  claim 1  further comprising providing means for activating an electrical connection with the electrical contacts of the pin.