Feed through interconnect assembly for an implantable stimulation system and methods of making and using

Abstract

A stimulation system includes an implantable pulse generator having a sealed chamber and an electronic subassembly disposed in the sealed chamber. Feed through pins are coupled to the electronic subassembly and extend out of the sealed chamber. Feed through interconnects are coupled to the electronic subassembly via the feed through pins. At least one tab is disposed on at least one feed through interconnect. The tab(s) are configured and arranged to flex away from the feed through interconnect and against a side of the feed through pin. A feed through interconnect assembly includes an assembly frame; feed through interconnects extending from the assembly frame; a first contact pad and a second contact pad disposed on at least one of the feed through interconnects; and a tab formed on a first contact pad of at least one of the feed through interconnects.

What is claimed as new and desired to be protected by Letters Patent of the United States is: 
     
         1 . An implantable pulse generator, comprising:
 a sealed chamber;   an electronic subassembly disposed in the sealed chamber;   a plurality of feed through pins electrically coupled to the electronic subassembly and extending out of the sealed chamber;   a plurality of feed through interconnects, each of the plurality of feed through interconnects electrically coupled to a one of the feed through pins and comprising a first contact pad, a second contact pad, and a tab on the first contact pad and in contact with the one of the feed through pins; and   a lead connector comprising a plurality of connector contacts and configured and arranged to receive a portion of a lead having lead contacts, wherein the connector contacts are electrically coupled to the second contact pads of the feed through interconnects.   
     
     
         2 . The implantable pulse generator of  claim 1 , wherein the tab is configured and arranged to flex away from the first contact pad. 
     
     
         3 . The implantable pulse generator of  claim 2 , wherein each of the tabs is flexed away from the first contact pad and rests against a side of the one of the feed through pins. 
     
     
         4 . The implantable pulse generator of  claim 1 , wherein each of the first contact pads defines a coupling aperture having a first edge and an opposing second edge. 
     
     
         5 . The implantable pulse generator of  claim 4 , wherein the tab has a proximal end and an opposing distal end, and wherein the tab is at least partially disposed over the coupling aperture with the proximal end of the tab attached to the first edge of the coupling aperture. 
     
     
         6 . The implantable pulse generator of  claim 4 , wherein at least one of the coupling apertures receives a one of the feedthrough pins. 
     
     
         7 . The implantable pulse generator of  claim 1 , wherein the feed through interconnects are spaced apart at uniform distances. 
     
     
         8 . The implantable pulse generator of  claim 1 , wherein each of the tabs is welded or soldered to the one of the feed through pins. 
     
     
         9 . The implantable pulse generator of  claim 1 , wherein the lead connector is a first lead connector and the implantable pulse generator comprises a second lead connector disposed adjacent the first lead connector and comprising a plurality of second connector contacts and configured and arranged to receive a portion of a lead having lead contacts, wherein the second connector contacts are electrically coupled to the second contact pads of the feed through interconnects. 
     
     
         10 . The implantable pulse generator of  claim 9 , wherein the plurality of feed through interconnects comprises a plurality of first feed through interconnects electrically coupled to the connector contacts of the first lead connector and a plurality of second feed through interconnects electrically coupled to the second connector contacts of the second lead connector. 
     
     
         11 . The implantable pulse generator of  claim 10 , wherein the first feed through interconnects and the second feed through interconnects are interleaved. 
     
     
         12 . The implantable pulse generator of  claim 9 , wherein the plurality of feed through pins comprises a first row of the feed through pins and a second row of the feed through pins, wherein the first feed through interconnects are electrically coupled to the first row and the second feed through interconnects are electrically coupled to the second row. 
     
     
         13 . The implantable pulse generator of  claim 12 , wherein the feed through pins of the first row are staggered relative to the feed through pins of the second row. 
     
     
         14 . The implantable pulse generator of  claim 9 , wherein each of the tabs is flexed away from the first contact pad and rests against the one of the feed through pins. 
     
     
         15 . The implantable pulse generator of  claim 9 , wherein each of the first contact pads defines a coupling aperture having a first edge and an opposing second edge. 
     
     
         16 . The implantable pulse generator of  claim 15 , wherein the tab has a proximal end and an opposing distal end, and wherein the tab is at least partially disposed over the coupling aperture with the proximal end of the tab attached to the first edge of the coupling aperture. 
     
     
         17 . The implantable pulse generator of  claim 15 , wherein at least one of the coupling apertures receives a one of the feedthrough pins. 
     
     
         18 . The implantable pulse generator of  claim 1 , wherein a width of the first and second contact pads is greater than a width of an intermediate portion of the feed through connector between the first and second contact pads. 
     
     
         19 . An electrical stimulation system, comprising
 the implantable pulse generator of  claim 1 ; and   a lead having a proximal portion and a distal portion and comprising a plurality of electrodes disposed along the distal portion of the lead and a plurality of lead contacts disposed along the proximal portion of the lead.   
     
     
         20 . An electrical stimulation system, comprising
 the implantable pulse generator of  claim 9 ;   a first lead having a proximal portion and a distal portion and comprising a plurality of electrodes disposed along the distal portion of the first lead and a plurality of lead contacts disposed along the proximal portion of the first lead; and   a second lead having a proximal portion and a distal portion and comprising a plurality of electrodes disposed along the distal portion of the second lead and a plurality of lead contacts disposed along the proximal portion of the second lead.