Molded headers for implantable signal generators, and associated systems and methods

Abstract

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 - 28 . (canceled) 
     
     
         29 . A signal generator, comprising:
 a header coupleable to a can and comprising a molded material at least partially encasing multiple components therein, the components including:
 an output terminal positioned to provide electrical power to a signal delivery device; 
 a charging coil; and 
 a communication antenna to receive control signals. 
   
     
     
         30 . The signal generator of  claim 29 , wherein the molded material comprises a polymer. 
     
     
         31 . The signal generator of  claim 29 , wherein the header includes a rounded rectangular shape, and wherein the charging coil is shaped to at least partially match the rounded rectangular shape. 
     
     
         32 . The signal generator of  claim 29 , 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. 
     
     
         33 . The signal generator of  claim 32 , wherein the header includes an access seal positioned to provide access to the set screw block. 
     
     
         34 . The signal generator of  claim 29 , wherein the header includes a curved shape, and wherein the charging coil and the communication antenna are shaped to at least partially match the curved shape of the header. 
     
     
         35 . The signal generator of  claim 29 , further comprising the can and a battery, and wherein the battery is positioned within the can and operably coupled to the output terminal and the charging coil. 
     
     
         36 . A signal generator, comprising:
 a header having a rounded upper surface and comprising a molded material at least partially encasing multiple components therein, the components including:
 a receiving element having a plurality of output terminals, wherein the plurality of output terminals are positioned to be electrically coupled to a signal delivery device; 
 a charging coil; 
 an antenna; and 
 a set screw block positioned at least partially within the header, the set screw block including a receiving passage having a funnel shaped sidewall. 
   
     
     
         37 . The signal generator of  claim 36 , wherein the molded material comprises a polymer. 
     
     
         38 . The signal generator of  claim 36 , wherein at least one of the charging coil and the antenna has a shape that at least partially matches the rounded upper surface of the header. 
     
     
         39 . The signal generator of  claim 36 , wherein the header includes an access seal positioned to provide access to the set screw block. 
     
     
         40 . The signal generator of  claim 36 , further comprising a can coupled to the header, and a battery positioned within the can and electrically coupled to the plurality of output terminals and the charging coil. 
     
     
         41 . The signal generator of  claim 40 , wherein the header has a base shaped to align with the can. 
     
     
         42 . A method of forming a signal generator, the method comprising:
 forming a header, including:
 positioning multiple components in a mold, the components including:
 a receiving element having a plurality of output terminals, 
 a charging coil; and 
 an antenna; 
 
 disposing a quantity of liquid material into the mold thereby encasing the multiple components; and 
 removing the header from the mold. 
   
     
     
         43 . The method of  claim 42 , further comprising attaching the header to a can having a shell and a lid. 
     
     
         44 . The method of  claim 43 , further comprising positioning a battery within the can. 
     
     
         45 . The method of  claim 43 , further comprising positioning a battery within the can and wherein attaching the header to the can includes aligning the header with the can and establishing an electrical connection between the charging coil and the battery. 
     
     
         46 . The method of  claim 42 , further comprising positioning a set screw block at least partially within the 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. 
     
     
         47 . The method of  claim 42 , wherein the multiple components are encased within the header and the header is molded into a shape substantially simultaneously. 
     
     
         48 . The method of  claim 47 , wherein the shape of the header includes a rounded rectangular portion.