Distal Connector Assemblies for Medical Lead Extensions

A medical lead extension, comprising:

• an elongated body;
• electrical connectors disposed in proximity to a proximal end of the elongated body;
• a plurality of conductors within the elongated body and electrically connected to corresponding electrical connectors;
• a distal connector assembly coupled to the elongated body, the distal connector assembly comprising:
• a rigid holder;
• a plurality of insulative spacers and electrical connectors disposed within the rigid holder with the electrical connectors being separated by the insulative spacers, wherein the plurality of insulative spacers are separate unitary bodies individually positioned within the rigid holder and wherein the conductors are electrically connected to corresponding electrical connectors within the rigid holder;
• and
• an overmold surrounding the rigid holder and the plurality of spacers and electrical connectors.

A method of constructing a distal connector assembly of a medical lead extension, comprising:

• loading electrical conductors into a compliant carrier that separates the electrical conductors;
• loading the compliant carrier with the electrical conductors into a rigid holder;
• routing conductors from an elongated cable to the electrical conductors and electrically coupling the conductors to the electrical conductors;
• and
• surrounding the rigid holder, compliant holder, and electrical conductors with an overmold.

A method of constructing a distal connector assembly of a medical lead extension, comprising:

• loading electrical conductors and individual insulative spacers in an interleaved configuration into a rigid holder;
• routing conductors from an elongated cable to the electrical conductors and electrically coupling the conductors to the electrical conductors;
• and
• surrounding the rigid holder, insulative spacers, and electrical conductors with an overmold.