Systems and methods for making and using improved contact arrays for electrical stimulation systems

• US 10,286,205 B2
• Filed: 01/29/2016
• Issued: 05/14/2019
• Est. Priority Date: 02/06/2015
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Steinke, G. Karl, Howard, Joshua Dale, Villarta, Geoffrey Abellana
• Primary Examiner(s): D Abreu, Michael J
• Application Number:
  US15/011,350
• Publication Number:
  US 20160228692A1
• Time in Patent Office: 1,201 Days
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/3752 Details of casing-lead connections

Abstract

An electrical stimulation lead includes a lead body that defines an alignment feature extending distally from a proximal end of the lead body and inwardly from an outer surface of the lead body. The lead also includes electrodes disposed along the distal portion of the lead body, segmented terminals disposed along the proximal portion of the lead and arranged in sets of segmented terminals, and lead conductors electrically coupling the electrodes to the terminals. Each set of segmented terminals includes at least two segmented terminals disposed in a circumferential arrangement at a same longitudinal position of the lead. A system can include the lead and a connector for receiving the proximal end of the lead. The connector can include an alignment protuberance extending into a connector lumen and configured to be received into the alignment groove of the lead to align the lead with the connector.

Claims

1. An electrical stimulation lead comprising:

a lead body having an outer surface, a proximal end, a proximal portion, at least one distal portion, an outer surface, a perimeter, and a longitudinal length, the lead body defining an alignment groove that begins at the proximal end of the lead body and extends distally, wherein the alignment groove also extends inwardly from the outer surface of the lead body;

a plurality of electrodes disposed along the at least one distal portion of the lead body;

a plurality of segmented terminals disposed along the proximal portion of the lead body and arranged in a plurality of sets of segmented terminals, wherein each set of segmented terminals comprises at least two of the segmented terminals disposed in a circumferential arrangement at a same longitudinal position of the lead body, wherein each segmented terminal is exposed on the proximal portion of the lead body to electrically couple to a contact of a connector when the proximal portion of the lead body is inserted into the connector, extends around less than the entire perimeter of the lead body, and is separated from all other segmented terminals by portions of the lead body; and

a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of segmented terminals.

2. An electrical stimulation system comprising:

the electrical stimulation lead of claim 1; and

a connector defining a connector lumen configured and arranged to receive the proximal end of the lead body of the electrical stimulation lead, wherein the connector comprises a plurality of segmented connector contacts disposed along the connector lumen and arranged in a plurality of sets of segmented connector contacts, wherein each set of segmented connector contacts comprises at least two of the segmented connector contacts disposed in a circumferential arrangement at a same longitudinal position along the connector lumen.

3. The electrical stimulation system of claim 2, further comprising a control module, wherein the control module comprises the connector, a housing, and an electrical subassembly disposed in the housing and electrical coupled to the segmented connector contacts of the connector.

4. The electrical stimulation system of claim 2, further comprising a lead extension, wherein the lead extension comprises the connector.

5. The electrical stimulation system of claim 2, wherein each of the segmented connector contacts comprises a leaf spring.

6. The electrical stimulation system of claim 2, wherein each of the segmented connector contacts comprises a coiled leaf spring.

7. The electrical stimulation system of claim 2, wherein the connector further comprises an alignment protuberance extending into the connector lumen and disposed at least at an opening into the connector lumen, wherein the alignment groove of the lead body is configured and arranged to receive the alignment protuberance to align the lead with the connector.

8. The electrical stimulation lead of claim 1, wherein the alignment groove terminates proximal to any of the segmented terminals.

9. The electrical stimulation lead of claim 1, wherein the alignment groove extends between at least two of the segmented terminals of at least one of the sets of segmented terminals.

10. The electrical stimulation lead of claim 1, wherein the alignment groove extends between at least two of the segmented terminals of each of the sets of segmented terminals.

11. The electrical stimulation lead of claim 1, wherein each of the sets of segmented terminals contains exactly two segmented terminals.

12. The electrical stimulation lead of claim 1, wherein the lead body further defines a central lumen along the lead body and configured and arranged to receive a stylet, wherein the alignment groove extends inwardly from the outer surface of the lead body to the central lumen.

13. An electrical stimulation system comprising:

a connector defining a connector lumen configured and arranged to receive the proximal end of the electrical stimulation lead, wherein the connector comprises

a connector housing containing the connector lumen and defining an opening into the connector lumen,

a plurality segmented connector contacts disposed within the connector housing and along the connector lumen and arranged in a plurality of sets of segmented connector contacts, wherein each set of segmented connector contacts comprises at least two of the segmented connector contacts disposed in a circumferential arrangement at a same longitudinal position along the connector lumen, wherein each of the segmented connector contacts comprises a leaf spring, and

an alignment protuberance extending into the connector lumen and disposed at least at the opening into the connector lumen.

14. The electrical stimulation system of claim 13, further comprising a lead, the lead comprising

a lead body having an outer surface, a proximal end, a proximal portion, at least one distal portion, an outer surface, a perimeter, and a longitudinal length, the lead body further defining an alignment groove extending distally from the proximal end of the lead body and extending inwardly from the outer surface of the lead body,

a plurality of electrodes disposed along the at least one distal portion of the lead body,

a plurality of terminals disposed along the proximal portion of the lead body, and

a plurality of lead conductors electrically coupling the plurality of electrodes to the plurality of terminals.

15. The electrical stimulation system of claim 14, wherein the plurality of terminals is a plurality of segmented terminals disposed along the proximal portion of the lead body and arranged in a plurality of sets of segmented terminals, wherein each set of segmented terminals comprises at least two of the segmented terminals disposed in a circumferential arrangement at a same longitudinal position of the lead, wherein each segmented terminals extends around less than the entire perimeter of the lead body and is separated from all other segmented terminals by portions of the lead body.

16. The electrical stimulation system of claim 15, wherein the alignment groove terminates proximal to any of the segmented terminals.

17. The electrical stimulation system of claim 15, wherein the alignment groove extends between at least two of the segmented terminals of at least one of the sets of segmented terminals.

18. The electrical stimulation system of claim 13, wherein the leaf spring is a coiled leaf spring.

19. The electrical stimulation system of claim 13, further comprising a control module, wherein the control module comprises the connector, a housing, and an electrical subassembly disposed in the housing and electrical coupled to the segmented connector contacts of the connector.

20. The electrical stimulation system of claim 13, further comprising a lead extension, wherein the lead extension comprises the connector.