Systems and leads with a radially segmented electrode array and methods of manufacture

• US 10,720,729 B2
• Filed: 01/25/2016
• Issued: 07/21/2020
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Pianca, Anne Margaret
• Primary Examiner(s): Tejani, Ankit D
• Application Number:
  US15/005,893
• Publication Number:
  US 20160141795A1
• Time in Patent Office: 1,639 Days
• Field of Search: None
• 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 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: H01R 13/567 Traverse cable outlet or wire connection
• CPC Class Codes: H01R 4/62 Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors H01R4/68 takes precedence
• CPC Class Codes: H01R 43/00 Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A method of making a lead for a stimulation device includes forming at least one pre-electrode in the shape of a ring, the at least one pre-electrode comprises at least two thin-walled portions separated by at least two thick-walled portions; disposing the at least one pre-electrode near a distal end of a lead body; joining at least one conductor to each thick-walled portion of the at least one pre-electrode; and grinding the lead body and the at least one pre-electrode to remove the thin-walled portions of the at least one pre-electrode to form segmented electrodes from the thick-walled portions of the at least one pre-electrode.

Claims

1. A pre-electrode, comprising:

at least two thin-walled portions; and

at least two thick-walled portions, wherein the at least two thick-walled portions separate the at least two thin-walled portions;

wherein the pre-electrode is formed in the shape of a ring having an isodiametric outer diameter and a non-isodiametric inner diameter, wherein the at least two thin-walled portions and the at least two thick-walled portions are conductive.

2. The pre-electrode of claim 1, wherein the at least two thin-walled portions of the pre-electrode are equally spaced around a circumference of the pre-electrode.

3. The pre-electrode of claim 1, wherein the at least two thick-walled portions and the at least two thin-walled portions have a same outer diameter.

4. The pre-electrode of claim 1, wherein an inner diameter of the at least two thick-walled portions is smaller than an inner diameter of the at least two thin-walled portions.

5. The pre-electrode of claim 1, wherein the at least two thin-walled portions is at least three thin-walled portions and the at least two thick-walled portions is at least three thick-walled portions.

6. The pre-electrode of claim 1, wherein each of the at least two thick-walled portions has a same circumferential length along the circumference of the pre-electrode.

7. The pre-electrode of claim 6, wherein each of the at least two thin-walled portions has a same circumferential length along the circumference of the pre-electrode.

8. The pre-electrode of claim 7, wherein the circumferential length of the at least two thick-walled portions is greater than the circumferential length of the at least two thin-walled portions.

9. The pre-electrode of claim 1, further comprising marks for coupling with a lead body.

10. The pre-electrode of claim 1, further comprising at least two conductors, wherein each of the at least two conductors is coupled to one of the thick-walled portions.

11. A pre-electrode, comprising:

at least two thin-walled portions; and

at least two thick-walled portions, wherein the at least two thick-walled portions separate the at least two thin-walled portions;

wherein the at least two thick-walled portions and the at least two thin-walled portions have a same outer diameter and an inner diameter of the at least two thick-walled portions is smaller than an inner diameter of the at least two thin-walled portions, wherein the at least two thin-walled portions and the at least two thick-walled portions are conductive.

12. The pre-electrode of claim 11, wherein the at least two thin-walled portions of the pre-electrode are equally spaced around a circumference of the pre-electrode.

13. The pre-electrode of claim 11, wherein the at least two thin-walled portions is at least three thin-walled portions and the at least two thick-walled portions is at least three thick-walled portions.

14. The pre-electrode of claim 11, wherein each of the at least two thick-walled portions has a same circumferential length along the circumference of the pre-electrode.

15. The pre-electrode of claim 14, wherein each of the at least two thin-walled portions has a same circumferential length along the circumference of the pre-electrode.

16. The pre-electrode of claim 15, wherein the circumferential length of the at least two thick-walled portions is greater than the circumferential length of the at least two thin-walled portions.

17. A pre-electrode, comprising:

at least two thin-walled portions; and

at least two thick-walled portions,

wherein the at least two thick-walled portions alternate with the at least two thin-walled portions around a circumference of the pre-electrode, wherein the pre-electrode has an isodiametric outer diameter and a non-isodiametric inner diameter and the at least two thin-walled portions and the at least two thick-walled portions are conductive.

18. The pre-electrode of claim 17, wherein the at least two thin-walled portions of the pre-electrode are equally spaced around a circumference of the pre-electrode.

19. The pre-electrode of claim 17, wherein the at least two thin-walled portions is at least three thin-walled portions and the at least two thick-walled portions is at least three thick-walled portions.

20. The pre-electrode of claim 17, wherein each of the at least two thick-walled portions has a same circumferential length along the circumference of the pre-electrode, each of the at least two thin-walled portions has a same circumferential length along the circumference of the pre-electrode, and the circumferential length of the at least two thick-walled portions is greater than the circumferential length of the at least two thin-walled portions.