Implantable lead and method of manufacture

• US 20020055765A1
• Filed: 01/09/2002
• Published: 05/09/2002
• Est. Priority Date: 04/26/1999
• Status: Active Grant

• Current Assignee: Damon Ray Black, John Erickson, Lauro B. Reno, Robert Earl Jones, Terry Daglow
• Original Assignee: Damon Ray Black, John Erickson, Lauro B. Reno, Robert Earl Jones, Terry Daglow
• Inventors: Erickson, John, Daglow, Terry, Jones, Robert Earl, Lauro, B. Reno, Black, Damon Ray
• Granted Patent: US 6,981,314 B2
• Time in Patent Office: Days
• US Class Current: 607/122
• 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 1/056 Transvascular endocardial electrode systems
• 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 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

An implantable, substantially isodiametric, low resistance implantable lead having at least one electrode positioned in a stimulation/sensing portion of the lead as well as a method of manufacturing the same. At least the stimulation/sensing portion is unitized through partially surrounding and supporting insulation and conductive element(s) of the stimulation/sensing portion with a fused matrix of material having mechanical properties consistent with a body of the lead.

Claims

1. A method for forming a substantially isodiametric lead having a prescribed diameter and at least one electrode separated from at least one terminal by a lead body, wherein the at least one electrode is electrically coupled to the at least one terminal by a conductor passing through a passage defined by the lead body, comprising the steps of:

assembling the at least one electrode and the at least one terminal relative to the lead body to form an assembly, including connecting the at least one electrode to the at least one terminal via the conductor;

over-molding the assembly with a first material to form an intermediate assembly, wherein the first material is compatible with and has mechanical properties consistent with a material of the lead body; and

removing all material of the intermediate assembly in excess of the prescribed diameter.

2. A method in accordance with claim 1, wherein the at least one electrode has an outer diameter greater than the prescribed diameter prior to the removing step.

3. A method in accordance with claim 1, wherein the at least one terminal has an outer diameter greater than the prescribed diameter prior to the removing step.

4. A method in accordance with claim 1, wherein the removing step involves subjecting the intermediate assembly to at least a centerless grinding process.

5. A method for forming a substantially isodiametric lead having a prescribed diameter and a first region separated from a second region by a lead body, the first region having a plurality of electrodes, and the second region having a plurality of terminals, each terminal being respectively and electrically joined to at least one electrode by a conductor passing through a passage defined by the first region, second region, and lead body, comprising the steps of:

assembling the plurality of electrodes and plurality of terminals relative to the lead body to form an assembly, this step including electrically coupling each terminal to at least one electrode by a conductor; and

unitizing at least that portion of the assembly corresponding to the first region of the lead, wherein subsequent to unitization, each electrode is separated by an insulative material, and the passage defined by at least the first region is substantially filled with the insulative material.

6. A method in accordance with claim 5, further comprising unitizing that portion of the assembly corresponding to the second region of the lead, wherein subsequent to unitization, each terminal is separated by a second insulative material, and the passage defined by at least the first region is substantially filled with the second insulative material.

7. A method in accordance with claim 6, wherein the second insulative material has mechanical properties consistent with the material of the lead body.

8. A method in accordance with claim 5, wherein the insulative material has mechanical properties consistent with the material of the lead body.

9. A method for forming a substantially isodiametric lead having a prescribed diameter and a first region separated from a second region by a lead body, the first region having a plurality of electrodes, and the second region having a plurality of terminals, each terminal being respectively and electrically joined to at least one electrode by a conductor passing through a passage defined by the first region, second region, and lead body, comprising the steps of:

assembling the plurality of electrodes and plurality of terminals relative to the lead body to form an assembly, this step including electrically coupling each terminal to at least one electrode by a conductor; and

unitizing at least that portion of the assembly corresponding to the first region of the lead, wherein each electrode is separated by an insulative material, and the passage defined by at least the first region is substantially filled with the insulative material,

wherein the step of unitizing involves over-molding the assembly with a second material to form an intermediate assembly, wherein the second material is compatible with and has mechanical properties consistent with the material of the lead body.

10. A method in accordance with claim 9, wherein the second material and the insulative material are the same.

11. A method in accordance with claim 9, further comprising the step of removing all material of the intermediate assembly in excess of the prescribed diameter.

12. A method in accordance with claim 11, wherein the step of removing involves subjecting the intermediate assembly to at least a centerless grinding process.

13. A method in accordance with claim 11, wherein the at least one electrode has an outer diameter greater than the prescribed diameter prior to the removing step.

14. A method in accordance with claim 11, wherein the at least one terminal has an outer diameter greater than the prescribed diameter prior to the removing step.