Method of manufacturing an electrical lead

• US 20050227398A1
• Filed: 05/05/2005
• Published: 10/13/2005
• Est. Priority Date: 10/20/2000
• Status: Active Grant

• Current Assignee: Cathrx Ltd
• Original Assignee: Advanced Metal Coatings Pty Limited
• Inventors: Chong, Evan Ka-Loke, Anderson, Neil Lawrence
• Granted Patent: US 7,629,015 B2
• Time in Patent Office: Days
• US Class Current: 438/36
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/25 Bioelectric electrodes therefor
• CPC Class Codes: A61B 5/268 containing conductive polymers, e.g. PEDOT:PSS polymers
• CPC Class Codes: A61B 5/283 Invasive
• CPC Class Codes: A61B 5/291 for electroencephalography [EEG]
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49224 with coating
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1303 Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/1334 Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
• CPC Class Codes: Y10T 428/1338 Elemental metal containing
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/139 Open-ended, self-supporting conduit, cylinder, or tube-type article

Abstract

An electrically conductive member (10) includes an elongate body (11) which has at least one electrically conductive region (20). The electrically conductive region (20) comprises a porous polymeric material coated with an electrically conductive material. A method of manufacturing the electrically conductive member (10) includes the steps of extruding an elongate body of polymeric material wherein at least one region of the elongate body is porous in nature; and coating said elongate body with an electrically conductive material such that the electrically conductive material substantially coats the pores of said at least one region.

Claims

1-27. -27. (canceled)

28. A method of manufacturing electrically conductive member method comprising:

(i) extruding an elongate body of polymeric material wherein at least one region of the elongate body is porous in nature; and

(ii) coating said elongate body with an electrically conductive material such that the electrically conductive material substantially coats the pores of said at least one region.

29. The method of claim 28 wherein the electrically conductive material is applied to the elongate body by electroless plating.

32. The method of claim 28 which includes, prior to step (ii), cleaning an outer surface of the elongate body.

33. The method of any one of claim 28 which includes, prior to step (ii), modifying an outer surface of the elongate body is to produce a wettable or hydrophilic surface such that the deposition of the coating is accelerated and chemical and mechanical adhesion of the coating to the surface is improved.

34. The method of claim 28 which includes, prior to step (ii), catalyzing a surface of the elongate body.

35. The method of claim 34 which includes catalyzing a surface of only the at least one electrically conductive region of the elongate body.

56. An electrically conductive member when made using the method of claim 28 or claim 48.

30. The method of claim wherein the electrically conductive material is forced through the pores of the at least one electrically conductive region by the application of pressure.

31. The method of claim 30 comprising a further step of one of electroplating and electroless plating.

36-47. -47. (canceled)

48. A method of manufacturing an electrically conductive member the method comprising:

(i) extruding an elongate inner member from a polymeric material;

(ii) applying at least one electrical conductor to an exposed surface of the inner member;

(iii) overlaying the inner member and the at least one electrical conductor with an outer member made from a polymeric material such that the at least one electrical conductor is covered by said outer member;

(iv) exposing at least a portion of the at least one electrical conductor; and

(v) coating the exposed portion of the at least one electrical conductor and at least a portion of the outer member with an electrically conductive material.

49. The method of claim 48 which includes exposing the at least one electrical conductor by a technique selected from the group consisting of the application of heat, chemicals, lasers and mechanical action in order to remove an area of the outer member covering the at least one portion of the electrical conductor.

50. The method of claim 48 which includes prior to step (v), catalyzing a surface of the elongate body to be coated.

53. The method of claim 48 which includes applying the electrically conductive coating by electroless plating.

54. The method of claim 48 which includes selecting the electrically conductive material is selected from the group consisting copper, silver, platinum or platinum alloy.

55. The method of claim 53 including an additional step of electroplating or further electroless plating.

51. The method of claim which includes selectively applying a catalyst using at least one pad printing and masking.

52. The method of claim which includes catalyzing a surface of the at least one electrically conductive region.