Method for fabricating an implantable apparatus for delivering electrical stimulation from a pulse generator

• US 20050246005A1
• Filed: 08/03/2005
• Published: 11/03/2005
• 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 7,047,627 B2
• Time in Patent Office: Days
• US Class Current: 607/116
• 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

In one embodiment, a method, for fabricating an implantable apparatus for delivering electrical stimulation from a pulse generator, comprises: providing a plurality of conductors, wherein at least one of the plurality of conductors passes through at least one interior passage of a body, wherein the body is formed of a first insulative material having prescribed mechanical properties; coupling at least one terminal to each conductor of the plurality of conductors, the terminals being adapted to receive electrical signals from the pulse generator, wherein adjacent terminals are separated by a second insulative material with prescribed mechanical properties that are consistent with the first insulative material; and over-molding a region of the apparatus containing the terminals with a third insulative material with prescribed mechanical properties that are consistent with the material of the body.

Claims

1. A method for fabricating an implantable apparatus for delivering electrical stimulation from a pulse generator, the method comprising:

providing a plurality of conductors, wherein at least one of said plurality of conductors passes through at least one interior passage of a body, wherein the body is formed of a first insulative material having prescribed mechanical properties;

coupling at least one terminal to each conductor of said plurality of conductors, said terminals being adapted to receive electrical signals from said pulse generator, wherein adjacent terminals are separated by a second insulative material with prescribed mechanical properties that are consistent with the first insulative material; and

over-molding a region of said apparatus containing said terminals with a third insulative material with prescribed mechanical properties that are consistent with the material of the body.

2. The method of claim 1 further comprising:

removing at least a portion of said third material to a prescribed diameter.

3. The method of claim 2 wherein said removing causes said apparatus to be substantially isodiametric.

4. The method of claim 2 wherein said terminals initially have an outer diameter that is greater than the prescribed diameter and said removing reduces a diameter of said terminals to said prescribed diameter.

5. The method of claim 2 wherein said removing comprises applying a centerless grinding process to said apparatus.

6. The method of claim 1 wherein the first insulative material, the second insulative material, and the third insulative material are the same material.

7. The method of claim 1 wherein said second insulative material is provided between said adjacent terminals using spacer elements.

8. The method of claim 7 wherein said spacer elements are placed in a state of flow when said over-molding is performed.

9. The method of claim 8 wherein said apparatus is substantially free of voids between insulative material and conductive material associated with said plurality of terminals after said over-molding is performed.

10. A method for fabricating an implantable apparatus for delivering electrical stimulation from a pulse generator, the method comprising:

providing a plurality of conductors, wherein at least one of said plurality of conductors passes through at least one interior passage of a body, wherein the body is formed of a first insulative material having prescribed mechanical properties;

coupling at least one terminal to each conductor of said plurality of conductors, said terminals being adapted to receive electrical signals from said pulse generator, wherein adjacent terminals are separated by a second insulative material with prescribed mechanical properties that are consistent with the first insulative material; and

over-molding a region of the apparatus containing said terminals with a third insulative material with prescribed mechanical properties that are consistent with the material of the body, wherein said region forms a substantially solid cross-section, expect for said plurality of conductors passing therethrough and said terminals, after said over-molding is performed.

11. The method of claim 10 further comprising:

removing at least a portion of said third material to a prescribed diameter.

12. The method of claim 11 wherein said removing causes said apparatus to be substantially isodiametric.

13. The method of claim 11 wherein said terminals initially have an outer diameter that is greater than the prescribed diameter and said removing reduces a diameter of said terminals to said prescribed diameter.

14. The method of claim 11 wherein said removing comprises applying a centerless grinding process to said apparatus.

15. The method of claim 10 wherein the first insulative material, the second insulative material, and the third insulative material are the same material.

16. The method of claim 10 wherein said second insulative material is provided between said adjacent terminals using spacer elements.

17. The method of claim 16 wherein said spacer elements are placed in a state of flow when said over-molding is performed.

18. A method for fabricating an implantable apparatus for delivering electrical stimulation from a pulse generator, the method comprising:

providing a plurality of conductors, wherein at least one of said plurality of conductors passes through at least one interior passage of a body, wherein the body is formed of a first insulative material having prescribed mechanical properties;

coupling at least one terminal to each conductor of said plurality of conductors, said terminals being adapted to receive electrical signals from said pulse generator, wherein adjacent terminals are separated by spacer elements of a second insulative material of prescribed mechanical properties that are consistent with the first insulative material; and

applying a third insulative material, with prescribed mechanical properties that are consistent with the first insulative material, over a region of the apparatus containing said plurality of terminals; and

causing said second and third insulative materials to enter a state of flow to form a fused matrix of materials in said region.

19. The method of claim 18 further comprising:

removing at least a portion of said fused matrix to a prescribed diameter.

20. The method of claim 19 wherein said removing causes said apparatus to be substantially isodiametric.