NOVEL MEDICAL ELECTRODE MOUNTING

• US 20080046050A1
• Filed: 08/21/2006
• Published: 02/21/2008
• Est. Priority Date: 08/21/2006
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Skubitz, Sean P., Boatwright, Mary L., Bolea, Stephen L., Metzler, Michael E., Tower, Jessica L.
• Granted Patent: US 7,742,824 B2
• Time in Patent Office: Days
• US Class Current: 607/115
• CPC Class Codes: A61N 1/0553 Paddle shaped electrodes, e.g. for laminotomy

Abstract

A medical electrical lead electrode assembly includes an insulative carrier and at least one conductive component. The at least one conductive component includes an electrode portion disposed on a first side of the carrier and at least one tab extending away from the electrode portion, through the carrier to a second side of the carrier. The electrode portion of the at least one component includes an outward facing contact surface and an inward facing surface, the inward facing surface being disposed opposite the contact surface and against a surface of the first side of the carrier. The electrode assembly further includes a joint coupling a flexible elongate conductor to the tab of the at least one component on the second side of the carrier, and an insulative layer extending over the joint and the tab and the conductor, the insulative layer being bonded to the second side of the carrier.

Claims

1. A medical electrical lead electrode assembly, comprising:

an insulative carrier including a first side and a second side;

at least one conductive component including an electrode portion disposed on the first side of the carrier and at least one tab extending away from the electrode portion, through the carrier to the second side of the carrier;

the electrode portion of the at least one component including an outward facing contact surface and an inward facing surface, the inward facing surface being disposed opposite the contact surface and against a surface of the first side of the carrier;

a joint coupling a flexible elongate conductor to the tab of the at least one component on the second side of the carrier; and

an insulative layer extending over the joint and the tab and the conductor, the insulative layer being bonded to the second side of the carrier.

2. The assembly of claim 1, wherein the first side of the carrier includes a pre-formed recess in which the electrode portion of the at least one component is disposed.

3. The assembly of claim 1, wherein the second side of the carrier includes a pre-formed recess in which the at least one tab of the at least one component is disposed.

4. The assembly of claim 3, wherein:

the second side of the carrier includes a pre-formed channel extending from the recess; and

the conductor is disposed within the channel.

5. The assembly of claim 4, further comprising a tubular channel extending from the carrier, and wherein the pre-formed channel extends to the tubular channel and the conductor is further disposed within the tubular channel.

6. The assembly of claim 5, wherein the insulative layer extends over a portion of the tubular channel and couples the tubular channel to the carrier;

the portion of the tubular channel including a pre-formed bend.

7. The assembly of claim 4, wherein:

the pre-formed channel extends at an angle to a longitudinal axis of the carrier;

the second side of the carrier further includes longitudinally extending pre-formed channel extending from the channel that extends from the recess; and

the conductor is further disposed within the other channel.

8. The assembly of claim 7, wherein the second side of the carrier includes at least one flap extending over the longitudinally extending channel.

9. The assembly of claim 4, wherein the second side of the carrier further includes a flap extending over the channel.

10. The assembly of claim 1, wherein a maximum thickness from the first side of the carrier to the second side of the carrier does not exceed approximately 0.075 inch.

11. The assembly of claim 1, wherein the first side of the carrier is generally concave.

12. The assembly of claim 1, wherein the carrier further includes a mesh panel embedded therein.

13. The assembly of claim 1, wherein the at least one tab of the at least one component comprises a pair of tabs, and the tab to which the conductor is coupled by the joint is one of the pair of tabs.

14. The assembly of claim 1, wherein the at least one tab is bent toward a surface of the second side of the carrier.

15. The assembly of claim 14, wherein the surface of the second side of the carrier is opposite the inward facing surface of the electrode portion of the component.

16. The assembly of claim 14, wherein the surface of the second side of the carrier is offset from the inward facing surface of the electrode portion of the component.

17. The assembly of claim 1, wherein the at least one tab includes a pre-formed projection extending along a surface of the second side of the carrier.

18. The assembly of claim 17, wherein the surface of the second side of the carrier is opposite the inward facing surface of the electrode portion of the component.

19. The assembly of claim 17, wherein the surface of the second side of the carrier is offset from the inward facing surface of the electrode portion of the component.

20. The assembly of claim 1, wherein the at least one tab includes a pre-formed projection extending toward a surface of the second side of the carrier.

21. The assembly of claim 20, wherein the surface of the second side of the carrier is opposite the inward facing surface of the electrode portion of the component.

22. The assembly of claim 20, wherein the surface of the second side of the carrier is offset from the inward facing surface of the electrode portion of the component.

23. The assembly of claim 1, wherein the at least one conductive component comprises a plurality of conductive components.

24. The assembly of claim 1, wherein the joint comprises a weld.

25. The assembly of claim 1, wherein the joint comprises a crimp.

26. The assembly of claim 1, wherein an extent of the insulative layer is limited to the second side of the carrier.

27. The assembly of claim 1, wherein the insulative layer is molded over the second side of the carrier.

28. The assembly of claim 1, further comprising:

a tubular channel extending from the carrier and through which the conductor extends;

wherein the insulative layer extends over a portion of the tubular channel and couples the tubular channel to the carrier; and

the portion of the tubular channel includes a pre-formed bend.

29. A medical electrical lead electrode assembly, comprising:

an insulative carrier including a first side and a second side;

a plurality of conductive components, each of the conductive components including an electrode portion disposed on the first side of the carrier and at least one tab extending away from the electrode portion, through the carrier to the second side of the carrier;

the electrode portions arranged in at least one longitudinally extending column, and each electrode portion including an outward facing contact surface and an inward facing surface, the inward facing surface being disposed opposite the contact surface and against a surface of the first side of the carrier;

a plurality of flexible elongate conductors;

a plurality of joints disposed on the second side of the carrier, each of the joints coupling a one of the plurality of flexible elongate conductors to the tab of a corresponding component of the plurality of components; and

an insulative layer extending over the joints and the tabs and the conductors, the insulative layer being bonded to the second side of the carrier.

30. The assembly of claim 29, wherein the at least one tab is a pair of tabs, and the tab of each component to which the corresponding conductor is coupled by the corresponding joint is one of the pair of tabs.

31. The assembly of claim 29, wherein the first side of the carrier includes a plurality of pre-formed recesses, the electrode portion of each of the plurality of components being disposed within a corresponding recess of the plurality of recesses.

32. The assembly of claim 29, wherein the second side of the carrier includes a plurality of pre-formed recesses, the at least one tab of each of the plurality of components being disposed within a corresponding recess of the plurality of recesses.

33. The assembly of claim 32, wherein:

the second side of the carrier includes a plurality of pre-formed channels, each channel of the plurality of channels extending laterally from a corresponding recess of the plurality of recesses; and

each conductor of the plurality of conductors is disposed within a corresponding channel of the plurality of channels.

34. The assembly of claim 33, wherein the second side of the carrier further includes a flap extending over each channel of the plurality of channels.

35. The assembly of claim 33, wherein:

the second side of the carrier further includes a longitudinally extending pre-formed channel extending from each of the plurality of pre-formed channels; and

each conductor of the plurality of conductors is further disposed within the longitudinally extending pre-formed channel.

36. The assembly of claim 35, wherein the second side of the carrier further includes at least one flap extending over the longitudinally extending channel.

37. The assembly of claim 35, further comprising a tubular channel extending from the carrier and wherein the plurality of conductors are further disposed within the tubular channel.

38. The assembly of claim 37, wherein:

the insulative layer extends over a portion of the tubular channel and couples the tubular channel to the carrier; and

the portion of the tubular channel includes a pre-formed bend.

39. The assembly of claim 33, wherein at least one of the plurality of channels extends laterally in a first direction, and at least one other of the plurality channels extends laterally in a second direction.

40. The assembly of claim 39, wherein:

the second side of the carrier further includes a first longitudinally extending pre-formed channel extending from the at least one of the plurality of channels, and a second longitudinally extending pre-formed channel extending from the at least one other of the plurality of channels;

the conductor disposed in the at least one channel is further disposed in the first longitudinally extending channel; and

the conductor disposed in the at least one other channel is further disposed in the second longitudinally extending channel.

41. The assembly of claim 40, further comprising:

a first tubular channel and a second tubular channel, each tubular channel extending from the carrier; and

wherein the conductor disposed in the first longitudinal channel is further disposed in the first tubular channel; and

the conductor disposed in the second longitudinal channel is further disposed in the second tubular channel.

42. The assembly of claim 41, wherein:

the insulative layer extends over a portion of each of the first and second tubular channels and couples the tubular channels to the carrier; and

the portion of each of the first and second channels includes a pre-formed bend.

43. The assembly of claim 29, wherein:

the at least one longitudinally extending column comprises a first longitudinally extending column and a second longitudinally extending column;

the plurality of conductive components includes a first set of components having each electrode portion thereof arranged in the first column and a second set of components having each electrode portion thereof arranged in the second column;

the second side of the carrier includes;

a first plurality of pre-formed recesses corresponding to the first column, the at least one tab of each of the first set of components being disposed within a corresponding recess of the first plurality of recesses,

a second plurality of pre-formed recesses corresponding to the second column, the at least one tab of the each of the second set of components being disposed within a corresponding recess of the second plurality of recesses,

a first plurality of pre-formed channels, each channel of the first plurality of channels extending laterally from a corresponding recess of the first plurality of recesses, and

a second plurality of pre-formed channels, each channel of the second plurality of channels extending laterally from a corresponding recess of the second plurality of recesses; and

each conductor of the plurality of conductors is disposed in a corresponding channel of the first and second plurality of channels

44. The assembly of claim 43, wherein the second side of the carrier further includes a longitudinally extending pre-formed channel extending from each of the first and second pluralities of channels;

and the plurality of conductors is further disposed in the longitudinally extending channel.

45. The assembly of claim 44, further comprising a tubular channel extending from the carrier;

and wherein the plurality of conductors are further disposed within the tubular channel.

46. The assembly of claim 45, wherein:

the insulative layer extends over a portion of the tubular channel and couples the tubular channel to the carrier; and

the portion of the tubular channel includes a pre-formed bend.

47. The assembly of claim 29, wherein:

the at least one longitudinally extending column comprises a first longitudinally extending column, a second longitudinally extending column and a third longitudinally extending column, the third column being disposed between the first and second columns;

the plurality of conductive components includes a first set of components having each electrode portion thereof arranged in the first column, a second set of components having each electrode portion thereof arranged in the second column, and a third set of components having each electrode portion thereof arranged in the third column;

the second side of the carrier includes;

a first plurality of pre-formed recesses corresponding to the first column, the at least one tab of each of the first set of components being disposed within a corresponding recess of the first plurality of recesses,

a second plurality of pre-formed recesses corresponding to the second column, the at least one tab of the each of the second set of components being disposed within a corresponding recess of the second plurality of recesses,

a third plurality of pre-formed recesses corresponding to the third column and including a first group of recesses and a second group of recesses, the at least one tab of each of the third set of components being disposed within a corresponding recess of the third plurality of recess,

a first plurality of pre-formed channels, each channel of the first plurality of channels extending laterally from a corresponding recess of the first plurality of recesses,

a second plurality of pre-formed channels, each channel of the second plurality of channels extending laterally from a corresponding recess of the second plurality of recesses, and

a third plurality of pre-formed channels including a first group of channels and a second group of channels, each channel of the first group extending laterally in a first direction from a corresponding recess of the first group of the third plurality of recesses, and each channel of the second group extending laterally in a second direction from a corresponding recess of the second group of the third plurality of recesses; and

each conductor of the plurality of conductors is disposed in a corresponding channel of the first, second and third plurality of channels.

48. The assembly of claim 47, wherein:

the second side of the carrier further includes a first longitudinally extending pre-formed channel disposed between the first column and the third column, and a second longitudinally extending pre-formed channel disposed between the second column and the third column;

the first longitudinally extending channel extending from each of the first plurality of recesses and each of the first group of the third plurality of recesses;

the second longitudinally extending channel extending from each of the second plurality of recesses and each of the second group of the third plurality of recesses;

each conductor disposed in the corresponding channel of the first plurality of channels and the first group of the third plurality of channels is further disposed in the first longitudinally extending channel; and

each conductor disposed in the corresponding channel of the second plurality of channels and the second group of the third plurality of channels is further disposed in the second longitudinally extending channel.

49. The assembly of claim 48, wherein adjacent columns of the three columns are staggered with respect to one another.

50. The assembly of claim 48, further comprising:

a first tubular channel and a second tubular channel, each tubular channel extending from the carrier;

wherein each conductor disposed in the first longitudinally extending channel is further disposed in the first tubular channel; and

each conductor disposed in the second longitudinally extending channel is further disposed in the second tubular channel.

51. The assembly of claim 50, wherein

the insulative layer extends over a portion of each of the first and second tubular channels and couples the first and second tubular channels to the carrier;

and

the portion of each of the first and second tubular channels includes a pre-formed bend.

52. The assembly of claim 29, wherein an extent of the insulative layer is limited to the second side of the carrier.

53. The assembly of claim 29, wherein the insulative layer is molded over the second side of the carrier.