ELECTRICAL STIMULATION LEADS HAVING RF COMPATIBILITY AND METHODS OF USE AND MANUFACTURE

• US 20100094364A1
• Filed: 09/29/2009
• Published: 04/15/2010
• Est. Priority Date: 10/09/2008
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: McDonald, Matthew Lee
• Granted Patent: US 8,335,570 B2
• Time in Patent Office: Days
• US Class Current: 607/2
• 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 1/086 Magnetic resonance imaging [MRI] compatible leads
• 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

An implantable lead has an inner core, a plurality of coiled conductor guides, and a plurality of conductors. The inner core defines a plurality of lumens. Each coiled conductor guide defines a plurality of helical lumens. Each coiled conductor guide is disposed in a coiled arrangement over a portion of the inner core. Each of the conductors electrically couples at least one electrode to at least one terminal. At least one of the conductors includes a plurality of units. Each unit includes a first conductor segment extending along the inner core from a beginning point to a first position, a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and a second conductor segment extending along the inner core from the second position to an endpoint.

Claims

1. An implantable lead having a distal end and a proximal end and comprising:

an inner core with a proximal end, a distal end, and a longitudinal length, the inner core defining a plurality of lumens;

a plurality of electrodes disposed on the distal end of the lead;

a plurality of terminals disposed on the proximal end of the lead;

a plurality of coiled conductor guides, each coiled conductor guide having a first end and a second end, each coiled conductor guide defining a plurality of helical lumens, each coiled conductor guide disposed in a coiled arrangement over a portion of the inner core; and

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein at least one of the conductors comprises a plurality of units, each unit comprising

a first conductor segment extending along the inner core from a beginning point to a first position,

a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and

a second conductor segment extending along the inner core from the second position to an endpoint.

2. The lead of claim 1, wherein the inner core comprises at least one open section.

3. The lead of claim 1, wherein the inner core comprises at least one open section in proximity to each of the first end and the second end of at least one of the coiled conductor guides.

4. The lead of claim 1, wherein at least one of the coiled conductor guides is coupled to the inner core.

5. The lead of claim 1, wherein at least one of the coiled conductor guides and at least one portion of the at least one conductor disposed within the coiled conductor guide comprise a multi-conductor ribbon.

6. The lead of claim 1, wherein at least one of the lumens extending along the inner core is configured and arranged for housing the first conductor segment and the second conductor segment of at least one of the conductors.

7. The lead of claim 1, wherein at least one of the lumens extending along the inner core is configured and arranged for housing either at least one first conductor segment or at least one second conductor segment.

8. The lead of claim 1, wherein the diameter of at least one of the lumens extending along the inner core is no more than 1.2 times the length of the diameter of at least one of the lumens of the coiled conductor guides and is at least 0.8 times the length of the diameter of at least one of the lumens of the coiled conductor guides.

9. The lead of claim 1, wherein the diameters of the lumens extending along the inner core are larger than the diameter of the lumens of the coiled conductor guides.

10. The lead of claim 1, wherein the number of lumens extending along the inner core and housing at least one of the conductor segments is equal to the number of lumens defined in the coiled conductor guides and housing at least one coiled conductor segment.

11. The lead of claim 1, wherein the number of lumens extending along the inner core and housing at least one of the conductor segments is twice the number of lumens defined in the coiled conductor guides and housing at least one coiled conductor segment.

12. The lead of claim 1, wherein the plurality of units are positioned in series.

13. The lead of claim 1, wherein for each unit, the length of the coiled conductor segment is no more than 1.25 times the combined length of the first conductor segment and the second conductor segment and is at least 0.75 times the combined length of the first conductor segment and the second conductor segment.

14. An electrical stimulating system comprising:

a lead having a distal end and a proximal end, the lead comprising

an inner core with a proximal end, a distal end, and a longitudinal length, the inner core defining a plurality of lumens,

a plurality of electrodes disposed on the distal end of the lead,

a plurality of terminals disposed on the proximal end of the lead,

a plurality of coiled conductor guides, each coiled conductor guide having a first end and a second end, each coiled conductor guide defining a plurality of helical lumens, each coiled conductor guide disposed in a coiled arrangement over a portion of the inner core, and

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein at least one of the conductors comprises a plurality of units, each unit comprising a first conductor segment extending along the inner core from a beginning point to a first position, a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and a second conductor segment extending along the inner core from the second position to an endpoint;

a control module configured and arranged to electrically couple to the proximal end of the lead, the control module comprising

a housing, and

an electronic subassembly disposed in the housing; and

a connector for receiving the lead, the connector having a proximal end, a distal end, and a longitudinal length, the connector configured and arranged to receive the lead, the connector comprising

a connector housing defining a port at the distal end of the connector, the port configured and arranged for receiving the proximal end of the lead, and

a plurality of connector contacts disposed in the connector housing, the connector contacts configured and arranged to couple to at least one of the plurality of terminals disposed on the proximal end of the lead.

15. The electrical stimulating system of claim 14, wherein the connector is disposed on the control module.

16. The electrical stimulating system of claim 14, further comprising a lead extension having a proximal end and a distal end, the connector disposed on the distal end of the lead extension.

17. The electrical stimulating system of claim 16, wherein the proximal end of the lead extension is configured and arranged for insertion into another connector.

18. The electrical stimulating system of claim 16, wherein the lead extension has a distal end and a proximal end, the lead extension comprising

an inner core with a proximal end, a distal end, and a longitudinal length, the inner core defining a plurality of lumens;

a plurality of conductor contacts disposed on the distal end of the lead extension;

a plurality of terminals disposed on the proximal end of the lead extension;

a plurality of coiled conductor guides, each coiled conductor guide having a first end and a second end, each coiled conductor guide defining a plurality of helical lumens, each coiled conductor guide disposed in a coiled arrangement over a portion of the inner core; and

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein at least one of the conductors comprises a plurality of units, each unit comprising

a first conductor segment extending along the inner core from a beginning point to a first position,

a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and

a second conductor segment extending along the inner core from the second position to an endpoint.

19. A method for making an implantable lead, the method comprising:

disposing a plurality of electrodes on a distal end of a lead, the lead comprising an inner core defining a plurality of lumens and at least one coiled conductor guide defining a plurality of helical lumens, the at least one coiled conductor guide disposed in a coiled arrangement over a portion of the inner core;

disposing a plurality of terminals on a proximal end of the lead; and

coupling the electrodes to the terminals using a plurality of conductors, wherein at least one of the conductors comprises a plurality of units, each unit comprising

a first conductor segment extending along the inner core from a beginning point to a first position,

a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and

a second conductor segment extending along the inner core from the second position to an endpoint.

20. The method of claim 19, wherein coupling the electrodes to the terminals using a plurality of conductors comprises disposing at least one of the first conductor segment and the second conductor segment in at least one of the plurality of lumens extending along the inner core.