METHOD OF FABRICATING STIMULATION LEAD BY FUSING CONNECTOR SEGMENT BETWEEN LEAD BODY AND ELECTRODE PORTION OF THE LEAD

• US 20100269339A1
• Filed: 04/23/2010
• Published: 10/28/2010
• Est. Priority Date: 04/24/2009
• Status: Active Grant

• Current Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Original Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Inventors: Dye, Don, Turner, Kevin
• Granted Patent: US 8,046,909 B2
• Time in Patent Office: Days
• US Class Current: 29/876
• CPC Class Codes: A61N 1/0531 Brain cortex electrodes
• CPC Class Codes: A61N 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49194 Assembling elongated conductors, e.g., splicing, etc.
• CPC Class Codes: Y10T 29/49195 with end-to-end orienting
• CPC Class Codes: Y10T 29/49201 with overlapping orienting
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

In one embodiment, a process, for fabricating a medical lead comprises: providing a splicing tube having a plurality of angularly spaced longitudinal grooves; placing a first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube; placing a second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends; positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends; electrically coupling the proximal ends of the first plurality of electrodes to respective proximal ends of the second plurality of electrodes; molding insulative material about at least the electrode assembly and the splicing tube; and fusing the splicing tube with the insulative material from the molding and the lead body.

Claims

1. A process for fabricating a medical lead for stimulation of tissue of a patient, the process comprising:

providing an electrode assembly comprising a plurality of electrodes electrically coupled to a first plurality of conductors;

providing a lead body comprising a second plurality of conductors;

providing a splicing tube having a plurality of angularly spaced longitudinal grooves;

placing proximal ends of the first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube;

placing distal ends of the second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the proximal ends of the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends;

positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends;

electrically coupling the proximal ends of the first plurality of electrodes to respective proximal ends of the second plurality of electrodes;

molding insulative material about at least the electrode assembly and the splicing tube; and

fusing the splicing tube with the insulative material from the molding and the lead body.

2. The process of claim 1, wherein the electrically coupling comprises laser welding the conductive filler material such that the conductive filler material couples the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors.

3. The process of claim 1, further comprising:

removing insulative material of the lead body to release the second plurality of conductors.

4. The process of claim 1, further comprising:

providing a center tubing about a mandrel;

positioning the electrode assembly over the center tubing; and

positioning at least one spacer adjacent to the at least one electrode assembly; and

providing a second electrode assembly adjacent to the at least one spacer.

5. The process of claim 4, further comprising:

positioning a ring electrode over the center tubing; and

positioning a spacer adjacent to the ring electrode.

6. The process of claim 1, further comprising performing centerless grinding after performing the molding.

7. The process of claim 1 wherein the plurality of electrodes of the electrode assembly are segmented electrodes.

8. The process of claim 7 further comprising:

attaching the segmented electrodes about a central tubing.

9. The process of claim 8 further comprising:

maintaining angular separation between the segmented electrodes using thermoplastic tape.

10. The process of claim 7 wherein the segmented electrodes are crescent shaped electrodes.

11. The process of claim 10 further comprising:

crushing each segmented about a respective conductor of the first plurality of conductors.

12. The process of claim 10 wherein the plurality of electrodes are disposed on a paddle structure.

13. A process for fabricating a medical lead for stimulation of tissue of a patient, the process comprising:

providing an electrode assembly comprising a plurality of segmented electrodes electrically coupled to a first plurality of conductors;

providing a lead body comprising a second plurality of conductors;

providing a splicing tube having a plurality of angularly spaced longitudinal grooves;

placing proximal ends of the first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube;

placing distal ends of the second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the proximal ends of the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends;

positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends;

electrically coupling the proximal ends of the first plurality of electrodes to respective proximal ends of the second plurality of electrodes;

molding insulative material about at least the electrode assembly and the splicing tube; and

fusing the splicing tube with the insulative material from the molding and the lead body.

14. The process of claim 13, wherein the electrically coupling comprises laser welding the conductive filler material such that the conductive filler material couples the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors.

15. The process of claim 13, further comprising:

removing insulative material of the lead body to release the second plurality of conductors.

16. The process of claim 13, further comprising:

providing a center tubing about a mandrel;

positioning the electrode assembly over the center tubing; and

positioning at least one spacer adjacent to the at least one electrode assembly; and

providing a second electrode assembly adjacent to the at least one spacer.

17. The process of claim 16, further comprising:

positioning a ring electrode over the center tubing; and

positioning a spacer adjacent to the ring electrode.

18. The process of claim 13, further comprising performing centerless grinding after performing the molding.

19. The process of claim 13 further comprising:

attaching the segmented electrodes about a central tubing.

20. The process of claim 19 further comprising:

maintaining angular separation between the segmented electrodes using thermoplastic tape.