SYSTEMS AND METHODS FOR COUPLING COILED CONDUCTORS TO CONDUCTIVE CONTACTS OF AN ELECTRICAL STIMULATION SYSTEM

• US 20110034978A1
• Filed: 08/05/2009
• Published: 02/10/2011
• Est. Priority Date: 08/05/2009
• 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 8,380,325 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: 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
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

An implantable lead includes an elongated member. A plurality of electrodes are disposed on a distal end of the elongated member. A plurality of terminals are disposed on a proximal end of the elongated member. Each of a plurality of conductors electrically couples at least one of the electrodes to at least one of the terminals. The plurality of conductors are disposed in the elongated member in a coiled configuration and have an end portion. Each of a plurality of constraining elements is disposed over at least one of the plurality of conductors such that the underlying at least one of the plurality of conductors is maintained in the coiled configuration. At least one of the plurality of electrodes or terminals is disposed over the constraining element and electrically coupled to at least one of the plurality of conductors.

Claims

1. An implantable lead comprising:

an elongated member having a distal end, a proximal end, and a longitudinal length;

a plurality of electrodes disposed on the distal end of the elongated member;

a plurality of terminals disposed on the proximal end of the elongated member;

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein the plurality of conductors have an end portion, and wherein the plurality of conductors are disposed in the elongated member in a coiled configuration; and

a plurality of constraining elements disposed along at least one of the distal end or the proximal end of the elongated member, wherein each of the constraining elements is disposed over at least one of the plurality of conductors such that the underlying at least one of the plurality of conductors is maintained in the coiled configuration beneath the constraining element, and wherein at least one of the plurality of electrodes or at least one of the plurality of terminals is disposed over the constraining element and electrically coupled to at least one of the plurality of conductors.

2. The lead of claim 1, wherein the end portion of the plurality of conductors are coiled such that the conductors form a single-layer region at the end portion.

3. The lead of claim 2, wherein at least one of the plurality of constraining elements is disposed over the coiled conductors within the single-layer region.

4. The lead of claim 2, wherein the coiled conductors are coiled such that the conductors form at least one multi-layer region.

5. The lead of claim 4, wherein at least one of the plurality of constraining elements is disposed over the coiled conductors within the multi-layer region.

6. The lead of claim 1, wherein at least one of the conductors comprises at least one unit, the at least one unit comprising

a first conductor segment extending along the elongated member from a beginning point to a first position,

a second conductor segment extending along the elongated member from the first position to a second position, and

a third conductor segment extending along the elongated member from the second position to an endpoint,

wherein the first position is between the second position and the endpoint, and the second position is between beginning point and the first position.

7. The lead of claim 1, wherein at least one of the constraining elements comprises an outer conductive member disposed over a spacer.

8. The lead of claim 7, wherein at least one of the plurality of conductors is electrically coupled to at least one of the plurality of electrodes or the plurality of terminals via the outer conductive member.

9. The lead of claim 1, wherein at least one of the constraining elements is C-shaped.

10. The lead of claim 1, wherein the lead is a percutaneous lead.

11. The lead of claim 1, wherein the lead is a paddle lead.

12. An electrical stimulating system comprising:

an elongated member having a distal end, a proximal end, and a longitudinal length;

a plurality of electrodes disposed on the distal end of the elongated member;

a plurality of terminals disposed on the proximal end of the elongated member;

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein the plurality of conductors have an end portion, and wherein the plurality of conductors are disposed in the elongated member in a coiled configuration;

a plurality of constraining elements disposed along at least one of the distal end or the proximal end of the elongated member, wherein each of the constraining elements is disposed over at least one of the plurality of conductors such that the underlying at least one of the plurality of conductors is maintained in the coiled configuration beneath the constraining element, and wherein at least one of the plurality of electrodes or at least one of the plurality of terminals is disposed over the constraining element and electrically coupled to at least one of the plurality of conductors;

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

a housing, and

an electronic subassembly disposed in the housing; and

a connector for receiving the elongated member, the connector having a proximal end, a distal end, and a longitudinal length, the connector configured and arranged to receive the elongated member, 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 elongated member, 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 elongated member.

13. The electrical stimulating system of claim 12, wherein the connector is disposed on the control module.

14. The electrical stimulating system of claim 12, further comprising a lead extension having a proximal end and a distal end, the connector disposed on the distal end of the lead extension.

15. The electrical stimulating system of claim 14, wherein the lead extension comprises

an elongated member having a distal end, a proximal end, and a longitudinal length;

a plurality of connector contacts disposed on the distal end of the elongated member;

a plurality of terminals disposed on the proximal end of the elongated member;

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein the plurality of conductors have an end portion, and wherein the plurality of conductors are disposed in the elongated member in a coiled configuration; and

a plurality of constraining elements disposed along at least one of the distal end or the proximal end of the elongated member, wherein each of the constraining elements is configured and arranged for being disposed over at least one of the plurality of conductors such that the underlying at least one conductor is maintained in a coiled configuration beneath the constraining element, and wherein at least one of the plurality of connector contacts or the plurality of terminals is disposed over at least one of the plurality of constraining elements.

16. A method for forming an implantable lead, the method comprising:

a) placing a plurality of elongated conductors into a coiled configuration;

b) disposing a first constraining element over the plurality of conductors in proximity to an end portion of the conductors;

c) uncoiling a first conductor of the plurality of conductors to the first constraining element from a location closer to the end portion than the first constraining element;

d) disposing a second constraining element over a portion of the plurality of conductors such that the second constraining element is axially spaced apart from the first constraining element and is disposed closer to the end portion of the conductors than the first constraining element, wherein the uncoiled end of the first conductor extends radially from the elongated coiled conductors between the first constraining element and the second constraining element;

e) uncoiling a second conductor of the plurality of conductors to the second constraining element from a location closer to the end portion than the second constraining element;

f) disposing a first conductive contact over the first constraining element; and

g) electrically coupling the uncoiled portion of the first conductor to the first conductive contact.

17. The method of claim 16, wherein placing a plurality of elongated conductors into a coiled configuration comprises placing the plurality of elongated conductors into a coiled configuration comprising at least one single-layer region and at least one multi-layer region.

18. The method of claim 16, wherein placing a plurality of elongated conductors into a coiled configuration comprises disposing the elongated conductors over a conductor placement sleeve.

19. The method of claim 16, further comprising

h) disposing a second conductive contact over the second constraining element;

and

i) electrically coupling the uncoiled portion of the second conductor to the second conductive contact.

20. The method of claim 19, further comprising repeating d), e), h), and i) for a plurality of second constraining elements and second conductive contacts.