ELECTRODE ARRAY HAVING EMBEDDED ELECTRODES AND METHODS OF MAKING THE SAME

• US 20110313500A1
• Filed: 06/13/2011
• Published: 12/22/2011
• Est. Priority Date: 06/18/2010
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Barker, John Michael, Pianca, Anne Margaret, Pandit, Aditya Vasudeo
• Granted Patent: US 8,868,206 B2
• Time in Patent Office: Days
• US Class Current: 607/116
• CPC Class Codes: A61N 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A method of manufacturing a device for brain stimulation includes forming a lead body having a distal end section and coupling at least one pre-electrode to the distal end section of the lead body. The pre-electrode defines a divider with a plurality of partitioning arms, and has a plurality of fixing lumens. A portion of the pre-electrode aligned with the portioning arms is removed to divide the pre-electrode into a plurality of segmented electrodes. Each of the plurality of segmented electrodes defines at least one of the plurality of fixing lumens at least partially disposed through the segmented electrode. A material is introduced through the at least one fixing lumen to couple the plurality of segmented electrodes to the lead body.

Claims

1. A method of manufacturing a device for brain stimulation, the method comprising:

forming a lead body having a distal end section;

coupling at least one pre-electrode to the distal end section of the lead body, the pre-electrode defining a divider with a plurality of partitioning arms, and having a plurality of fixing lumens;

removing a portion of the pre-electrode aligned with the partitioning arms to divide the pre-electrode into a plurality of segmented electrodes, each of the plurality of segmented electrodes defining at least one of the plurality of fixing lumens at least partially disposed through the segmented electrode; and

introducing a material through the at least one fixing lumen to couple the plurality of segmented electrodes to the lead body.

2. The method of claim 1, wherein the at least one fixing lumen is a through hole.

3. The method of claim 1, wherein each of the at least one segmented electrode further defines at least one conductor lumen.

4. The method of claim 3, further comprising disposing at least one conductor within each of the at least one conductor lumen.

5. The method of claim 1, wherein introducing a material comprises reflowing a portion of the lead body through the at least one fixing lumen.

6. A device for brain stimulation, comprising:

an insulative tubing having a distal end section;

at least one electrode frame disposed on the distal end section of the insulative tubing, the at least one electrode frame being formed of an insulative material, each of the at least one electrode frame defining at least one electrode cavity; and

a plurality of segmented electrodes, wherein at least one of the plurality of segmented electrodes is disposed within each of the at least one electrode cavity.

7. The device of claim 6, wherein the insulative tubing further defines a plurality of conductor lumens configured and arranged to receive a plurality of conductors.

8. The device of claim 6, wherein the insulative tubing further defines a stylet lumen configured and arranged to receive a stylet.

9. The device of claim 6, wherein each of the at least one electrode frame is substantially cylindrical and has a longitudinal cutout for coupling the at least one electrode frame to the insulative tubing.

10. The device of claim 6, wherein each of the at least one electrode frame further defines at least one groove for housing a conductor.

11. The device of claim 6, wherein the cross-sectional shape of the at least one electrode cavity corresponds to the cross-sectional shape of the plurality of segmented electrodes.

12. The device of claim 6, wherein at least one portion of the outer surface of each of the at least one electrode frame is removed to expose a portion of a segmented electrode.

13. The device of claim 6, wherein each of the plurality of segmented electrodes comprises at least one fastening feature for coupling the segmented electrode to a one of the at least one electrode cavity.

14. A method of manufacturing a device for brain stimulation, the method comprising:

forming an insulative carrier having a plurality of apertures for receiving a plurality of segmented electrodes;

coupling a plurality of segmented electrodes to the insulative carrier, wherein a one of the plurality of segmented electrodes is disposed within each of the plurality of apertures, each of the plurality of segmented electrodes having at least one flange for securing the segmented electrode within the insulative carrier; and

wrapping the insulative carrier around a mandrel to form a cylindrical lead body.

15. The method of claim 14, wherein each of the at least one flange is configured to mate with a side of at least one of the apertures.

16. The method of claim 14, further comprising forming at least one hole on a face of the insulative carrier, the at least one hole being configured and arranged to receive a conductor.

17. The method of claim 14, wherein coupling a plurality of segmented electrodes comprises press fitting the plurality of segmented electrodes into the plurality of apertures of the insulative carrier.

18. A method of manufacturing a device for brain stimulation, the method comprising:

forming an insulative tubing having a distal end section;

forming at least one conductor lumen through the insulative tubing, the at least one conductor lumen extending longitudinally through the insulative tubing;

introducing a plurality of electrode tubes through the at least one conductor lumen of the insulative tubing, and

removing a portion of the outer surface of the insulative tubing to expose a portion of a one of the at least one electrode tube.

19. The method of claim 18, wherein each of the at least one electrode tube defines a groove configured to secure the electrode tube to the insulative tubing.

20. The method of claim 18, wherein forming at least one conductor lumen comprises forming a plurality of conductor lumens equally spaced about the circumference of the insulative tubing.