MODULAR LEAD END

• US 20170266432A1
• Filed: 06/02/2017
• Published: 09/21/2017
• Est. Priority Date: 10/28/2011
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Seeley, Dale F., Hegland, Michael T.
• Granted Patent: US 9,962,539 B2
• Time in Patent Office: Days
• CPC Class Codes: A61B 2562/0209 Special features of electrodes classified in A61B5/24, A61B5/25, A61B5/283, A61B5/291, A61B5/296, A61B5/053
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 2562/222 Electrical cables or leads therefor, e.g. coaxial cables or ribbon cables
• CPC Class Codes: A61B 2562/227 Sensors with electrical connectors
• CPC Class Codes: A61B 5/283 Invasive
• CPC Class Codes: A61B 5/6867 specially adapted to be attached or implanted in a specific body part A61B5/6847 takes precedence
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

Various embodiments of this disclosure concern assembly of a lead having one or two modular lead ends. A modular lead end can be made by aligning a plurality of wires exposed on an end of a main lead body with a plurality of conductors exposed on an end of a lead end. The lead end may comprise a spine, the plurality of conductors circumferentially arrayed about the spine, and an outer surface comprising a plurality of exposed electrical elements and polymer material, the plurality of electrical elements arrayed on the spine and electrically connected with the plurality of conductors. The assembly can further include making electrical connections between the plurality of electrical wires and the plurality of conductors and insulating the plurality of wires and the plurality of conductors.

Claims

1. A modular lead end comprising:

a spine formed from a polymer material and extending over a length from a proximal end thereof to a distal end thereof, the spine comprising a plurality paths extending lengthwise, and a plurality of projection sets spaced apart from one another along the length of the spine, each projection set including a plurality of outward extending projections spaced apart from one another around a periphery of the spine, and each path being formed between adjacent projections within each projection set;

a plurality of electrical elements, each electrical element extending over, and being supported by a corresponding projection set of the spine_so that an inner surface of each electrical element faces the corresponding projection set, the inner surface of each electrical element being terminated by an edge that defines an end of the corresponding electrical element;

a plurality of conductors, each conductor extending within a respective path of the plurality of paths of the spine, and each conductor including a feature that projects outward from the corresponding path and abuts the edge of a corresponding electrical element; and

a plurality of electrical connections, each connection comprising a weld between the feature of each conductor and the corresponding electrical element where the feature abuts the edge of the electrical element; and

wherein a degree to which the feature of each conductor projects outward prevents movement of the feature past the edge and along the inner surface of the corresponding electrical element.

2. The modular lead end of claim 1, wherein each electrical element includes an inward projection engaged with one of the plurality of projections of the corresponding projection set of the spine.

3. The modular lead end of claim 1, wherein the end of each electrical element is circular, and the feature of each conductor comprises a circular end matching up with the circular end of the corresponding electrical element.

4. The modular lead end of claim 1, wherein:

the plurality of electrical elements comprise a plurality of electrodes;

the spine further comprises a proximal section extending between the plurality of projection sets and the proximal end of the spine, the proximal section having a plurality of longitudinal channels arrayed around a circumference of the spine, the channels being aligned with the paths; and

each conductor extends within a corresponding channel of the plurality of longitudinal channels of the spine proximal section so that a proximal end of each conductor is aligned with the proximal end of the spine.

5. The modular lead end of claim 4, further comprising:

a plurality of polymer sections extending around the spine and being spaced from one another along the length of the spine; and

wherein each electrode is located between each adjacent pair of polymer sections, being in contact therewith proximally and distally; and

the proximal section of the spine extends between the plurality of polymer sections and the proximal end of the spine.

6. An implantable lead comprising:

a main lead body including a plurality of electrical wires;

a modular lead end comprising;

a spine formed from a polymer material and extending over a length from a proximal end thereof to a distal end thereof, the spine comprising a plurality paths extending lengthwise, and a plurality of projection sets spaced apart from one another along the length of the spine, each projection set including a plurality of outward extending projections spaced apart from one another around a periphery of the spine, and each path being formed between adjacent projections within each projection set;

a plurality of electrodes, each electrode extending over, and being supported by a corresponding projection set of the spine so that an inner surface of each electrode faces the corresponding projection set, the inner surface of each electrode being terminated by an edge that defines an end of the corresponding electrode;

a plurality of conductors, each conductor extending within a respective path of the plurality of paths of the spine, each conductor including a feature that projects outward from the corresponding path and abuts the edge of a corresponding electrode, each conductor having a proximal end aligned with the proximal end of the spine, and each conductor, in proximity to the proximal end thereof, being overlapped by a corresponding wire of the plurality of electrical wires of the main lead body; and

a plurality of electrical connections, each connection comprising a weld between the feature of each conductor and the corresponding electrode where the feature abuts the edge of the electrode; and

a plurality of joints, each joint formed between one of the plurality of electrical wires and a corresponding conductor where the wire overlaps the conductor; and

wherein a degree to which the feature of each conductor projects outward prevents movement of the feature past the edge and along the inner surface of the corresponding electrode.

7. The lead of claim 6, wherein each electrode of the modular lead end includes an inward projection engaged with one of the plurality of projections of the corresponding projection set of the spine.

8. The lead of claim 6, wherein the end of each electrode of the modular lead end is circular, and the feature of each conductor of the modular lead end comprises a circular end matching up with the circular end of the corresponding electrode.

9. The lead of claim 6, wherein:

the spine of the modular lead end further comprises a proximal section extending between the plurality of projection sets and the proximal end of the spine, the proximal section having a plurality of longitudinal channels arrayed around a circumference of the spine, the channels being aligned with the paths; and

each conductor of the modular lead end extends within a corresponding channel of the plurality of longitudinal channels of the spine proximal section.