SYSTEMS AND METHODS FOR MAKING AND USING AN ENHANCED CONNECTOR OF AN ELECTRICAL STIMULATION SYSTEM

• US 20190030345A1
• Filed: 07/20/2018
• Published: 01/31/2019
• Est. Priority Date: 07/25/2017
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Funderburk, Jeffery Van
• Granted Patent: US 10,918,873 B2
• Time in Patent Office: Days
• CPC Class Codes: A61N 1/0476 Array electrodes (including any electrode arrangement with more than one electrode for at least one of the polarities)
• 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 1/08 Arrangements or circuits for monitoring, protecting, controlling or indicating for external stimulators A61N1/3603; for implantable neurostimulators A61N1/36128; for heart stimulators A61N1/37; for defibrillators A61N1/3925
• CPC Class Codes: A61N 1/36 for stimulation
• CPC Class Codes: A61N 1/36062 Spinal stimulation
• CPC Class Codes: A61N 1/36071 Pain
• CPC Class Codes: A61N 1/37211 Means for communicating with stimulators
• CPC Class Codes: A61N 1/37223 Circuits for electromagnetic coupling
• CPC Class Codes: A61N 1/3752 Details of casing-lead connections
• CPC Class Codes: A61N 1/3754 Feedthroughs

Abstract

An implantable control module for an electrical stimulation system includes a housing and a connector shell extending into the housing. The housing and the connector shell collectively form a sealed cavity. The connector shell has a longitudinal length, a sidewall with a cavity-facing surface, a first end open to an environment external to the housing, and an opposing closed second end. The connector shell defines a connector lumen extending within the connector shell and open at the first end to receive a portion of a lead or lead extension. Connector contacts are arranged along the connector lumen within the connector shell. An electronic subassembly is disposed in the sealed cavity. Interconnect conductors electrically couple the electronic subassembly to the connector contacts and extend from the connector shell within the sealed cavity.

Claims

1. An implantable control module for an electrical stimulation system, the control module comprising:

a housing;

a connector shell extending into the housing and collectively with the housing forming a sealed cavity, the connector shell having a longitudinal length, a sidewall with a cavity-facing surface, a first end open to an environment external to the housing, and an opposing closed second end, the connector shell defining a connector lumen extending within the connector shell and open at the first end to receive a portion of a lead or lead extension, and

a plurality of connector contacts arranged along the connector lumen within the connector shell;

an electronic subassembly disposed in the sealed cavity; and

a plurality of interconnect conductors electrically coupling the electronic subassembly to the plurality of connector contacts and extending from the connector shell within the sealed cavity.

2. The control module of claim 1, wherein the cavity is hermetically sealed.

3. The control module of claim 1, wherein the plurality of interconnect conductors extend entirely within the sealed cavity.

4. The control module of claim 1, wherein the connector shell is formed from at least one of ceramic or glass.

5. The control module of claim 1, wherein the connector shell is formed from a plurality of electrically conductive sections alternating along the longitudinal length of the connector shell with a plurality of electrically nonconductive sections, and wherein the electrically conductive sections and the electrically nonconductive sections are fixedly attached together.

6. The control module of claim 5, wherein the plurality of connector contacts comprises a first connector contact, wherein the plurality of electrically conductive sections comprises a first electrically conductive section, and wherein the first connector contact is electrically coupled to the first electrically conductive section.

7. The control module of claim 6, wherein the plurality of interconnect conductors comprises a first interconnect conductor electrically coupled to the first connector contact, the first interconnect conductor attached to the first electrically conductive section along the cavity-facing surface of the connector shell.

8. The control module of claim 1, further comprising a plurality of electrically conductive vias formed through the sidewall of the connector shell and electrically coupled to the plurality of connector contacts.

9. The control module of any one of claim 8, wherein each electrically conductive via of the plurality of electrically conductive vias is aligned along the longitudinal length of the connector shell, and electrically coupled, with a different connector contact of the plurality of connector contacts.

10. The control module of any one of claim 8, wherein the plurality of electrically conductive vias are brazed to the sidewall of the connector shell.

11. The control module of any one of claim 8, wherein the plurality of electrically conductive vias are welded to the sidewall of the connector shell.

12. The control module of any one of claim 8, wherein at least one interconnect conductor of the plurality of interconnect conductors extends through at least one electrically conductive via of the plurality of electrically conductive vias and attaches directly to one connector contact of the plurality of connector contacts.

13. The control module of any one of claim 8, wherein at least one interconnect conductor of the plurality of interconnect conductors electrically couples to at least one electrically conductive via of the plurality of electrically conductive vias.

14. An electrical stimulation system comprising:

the control module of claim 1; and

an electrical stimulation lead coupleable to the control module; and

optionally, a lead extension coupleable between the electrical stimulation lead and the control module.

15. A method for making a control module, the method comprising:

inserting a connector contact into a connector lumen extending into an open first end of a connector shell, the connector lumen configured and arranged to receive a lead or lead extension;

electrically coupling a first end of an interconnect conductor to the connector contact;

electrically coupling an opposing second end of the interconnect conductor to an electronic subassembly;

extending the connector shell into the housing with the first end of the connector shell open to an environment external to the housing; and

creating a sealed cavity formed collectively by the connector shell and the housing, wherein the electronic subassembly is disposed in the sealed cavity, and wherein the interconnect conductor extends from the connector shell to the electronic subassembly within the sealed cavity.

16. The method of claim 15, wherein electrically coupling a first end of an interconnect conductor to the connector contact comprises forming an electrically conductive via along an interconnect aperture defined along a sidewall of the connector shell.

17. The method of claim 16, wherein forming an electrically conductive via along an interconnect aperture defined along a sidewall of the connector shell comprises forming the electrically conductive via around the interconnect conductor electrically coupled to the connector contact.

18. The method of claim 16, wherein electrically coupling a first end of an interconnect conductor to the connector contact comprises electrically coupling the electrically conductive via to the connector contact and electrically coupling the first end of the interconnect conductor to the electrically conductive via.

19. The method of claim 15, wherein inserting a connector contact into a connector lumen extending into an open first end of a connector shell comprises inserting a connector contact into a connector shell comprising an electrically conductive section electrically coupled to the connector contact and attached on both sides along a longitudinal length of the connector shell to a different electrically nonconductive section.

20. The method of claim 19, wherein electrically coupling a first end of an interconnect conductor to the connector contact comprises electrically coupling the first end of the interconnect conductor to a cavity-facing surface of the electrically conductive section of the connector shell.