Catheter with thin film electrodes and method for making same

• US 6,400,976 B1
• Filed: 08/09/2000
• Issued: 06/04/2002
• Est. Priority Date: 10/20/1998
• Status: Expired due to Fees

• Current Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Original Assignee: Micronet Medical, Inc. (Abbott Laboratories Incorporated)
• Inventors: Champeau, Eugene J.
• Primary Examiner(s): LAYNO, CARL HERNANDZ
• Application Number:
  US09/635,319
• Time in Patent Office: 664 Days
• Field of Search: 607/116, 607/119, 607/122, 600/374
• US Class Current: 600/374
• CPC Class Codes: A61B 18/1492 having a flexible, catheter-like structure, e.g. for heart ablation A61B18/1477 takes precedence
• CPC Class Codes: A61B 2018/00011 with fluids
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61B 2018/00148 with metal
• CPC Class Codes: A61B 2018/0016 Energy applicators arranged in a two- or three dimensional array
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/287 Holders for multiple electrodes, e.g. electrode catheters for electrophysiological study [EPS]
• CPC Class Codes: A61B 5/6852 Catheters

Abstract

An electrical lead for sensing electrical activity with the body of the patient and for applying electrical energy to selected body tissue comprises an elongated, flexible polymeric lead body having one or more conductors extending the length thereof, the conductors being connected at their distal end to electrode pads where the pads each comprise a multi-layer thin metallic film structure formed on the surface of the lead body where the overall thickness of the composite electrodes are less than about 5 microns. As such, the electrodes do not adversely impact the ability of the distal end portion of the catheter to flex and conform to tissue structures where sensing is to be taken and therapy delivered via the lead.

Claims

1. A medical lead, comprising:

a lead body including at least one conductor, the lead body having an outer surface; and

at least one electrode attached to the outer surface, the electrode comprising a plurality of adjacent metallic film layers, at least two adjacent metallic film layers bonded by electron bombardment.

2. A lead, as in claim 1, wherein an innermost metallic film layer is a metal selected from a group consisting of Ti, Cr, Ni, and Al.

3. A lead, as in claim 2, wherein the metallic film layer adjacent the innermost metallic film layer is a metal selected from a group consisting of Pd and Pt.

4. A lead, as in claim 1 wherein an outermost metallic film layer is a metal selected from a group consisting of Au, Pt and Pt—

Ir.

5. A lead, as in claim 4, wherein a metallic film layer adjacent the outermost metallic film layer is a metal selected from a group consisting of Ag, Pt, Cu and Au.

6. A lead, as in claim 1, wherein the lead body has an outside diameter in a range of from about 2 F to about 11.5 F.

7. A method of manufacturing medical leads, comprising:

providing a lead body including at least one conductor, the lead body having an outer surface;

depositing a plurality of metallic film layers, at least two of the metallic film layers adjacent to one another; and

bombarding the metallic film layers with accelerated ions to bond at least two of the adjacent metallic film layers.

8. A method, as in claim 7, further comprising masking the lead body to form a plurality of discrete areas on the lead body on which the metal film layers are formed.

9. A method, as in claim 7, wherein at least one of the metallic film layers has a thickness between 500 angstroms and 1 micron.

10. The method as in claim 7, wherein at least one of the metallic film layer has a thickness less than about 250 microns.

11. A method, as in claim 7, wherein at least one metallic film layer is a metal selected from a group consisting of Ag, Al, Au, Cr, Cu, Ni, Pd, Pt, Pt—

Ir and Ti.

12. A method, as in claim 7, wherein the lead body is a polymer selected from a group consisting of PTFE, PET, PVC, PFA, e-PTEB, polyethylene, silicone rubber, polyurethane, polyamide, polyimide and FEP.

13. A method, as in claim 7, wherein the bombarding ions are selected from a group consisting of Ar, N, and O.