Medical lead with segmented electrode

• US 8,000,808 B2
• Filed: 01/31/2006
• Issued: 08/16/2011
• Est. Priority Date: 01/31/2005
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Hegland, Michael, Stone, Richard T.
• Primary Examiner(s): Patel; Niketa I
• Assistant Examiner(s): Lavert; Nicole F
• Application Number:
  US11/343,667
• Publication Number:
  US 20060173262A1
• Time in Patent Office: 2,023 Days
• Field of Search: 600/393, 607/118, 607/122
• US Class Current: 607/122
• 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: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49151 by deforming or shaping
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49181 by deforming
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

A medical lead having a conductor assembly and a segmented electrode assembly. The segmented electrode assembly includes a conductive segment electrically coupled to a conductor of the conductor assembly. A passageway is positioned between an inner surface and outer surface of the conductive segment. An electrically insulating material extends through the first passageway and into a gap adjacent the conductive segment. A segmented electrode assembly is also provided. The segmented electrode assembly includes a conductive segment having a passageway between an inner surface and outer surface of the conductive segment. An electrically insulating material extends through the passageway and into a gap adjacent the conductive segment.

Claims

1. A medical lead comprising:

a conductor assembly comprising at least a first conductor;

a first segmented electrode assembly defining a hole wherein the conductor assembly passes through the hole, and wherein the first segmented electrode assembly comprises;

(i) at least a first conductive segment electrically coupled to the first conductor, the first conductive segment comprising

a first inner surface facing inward toward the conductor assembly,

a first outer surface facing tissue upon implantation, and

a first passageway defining an encapsulated space between the first inner surface and the first outer surface,

a first longitudinal edge extending from the first inner surface to the first outer surface and defining an inlet into the first passageway; and

(ii) a first gap adjacent the first longitudinal edge; and

an insulating material that extends through the first passageway and into the first gap adjacent the first conductive segment.

2. The medical lead of claim 1 wherein the first conductive segment comprises the first longitudinal edge and a second longitudinal edge, wherein the conductor assembly further comprises a second conductor, and wherein the first segmented electrode assembly further comprises:

a second conductive segment electrically coupled to the second conductor, wherein the second conductive segment comprises a second inner surface, a second outer surface, a third longitudinal edge and a fourth longitudinal edge, and wherein the second segment defines a second passageway between the second inner surface and the second outer surface, wherein the first gap is between the first longitudinal edge of the first conductive segment and the third longitudinal edge of the second conductive segment;

a second gap between the second longitudinal edge of the first conductive segment and the fourth longitudinal edge of the second conductive segment, wherein the insulating material further extends through the second passageway and extends into the second gap.

3. The medical lead of claim 1 wherein the first conductive segment comprises an inner component welded to an outer component, wherein the inner component comprises the first inner surface of the conductive segment, and a third outer surface, and wherein the outer component comprises the first outer surface of the conductive segment and a third inner surface, wherein the third inner surface faces the third outer surface.

4. The medical lead of claim 3 wherein the third outer surface comprises a first higher portion having a first diameter, and a first lower portion having a second diameter, wherein the first diameter is greater than the second diameter.

5. The medical lead of claim 1 wherein the electrically insulating material extends circumferentially along the inner surface of the first conductive segment.

6. The medical lead of claim 1, wherein the conductor assembly further comprises a second conductor, and wherein the medical lead further comprises a second segmented electrode assembly defining a second hole wherein the conductor assembly passes through the second hole, and wherein the second segmented electrode assembly comprises:

at least a second conductive segment electrically coupled to the second conductor, the second conductive segment comprising a second inner surface and a second outer surface and defining a second passageway between the second inner surface and the second outer surface; and

a second insulating material that extends through the second passageway, and wherein the second insulating material extends into at least a second gap adjacent the second conductive segment.

7. The medical lead of claim 6 wherein the first segmented electrode assembly is longitudinally spaced apart from the second segmented electrode assembly by a first space, and wherein the first space is at least partially filled with a third insulating material, wherein the first and second segmented electrode assemblies and the third insulating material form a substantially cylindrical outer shape.

8. The medical lead of claim 7 further comprising third and fourth segmented electrode assemblies, and wherein the third segmented electrode assembly is spaced apart from the second segmented electrode assembly by a second space, and wherein the fourth segmented electrode assembly is spaced apart from the third segmented electrode assembly by a third space, and wherein the second and third spaces are at least partially filled with the third insulating material, wherein the substantially cylindrical outer shape includes the third and fourth segmented electrode assemblies and the third insulating material within the second and third spaces.

9. The medical lead of claim 8 wherein the first, second, third and fourth segmented electrode assemblies each further comprise second, third and fourth conductive segments each electrically coupled to a conductor of the conductor assembly.

10. The medical lead of claim 6 wherein the first second insulating material is the same type of material as the first insulating material.

11. The medical lead of claim 10 wherein the first and second insulating materials comprise polysulfone.

12. The medical lead of claim 10 wherein the first and second insulating materials comprise PEEK.

13. The medical lead of claim 7 wherein the third insulating material comprises polyurethane.

14. The medical lead of claim 1 wherein the first conductor of the conductor assembly is coiled.

15. The medical lead of claim 1 wherein the first conductive segment is configured to define an end slot, and wherein the first conductor is welded to the first conductive segment in the end slot.

16. A segmented electrode assembly comprising:

at least a first conductive segment defining a hole, the first conductive segment comprising

a first inner surface facing the hole,

a first outer surface configured to face tissue upon implantation, and

a first passageway defining an encapsulated space between the first inner surface and the first outer surface,

a first longitudinal edge extending from the first inner surface to the first outer surface and defining an inlet into the first passageway;

a first gap adjacent the first longitudinal edge; and

an insulating material that extends through the first passageway and into the first gap adjacent the first conductive segment.

17. The segmented electrode assembly of claim 16 wherein the first conductive segment comprises the first longitudinal edge and a second longitudinal edge, the segmented electrode assembly further comprising:

a second conductive segment, wherein the second conductive segment comprises a second inner surface, a second outer surface, a third longitudinal edge and a fourth longitudinal edge, and wherein the second segment defines a second passageway between the second inner surface and the second outer surface, wherein the first gap is between the first longitudinal edge of the first conductive segment and the third longitudinal edge of the second conductive segment; and

a second gap between the second longitudinal edge of the first conductive segment and the fourth longitudinal edge of the second conductive segment, wherein the insulating material further extends through the second passageway and extends into the second gap.

18. The segmented electrode assembly of claim 16 wherein the first conductive segment comprises an inner component welded to an outer component, wherein the inner component comprises the first inner surface of the conductive segment, and a third outer surface, and wherein the outer component comprises the first outer surface of the conductive segment and a third inner surface, wherein the third inner surface faces the third outer surface.

19. The segmented electrode assembly of claim 18 wherein the third outer surface comprises a first higher portion having a first diameter, and a first lower portion having a second diameter, wherein the first diameter is greater than the second diameter.

20. The segmented electrode assembly of claim 16 wherein the electrically insulating material extends circumferentially along the inner surface of the first conductive segment.