Lead body with inner and outer co-axial coils

• US 8,560,084 B2
• Filed: 08/30/2011
• Issued: 10/15/2013
• Est. Priority Date: 08/30/2011
• Status: Active Grant

• Current Assignee: Cirtec Medical Corp.
• Original Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Inventors: Geroy, Jesse, Swoyer, John
• Primary Examiner(s): MALAMUD, DEBORAH LESLIE
• Application Number:
  US13/220,913
• Publication Number:
  US 20130053864A1
• Time in Patent Office: 777 Days
• Field of Search: 607 1- 2, 607115-116, 607/118, 600372-373, 600/377, 606/129
• US Class Current: 607/116
• 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: H01B 7/048 for implantation into a human or animal body, e.g. pacemaker leads
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

A biomedical conductor assembly adapted for at least partial insertion in a living body. The conductor assembly includes a plurality of the first electrical conductors each covered with an insulator and helically wound in a first direction to form an inner coil with a lumen. A plurality of second electrical conductors each including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a plurality of cables. Each cable is covered with an insulator and helically wound in a second opposite direction forming an outer coil in direct physical contact with the inner coil. The inner and outer coils are covered by an insulator. A method of making the conductor assembly and implanting a neurostimulation system is also disclosed.

Claims

1. A biomedical conductor assembly adapted for at least partial insertion in a living body, the conductor assembly comprising:

a plurality of first electrical conductors, each first electrical conductor being covered with an insulator;

a plurality of second electrical conductors, at least one of the plurality of second electrical conductors including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a cable, each cable being covered with an insulator, the un-insulated wires being movable with respect to each other within the insulator, wherein the plurality of the first electrical conductors are helically wound in a first direction to form an inner coil with a lumen, and the plurality of the second electrical conductors are helically wound in a second opposite direction to form an outer coil around an outside of the inner coil and in direct physical contact with the inner coil, wherein the inner coil is substantially concentric with the outer coil; and

an insulator covering the inner and outer coils.

2. The conductor assembly of claim 1, wherein the inner coil is slidable relative to the outer coil within the conductor assembly.

3. The conductor assembly of claim 1, wherein at least one of the plurality of first electrical conductors includes a plurality of discrete insulated wires.

4. The conductor assembly of claim 1, wherein at least one of the plurality of first electrical conductors includes a plurality of un-insulated wires that are twisted in a ropelike configuration around a central axis to form a cable, wherein the cable is covered with an insulator.

5. The conductor assembly of claim 1, wherein at least one of the un-insulated wires of the at least one of the plurality of second electrical conductors includes a core of a first material surrounded by a covering of a second material.

6. The conductor assembly of claim 1, wherein at least one of the plurality of second electrical conductors includes a center wire of a homogeneous material and a plurality of un-insulated wires that are twisted in a ropelike configuration around the center wire.

7. The conductor assembly of claim 1, wherein at least one of the plurality of second electrical conductors includes a plurality of un-insulated wires wrapped around a center wire, wherein the center wire includes a breaking strength greater than a breaking strength of the un-insulated wires.

8. The conductor assembly of claim 1, wherein the inner coil includes four discrete insulated wires and the outer coil includes four or eight discrete insulated cables.

9. A biomedical conductor assembly adapted for at least partial insertion in a living body, the conductor assembly comprising:

a plurality of first electrical conductors that are each covered with an insulator and are helically wound in a first direction to form an inner coil with a lumen;

a plurality of second electrical conductors that are helically wound in a second opposite direction forming an outer coil around an outside of the inner coil and in direct physical contact with the inner coil, each of the second electrical conductors including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis and covered with an insulator, wherein the inner coil is substantially concentric with the outer coil; and

an insulator covering the inner and outer coils.

10. A therapy delivery element comprising:

an elongated lead body including a proximal end and a distal end, the lead body including;

a plurality of first electrical conductors, each of the plurality of first electrical conductors being covered with an insulator and helically wound in a first direction to form an inner coil with a lumen;

a plurality of second electrical conductors, each of the plurality of second electrical conductors including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a plurality of cables, each cable being covered with an insulator and helically wound in a second opposite direction to form an outer coil around an outside of the inner coil and in direct physical contact with the inner coil, wherein the inner coil is substantially concentric with the outer coil; and

an insulator covering the inner and outer coils.

11. The therapy delivery element of claim 10, comprising a stylet wire including:

a distal end configured to be inserted into the lumen of the inner coil through an opening at the proximal end of the lead body; and

a proximal end attached to a stylet handle.

20. A method of implanting a neurostimulation system comprising:

steering, using the stylet wire, the distal end of the therapy delivery element of claim 11 to a target location within the living body;

removing the stylet from the therapy delivery element;

implanting an implantable pulse generator within the living body; and

electrically coupling the electrical contacts at the proximal end of the therapy delivery element with the implantable pulse generator.

12. A neurostimulation system comprising:

an implantable pulse generator; and

a therapy delivery element including;

an elongated lead body including a proximal end and a distal end, the distal end including at least one electrode, the lead body including;

a plurality of first electrical conductors, each of the plurality of first electrical conductors being covered with an insulator and helically wound in a first direction to form an inner coil with a lumen;

a plurality of second electrical conductors, each of the plurality of second electrical conductors including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a plurality of cables, each cable being covered with an insulator and helically wound in a second opposite direction to form an outer coil around an outside of the inner coil and in direct physical contact with the inner coil, wherein the inner coil is substantially concentric with the outer coil; and

an insulator covering the inner and outer coils;

an electrically conductive connector operatively associated with the proximal end of the lead body, wherein the connector and the at least one electrode are electrically coupled with one of the plurality of first electrical conductors or the plurality of second electrical conductors, wherein the connector is configured to electrically couple with the implantable pulse generator; and

a stylet wire including;

a distal end configured to be inserted into the lumen of the inner coil through an opening at the proximal end of the lead body; and

a proximal end attached to a stylet handle.

13. A method of making a therapy delivery element adapted for at least partial insertion in a living body, the method comprising:

helically winding a plurality of first electrical conductors in a first direction to form an inner coil with a lumen, each of the plurality of first electrical conductors being covered with an insulator;

helically winding a plurality of second electrical conductors in a second opposite direction to form an outer coil around an outside of the inner coil and in direct physical contact with the inner coil, each of the second electrical conductors including a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a plurality of cables, each cable being covered with an insulator, wherein the inner coil is substantially concentric with the outer coil;

applying an insulator covering to the inner and outer coils to form a lead body;

attaching at least one electrically conductive connector to a proximal end of the lead body; and

attaching at least one electrode to a distal end of the lead body, wherein the at least one electrode and the at least one connector are electrically coupled with one of the plurality of first electrical conductors or the plurality of second electrical conductors.

14. The method of claim 13, wherein the inner coil is slidable relative to the outer coil within the conductor assembly.

15. The method of claim 13, wherein at least one of the plurality of first electrical conductors includes a plurality of discrete insulated wires.

16. The method of claim 13, wherein at least one of the plurality of first electrical conductors includes a plurality of un-insulated wires twisted in a ropelike configuration around a central axis to form a cable, the cable being covered with an insulator, the un-insulated wires being movable with respect to each other within the insulator.

17. The method of claim 13, wherein at least one of the plurality of second electrical conductors includes a plurality of un-insulated wires wrapped around a center wire, wherein the center wire includes a breaking strength greater than a breaking strength of the un-insulated wires.

18. The method of claim 13, wherein the inner coil includes four discrete insulated wires and the outer coil includes four or eight discrete insulated cables.

19. The method of claim 13, comprising inserting a distal end of a stylet wire into the lumen of the inner coil through an opening at the proximal end of the therapy delivery element.