Electrode arrangements for tissue stimulation and methods of use and manufacture

• US 8,660,665 B2
• Filed: 09/14/2012
• Issued: 02/25/2014
• Est. Priority Date: 12/12/2006
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Walter, Jeryle L., Terterian, Greg, Flowers, Matthew, Tong, Robert R.
• Primary Examiner(s): Layno, Carl H
• Assistant Examiner(s): GHAND, JENNIFER LEIGH-STEWAR
• Application Number:
  US13/620,196
• Publication Number:
  US 20130008026A1
• Time in Patent Office: 529 Days
• Field of Search: 600/372, 600/374, 607/2, 607/54, 607115-119, 607/129, 607141-142, 607/152
• US Class Current: 607/117
• CPC Class Codes: A61N 1/0553 Paddle shaped electrodes, e.g. for laminotomy
• CPC Class Codes: A61N 1/0558 Anchoring or fixation means therefor
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

A lead has a paddle body with a non-conductive material and multiple electrodes disposed within the non-conductive material. At least one of the electrodes includes one or more anchoring arrangement, such as opening(s) through the electrode through which the non-conductive material can pass; anchors that extend away from the electrode and into the non-conductive material of the paddle body; or flow-through anchors attached to the electrode with an opening through which the non-conductive material may pass.

Claims

1. A method of making a lead, comprising:

providing a plurality of electrodes including a first electrode, wherein the first electrode comprises a top portion, a bottom portion, and a sidewall portion extending from the top portion to the bottom portion, the first electrode defining at least one opening, wherein the sidewall portion of the first electrode defines the at least one opening; and

in a single molding operation, molding a homogeneous non-conductive material around the plurality of electrodes to form a portion of a paddle body with the non-conductive material holding the plurality of electrodes together, wherein a portion of the non-conductive material flows into and through the at least one opening of the first electrode, a portion of the non-conductive material defines at least a top surface of the paddle body, and a portion of the non-conductive material extends from the top surface of the paddle body through the at least one opening of the first electrode.

2. The method of claim 1, wherein molding a homogenous non-conductive material around the plurality of electrodes comprises flowing the non-conductive material through the at least one opening of the first electrode and then forming a solid mass with the non-conductive material.

3. The method of claim 2, wherein forming a solid mass with the non-conductive material comprises polymerizing or cross-linking the non-conductive material.

4. The method of claim 1, wherein each of the plurality of electrodes comprises a top portion, a bottom portion, and a sidewall portion extending from the top portion to the bottom portion and each of the plurality of electrodes defines at least one opening, wherein molding a homogenous non-conductive material around the plurality of electrodes comprises flowing the non-conductive material through the at least one opening of each of the plurality of electrodes.

5. The method of claim 1, further comprising attaching a conductor to each of the plurality of electrodes.

6. The method of claim 1, wherein molding the non-conductive material comprises molding the non-conductive material leaving exposed at least a portion of a top surface of each of the plurality of electrodes.

7. The method of claim 1, wherein at least one of the plurality of electrodes further comprises a first elongated side, a second elongated side opposite the first elongated side, shorter third and fourth rounded sides that extend between the first and second elongated sides, and at least one anchor that extends into the non-conductive material of the paddle body and away from the first elongated side or the second elongated side of the electrode in a direction that is parallel to a top surface of the at least one of the plurality of electrodes.

8. The method of claim 7, wherein the at least one anchor has a lateral width that is substantially less than a lateral width of the first or second elongated side from which it extends.

9. The method of claim 1, wherein the at least one opening has a slot shape.

10. A method of making a lead, comprising:

providing a plurality of electrodes including a first electrode, wherein the first electrode comprises a top surface, a first elongated side, a second elongated side opposite the first elongated side, shorter third and fourth rounded sides that extend between the first and second elongated sides, wherein the first electrode comprises a top portion, a bottom portion opposite the top portion, and a sidewall portion extending from the top portion to the bottom portion, and wherein the top portion defines a bottom surface of the top portion that is surrounded by the sidewall portion, wherein one or more flow-through anchors are disposed on the bottom surface of the top portion of the first electrode and at least one anchor that extends away from the first elongated side or the second elongated side of the first electrode in a direction that is parallel to the top surface of the first electrode, wherein the at least one anchor has a lateral width that is substantially less than a lateral width of the first or second elongated side from which it extends; and

molding a homogeneous non-conductive material around the plurality of electrodes to form a paddle body with a portion of the non-conductive material surrounding the at least one anchor.

11. The method of claim 10, wherein the at least one anchor comprises a first anchor disposed on and extending away from the first elongated side and a second anchor disposed on and extending away from the second elongated side.

12. The method of claim 11, wherein the first anchor and the second anchor are laterally offset from each other.

13. The method of claim 10, wherein the first electrode further comprises a top portion, a bottom portion opposite the top portion, and a sidewall portion extending from the top portion to the bottom portion, wherein the at least one anchor extends from, or near, the bottom portion of the first electrode.

14. The method of claim 10, wherein each of the plurality of electrodes comprises a top surface, a first elongated side, a second elongated side opposite the first elongated side, shorter third and fourth rounded sides that extend between the first and second elongated sides, and at least one anchor that extends away from the first elongated side or the second elongated side in a direction that is parallel to the top surface of the electrode from which it extends, wherein the at least one anchor has a lateral width that is substantially less than a lateral width of the first or second elongated side from which it extends.

15. The method of claim 14, wherein, for each of the plurality of electrodes, the at least one anchor comprises a first anchor disposed on and extending away from the first elongated side and a second anchor disposed on and extending away from the second elongated side.

16. The method of claim 15, wherein the first anchor and the second anchor are laterally offset from each other.

17. The method of claim 10, wherein each of the at least one anchor comprises an opening through the anchor.

18. The method of claim 17, wherein molding a homogeneous non-conductive material comprises flowing the non-conductive material through the opening of the at least one anchor.