Lead with transition and methods of manufacture and use

• US 8,688,235 B1
• Filed: 07/22/2008
• Issued: 04/01/2014
• Est. Priority Date: 07/22/2008
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Pianca, Anne M., Phillips, Mathew J., Howard, Joshua D.
• Primary Examiner(s): Koharski, Christopher D
• Assistant Examiner(s): Dinga, Roland
• Application Number:
  US12/177,823
• Time in Patent Office: 2,079 Days
• Field of Search: 607115-117, 607/119, 607/122
• US Class Current: 607/122
• 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 1/372 Arrangements in connection with the implantation of stimulators

Abstract

A lead has a first lead section; a second lead section; and a transition member disposed between the first and second lead sections at a transition site. Material of at least one of the first lead section and the second lead section passes through openings in the transition member.

Claims

1. A lead, comprising:

a first lead section having a proximal end and a distal end;

a plurality of conductive contacts disposed along the proximal end of the first lead section;

a second lead section having a proximal end and a distal end;

a plurality of electrodes disposed along the distal end of the second lead section; and

a transition member disposed radially between the distal end of the first lead section and the proximal end of the second lead section at a transition site, wherein the transition member comprises a first opening in a first end, a second opening in a second end, and a plurality of additional openings between the first and second ends of the transition member, wherein material of at least one of the first lead section and the second lead section passes through the additional openings in the transition member to facilitate joining the first lead section to the second lead section.

2. The lead of claim 1, wherein the first lead section comprises a first material and the second lead section comprises a second material different from the first material.

3. The lead of claim 2, wherein the first material is polyurethane and the second material is silicone.

4. The lead of claim 2, wherein the first material is silicone and the second material is polyurethane.

5. The lead of claim 1, wherein the lead is isodiametric along the transition site and portions of the first and second lead sections adjacent the transition member.

6. The lead of claim 1, wherein the distal end of the first lead section has an outer diameter smaller than a portion of the first lead section adjacent the distal end and wherein the transition member is at least partially disposed over the distal end of the first lead section.

7. The lead of claim 6, wherein the distal end of the first lead section is stepped.

8. The lead of claim 6, wherein the transition member is a weave with a helical, spiral, or double helical shape disposed on the distal end of the first lead section with the smaller outer diameter.

9. The lead of claim 1, wherein the transition member is a weave with a helical, spiral, or double helical shape.

10. The lead of claim 1, wherein the first lead section comprises at least one rib extending along a primary surface of the distal end of the first lead section, wherein the second lead section and the distal end of the first lead section overlap so that the at least one rib interacts with material of the second lead section to facilitate joining of the first and second lead sections.

11. The lead of claim 1, wherein the second lead section comprises at least one rib extending along a primary surface of the proximal end of the second lead section, wherein the first lead section and the proximal end of the second lead section overlap so that the at least one rib interacts with material of the first lead section to facilitate joining of the first and second lead sections.

12. The lead of claim 1, wherein the distal end of the first lead section comprises a first portion that has an outer diameter smaller than a portion of the first lead section proximally adjacent the distal end and a second portion, distal to the first portion, that has an outer diameter larger then the first portion, wherein the transition member is at least partially disposed over the first and second portions of the distal end of the first lead section.

13. The lead of claim 1, wherein the proximal end of the second lead section comprises a first portion that has an outer diameter smaller than a portion of the second lead section distally adjacent the proximal end and a second port on, proximal to the first portion, that has an outer diameter larger then the first portion, wherein the transition member is at least partially disposed over the first and second portions of the proximal end of the second lead section.

14. A method of making a lead, the method comprising

joining a first lead portion and a second lead portion at a transition site, wherein the lead comprises a plurality of conductive contacts disposed along a proximal end of the first lead portion and a plurality of electrodes disposed along a distal end of the second lead portion;

and

disposing a transition member radially between the distal end of the first lead portion and the proximal end of the second lead portion, wherein the transition member comprises a first opening in a first end, a second opening in a second end, and a plurality of additional openings between the first and second ends of the transition member with material of at least one of the first lead portion and the second lead portion passing through the additional openings in the transition member to facilitate joining of the first and second lead portions.

15. The method of claim 14, wherein disposing a transition member comprises, prior to joining the first and second lead portions, disposing the transition member on the distal end of the first lead portion that has an outer diameter smaller than a portion of the first lead portion adjacent the distal end.

16. The method of claim 15, wherein disposing the transition member on the distal end of the first lead portion comprising disposing the transition member on the distal end of the first lead portion, wherein the distal end is tapered.

17. The method of claim 15, wherein disposing the transition member on the distal end of the first lead portion comprising disposing the transition member on the distal end of the first lead portion, wherein the distal end is stepped.