Electrical stimulation leads having RF compatibility and methods of use and manufacture

• US 8,774,939 B2
• Filed: 12/17/2012
• Issued: 07/08/2014
• Est. Priority Date: 10/09/2008
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: McDonald, Matthew Lee
• Primary Examiner(s): Layno, Carl H
• Assistant Examiner(s): Wu, Eugene
• Application Number:
  US13/717,325
• Publication Number:
  US 20130123892A1
• Time in Patent Office: 568 Days
• Field of Search: 607/63, 607115-117, 607/119, 607/121, 607/122, 600372-374, 600/377, 600/378
• 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: A61N 1/086 Magnetic resonance imaging [MRI] compatible leads
• CPC Class Codes: H01R 43/00 Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

An implantable lead has an inner core, a plurality of coiled conductor guides, and a plurality of conductors. The inner core defines a plurality of lumens. Each coiled conductor guide defines a plurality of helical lumens. Each coiled conductor guide is disposed in a coiled arrangement over a portion of the inner core. Each of the conductors electrically couples at least one electrode to at least one terminal. At least one of the conductors includes a plurality of units. Each unit includes a first conductor segment extending along the inner core from a beginning point to a first position, a coiled conductor segment disposed at least partially in one of the lumens of the coiled conductor guides and extending from the first position to the second position, and a second conductor segment extending along the inner core from the second position to an endpoint.

Claims

1. An implantable lead having a distal end portion and a proximal end portion and comprising:

an inner core with a proximal end portion, a distal end portion, an outer surface, and a longitudinal length, the inner core defining a central lumen and a plurality of inner-core conductor lumens;

a plurality of electrodes disposed along the distal end portion of the lead;

a plurality of terminals disposed along the proximal end portion of the lead;

a plurality of coiled conductor guides wrapped around at least a portion of the inner core, each coiled conductor guide having a first end and a second end, each coiled conductor guide defining a plurality of helical lumens, wherein the plurality of coiled conductor guides are spaced apart from one another along the longitudinal length of the inner core; and

a plurality of conductors, each conductor electrically coupling at least one of the plurality of electrodes to at least one of the plurality of terminals, wherein each of the plurality of conductors is encased in conductor insulation that is separate and distinct from each of the inner core and the plurality of coiled conductor guides, wherein at least one of the plurality of conductors is a first conductor that comprises a plurality of units, each unit comprising

a first conductor segment of the first conductor extending from a beginning point to a first position,

a coiled conductor segment of the first conductor extending from the first position to a second position, and

a second conductor segment of the first conductor extending from the second position to an endpoint,

wherein the first position is between the second position and the endpoint, and the second position is between the beginning point and the first position;

wherein the first conductor extends along at least one of the plurality of inner-core conductor lumens and at least one of the plurality of helical lumens.

2. The lead of claim 1, wherein the inner core comprises a first open section and a second open section, wherein the first open section and the second open section each extend between at least one of the plurality of inner-core conductor lumens and the outer surface of the inner core.

3. The lead of claim 2, wherein one of the plurality of coiled conductor guides is a first coiled conductor guide, wherein the first open section of the inner core is defined in proximity to the first end of the first coiled conductor guide, and wherein the second open section of the inner core is defined in proximity to the second end of the first coiled conductor guide.

4. The lead of claim 1, wherein the plurality of helical lumens are concentrically arranged within the plurality of coiled conductor guides.

5. The lead of claim 1, wherein at least one of the plurality of inner-core conductor lumens houses the first conductor segment of the first conductor.

6. The lead of claim 1, wherein at least one of the plurality of inner-core conductor lumens houses the second conductor segment of the first conductor.

7. The lead of claim 1, wherein at least one of the plurality of inner-core conductor lumens houses both the first conductor segment and the second conductor segment of the first conductor.

8. The lead of claim 1, wherein at least one of the plurality of helical lumens houses the coiled conductor segment of the first conductor.

9. The lead of claim 1, wherein the plurality of inner-core conductor lumens have diameters that are no more than 1.2 times diameters of the plurality of helical lumens.

10. The lead of claim 1, wherein the plurality of inner-core conductor lumens have diameters that are at least 0.8 times diameters of the plurality of helical lumens.

11. The lead of claim 1, wherein the plurality of inner-core conductor lumens have diameters that are larger than diameters of the plurality of helical lumens.

12. The lead of claim 1, wherein the number of inner-core conductor lumens is equal to the number of helical lumens.

13. The lead of claim 1, wherein the number of inner-core conductor lumens is twice the number of helical lumens.

14. The lead of claim 1, wherein the plurality of units are positioned in series.

15. The lead of claim 1, wherein for each unit, the length of the coiled conductor segment is no more than 1.25 times the combined length of the first conductor segment and the second conductor segment and is at least 0.75 times the combined length of the first conductor segment and the second conductor segment.

16. An electrical stimulating system comprising:

the lead of claim 1;

a control module configured and arranged to electrically couple to the proximal end portion of the lead, the control module comprising

a housing, and

an electronic subassembly disposed in the housing; and

a connector configured and arranged to receive the lead, the connector comprising

a connector housing defining a port configured and arranged for receiving the proximal end portion of the lead, and

a plurality of connector contacts disposed in the connector housing, the connector contacts configured and arranged to couple to at least one of the plurality of terminals of the lead when the proximal end portion of the lead is received by the port.

17. The electrical stimulating system of claim 16, wherein the connector is disposed on the control module.

18. The electrical stimulating system of claim 16, further comprising a lead extension having a proximal end portion and a distal end portion, the connector disposed along the distal end portion of the lead extension.

19. The electrical stimulating system of claim 18, wherein the proximal end portion of the lead extension is configured and arranged for insertion into another connector.

20. A method for making an implantable lead, the method comprising:

disposing a plurality of electrodes along a distal end portion of a lead, the lead comprising an inner core defining a central lumen and a plurality of inner-core conductor lumens, and a plurality of coiled conductor guides wrapped around at least a portion of the inner core, each coiled conductor guide defining a plurality of helical lumens, wherein the plurality of coiled conductor guides are spaced apart from one another along a longitudinal length of the inner core;

disposing a plurality of terminals along a proximal end portion of the lead; and

coupling the plurality of electrodes to the plurality of terminals using a plurality of conductors, wherein each of the plurality of conductors is encased in conductor insulation that is separate and distinct from each of the inner core and the plurality of coiled conductor guides, wherein at least one of the plurality of conductors is a first conductor that comprises a plurality of units, each unit comprising

a first conductor segment of the first conductor extending from a beginning point to a first position,

a coiled conductor segment of the first conductor extending from the first position to a second position, and

a second conductor segment of the first conductor extending from the second position to an endpoint,

wherein the first position is between the second position and the endpoint, and the second position is between the beginning point and the first position;

wherein the first conductor extends along at least one of the plurality of inner-core conductor lumens and at least one of the plurality of helical lumens.