System for separating conductors

• US 8,857,048 B2
• Filed: 12/03/2012
• Issued: 10/14/2014
• Est. Priority Date: 06/29/2009
• 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): ARBES, CARL J
• Application Number:
  US13/692,824
• Publication Number:
  US 20130087541A1
• Time in Patent Office: 680 Days
• Field of Search: 297/45, 297/49, 297/50
• US Class Current: 29/745
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: B23K 26/00 Working by laser beam, e.g. welding, cutting or boring
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49158 with molding of insulated base
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/532 Conductor
• CPC Class Codes: Y10T 29/53217 Means to simultaneously assemble multiple, independent conductors to terminal
• CPC Class Codes: Y10T 29/53222 Means comprising hand-manipulatable implement

Abstract

A method for forming a lead or lead extension includes forming an arrangement of elongated conductors. Each of the conductors extends from a proximal end of the arrangement to a distal end of the arrangement. Each of the conductors includes a layer of insulation disposed over a conductive core. A conductor-separating element is disposed over either the proximal end or the distal end of the arrangement. The conductor-separating element includes a plurality of ablation windows defined in a body. An end of at least one of the elongated conductors is radially extended over a portion of the conductor-separating element such that a portion of the at least one elongated conductor extends across at least one of the ablation windows. Insulation from the portion of the at least one conductor extending across the ablation window is ablated to expose a portion of the conductive core of the elongated conductor.

Claims

1. A kit for making a lead or lead extension, the kit comprising

an elongated bundle of conductor wires, each conductor wire comprising a conductive core and a layer of insulation disposed over the conductive core;

a wire-separating element comprising

a solid body defining a center, an outer rim, and a plurality of windows disposed circumferentially around the body,

a mounting aperture configured and arranged to receive the bundle of conductor wires, wherein the mounting aperture is positioned at the center of the body,

a plurality of retention devices disposed around the outer rim of the body, each retention device configured and arranged to receive, and retain, an end of one of the conductor wires which passes through the center aperture and is bent over, and extended along, the body of the conductor-separating element,

wherein, the plurality of windows are positioned such that, when a one of the conductors is extended along the body of the conductor-separating element and received in a one of the retention devices, the one of the conductors has a portion that is entirely exposed through a one of the windows; and

a laser ablation system configured and arranged to ablate a portion of the layer of insulation of each of the conductor wires through the windows.

2. The kit of claim 1, wherein the plurality of windows are radially staggered so that each window is a different distance from the center of the body.

3. The kit of claim 2, wherein the plurality of windows are arranged in a spiral.

4. The kit of claim 1, wherein the wire-separating element comprises a plurality of spokes coupling the outer rim to the mounting aperture.

5. The kit of claim 4, wherein each of the windows is defined by the outer rim, the mounting aperture, and two adjacent spokes of the plurality of spokes.

6. The kit of claim 1, wherein the wire-separating element comprises a plurality of lumens radiating out from the mounting aperture and configured and arranged to receive individual ones of the conductor wires.

7. The kit of claim 1, wherein the bundle of conductor wires comprises at least eight conductor wires.

8. The kit of claim 7, wherein the wire-separating element is configured and arranged to simultaneously and individually receive each of the conductor wires in different retention devices of the plurality of retention devices.

9. The kit of claim 1, further comprising a plurality of electrodes configured and arranged for electrically coupling to the conductor wires after ablation of the layer of insulation, wherein the windows are sized to permit coupling of the electrodes to the conductor wires while the conductor wires are exposed through the windows.

10. The kit of claim 1, further comprising a plurality of terminals configured and arranged for electrically coupling to the conductor wires after ablation of the layer of insulation, wherein the windows are sized to permit coupling of the terminals to the conductor wires while the conductor wires are exposed through the windows.

11. The kit of claim 1, further comprising a plurality of conductive contacts configured and arranged for electrically coupling to the conductor wires after ablation of the layer of insulation, wherein the windows are sized to permit coupling of the conductive contacts to the conductor wires while the conductor wires are exposed through the windows.

12. The kit of claim 1, wherein each of the conductor wires is multi-filar.

13. The kit of claim 1, wherein each of the conductor wires is a single filament.

14. A wire-separating element, comprising:

a solid body defining a center, an outer rim, and a plurality of windows disposed circumferentially around the body;

a mounting aperture configured and arranged to receive a bundle of conductor wires, wherein the mounting aperture is positioned at the center of the body; and

a plurality of retention devices disposed around the outer rim of the body, each retention device configured and arranged to receive, and retain, an end of one of the conductor wires which passes through the center aperture and is bent over, and extended along, the body of the conductor-separating element;

wherein the plurality of windows are positioned such that, when a one of the conductors is extended along the body of the conductor-separating element and received in a one of the retention devices, the one of the conductor wires has a portion that is entirely exposed through a one of the windows to allow ablation of a layer of insulation on the conductor wire.

15. The wire-separating element of claim 14, wherein the plurality of windows are radially staggered so that each window is a different distance from the center of the body.

16. The wire-separating element of claim 15, wherein the plurality of windows are arranged in a spiral.

17. The wire-separating element of claim 14, further comprising a plurality of spokes coupling the outer rim to the mounting aperture.

18. The wire-separating element of claim 17, wherein each of the windows is defined by the outer rim, the mounting aperture, and two adjacent spokes of the plurality of spokes.

19. The wire-separating element of claim 14, further comprising a plurality of lumens radiating out from the mounting aperture and configured and arranged to receive individual ones of the conductor wires.

20. The wire-separating element of claim 14, wherein the wire-separating element is configured and arranged to simultaneously and individually receive at least eight conductor wires in different retention devices of the plurality of retention devices.