Methods for making leads with radially-aligned segmented electrodes for electrical stimulation systems

• US 8,875,391 B2
• Filed: 12/13/2010
• Issued: 11/04/2014
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Pianca, Anne Margaret, Orinski, William George
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US12/966,740
• Publication Number:
  US 20110078900A1
• Time in Patent Office: 1,422 Days
• Field of Search: 29842-844, 29846-848, 298/57, 298/58, 298/60, 298/61, 298/74, 298/76, 29882-884, 600/373, 600/393, 600/395, 607/115, 607/11, 607/116, 607/118
• US Class Current: 29/883
• 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 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: Y10T 29/49149 by metal fusion bonding
• CPC Class Codes: Y10T 29/49151 by deforming or shaping
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/49218 with deforming
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

A method of making a stimulation lead includes attaching multiple segmented electrodes to a carrier. Each of the segmented electrodes has a curved form extending over an arc in the range of 10 to 345 degrees. The method further includes attaching conductors to the segmented electrodes; forming the carrier into a cylinder with segmented electrodes disposed within the cylinder; molding a lead body around the segmented electrodes disposed on the carrier; and removing at least a portion of the carrier to separate the segmented electrodes.

Claims

1. A method of making a stimulation lead, the method comprising:

attaching a plurality of segmented electrodes to a carrier, each of the segmented electrodes has a curved rectangular form extending over an arc in the range of 10 to 345 degrees;

attaching a plurality of conductors to the plurality of segmented electrodes;

forming the carrier into a cylinder with the plurality of segmented electrodes disposed within the cylinder, wherein the carrier has at least one slot or tab formed on an edge or perimeter of the carrier to aid in alignment when the carrier is formed into the cylinder;

molding a lead body around the plurality of segmented electrodes disposed on the carrier, wherein the plurality of segmented electrodes form at least two sets of segmented electrodes, wherein each of the at least two sets contains at least two of the segmented electrodes disposed around a circumference of the lead body at a same longitudinal position on the lead body; and

removing at least a portion of the carrier to separate the segmented electrodes.

2. The method of claim 1, wherein removing at least a portion of the carrier comprises grinding the carrier to remove the portion of the carrier.

3. The method of claim 2, wherein grinding the carrier to remove the portion of the carrier comprises grinding all of the carrier away.

4. The method of claim 1, wherein the carrier is a metal or alloy carrier.

5. The method of claim 1, wherein molding the lead body comprises disposing the carrier and plurality of segmented electrodes in a mold and introducing a material into the mold to form the lead body.

6. The method of claim 1, further comprising attaching at least one ring electrode to the carrier.

7. The method of claim 6, where each of the at least one ring electrode has a notch in an edge of the ring electrode to facilitate attached of a conductor to the ring electrode.

8. The method of claim 1, wherein each of the segmented electrodes comprises a tab and wherein molding the lead body comprises molding the lead body around the segmented electrodes so that the tabs on the segmented electrodes extend into the lead body.

9. The method of claim 8, wherein the tab defines at least one hole through the tab.

10. The method of claim 1, wherein each of the segmented electrodes has a curved form extending over an arc in the range of 50 to 180 degrees.

11. The method of claim 1, wherein forming the carrier into a cylinder comprises forming the carrier into a cylinder around a mandrel.

12. The method of claim 1, wherein attaching the plurality of conductors to the plurality of segmented electrodes comprises attaching at least one of the plurality of conductors to each of the segmented electrodes.

13. The method of claim 1, wherein each of the segmented electrodes comprises a corrugated interior surface.

14. The method of claim 1, wherein each of the sets comprises at least three of the segmented electrodes.

15. The method of claim 14, further comprising attaching two ring electrodes to the carrier.

16. The method of claim 15, wherein one of the two ring electrodes is disposed distal to all of the segmented electrodes and another of the two ring electrodes is disposed proximal to all of the segmented electrodes.

17. The method of claim 1, wherein each of the segmented electrodes comprises two tabs disposed on opposite ends of the segmented electrode and wherein molding the lead body comprises molding the lead body around the segmented electrodes so that the tabs on the segmented electrodes extend into the lead body.

18. The method of claim 1, wherein carrier comprises two slots or tabs formed in the carrier opposite each other to aid in alignment when the carrier is formed into a cylinder.