Leads with electrode carrier for segmented electrodes and methods of making and using

• US 8,897,891 B2
• Filed: 07/25/2013
• Issued: 11/25/2014
• Est. Priority Date: 08/03/2012
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Romero, Daniel James
• Primary Examiner(s): Holmes, Rex R
• Application Number:
  US13/951,057
• Publication Number:
  US 20140039587A1
• Time in Patent Office: 488 Days
• Field of Search: 607115-122
• US Class Current: 607/116
• CPC Class Codes: A61N 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/0556 Cuff electrodes
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A stimulation lead includes a lead body having a longitudinal length, a distal portion, and a proximal portion; terminals disposed along the proximal portion of the lead body; an electrode carrier coupled to, or disposed along, the distal portion of the lead body; segmented electrodes disposed along the electrode carrier; and conductors extending along the lead body and coupling the segmented electrodes to the terminals. The electrode carrier includes a lattice region defining segmented electrode receiving openings. Each of the segmented electrodes extends around no more than 75% of a circumference of the lead and is disposed in a different one of the segmented electrode receiving openings of the electrode carrier.

Claims

1. A stimulation lead, comprising:

a lead body comprising a longitudinal length, a distal portion, and a proximal portion;

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

a single electrode carrier coupled to, or disposed along, the distal portion of the lead body, the electrode carrier comprising a lattice region defining a plurality of segmented electrode receiving openings, wherein the lattice region is formed of a non-conductive material;

wherein the segmented electrode recieving openings are arranged in a plurality of sets with each of the sets being disposed at a different longitudinal position along the lead;

a plurality of electrodes comprising a plurality of segmented electrodes, each of the segmented electrodes extending around no more than 75% of a circumference of the lead, each of the segmented electrodes disposed in a different one of the segmented electrode receiving openings of the electrode carrier; and

wherein a proximal portion of the electrode carrier is disposed proximal to all of the segmented electrodes and a portion of the lead body is disposed over the proximal portion of the electrode carrier; and

a plurality of conductors extending along the lead body and coupling the plurality of electrodes to the plurality of terminals.

2. The stimulation lead of claim 1, wherein the plurality of electrodes comprises a plurality of sets of the segmented electrodes, each set of the segmented electrodes comprising a plurality of the segmented electrodes disposed at a same longitudinal position along the lead.

3. The stimulation lead of claim 1, wherein the plurality of electrodes further comprises at least one ring electrode.

4. The stimulation lead of claim 3, wherein the at least one ring electrode is disposed on the electrode carrier.

5. The stimulation lead of claim 4, wherein the electrode carrier comprises at least one tubular structure upon which at least one of the at least ring electrode is disposed.

6. The stimulation lead of claim 5, wherein at least one of the at least one tubular structure is disposed on a distal end of the electrode carrier.

7. The stimulation lead of claim 5, wherein at least one of the at least one tubular structure is disposed on a proximal end of the electrode carrier.

8. The stimulation lead of claim 1, wherein the electrode carrier further comprises at least one breakage position configured and arranged to be weakened relative to adjacent portions of the electrode carrier to permit breakage of the electrode carrier after manufacture of the stimulation lead.

9. The stimulation lead of claim 8, wherein the plurality of segmented electrode receiving openings comprises a plurality of sets of the segmented electrode receiving openings, each set of the segmented electrode receiving openings comprising a plurality of the segmented electrode receiving openings disposed at a same longitudinal position along the electrode carrier, wherein the at least one breakage position comprises a first breakage position disposed between two sets of the segmented electrode receiving openings.

10. The stimulation lead of claim 8, wherein the electrode carrier comprises at least one tubular structure and the at least one breakage position comprises a second breakage position disposed between the lattice region and a one of the at least one tubular structure.

11. The stimulation lead of claim 1, wherein the electrode carrier defines a central lumen through which at least a portion of the plurality of conductors passes.

12. The stimulation lead of claim 1, wherein the electrode carrier is formed of the non-conductive material.

13. The stimulation lead of claim 1, wherein the lead body is formed of a different material from the electrode carrier.

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

providing an electrode carrier comprising a lattice region defining a plurality of segmented electrode receiving openings, wherein the lattice region is formed of a non-conductive material;

disposing a plurality of segmented electrodes in the plurality of segmented electrode receiving openings, each of the segmented electrodes extending around no more than 75% of a circumference of the lead, each of the segmented electrodes disposed in a different one of the segmented electrode receiving openings of the electrode carrier; and

electrically coupling a plurality of conductors to the plurality of segmented electrodes and electrically coupling the plurality of conductors to a plurality of terminals disposed along an opposing end of the lead.

15. The method of claim 14, wherein electrically coupling the plurality of conductors to the plurality of segmented electrodes occurs prior to disposing the plurality of segmented electrodes in the plurality of segmented electrode receiving openings.

16. The method of claim 14, further comprising threading the plurality of conductors through the plurality of segmented electrode receiving openings and into a central lumen of the electrode carrier.

17. The method of claim 14, wherein the electrode carrier further comprises at least one tubular structure and the method further comprises disposing at least one ring electrode on the at least one tubular structure of the electrode carrier.

18. The method of claim 17, further comprising electrically coupling at least one second conductor to the at least one ring electrode and threading the at least one second conductors through the at least one tubular structure and into a central lumen of the electrode carrier.

19. The method of claim 14, further comprising forming a portion of a lead body over a portion the electrode carrier.

20. The method of claim 14, further comprising breaking the electrode carrier at at least one breakage point after disposing the plurality of segmented electrodes in the plurality of segmented electrode receiving openings.