Methods of manufacturing a contact array assembly and leads and systems containing the assembly
First Claim
1. A method of making an electrical stimulation lead, the method comprising:
- disposing a plurality of conductive contacts on a conductor guide or stylet tube in a spaced-apart longitudinal arrangement;
coupling a plurality of conductive wires disposed within the conductor guide or around the stylet tube to the plurality of conductive contacts, wherein each conductive contact is coupled to at least one of the conductive wires;
sliding a temporary tube over the plurality of conductive contacts, wherein the temporary tube is made of polymeric material and has a length;
introducing a flowable non-conductive material into the temporary tube and flowing the flowable non-conductive material between adjacent pairs of conductive contacts and over the conductor guide or stylet tube;
forming at least one spacer from the flowable non-conductive material to separate the conductive contacts; and
cutting a slit along the length of the temporary tube and removing the temporary tube to expose the conductive contacts.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of making an electrical stimulation lead includes disposing conductive contacts in a spaced-apart longitudinal arrangement within a mold. A portion of a stylet tube is disposed within the mold, and the stylet tube extends through the conductive contacts. Conductive wires are positioned external to the stylet tube and each contact is coupled to at least one of the wires. A non-conductive material is molded between adjacent pairs of the contacts, around the wires, and over the stylet tube, to form a portion of the lead. This portion includes the contacts, the stylet tube, the wires, and one or more non-conductive spacers formed from the non-conductive material. Finally, the portion of the lead is removed from the mold. Another method includes placing a temporary tube around the conductive contacts and forming spacers by introducing flowable, curable, non-conductive material within the tube and between the conductive contacts.
30 Citations
10 Claims
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1. A method of making an electrical stimulation lead, the method comprising:
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disposing a plurality of conductive contacts on a conductor guide or stylet tube in a spaced-apart longitudinal arrangement; coupling a plurality of conductive wires disposed within the conductor guide or around the stylet tube to the plurality of conductive contacts, wherein each conductive contact is coupled to at least one of the conductive wires; sliding a temporary tube over the plurality of conductive contacts, wherein the temporary tube is made of polymeric material and has a length; introducing a flowable non-conductive material into the temporary tube and flowing the flowable non-conductive material between adjacent pairs of conductive contacts and over the conductor guide or stylet tube; forming at least one spacer from the flowable non-conductive material to separate the conductive contacts; and cutting a slit along the length of the temporary tube and removing the temporary tube to expose the conductive contacts. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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Specification