Systems and methods for making and using contact assemblies for leads of electrical stimulation systems
First Claim
1. An electrical stimulation lead, comprising:
- a lead body having a distal end portion and a proximal end portion;
a plurality of first contacts disposed along one of the distal end portion or the proximal end portion of the lead body;
a contact assembly disposed along the other of the distal end portion or the proximal end portion of the lead body, the contact assembly comprisinga plurality of micro-circuits laminated to a first electrically-nonconductive substrate and rolled into a tube, the micro-circuits each having a first end portion and an opposing second end portion, wherein a plurality of through-holes are defined through the first electrically-nonconductive substrate with at least one through-hole disposed between each adjacent pair of the micro-circuits, anda plurality of second contacts disposed over the tube formed by the plurality of micro-circuits and the first electrically-nonconductive substrate, wherein each of the second contacts is electrically coupled to the first end portion of at least one of the plurality of micro-circuits; and
a plurality of lead-body conductors electrically coupling the plurality of first contacts to the plurality of second contacts, wherein each of the plurality of lead-body conductors is attached to the second end portion of at least one of the plurality of micro-circuits.
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Abstract
First contacts are disposed along a distal end portion or a proximal end portion of a lead body of an electrical stimulation lead. A contact assembly is disposed along the other of the distal end portion or the proximal end portion of the lead body. The contact assembly includes a tubular-shaped composite structure formed from multiple layered elements mechanically coupled together and rolled together into a tube. Each of the layered elements includes a first electrically-nonconductive substrate, a second electrically-nonconductive substrate, and micro-circuits laminated therebetween. Second contacts are disposed over the composite structure and electrically coupled to a first end portion of at least one of the micro-circuits. Lead-body conductors electrically couple the first contacts to the second contacts. Each of each of the lead-body conductors is attached to a second end portion of at least one of the micro-circuits.
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Citations
20 Claims
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1. An electrical stimulation lead, comprising:
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a lead body having a distal end portion and a proximal end portion; a plurality of first contacts disposed along one of the distal end portion or the proximal end portion of the lead body; a contact assembly disposed along the other of the distal end portion or the proximal end portion of the lead body, the contact assembly comprising a plurality of micro-circuits laminated to a first electrically-nonconductive substrate and rolled into a tube, the micro-circuits each having a first end portion and an opposing second end portion, wherein a plurality of through-holes are defined through the first electrically-nonconductive substrate with at least one through-hole disposed between each adjacent pair of the micro-circuits, and a plurality of second contacts disposed over the tube formed by the plurality of micro-circuits and the first electrically-nonconductive substrate, wherein each of the second contacts is electrically coupled to the first end portion of at least one of the plurality of micro-circuits; and a plurality of lead-body conductors electrically coupling the plurality of first contacts to the plurality of second contacts, wherein each of the plurality of lead-body conductors is attached to the second end portion of at least one of the plurality of micro-circuits. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of forming an electrical stimulation lead, the method comprising:
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forming a contact assembly comprising a plurality of micro-circuits laminated to at least one electrically-nonconductive substrate, wherein each of the micro-circuits has a first end portion and an opposing second end portion and each of the micro-circuits is coupled to at least one adjacent micro-circuit by a conductor tie bar; severing the conductor tie bars and forming a plurality of through-holes through the at least one electrically-nonconductive substrate; exposing a contact interface along the first end portion of each of the plurality of micro-circuits; mechanically coupling a plurality of contacts to the contact assembly; and electrically coupling each of the contacts to the exposed contact interface of a one of the plurality of micro-circuits. - View Dependent Claims (13, 14, 15, 16)
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17. An electrical stimulation lead, comprising:
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a lead body having a distal end portion and a proximal end portion; a plurality of first contacts disposed along one of the distal end portion or the proximal end portion of the lead body; a contact assembly disposed along the other of the distal end portion or the proximal end portion of the lead body, the contact assembly comprising a tubular-shaped composite structure comprising a plurality of layered elements mechanically coupled together and rolled into a tube, each of the plurality of layered elements comprises a first electrically-nonconductive substrate, and a plurality of micro-circuits laminated to the first electrically-nonconductive substrate, the micro-circuits each having a first end portion and an opposing second end portion, wherein a plurality of through-holes are defined through the first electrically-nonconductive substrate with at least one through-hole disposed between each adjacent pair of the micro-circuits, and a plurality of second contacts disposed over the composite structure, wherein each of the second contacts is electrically coupled to the first end portion of at least one of the plurality of micro-circuits; and a plurality of lead-body conductors electrically coupling the plurality of first contacts to the plurality of second contacts, wherein each of each of the plurality of lead-body conductors is attached to the second end portion of at least one of the plurality of micro-circuits. - View Dependent Claims (18, 19, 20)
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Specification