Leads containing segmented electrodes with non-perpendicular legs and methods of making and using

• US 9,498,620 B2
• Filed: 05/23/2014
• Issued: 11/22/2016
• Est. Priority Date: 05/31/2013
• 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, Orinski, William George, Howard, Joshua Dale
• Primary Examiner(s): Tso, Stanley
• Application Number:
  US14/286,940
• Publication Number:
  US 20140353001A1
• Time in Patent Office: 914 Days
• Field of Search: 606/32
• US Class Current: 1/1
• 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: H01R 13/02 Contact members
• CPC Class Codes: H01R 43/26 for engaging or disengaging the two parts of a coupling device structural association with two-part coupling device H01R13/629
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

Abstract

A method of making an electrical stimulation lead method includes attaching a pre-electrode to a lead body. The pre-electrode is a single, unitary, undifferentiated construct with a ring-shaped exterior. The method further includes attaching a plurality of conductor wires to the pre-electrode; and, after coupling to the lead body, removing an outer portion of the pre-electrode to separate remaining portions of the pre-electrode into a plurality of segmented electrodes spaced around the circumference of the lead body. When separated, each of the segmented electrodes includes a body and at least one leg extending inwardly from the body. The body defines an external stimulating surface and each of the at least one leg has an outer surface. For at least one of the at least one leg, the outer surface of the leg forms a non-perpendicular angle with the external stimulating surface of the body.

Claims

1. A pre-electrode, comprising:

an outer portion; and

a plurality of separated segmented electrodes distributed around a circumference of the pre-electrode and within the outer portion;

wherein the pre-electrode is a single, unitary, undifferentiated construct with a ring-shaped exterior and is configured and arranged so that removal of the outer portion results in the remaining portions forming the plurality of separated segmented electrodes, wherein each of the separated segmented electrodes comprises a body and at least one leg extending inwardly from the body, the body defining an external stimulating surface and each of the at least one leg having an outer surface, wherein, for at least one of the at least one leg, the outer surface of the leg forms a non-perpendicular angle with the external stimulating surface of the body, wherein the outer portion and the plurality of segmented electrodes are made of a same conductive material.

2. A method of making an electrical stimulation lead, the method comprising:

attaching the pre-electrode of claim 1 to a lead body;

b) attaching a plurality of conductor wires to the pre-electrode; and

c) after attaching to the lead body, removing the outer portion of the pre-electrode to separate remaining portions of the pre-electrode into the plurality of segmented electrodes spaced around a circumference of the lead body, wherein, for at least one of the at least one leg, the outer surface of the leg forms an acute angle with the external stimulating surface of the body.

3. The method of claim 2, wherein, after removing the outer portion of the pre-electrode, the plurality of segmented electrodes are spaced evenly around the circumference of the lead body.

4. The method of claim 2, wherein removing the outer portion of the pre-electrode comprises grinding the outer portion of the pre-electrode to separate the plurality of segmented electrodes from each other.

5. The method of claim 2, further comprising repeating steps a)-c) for at least one additional pre-electrode.

6. A method of making an electrical stimulation lead, the method comprising:

a) attaching the pre-electrode of claim 1 to a lead body;

b) attaching a plurality of conductor wires to the pre-electrode; and

c) after attaching to the lead body, removing the outer portion of the pre-electrode to separate remaining portions of the pre-electrode into the plurality of segmented electrodes spaced around a circumference of the lead body, wherein, for at least one of the at least one leg, the outer surface of the leg forms an obtuse angle with the external stimulating surface of the body.

7. The method of claim 6, wherein, after removing the outer portion of the pre-electrode, the plurality of segmented electrodes are spaced evenly around the circumference of the lead body.

8. The method of claim 6, wherein removing the outer portion of the pre-electrode comprises grinding the outer portion of the pre-electrode to separate the plurality of segmented electrodes from each other.

9. The method of claim 6, further comprising repeating steps a)-c) for at least one additional pre-electrode.

10. The method of claim 6, wherein the at least one leg is a plurality of legs and wherein, for each of the legs, the outer surface of the leg forms an obtuse angle with the external stimulating surface of the body.

11. The pre-electrode of claim 1, wherein the pre-electrode defines a longitudinal slit along at least a portion of a longitudinal length of the pre-electrode.

12. The pre-electrode of claim 1, wherein the pre-electrode defines a plurality of holes extending from an interior to an exterior of the pre-electrode.

13. The pre-electrode of claim 1, wherein the at least one leg is a plurality of legs and wherein, for each of the legs, the outer surface of the leg forms an acute angle with the external stimulating surface of the body.

14. The pre-electrode of claim 1, wherein the non-perpendicular angle is in a range from 20 to 85 degrees.

15. The pre-electrode of claim 1, wherein the non-perpendicular angle is in a range from 45 to 80 degrees.

16. The pre-electrode of claim 1, further comprising at least one channel formed in an interior surface of the body of at least one of the segmented electrodes.

17. The pre-electrode of claim 1, wherein the non-perpendicular angle is in a range from 95 to 135 degrees.

18. The pre-electrode of claim 1, wherein the non-perpendicular angle is in a range from 110 to 125 degrees.

19. The pre-electrode of claim 1, wherein the at least one leg is a plurality of legs and wherein, for each of the legs, the outer surface of the leg forms an obtuse angle with the external stimulating surface of the body.