Systems and methods for making and using tip electrodes for leads of electrical stimulation systems

• US 9,616,220 B2
• Filed: 09/18/2015
• Issued: 04/11/2017
• Est. Priority Date: 05/15/2013
• 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, Orsinski, William George, Howard, Joshua Dale, Pianca, Anne Margaret
• Primary Examiner(s): Porter, Jr., Allen
• Application Number:
  US14/858,722
• Publication Number:
  US 20160008592A1
• Time in Patent Office: 571 Days
• Field of Search: 607 9, 607115, 607116, 607117, 607119, 607122
• 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 1/0529 Electrodes for brain stimulation
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/3605 Implantable neurostimulators for stimulating central or peripheral nerve system
• CPC Class Codes: B29C 2045/14122 using fixed mould wall projections for centering the insert
• CPC Class Codes: B29C 70/84 by moulding material on preformed parts to be joined joining plastic parts by moulding B29C65/70
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49172 by molding of insulating material
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

An implantable electrical stimulation lead includes a lead body, electrodes disposed along a distal end of the lead body, terminals disposed along the proximal end of the lead body, and conductors coupling the terminals to the electrodes. The electrodes include a tip electrode having an electrode body with an outer stimulating surface. An internal lumen is defined in the electrode body and extends inwardly from an opening in a proximal end of the electrode body. Side apertures are formed between the outer stimulating surface and the internal lumen. A portion of the lead body is disposed within the internal lumen and side apertures through the opening in the proximal end of the electrode body. That portion of the lead body facilitates retention of the tip electrode on a distal tip of the lead body.

Claims

1. An implantable electrical stimulation lead, comprising:

a non-conductive lead body having a proximal end portion, a distal end portion, a distal tip, and a longitudinal length;

a plurality of electrodes disposed along the distal end portion of the lead body, the plurality of electrodes comprising a tip electrode disposed on the distal tip of the lead body, the tip electrode comprising

an electrode body having an outer stimulating surface, a proximal end, a closed distal end, a circumference, and a longitudinal length,

an internal lumen defined in the electrode body and extending inwardly from an opening in the proximal end of the electrode body, and

a plurality of side apertures formed through the outer stimulating surface and opening into the internal lumen,

wherein a portion of the lead body is disposed within the internal lumen and into the plurality of side apertures through the opening in the proximal end of the electrode body, wherein the portion of the lead body within the internal lumen and the plurality of side apertures facilitates retention of the tip electrode on the distal tip of the lead body;

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

a plurality of conductors electrically coupling the terminals to the electrodes.

2. The implantable electrical stimulation lead of claim 1, wherein the tip electrode further comprises a channel defined in the internal lumen, the channel extending deeper into the electrode body than adjacent portions of the internal lumen, the channel extending along at least 25% of the circumference of the electrode body.

3. The implantable electrical stimulation lead of claim 2, wherein the channel extends around the entire circumference of the electrode body.

4. The implantable electrical stimulation lead of claim 2, wherein the channel intersects at least a portion of at least one of the plurality of side apertures.

5. The implantable electrical stimulation lead of claim 2, wherein the channel intersects at least a portion of each of the plurality of side apertures.

6. The implantable electrical stimulation lead of claim 1, wherein the plurality of side apertures comprises at least three side apertures.

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

8. The implantable electrical stimulation lead of claim 1, wherein the plurality of electrodes further comprises at least one segmented electrode.

9. The implantable electrical stimulation lead of claim 8, wherein the at least one segmented electrode is a plurality of segmented electrodes divided into at least two sets of segmented electrodes with each set disposed at a different longitudinal position along the lead body.

10. The implantable electrical stimulation lead of claim 1, wherein the internal lumen extends along at least 75% of the longitudinal length of the electrode body.

11. The implantable electrical stimulation lead of claim 1, wherein the tip electrode is isodiametric with the lead body.

12. The implantable electrical stimulation lead of claim 1, wherein the electrode body defines at least one longitudinal groove formed along the internal lumen and extending deeper into the electrode body than adjacent portions of the internal lumen, wherein each longitudinal groove extends along the internal lumen in a direction that is parallel to the longitudinal length of the electrode body.

13. The implantable electrical stimulation lead of claim 12, wherein at least one of the at least one longitudinal groove extends from the opening in the proximal end of the internal lumen.

14. The implantable electrical stimulation lead of claim 12, wherein at least one of the at least one longitudinal groove extends along at least 50% of the longitudinal length of the electrode body.

15. The implantable electrical stimulation lead of claim 12, wherein the at least one longitudinal groove is a plurality of longitudinal grooves.

16. The implantable electrical stimulation lead of claim 12, wherein the tip electrode further comprises a channel defined in the internal lumen, the channel extending deeper into the electrode body than adjacent portions of the internal lumen, the channel extending along at least 25% of the circumference of the electrode body, wherein the channel intersects at least a portion of at least one of the at least one longitudinal groove.

17. An electrical stimulating system comprising:

the implantable electrical stimulation lead of claim 1;

a control module coupleable to the implantable electrical stimulation lead, the control module comprising

a housing, and

an electronic subassembly disposed in the housing; and

a connector for receiving the implantable electrical stimulation lead, the connector comprising

a connector housing defining a port, the port configured and arranged for receiving the proximal end portion of the lead body of the implantable electrical stimulation lead, and

a plurality of connector contacts disposed in the port, the plurality of connector contacts configured and arranged to couple to the plurality of terminals disposed along the proximal end portion of the lead body when the proximal end portion of the lead body is received by the port.

18. The electrical stimulation system of claim 17, wherein the control module comprises the connector.

19. The electrical stimulation system of claim 17, further comprising a lead extension coupleable to both the implantable electrical stimulation lead and the control module, wherein the lead extension comprises the connector.

20. A method of stimulating a patient using an electrical stimulation lead, the method comprising:

implanting the electrical stimulation lead of claim 1 into the patient; and

providing electrical stimulation to the patient using the electrodes of the electrical stimulation lead.