Methods for making and using improved leads for electrical stimulation systems

• US 9,775,983 B2
• Filed: 05/26/2015
• Issued: 10/03/2017
• Est. Priority Date: 11/02/2011
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: DiGiore, Andrew, Barker, John Michael, Pianca, Anne Margaret, Moffitt, Michael Adam, McDonald, Matthew Lee, Howard, Joshua Dale
• Primary Examiner(s): Trinh, Minh
• Application Number:
  US14/722,029
• Publication Number:
  US 20150250999A1
• Time in Patent Office: 861 Days
• 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 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: H01R 43/00 Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding

Abstract

A method for manufacturing a lead includes pre-forming at least one relief section along a length of an elongated conductor having a first end and an opposing second end. The conductor with the pre-formed relief section is inserted into a conductor lumen defined along a length of an elongated lead body. The lead body has a first end and an opposing second end. An electrode is disposed at the first end of the lead body. The first end of the conductor is electrically coupled to the electrode. A terminal is disposed at the second end of the lead body. The second end of the conductor is electrically coupled to the terminal.

Claims

1. A method for manufacturing a lead, the method comprising:

inserting a conductor into a conductor lumen defined along a length of an elongated lead body, the lead body having a first end and an opposing second end, wherein the conductor lumen defines a plurality of helical sections separated from one another by straight, wherein each of the helical sections is arranged in counterrotaion to adjacent ones of the plurality of helical sections;

disposing a first conductive contact at the first end of the lead body with a first gap formed between the first conductive contact and the first end of the lead body;

electrically coupling the first end of the conductor to the first conductive contact;

disposing a second conductive contact at the second end of the lead body;

electrically coupling the second end of the conductor to the second conductive contact; and

reducing the first gap between the first conductive contact and the first end of the lead body, wherein reducing the first gap causes the conductor to form at least one first relief section.

2. The method of claim 1, wherein disposing a second conductive contact at the second end of the lead body comprises disposing the second conductive contact at the second end of the lead body with a second gap formed between the second conductive contact and the second end of the lead body.

3. The method of claim 1, wherein the first conductive contact is a terminal and the second conductive contact is an electrode.

4. The method of claim 1, wherein the first conductive contact is an electrode and the second conductive contact is a terminal.

5. The method of claim 1, wherein the first conductive contact is either an electrode or a terminal and the second conductive contact is a terminal when the first conductive contact is the electrode and the second conductive contact is an electrode when the first conductive contact is the terminal.

6. A method for manufacturing a lead, the method comprising:

inserting a conductor into a conductor lumen defined along a length of an elongated lead body, the lead body having a first end and an opposing second end;

disposing a first conductive contact at the first end of the lead body with a first gap formed between the first conductive contact and the first end of the lead body;

electrically coupling the first end of the conductor to the first conductive contact;

disposing a second conductive contact at the second end of the lead body with a second gap formed between the second conductive contact and the second end of the lead body;

electrically coupling the second end of the conductor to the second conductive contact;

reducing the first gap between the first conductive contact and the first end of the lead body, wherein reducing the first gap causes the conductor to form at least one first relief section; and

reducing the second gap between the second conductive contact and the second end of the lead body, wherein reducing the second gap causes the conductor to form at least one second relief section.

7. The method of claim 6, wherein the conductor lumen defines at least one helical section.

8. The method of claim 7, wherein the conductor lumen defines a plurality of the helical sections separated from one another by straight sections.

9. The method of claim 8, wherein each of the helical sections is arranged in counterrotation to adjacent ones of the plurality of helical sections.

10. The method of claim 7, wherein the conductor lumen defines a plurality of the helical sections and at least one of the helical sections is arranged in a clockwise configuration and at least one of the helical sections is arranged in a counterclockwise configuration.

11. The method of claim 7, wherein the conductor lumen defines a plurality of the helical sections and each of the helical sections has a length that is different from at least one other of the plurality of helical sections.

12. A method for manufacturing a lead, the method comprising:

inserting a conductor into a conductor lumen defined along a length of an elongated lead body, the lead body having a first end and an opposing second end, wherein the conductor lumen defines a plurality of helical sections, wherein each of the helical sections has a length that is different from at least one other of the plurality of helical sections;

disposing a first conductive contact at the first end of the lead body with a first gap formed between the first conductive contact and the first end of the lead body;

electrically coupling the first end of the conductor to the first conductive contact;

disposing a second conductive contact at the second end of the lead body;

electrically coupling the second end of the conductor to the second conductive contact; and

reducing the first gap between the first conductive contact and the first end of the lead body, wherein reducing the first gap causes the conductor to form at least one first relief section.

13. The method of claim 12, wherein the conductor lumen defines the plurality of the helical sections separated from one another by straight sections.

14. The method of claim 13, wherein each of the helical sections is arranged in counterrotation to adjacent ones of the plurality of helical sections.

15. The method of claim 12, wherein at least one of the helical sections is arranged in a clockwise configuration and at least one of the helical sections is arranged in a counterclockwise configuration.