Electrical stimulation leads with helically arranged electrodes and methods of making and using
First Claim
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1. A method of making a stimulation lead, the method comprising:
- forming a rib framework comprising a plurality of pre-electrodes attached together in a single helix or a double helix, wherein the rib framework comprises at least one alignment tab;
attaching a conductor to each of the pre-electrodes;
disposing the rib framework into a mold with the at least one alignment tab of the rib framework disposed in a corresponding slot of the mold;
forming a lead body between the pre-electrodes; and
removing a portion of the lead body and the pre-electrodes to generate a plurality of separated segmented electrodes arranged in the single helix or the double helix, wherein each of the pre-electrodes has a greater thickness at a portion of the pre-electrode corresponding to the segmented electrode and a smaller thickness at the portion of the pre-electrode that is removed.
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Abstract
A stimulation lead can include segmented electrodes arranged in a single or double helix or other helical arrangement. In one method of manufacture, an electrode carrier with segmented electrode receiving openings is used. Another method employs a connected framework of helically arranged pre-electrodes that are separated during manufacture. Yet another method employs a mold to generate a planar carrier over the segmented electrodes followed by rolling the carrier into a cylinder. A further method includes forming an electrode assembly by alternative segmented electrodes with non-conducting spacers.
163 Citations
16 Claims
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1. A method of making a stimulation lead, the method comprising:
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forming a rib framework comprising a plurality of pre-electrodes attached together in a single helix or a double helix, wherein the rib framework comprises at least one alignment tab; attaching a conductor to each of the pre-electrodes; disposing the rib framework into a mold with the at least one alignment tab of the rib framework disposed in a corresponding slot of the mold; forming a lead body between the pre-electrodes; and removing a portion of the lead body and the pre-electrodes to generate a plurality of separated segmented electrodes arranged in the single helix or the double helix, wherein each of the pre-electrodes has a greater thickness at a portion of the pre-electrode corresponding to the segmented electrode and a smaller thickness at the portion of the pre-electrode that is removed. - View Dependent Claims (2, 3, 4, 5, 6, 13, 14)
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7. A method of making a stimulation lead, the method comprising:
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disposing a plurality of segmented electrodes and conductors in a first mold; attaching each of the conductors to one of the segmented electrodes; molding a carrier over the segmented electrodes using the first mold and forming a plurality of notches on a surface of the carrier opposite the segmented electrodes, wherein each of the notches extends an entire longitudinal length of the carrier and is parallel to the conductors; rolling the carrier with the segmented electrodes into a cylinder, wherein the segmented electrodes are arranged in the first mold so that when rolled into a cylinder with the carrier, the segmented electrodes are arranged in a single helix or a double helix; placing the cylinder into a second mold; and molding a lead body between the segmented electrodes using the second mold. - View Dependent Claims (8, 9)
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10. A method of making a stimulation lead, the method comprising:
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providing a plurality of segmented electrodes and a plurality of non-conductive spacers, wherein each of the segmented electrode comprises at least one alignment tab and each of the spacers comprises at least one notch; forming an electrode assembly by alternating the segmented electrodes with the non-conductive spacers with each of the at least one alignment tab of each of the segmented electrodes disposed in one of the at least one notch of the spacers, wherein each of the spacers is shaped to receive, and fit around a portion of, at least one of the segmented electrodes, wherein the segmented electrodes are positioned in the electrode assembly in a single helix or a double helix; placing the electrode assembly into a mold; molding a lead body; and removing the at least one alignment tab from each of the segmented electrodes after molding the lead body. - View Dependent Claims (11, 12, 15, 16)
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Specification