Connectors for electrical stimulation systems and methods of making and using

• US 9,956,394 B2
• Filed: 09/09/2016
• Issued: 05/01/2018
• Est. Priority Date: 09/10/2015
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Howard, Joshua Dale, Govea, Michael X.
• Primary Examiner(s): MANUEL, GEORGE C
• Application Number:
  US15/261,610
• Publication Number:
  US 20170072187A1
• Time in Patent Office: 599 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 1/3752 Details of casing-lead connections
• CPC Class Codes: H01R 13/621 Bolt, set screw or screw clamp
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 2201/12 for medicine and surgery
• CPC Class Codes: H01R 24/58 Contacts spaced along longitudinal axis of engagement

Abstract

A connector to couple an electrical stimulation lead to a lead extension can include lead terminals and extension connector contacts that interlock with each other. Another connector can include lead terminals and extension connector contacts that form a hook and loop fastener. Yet another connector defines a lumen for receiving a proximal portion of an electrical stimulation lead and a side-loading slit extending along at least a portion of the longitudinal surface of the connector and extending inwardly to the lumen for side-loading the electrical stimulation lead into the lumen through the side-loading slit.

Claims

1. An electrical stimulation system, comprising:

an electrical stimulation lead, comprising

a lead body having a distal end portion, a proximal end, and a longitudinal length,

a plurality of electrodes disposed along the distal end portion of the lead body,

a proximal connector body disposed at the proximal end of the lead body,

a plurality of terminals disposed along the proximal connector body and extending laterally out of, and away from, the proximal connector body, and

a plurality of conductors electrically coupling the plurality of terminals to the plurality of electrodes; and

a lead extension, comprising

an extension body having a distal end, a proximal end portion, and a longitudinal length,

a plurality of terminal disposed along the proximal end portion of the extension body,

a distal connector body disposed at the distal end of the extension body,

a plurality of conductive contacts disposed along the distal connector body and extending laterally out of, and away from, the distal connector body, and

a plurality of conductors electrically coupling the plurality of terminals to the plurality of conductive contacts;

wherein the proximal connector body of the electrical stimulation lead and the distal connector body of the lead extension are configured and arranged to be joined together opposite each other to form a connector with the terminals of the electrical stimulation lead interlocking with, and electrically coupled to, the conductive contacts of the lead extension.

2. The electrical stimulation system of claim 1, wherein either of the terminals or the conductive contacts each include a cut so that another of the terminals or the conductive contacts can slide into the cut for interlocking the terminals with the conductive contacts.

3. The electrical stimulation system of claim 1, wherein both the terminals and the conductive contacts each include a cut so that the terminals and the conductive contacts can slide into the cuts for interlocking the terminals with the conductive contacts.

4. The electrical stimulation system of claim 1, further comprising an outer sleeve configured and arranged to be disposed over the connector for maintenance of the joining of the proximal connector body of the electrical stimulation lead and the distal connector body of the lead extension.

5. The electrical stimulation system of claim 1, wherein each of the terminals and the conductive contacts comprises an interlocking portion in a form of a portion of a ring.

6. The electrical stimulation system of claim 1, wherein each of the proximal connector body and the distal connector body have a form of a half cylinder and, when joined, the connector has a form of a cylinder.

7. An electrical stimulation system, comprising:

an electrical stimulation lead, comprising

a lead body having a distal end portion, a proximal end, and a longitudinal length,

a plurality of electrodes disposed along the distal end portion of the lead body,

a proximal connector body disposed at the proximal end of the lead body,

a plurality of terminals disposed along the proximal connector body, and

a plurality of conductors electrically coupling the plurality of terminals to the plurality of electrodes; and

a lead extension, comprising

an extension body having a distal end, a proximal end portion, and a longitudinal length,

a plurality of terminals disposed along the proximal end portion of the extension body,

a distal connector body disposed at the distal end of the extension body,

a plurality of conductive contacts disposed along the distal connector body, and

a plurality of conductors electrically coupling the plurality of terminals to the plurality of conductive contacts;

wherein the proximal connector body of the electrical stimulation lead and the distal connector body of the lead extension are configured and arranged to be joined together opposite each other to form a connector with the terminals of the electrical stimulation lead and the conductive contacts of the lead extension jointly forming a conductive, hook and loop fastener to electrically and physically couple the terminals to the conductive contacts.

8. The electrical stimulation system of claim 7, wherein the hook and loop fastener comprises 1) one of a) the terminals of the electrical stimulation lead or b) the conductive contacts of the lead extension comprising a base and hooks extending from the base and 2) another of a) the terminals of the electrical stimulation lead or b) the conductive contacts of the lead extension comprising a base and loops extending from the base.

9. The electrical stimulation system of claim 7, wherein the conductive, hook and loop fastener comprises a polymeric hook and loop fastener and a conductive coating disposed over the polymeric hook and loop fastener.

10. The electrical stimulation system of claim 7, further comprising an outer sleeve configured and arranged to be disposed over the connector for maintenance of the joining of the proximal connector body of the electrical stimulation lead and the distal connector body of the lead extension.

11. The electrical stimulation system of claim 7, further comprising alignment features formed on both the proximal connector body and the distal connector body, wherein the alignment features jointly form a hook and loop fastener.

12. The electrical stimulation lead of claim 11, wherein the alignment features are disposed around at least a portion of a perimeter of both the proximal connector body and the distal connector body.

13. A lead extension for an electrical stimulation system, comprising:

an extension body having a distal end, a proximal end portion, and a longitudinal length;

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

a distal connector disposed at the distal end of the extension body, the distal connector comprising a proximal end, a distal end, and a longitudinal surface extending from the proximal end to the distal end of the distal connector, the distal connector defining a lumen for receiving a proximal portion of an electrical stimulation lead, an end aperture at the distal end of the distal connector from which a lead body of the electrical stimulation lead can extend, and a side-loading slit extending along at least a portion of the longitudinal surface and extending inwardly to the lumen and configured and arranged for side-loading the electrical stimulation lead into the lumen through the side-loading slit;

a plurality of conductive contacts disposed along the lumen of the distal connector, each of the conductive contacts having an opening aligned with the side-loading slit; and

a plurality of conductors electrically coupling the plurality of terminals to the plurality of conductive contacts.

14. The lead extension of claim 13, further comprising an outer sleeve configured and arranged to be disposed over the distal connector to cover the distal connector and a proximal portion of a stimulation lead, if any, disposed in the distal connector.

15. The lead extension of claim 14, wherein the outer sleeve comprises a transverse lumen intersecting the lumen of the distal connector and configured and arranged to receive a fastener for securement of an electrical stimulation lead within the lumen of the distal connector.

16. The lead extension of claim 13, wherein the distal connector comprises a transverse lumen intersecting the lumen of the distal connector and configured and arranged to receive a fastener for securement of an electrical stimulation lead within the lumen of the distal connector.

17. The lead extension of claim 13, wherein the distal connector further comprises a flap configured and arranged to fold over and cover the side-loading slit.

18. The lead extension of claim 17, wherein the flap comprises a lip to at least partially fill the side-loading slit when the flap is folded over and covering the side-loading slit.

19. The lead extension of claim 13, wherein each of the conductor contacts is ring-shaped except for the opening.

20. An electrical stimulation system, comprising:

the lead extension of claim 13; and

an electrical stimulation lead comprising

a lead body having a distal end portion, a proximal end portion, and a longitudinal length,

a plurality of electrodes disposed along the distal end portion of the lead body,

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

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

wherein the lumen of the lead extension is configured and arranged to receive the proximal end portion of the electrical stimulation lead.