SYSTEMS AND METHODS FOR REMOVING INSULATION DISPOSED OVER CONDUCTORS OF IMPLANTABLE ELECTRIC STIMULATION SYSTEMS

• US 20100326701A1
• Filed: 06/29/2009
• Published: 12/30/2010
• Est. Priority Date: 06/29/2009
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: McDonald, Matthew Lee
• Granted Patent: US 8,322,026 B2
• Time in Patent Office: Days
• US Class Current: 174/168
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: B23K 26/00 Working by laser beam, e.g. welding, cutting or boring
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49158 with molding of insulated base
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/532 Conductor
• CPC Class Codes: Y10T 29/53217 Means to simultaneously assemble multiple, independent conductors to terminal
• CPC Class Codes: Y10T 29/53222 Means comprising hand-manipulatable implement

Abstract

A method for forming a lead or lead extension includes forming an arrangement of elongated conductors. Each of the conductors extends from a proximal end of the arrangement to a distal end of the arrangement. Each of the conductors includes a layer of insulation disposed over a conductive core. A conductor-separating element is disposed over either the proximal end or the distal end of the arrangement. The conductor-separating element includes a plurality of ablation windows defined in a body. An end of at least one of the elongated conductors is radially extended over a portion of the conductor-separating element such that a portion of the at least one elongated conductor extends across at least one of the ablation windows. Insulation from the portion of the at least one conductor extending across the ablation window is ablated to expose a portion of the conductive core of the elongated conductor.

Claims

1. A method for forming a lead or lead extension, the method comprising:

forming an arrangement of a plurality of elongated conductors, each conductor extending from a proximal end of the arrangement to a distal end of the arrangement, each of the plurality of conductors comprises a layer of insulation disposed over a conductive core;

disposing a conductor-separating element over one of the proximal end or the distal end of the arrangement, the conductor-separating element comprising a plurality of ablation windows defined in a body;

radially extending an end of at least one of the elongated conductors over a portion of the conductor-separating element such that a portion of the at least one elongated conductor extends across at least one of the ablation windows; and

ablating insulation from the portion of the at least one conductor extending across the ablation window to expose a portion of the conductive core of the elongated conductor.

2. The method of claim 1, further comprising electrically coupling the exposed portion of the conductive core of the at least one conductor to one of a terminal, an electrode, or a conductive contact.

3. The method of claim 2, wherein electrically coupling the exposed portion of the conductive core of the at least one conductor to one of a terminal, an electrode, or a conductive contact is performed while the at least one conductor remains radially extended along the conductor-separating element.

4. The method of claim 1, further comprising removing the at least one conductor from the conductor-separating element and disposing the conductor-separating element over the other of the proximal end or the distal end of the arrangement.

5. The method of claim 4, further comprising radially extending an end of at least one of the elongated conductors along the conductor-separating element such that a portion of the at least one elongated conductor extends across one of the ablation windows.

6. The method of claim 5, further comprising ablating insulation from the portion of the at least one conductor extending across the ablation window to expose a portion of the conductive core of the elongated conductor.

7. The method of claim 1, wherein ablating insulation from the portion of the at least one conductor comprises laser ablating insulation.

8. The method of claim 7, wherein laser ablating insulation from the portion of the at least one conductor comprises inserting the conductor-separating element into a laser ablation system.

9. The method of claim 1, wherein radially extending an end of at least one of the elongated conductors along the conductor-separating element comprises extending the end of the at least one of the elongated conductors across the one of the ablation windows such that line-of-sight access is provided entirely around a transverse circumference of the at least one conductor.

10. The method of claim 1, wherein ablating insulation from the portion of the at least one conductor extending across the ablation window comprises ablating the insulation entirely around a transverse circumference of the at least one conductor.

11. The method of claim 1, wherein the conductor-separating element comprises at least one retention device configured and arranged to retain the at least one conductor in a radially-extended position.

12. The method of claim 1, wherein the body of the conductor-separating element defines at least one lumen configured and arranged to receive the at least one conductor.

13. The method of claim 12, wherein the at least one lumen extends radially along the body of the conductor-separating element from a lateral end of one of the ablation windows to an outer rim of the body.

14. The method of claim 1, wherein the conductors extend from the proximal end of the arrangement to the distal end of the arrangement along at least one unit.

15. The method of claim 1, wherein the conductor-separating element has a round transverse cross-sectional shape.

16. The method of claim 1, wherein disposing the conductor-separating element over one of the proximal end or the distal end of the arrangement comprises disposing a coupler of the conductor-separating element over a portion of the arrangement.

17. The method of claim 16, wherein the coupler comprises a mounting aperture defined in the body.

18. The method of claim 17, wherein the mounting aperture is defined in the center of the body.

19. A conductor-separating element comprising:

a body defining an outer rim and a plurality of ablation windows disposed circumferentially around the body;

a mounting aperture configured and arranged to receive a plurality of elongated conductors, the mounting aperture positioned in a center of the body;

a plurality of retention devices disposed around the outer rim of the body, each retention device configured and arranged to receive, and retain, an end of one of the conductors which passes through the center aperture and is bent over, and extended along, the body of the conductor-separating element,

wherein the plurality of ablation windows are positioned such that, when the end of one of the conductors is extended along the body of the conductor-separating element, the conductor has a portion that is exposed entirely around a transverse circumference of the conductor within the ablation window.

20. The conductor-separating element of claim 19, wherein the plurality of ablation windows are positioned such that, when the end of one of the conductors is extended along the body of the conductor-separating element, the conductor has a portion that is accessible for ablation entirely around the transverse circumference of the conductor within the ablation window.