Method of forming a lead

• US 6,981,314 B2
• Filed: 01/09/2002
• Issued: 01/03/2006
• Est. Priority Date: 04/26/1999
• Status: Expired due to Fees

• Current Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Original Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Inventors: Erickson, John, Daglow, Terry, Jones, Robert Earl, Lauro, B. Reno, Black, Damon Ray
• Primary Examiner(s): CHANG, RICK KILTAE
• Application Number:
  US10/042,992
• Publication Number:
  US 20020055765A1
• Time in Patent Office: 1,455 Days
• Field of Search: 298/25, 607/116, 607/119, 607/122, 600373-375, 600/381, 600/377
• US Class Current: 29/825
• 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 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/056 Transvascular endocardial electrode systems
• 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 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

An implantable, substantially isodiametric, low resistance implantable lead having at least one electrode positioned in a stimulation/sensing portion of the lead as well as a method of manufacturing the same. At least the stimulation/sensing portion is unitized through partially surrounding and supporting insulation and conductive element(s) of the stimulation/sensing portion with a fused matrix of material having mechanical properties consistent with a body of the lead.

Claims

1. A method for forming a substantially isodiametric lead having a prescribed diameter and at least one electrode separated from at least one terminal by a lead body, wherein the at least one electrode is electrically coupled to the at least one terminal by a conductor passing through a passage defined by the lead body, comprising the steps of:

assembling the at least one electrode and the at least one terminal relative to the lead body to form an assembly, including connecting the at least one electrode to the at least one terminal via the conductor;

over-molding the assembly with a first material to form an intermediate assembly, wherein the first material is compatible with and has mechanical properties consistent with a second material of the lead body; and

removing at least a portion of the first material of the intermediate assembly in excess of the prescribed diameter of the lead, where the lead comprises the at least one electrode, the at least one terminal and the lead body.

2. A method in accordance with claim 1, wherein the at least one electrode has an outer diameter greater than the prescribed diameter prior to the removing step.

3. A method in accordance with claim 1, wherein the at least one terminal has an outer diameter greater than the prescribed diameter prior to the removing step.

4. A method in accordance with claim 1, wherein the removing step involves subjecting the intermediate assembly to at least a centerless grinding process.