Methods of manufacture of leads with a radially segmented electrode array

• US 8,887,387 B2
• Filed: 07/07/2009
• Issued: 11/18/2014
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Pianca, Anne Margaret
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US12/498,650
• Publication Number:
  US 20110005069A1
• Time in Patent Office: 1,960 Days
• Field of Search: 600/373, 600/393, 600/395, 607/116, 607/118, 298/25, 298/43, 298/44, 298/48, 298/57, 298/58, 298/60, 298/61, 298/74, 29882-884, 298/34
• US Class Current: 29/858
• 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 13/567 Traverse cable outlet or wire connection
• CPC Class Codes: H01R 4/62 Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors H01R4/68 takes precedence
• 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 29/49117 Conductor or circuit manufacturing

Abstract

A method of making a lead for a stimulation device includes forming at least one pre-electrode in the shape of a ring, the at least one pre-electrode comprises at least two thin-walled portions separated by at least two thick-walled portions; disposing the at least one pre-electrode near a distal end of a lead body; joining at least one conductor to each thick-walled portion of the at least one pre-electrode; and grinding the lead body and the at least one pre-electrode to remove the thin-walled portions of the at least one pre-electrode to form segmented electrodes from the thick-walled portions of the at least one pre-electrode.

Claims

1. A method of making a lead for a stimulation device comprising:

coupling a plurality of electrodes to a plate;

joining individual conductors to each of the plurality of electrodes;

after joining the conductors to the electrodes, placing a mandrel along the midline of the plate;

forming the plate around the mandrel and into a cylinder with the conductors extending through a hollow central lumen of the cylinder;

filling the hollow central lumen of the cylinder with an insulative material to create a lead assembly; and

removing the plate to expose the plurality of electrodes.

2. The method of claim 1, wherein forming the plate into a cylinder comprises

drawing the plate through at least one die to form a substantially cylindrical shape.

3. The method of claim 1, wherein coupling a plurality of electrodes to a plate comprises coupling a plurality of the electrodes to an iron plate.

4. The method of claim 1, wherein coupling a plurality of electrodes to a plate comprises resistance welding sets of the electrodes at multiple levels on the plate, wherein each set of the electrodes is aligned with an adjacent set of the electrodes.

5. The method of claim 1, wherein coupling a plurality of electrodes to a plate comprises resistance welding sets of the electrodes at multiple levels on the plate, wherein adjacent sets of the electrodes are staggered.

6. The method of claim 1, wherein removing the plate comprises placing the lead assembly in an acid bath to dissolve the plate.

7. The method of claim 1, wherein coupling a plurality of electrodes to a plate comprises coupling the plurality of electrodes in an arrangement with a plurality of rows, wherein each row has a plurality of the electrodes.

8. The method of claim 7, wherein the plurality of rows are arranged so that adjacent rows are offset from one another.

9. The method of claim 1, wherein coupling the plurality of electrodes to the plate comprises coupling the plurality of the electrodes to the plate using an adhesive.

10. A method of making a lead for a stimulation device comprising:

coupling a plurality of electrodes to a plate using an adhesive;

joining individual conductors to each of the plurality of electrodes;

forming the plate into a hollow cylinder with the conductors extending through a hollow central lumen of the cylinder;

filling the hollow central lumen of the hollow cylinder with an insulative material to create a lead assembly; and

removing the plate to expose the plurality of electrodes.

11. The method of claim 10, wherein forming the plate into a hollow cylinder comprises:

placing a mandrel along the midline of the plate; and

drawing the plate through at least one die to form a substantially cylindrical shape.

12. The method of claim 10, wherein coupling a plurality of electrodes to a plate comprises coupling a plurality of the electrodes to an iron plate.

13. The method of claim 10, wherein coupling a plurality of electrodes to a plate comprises coupling sets of the electrodes at multiple levels on the plate, wherein each set of the electrodes is aligned with an adjacent set of the electrodes.

14. The method of claim 10, wherein coupling a plurality of electrodes to a plate comprises coupling sets of the electrodes at multiple levels on the plate, wherein adjacent sets of the electrodes are staggered.

15. A method of making a lead for a stimulation device comprising:

coupling a plurality of electrodes to a plate;

joining individual conductors to each of the plurality of electrodes;

forming the plate into a hollow cylinder with the conductors extending through a hollow central lumen of the cylinder;

filling the hollow central lumen of the hollow cylinder with an insulative material to create a lead assembly; and

removing the plate to expose the plurality of electrodes.

16. The method of claim 15, wherein forming the plate into a hollow cylinder comprises:

placing a mandrel along the midline of the plate; and

drawing the plate through at least one die to form a substantially cylindrical shape.

17. The method of claim 15, wherein coupling a plurality of electrodes to a plate comprises coupling a plurality of the electrodes to an iron plate.

18. The method of claim 15, wherein coupling a plurality of electrodes to a plate comprises coupling sets of the electrodes at multiple levels on the plate, wherein each set of the electrodes is aligned with an adjacent set of the electrodes.

19. The method of claim 15, wherein coupling a plurality of electrodes to a plate comprises coupling sets of the electrodes at multiple levels on the plate, wherein adjacent sets of the electrodes are staggered.