Thin film for a lead for brain applications

• US 9,956,396 B2
• Filed: 02/08/2013
• Issued: 05/01/2018
• Est. Priority Date: 02/08/2012
• Status: Active Grant

• Current Assignee: Medtronic Bakken Research Center B.V. (Medtronic Plc)
• Original Assignee: Medtronic Bakken Research Center B.V. (Medtronic Plc)
• Inventors: Young, Edward Willem Albert, Pham, Hoa Thi Mai, Vorstenbosch, Martinus Lambertus Wilhelmus, Wang, Ke
• Primary Examiner(s): WEHRHEIM, LINDSEY GAIL
• Application Number:
  US13/762,426
• Publication Number:
  US 20130204318A1
• Time in Patent Office: 1,908 Days
• Field of Search: 607 45, 607 46, 607116, 600373, 600378
• 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: A61N 1/3606 adapted for a particular treatment
• CPC Class Codes: A61N 1/36125 Details of circuitry or electric components
• CPC Class Codes: H05K 1/11 Printed elements for providing electric connections to or between printed circuits
• CPC Class Codes: H05K 2203/1322 Encapsulation comprising more than one layer
• CPC Class Codes: H05K 3/108 by semi-additive methods; masks therefor characterised by metallic etch mask H05K3/062; electroplating methods or apparatus H05K3/241
• CPC Class Codes: H05K 3/16 by cathodic sputtering
• CPC Class Codes: H05K 3/28 Applying non-metallic protective coatings H05K3/0091 takes precedence; methods for intermediate insulating layers for build-up multilayer circuits H05K3/4673

Abstract

A thin film for a lead for brain applications includes at least one section comprising a high conductive metal and a low conductive metal, whereby the low conductive metal is a biocompatible metal and has a lower electrical conductivity than the high conductive metal and whereby the high conductive metal is at least partially encapsulated by the low conductive metal. Furthermore, the present invention relates to a method of manufacturing a thin film for a lead for brain applications and a deep brain stimulation system.

Claims

1. A medical lead comprising:

a proximal portion;

at least one electrode located distal to the proximal portion; and

an electrically conductive thin film extending from the proximal portion to the at least one electrode, the electrically conductive thin film comprising a metal trace formed of a high conductive metal extending from the proximal portion to the at least one electrode and a low conductive metal that encapsulates all sides of the high conductive metal extending from the proximal portion to the at least one electrode, wherein the low conductive metal comprises platinum, is biocompatible and has a lower electrical conductivity than the high conductive metal, and wherein the metal trace is electrically coupled to the at least one electrode such that electrical signals are conducted via the metal trace between the at least one electrode and a medical device electrically coupled to the medical lead.

2. The medical lead according to claim 1, wherein the electrically conductive thin film includes a ceramic material encapsulating all sides of the low conductive metal extending from the proximal portion to the at least one electrode.

3. The medical lead according to claim 2, wherein the ceramic material comprises at least one of SiN, SiOX, Si-Carbid or Alumina.

4. The medical lead according to claim 2, wherein the electrically conductive thin film comprises a flexible polymer encapsulating all sides of the ceramic material extending from the proximal portion to the at least one electrode.

5. The medical lead according to claim 1, wherein the high conductive metal comprises at least one of gold, copper, aluminum, or silver.

6. The medical lead according to claim 1, wherein the low conductive metal further comprises at least one of titanium, or titanium nitride.

7. The medical lead according to claim 1, wherein the high conductive metal is gold and the low conductive metal is platinum.

8. The medical lead according to claim 1, wherein the electrically conductive thin film comprises titanium on at least a portion of an outer perimeter of the low conductive metal.

9. The medical lead of claim 1, further comprising a carrier material, and wherein the electrically conductive thin film is attached to the carrier material.

10. The medical lead of claim 9, further comprising a polymer material encapsulating the carrier material and the electrically conductive thin film from the proximal portion to the at least one electrode.

11. The medical lead of claim 1, wherein the at least one electrode is defined by an exposed portion of the low conductive metal.

12. The medical lead of claim 1, wherein the low conductive metal encapsulating all sides of the high conductive metal has a substantially uniform composition.

13. The medical lead of claim 1, wherein the platinum is directly on all sides of the high conductive metal.

14. A method comprising manufacturing a medical lead, the lead comprising:

a proximal portion;

at least one electrode located distal to the proximal portion; and

an electrically conductive thin film extending from the proximal portion to the at least one electrode, the electrically conductive thin film comprising a metal trace formed of a high conductive metal extending from the proximal portion to the at least one electrode and a low conductive metal that encapsulates all sides of the high conductive metal extending from the proximal portion to the at least one electrode, wherein the low conductive metal comprises platinum, is biocompatible and has a lower electrical conductivity than the high conductive metal, and wherein the metal trace is electrically coupled to the at least one electrode such that electrical signals are conducted via the metal trace between the at least one electrode and a medical device electrically coupled to the medical lead.

15. The method of claim 14, wherein the electrically conductive thin film includes a ceramic material encapsulating all sides of the low conductive metal extending from the proximal portion to the at least one electrode.

16. The method of claim 15, wherein the ceramic material comprises at least one of SiN, SiOX, Si-Carbide or Alumina.

17. The method of claim 14, wherein the high conductive metal comprises at least one of gold, copper, aluminum, or silver.

18. The method of claim 14, wherein the low conductive metal further comprises at least one of titanium or titanium nitride.

19. The method of claim 14, wherein the high conductive metal is gold and the low conductive metal is platinum.

20. The method of claim 14, wherein the electrically conductive thin film comprises a flexible polymer encapsulating all sides of the low conductive metal extending from the proximal portion to the at least one electrode.

21. The method of claim 14, wherein an additional pattern is arranged on the low conductive metal, and wherein the additional pattern comprises titanium.

22. The method of claim 14, wherein the lead body comprises a carrier material, and wherein the electrically conductive thin film is attached to the carrier material.

23. The method of claim 22, wherein the lead body comprises a polymer material encapsulating the carrier material and the electrically conductive thin film.

24. The method of claim 14, wherein the at least one electrode is defined by an exposed portion of the low conductive metal.

25. The method of claim 14, wherein the low conductive metal encapsulating all sides of the high conductive metal has a substantially uniform composition.

26. The method of claim 14, wherein manufacturing the lead comprises:

sputter depositing a layer of the low conductive metal;

selective plating of the high conductive metal on the low conductive metal through a resist mask to form the metal trace;

patterning of the low conductive metal; and

electroplating of the low conductive metal on exposed portions of the high conductive metal.

27. A deep brain stimulation system comprising:

an implantable pulse generator; and

a medical lead coupled to the implantable pulse generator and configured to deliver electrical stimulation pulses from the implantable pulse generator to a target site via an electrode, the medical lead comprising;

a proximal portion;

at least one electrode located distal to the proximal portion; and

an electrically conductive thin film extending from the proximal portion to the at least one electrode, the electrically conductive thin film comprising a metal trace formed of a high conductive metal extending from the proximal portion to the at least one electrode and a low conductive metal that encapsulates all sides of the high conductive metal extending from the proximal portion to the at least one electrode, wherein the low conductive metal comprises platinum, is biocompatible and has a lower electrical conductivity than the high conductive metal, and wherein the metal trace is electrically coupled to the at least one electrode such that electrical signals are conducted via the metal trace between the at least one electrode and a medical device electrically coupled to the medical lead.

28. The deep brain stimulation system of claim 27, wherein the platinum is directly on all sides of the high conductive metal.