# US 2014/0155971 A1 · Systems and methods for making and using radially-aligned segmented electrodes for leads of electrical stimulation systems

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- Number: US 2014/0155971 A1
- Document ID: US20140155971A1
- Status: Published application
- Kind: A1
- Application number: 14/173,593
- Filed: 2014-02-05
- Published: 2014-06-05
- Earliest claimed: 2010-09-21
- Assignees: Boston Scientific Neuromodulation Corporation
- Applicants: Boston Scientific Neuromodulation Corporation
- Inventors: Anne Margaret Pianca; Priya Sundaramurthy
- Web page: https://patentgrep.com/patent/US20140155971A1

## CPC

- A61N 1/0534: {Electrodes for deep brain stimulation}
- A61N 1/05: for implantation or insertion into the body, e.g. heart electrode (A61N1/06 takes precedence)
- A61N 1/36182: {Direction of the electrical field, e.g. with sleeve around stimulating electrode}
- A61N 1/048: {Electrodes characterised by a specific connection between lead and electrode}
- Y10T 29/49117: Conductor or circuit manufacturing
- Y10T 29/49204: Contact or terminal manufacturing
- A61N: ELECTROTHERAPY; MAGNETOTHERAPY; RADIATION THERAPY; ULTRASOUND THERAPY (measurement of bioelectric currents A61B; surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body A61B18/00; anaesthetic apparatus in general A61M; incandescent lamps H01K; infrared radiators for heating H05B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An electrical stimulation lead includes a lead body insertable into a patient. Electrodes are disposed along the lead body. The electrodes include at least two sets of segmented electrodes. Each set of segmented electrodes includes a first segmented electrode and a second segmented electrode radially spaced apart from one another around a circumference of the lead body. A tab is disposed on the first segmented electrode of each set of segmented electrodes. The tabs extend into the lead body. A guide feature is disposed on the tabs. The guide features are each radially aligned with one another along the length of the lead body. Conductors extend along the length of the lead body from a proximal end to the electrodes. Each of the conductors is electrically coupled to at least one of the electrodes. At least one of the conductors extends through the radially-aligned guide features of the tabs.

## Claims

### Claim 1

An electrical stimulation lead comprising:
an elongated lead body having a distal end portion, a proximal end portion, a longitudinal length, and a circumference, the lead body configured and arranged for insertion into a patient;
a plurality of terminals disposed along the proximal end portion of the lead body;
a plurality of conductors coupled to the plurality of terminals and extending along the longitudinal length of the lead body to the distal end portion of the lead body, the plurality of conductors comprising a first conductor and a second conductor;
a plurality of electrodes disposed along the distal end portion of the lead body and coupled to the plurality of conductors, the plurality of electrodes comprising
a first set of segmented electrodes comprising a first segmented electrode and a second segmented electrode spaced apart from one another around the circumference of the lead body, wherein the first conductor is coupled to the first segmented electrode, and
a second set of segmented electrodes comprising a third segmented electrode and a fourth segmented electrode spaced apart from one another around the circumference of the lead body, wherein the second conductor is coupled to the third segmented electrode,
wherein the first set of segmented electrodes is disposed proximal to the second set of segmented electrodes along the longitudinal length of the lead body,
wherein the first segmented electrode and the third segmented electrode are circumferentially-aligned with one another along the longitudinal length of the lead body; and
a tab disposed on the first segmented electrode, the tab extending inwardly from the first segmented electrode into the lead body, the tab comprising a guide feature;
wherein the second conductor physically contacts the guide feature of the tab.

### Claim 2 (depends on 1)

The electrical stimulation lead of claim 1, further comprising a connection element disposed along the first segmented electrode, wherein the first conductor is coupled to the first segmented electrode along the connection element.

### Claim 3 (depends on 2)

The electrical stimulation lead of claim 2, wherein the tab is disposed apart from the connection element along the first segmented electrode so that the tab does not interfere with the coupling of the first conductor to the connection element.

### Claim 4 (depends on 1)

The electrical stimulation lead of claim 1, wherein the tab is a first tab and the guide feature is a first guide feature, and wherein a second tab that defines a second guide feature is disposed on the second segmented electrode, wherein the second tab extends inwardly from the second segmented electrode into the lead body.

### Claim 5 (depends on 4)

The electrical stimulation lead of claim 4, wherein the plurality of conductors further comprises a third conductor and a fourth conductor, wherein the third conductor is coupled to the second segmented electrode, and wherein the fourth conductor physically contacts the second guide feature of the second tab and couples to the fourth segmented electrode.

### Claim 6 (depends on 5)

The electrical stimulation lead of claim 5, wherein the second segmented electrode and the fourth segmented electrode are circumferentially-aligned with one another along the longitudinal length of the lead body.

### Claim 7 (depends on 1)

The electrical stimulation lead of claim 1, wherein the guide feature comprises an aperture defined in the tab.

### Claim 8 (depends on 1)

The electrical stimulation lead of claim 1, wherein the guide feature comprises hook formed along the tab.

### Claim 9 (depends on 1)

The electrical stimulation lead of claim 1, wherein the first set of segmented electrodes further comprising a fifth segmented electrode spaced apart from each of the first segmented electrode and the second segmented electrode around the circumference of the lead body.

### Claim 10 (depends on 9)

The electrical stimulation lead of claim 9, wherein the second set of segmented electrodes further comprising a sixth segmented electrode spaced apart from each of the third segmented electrode and the fourth segmented electrode around the circumference of the lead body.

### Claim 11 (depends on 1)

The electrical stimulation lead of claim 1, wherein the plurality of electrodes further comprises at least one ring electrode disposed along the distal end portion of the lead body.

### Claim 12 (depends on 11)

The electrical stimulation lead of claim 11, wherein the at least one ring electrode is disposed proximal to each of the first set of segmented electrodes and the second set of segmented electrodes along the longitudinal length of the lead body.

### Claim 13 (depends on 11)

The electrical stimulation lead of claim 11, wherein the at least one ring electrode is disposed distal to each of the first set of segmented electrodes and the second set of segmented electrodes along the longitudinal length of the lead body.

### Claim 14 (depends on 1)

The electrical stimulation lead of claim 1, wherein the plurality of electrodes comprises a first ring electrode disposed proximal to each of the first set of segmented electrodes and the second set of segmented electrodes along the longitudinal length of the lead body and a second ring electrode disposed distal to each of the first set of segmented electrodes and the second set of segmented electrodes along the longitudinal length of the lead body.

### Claim 15 (depends on 1)

The electrical stimulation lead of claim 1, wherein the plurality of electrodes comprises eight electrodes.

### Claim 16 (depends on 1)

An electrical stimulation system comprising:
the electrical stimulation lead of claim 1; and
a control module coupled to the proximal end portion of the electrical stimulation lead, the control module configured and arranged for providing stimulation energy to the plurality of electrodes.

### Claim 17

A method of forming a lead of an electrical stimulation system, the method comprising:
forming a plurality of pre-electrodes that comprises a first pre-electrode and a second pre-electrode, wherein each of the plurality of pre-electrodes is formed in the shape of a ring, wherein each of the plurality of pre-electrodes comprises at least two thin-walled portions separated by at least two thick-walled portions, wherein the first pre-electrode comprises a tab disposed on a first thick-walled portion of the at least two thick-walled portions, wherein the tab comprises a guide feature;
disposing a plurality of terminals along a proximal end portion of a lead body;
coupling a plurality of conductors to the plurality of terminals and extending the plurality of conductors along a longitudinal length of the lead body;
disposing the plurality of pre-electrodes along a distal end portion of a lead body with the first pre-electrode disposed proximal to the second pre-electrode along the longitudinal length of the lead body;
coupling a first conductor of the plurality of conductors to the first thick-walled portion of the first pre-electrode;
coupling a second conductor of the plurality of conductors to a second thick-walled portion of the at least two thick-walled portions of the second pre-electrode;
physically contacting the second conductor to the guide feature of the tab disposed on the first thick-walled portion of the first pre-electrode to circumferentially-align the second thick-walled portion of the second pre-electrode with the first thick-walled portion of the first pre-electrode along the longitudinal length of the lead body; and
grinding the plurality of pre-electrodes to remove the thin-walled portions of each of the plurality of pre-electrodes to form a plurality of segmented electrodes from the thick-walled portions of each of the plurality of pre-electrodes.

### Claim 18 (depends on 17)

The method of claim 17, wherein physically contacting the second conductor to the guide feature of the tab is performed prior to coupling the second conductor to the second thick-walled portion of the second pre-electrode.

### Claim 19 (depends on 17)

The method of claim 17, wherein physically contacting the second conductor to the guide feature of the tab comprises extending the second conductor through an aperture defined in the tab.

### Claim 20 (depends on 17)

The method of claim 17, wherein physically contacting the second conductor to the guide feature of the tab comprises physically contacting the second conductor to a hook formed along the tab.