US 8,712,542 B2Granted

Deposited conductive layers for leads of implantable electric stimulation systems and methods of making and using

AssigneeBoston Scientific Neuromodulation Corporation

InventorsDavid Michael McMorrow, Anne M. Pianca

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Abstract

An implantable lead includes an inner core substrate. A plurality of conductors that include at least one layer of at least one conductive material are deposited on the inner core substrate. A patterned insulator layer is disposed over the conductors such that at least two regions of each conductor remain exposed through the insulator. A patterned terminal layer defines a plurality of separated terminals that are deposited at a proximal end of the lead. At least one terminal is electrically coupled to each conductor via at least one of the exposed regions of the at least one conductor. A patterned electrode layer defines a plurality of separated electrodes that are deposited at a distal end of the lead. At least one electrode is electrically coupled to each conductor via at least one of the exposed regions of the at least one conductor.

Claims20

Dependent claims

An implantable lead comprising:

a lead body with a distal end portion, a proximal end portion, and an inner core substrate having a surface, the lead body configured and arranged for implanting into a patient;
a plurality of conductors attached directly to the surface of the inner core substrate by deposition, each conductor comprising at least one layer of at least one conductive material extending between the proximal end portion and the distal end portion of the lead body;
a patterned insulator layer distinct from the inner core substrate, the patterned insulator layer attached directly to the plurality of conductors such that each conductor of the plurality of conductors is sandwiched between the inner core substrate and the patterned insulator layer, the patterned insulator layer attached to the plurality of conductors such that at least two regions of each conductor of the plurality of conductors remain exposed through the insulator layer, including a first exposed region at the proximal end portion of the lead body and a second exposed region at the distal end portion of the lead body;
a patterned terminal layer, defining a plurality of separated terminals, attached by deposition to the proximal end portion of the lead body, wherein for each conductor of the plurality of conductors at least one terminal of the plurality of separated terminals is attached by deposition to the conductor via the first exposed region of that conductor, wherein each terminal of the plurality of separated terminals is attached by deposition to at least one of a portion of the patterned insulator layer or the inner core substrate along the proximal end portion of the lead body;
and
a patterned electrode layer, defining a plurality of separated electrodes, attached by deposition to the distal end portion of the lead body, wherein for each conductor of the plurality of conductors at least one electrode of the plurality of separated electrodes is attached by deposition to the conductor via the second exposed region of that conductor, wherein each electrode of the plurality of separated is attached by deposition to at least one of a portion of the patterned insulator layer or the inner core substrate along the distal end portion of the lead body.

3 more elements

A method for making an implantable lead, the method comprising:

attaching, by deposition, a plurality of conductors directly to a surface of an inner core substrate of a lead body of the lead, wherein each conductor of the plurality of conductors comprises at least one layer of at least one conductive material extending between a proximal end portion and a distal end portion of the lead body;
attaching a patterned insulator layer that is distinct from the inner core substrate directly to the plurality of conductors such that each conductor of the plurality of conductors is sandwiched between the inner core substrate and the patterned insulator layer, the patterned insulator layer attached to the plurality of conductors such that at least two regions of each conductor of the plurality of conductors remains exposed through the insulator layer, including a first exposed region at the proximal end portion of the lead body and a second exposed region at the distal end portion of the lead body;
attaching, by deposition, a patterned terminal layer, defining a plurality of separated terminals, to the proximal end portion of the lead body, wherein for each conductor of the plurality of conductors at least one terminal of the plurality of separated terminals is attached by deposition to the conductor via the first exposed region of that conductor, wherein each terminal of the plurality of separated terminals is attached by deposition to at least one of a portion of the patterned insulator layer or the inner core substrate along the proximal end portion of the lead body;
and
attaching, by deposition, a patterned electrode layer, defining a plurality of separated electrodes, to the distal end portion of the lead body, wherein for each conductor of the plurality of conductors at least one electrode of the plurality of separated electrodes is attached by deposition to the conductor via the second exposed region of that conductor, wherein each electrode of the plurality of separated electrodes is attached by deposition to at least one of a portion of the patterned insulator layer or the inner core substrate along the distal end portion of the lead body.

2 more elements

Dependencies are inferred from the claim text.