Method of forming a lead

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.

1 .- 14 . (canceled)  
   
   
       15 . An implantable lead comprising: 
 a distal end having a first electrode and a second electrode;    a proximal end having a first terminal and a second terminal;    a lead body extending between the distal end and the proximal end, the lead body comprising a first insulative material having prescribed mechanical properties;    a second insulative material separating the first terminal and the terminal electrode, the second insulative material having mechanical properties consistent with the first insulative material;    a first conductor coupling the first electrode to the first terminal, and wherein the first conductor extends within the lead body; and    a second conductor coupling the second electrode and the second terminal, and wherein the second conductor extends through the lead body.    
   
   
       16 . An implantable lead in accordance with  claim 15  wherein the first insulative material and the second insulative material are the same.  
   
   
       17 . An implantable lead in accordance with  claim 15  wherein a third insulative material substantially fills an interior passage region beneath the first electrode, the third insulative material having mechanical properties consistent with the first insulative material and the first insulative material, the second insulative material, and the third insulative material are the same.  
   
   
       18 . An implantable lead in accordance with  claim 15  wherein the implantable lead is substantially isodiametric.  
   
   
       19 . An implantable lead in accordance with  claim 15  wherein the at least one conductor has a resistance less than 4 ohms for a conductor length equal to or less than 60 cm.  
   
   
       20 . An implantable lead in accordance with  claim 19  wherein an outer diameter of the lead body is approximately 0.05 inches.  
   
   
       21 . An implantable lead in accordance with  claim 15  wherein the first electrode is joined to the first conductor by a laser weld.  
   
   
       22 . An implantable lead comprising: 
 a distal end having a first electrode and a second electrode;    a proximal end having a first terminal and a second terminal;    a lead body extending between the distal end and the proximal end;    a first insulative material separating the first terminal and the second terminal, the second insulative material having prescribed mechanical properties;    a second insulative material substantially filling a portion of a region of the proximal end, the second insulative material having mechanical properties consistent with the first insulative material;    a first conductor coupled to the first terminal, and wherein the first conductor extends within the lead body; and    a stylet guide extending from the proximal end through the lead body.    
   
   
       23 . An implantable lead in accordance with  claim 22  wherein the first insulative material and the second insulative material are the same.  
   
   
       24 . An implantable lead in accordance with  claim 22  wherein the lead body comprises a third insulative material, and the first insulative material, the second insulative material, and the third insulative material are the same.  
   
   
       25 . An implantable lead in accordance with  claim 22  wherein the implantable lead is substantially isodiametric.  
   
   
       26 . An implantable lead in accordance with  claim 22  wherein the at least one conductor has a resistance less than 4 ohms for a conductor length equal to or less than 60 cm.  
   
   
       27 . An implantable lead in accordance with  claim 26  wherein an outer diameter of the lead body is approximately 0.05 inches.  
   
   
       28 . An implantable lead in accordance with  claim 22  wherein the first electrode is joined to the first conductor by a laser weld.  
   
   
       29 . An implantable lead comprising: 
 a distal end having at least four electrodes;    a proximal end having at least four terminals;    a lead body extending between the distal end and the proximal end;    a first insulative material separating each of the at least four electrodes, the second insulative material having prescribed properties;    a second insulative material substantially filling a portion of regions beneath each of the at least four electrodes, the second insulative material having properties consistent with the first insulative material;    at least a first conductor coupling one of the at least four electrodes to a corresponding one of the at least four terminals, and wherein the first conductor extends within the lead body.    
   
   
       30 . An implantable lead comprising: 
 a distal end having at least eight electrodes;    a proximal end having at least eight terminals;    a lead body extending between the distal end and the proximal end, the lead body comprising a first insulative material having prescribed properties;    a second insulative material separating each of the at least eight electrodes, the second insulative material having properties consistent with the first insulative material;    a third insulative material substantially filling a portion of regions beneath each of the at least eight electrodes, the third insulative material having properties consistent with the first insulative material;    at least a first conductor coupling one of the at least eight electrodes to a corresponding one of the at least eight terminals, and wherein the first conductor extends within the lead body.    
   
   
       31 . An implantable lead in accordance with  claim 30  wherein the at least one conductor is joined to the at least one of the eight electrodes by a laser weld.  
   
   
       32 . An implantable lead in accordance with  claim 30  wherein the third insulative material is a fused matrix.  
   
   
       33 . An implantable lead comprising: 
 a distal end having a first electrode and a second electrode;    a proximal end having a first terminal and a second terminal;    a lead body extending between the distal end and the proximal end, the lead body comprising a first insulative material having prescribed mechanical properties, and wherein an outer diameter of the lead body is approximately 0.05 inches;    a second insulative material separating the first electrode and the second electrode, the second insulative material having mechanical properties consistent with the first insulative material;    a third insulative material substantially filling a portion of a region beneath the first electrode, the third insulative material having mechanical properties consistent with the first insulative material, and wherein the second insulative material and the third insulative material are the same material;    a first conductor coupling the first electrode to the first terminal, and wherein the first conductor extends through the lead body, and wherein the first conductor has a resistance less than 4 ohms for a conductor length equal to or less than 60, and wherein the first conductor is joined to the first electrode by a laser weld; and    a second conductor coupling the second electrode and the second terminal, wherein the second conductor has a resistance less than 4 ohms for a conductor length equal to or less than 60 cm, and wherein the second conductor is joined to the second electrode by a laser weld, and wherein the second conductor extends through the lead body.    
   
   
       34 . An implantable lead in accordance with  claim 33  wherein the implantable lead is substantially isodiametric.