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 lead body having a distal end and a proximal end having a terminal;    a first region extending distally from the distal end of the lead body, wherein the first region includes a plurality of electrodes, and adjacent electrodes are separated by a first insulative material having prescribed mechanical properties;    at least one conductor electrically coupling the terminal with at least one corresponding electrode of the plurality of electrodes, wherein the at least one conductor extends along the lead body and the first region, and    wherein in addition to the at least one conductor, a portion of the first region is substantially filled with a second insulative material having mechanical properties consistent with the first insulative material.    
   
   
       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 the lead body is formed of a material having properties consistent with the first insulative material.  
   
   
       18 . An implantable lead in accordance with  claim 15  wherein the at least one conductor is formed of stranded wire and has a resistance equal to or less than 25 ohms for a conductor length equal to or less than 60 cm.  
   
   
       19 . An implantable lead in accordance with  claim 15  wherein an outer diameter of the lead body is approximately 0.05 inches.  
   
   
       20 . An implantable lead in accordance with  claim 15  further comprising a stylet guide, positioned within the lead body and the first region, and the second material substantially surrounds the stylet guide.  
   
   
       21 . An implantable lead in accordance with  claim 15  wherein the implantable lead is substantially isodiametric.  
   
   
       22 . An implantable lead in accordance with  claim 15  wherein the second insulative material is a fused matrix.  
   
   
       23 . An implantable lead in accordance with  claim 15  wherein at least one interior passage is within a second region extending proximally from the proximal end of the lead body, and in addition to the at least one conductor, the interior passage of the second region is substantially filled with a third insulative material having mechanical properties consistent with the first insulative material.  
   
   
       24 . An implantable lead in accordance with  claim 23  wherein the first insulative material, the second insulative material, and the third insulative material are the same.  
   
   
       25 . An implantable lead in accordance with  claim 23 , wherein the third insulative material is a fused matrix.  
   
   
       26 . 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.  
   
   
       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 15  wherein the at least one conductor has a resistance less than 4 ohms.  
   
   
       29 . An implantable lead in accordance with  claim 15  wherein the corresponding electrode is joined to the at least one conductor by a laser weld.  
   
   
       30 . An implantable lead in accordance with  claim 15  wherein the plurality of electrodes equals eight.  
   
   
       31 . An implantable lead comprising: 
 a lead body having a distal end and a proximal end having a terminal;    a first region extending distally from the distal end of the lead body, wherein the first region includes a plurality of electrodes, and adjacent electrodes are separated by a first insulative material having prescribed mechanical properties;    at least one conductor electrically coupling the terminal with at least one corresponding electrode of the plurality of electrodes, wherein the at least one conductor extends through at least a portion of each of the lead body and the first region; and    wherein at least the first region has a substantially solid cross-section, and excepting the at least one conductor passing therethrough and the plurality of electrodes thereof, material(s) forming the first region has mechanical properties consistent with the first insulative material.    
   
   
       32 . An implantable lead in accordance with  claim 31  wherein the material(s) forming the first region, which supports the plurality of electrodes and carries the at least one conductor, is a fused matrix.  
   
   
       33 . An implantable lead comprising: 
 a lead body having a distal end and a proximal end having a terminal;    a stimulation portion extending distally from the distal end of the lead body, wherein the stimulation portion includes a plurality of electrodes, and adjacent electrodes are separated by an insulative material having prescribed mechanical properties;    at least one conductor electrically coupling the terminal with at least one corresponding electrode of the plurality of electrodes, wherein the at least one conductor extends through at least a portion of each of the lead body and the stimulation portion; and    wherein at least the stimulation portion is formed from a substantially solid, fused matrix of materials having consistent mechanical characteristics, and the fused matrix of material(s) supports the plurality of electrodes and the at least one conductor extends at least partially therethrough.    
   
   
       34 . An implantable lead comprising: 
 a lead body having a distal end and a proximal end having a terminal;    a first region extending distally from the distal end of the lead body, wherein the first region includes a plurality of electrodes, and adjacent electrodes are separated by a first insulative material, the first insulative material having prescribed mechanical properties;    at least one conductor electrically coupling the terminal with at least one corresponding electrode of the plurality of electrodes, wherein the at least one conductor extends along within the lead body and the first region, and    wherein in addition to the at least one conductor, the a portion of the first region is substantially filled with a second insulative material having mechanical properties consistent with material of the first insulative material.