Method of forming a crimp-through crimp connector for connecting a conductor cable to an electrode

Abstract

An implantable cardiac electrotherapy lead is manufactured by providing an electrode on a tubular body of the lead, forming a crimp connector from a tubing, forming at least one splice opening at the tubing, receiving and end of a cable conductor in a cavity of the crimp connector, and welding an outer surface of the crimp connector to an edge of the electrode. In a post-crimp position, proximal and distal ends of an inner surface of the tubing contact an insulation jacket of the cable conductor and a sharp edge of the at least one splice opening penetrates the insulation jacket and contacts a conductive core of the cable conductor to provide electrical communication between the crimp connector and the cable connector.

What is claimed is: 
     
         1 . A method of manufacturing an implantable cardiac electrotherapy lead, the method comprising:
 providing an electrode on a tubular body of the lead;   forming a crimp connector from a tubing, the tubing having a tubular wall with an outer tubular surface, an inner tubular surface, a proximal end, and a distal end;   forming at least one splice opening at the tubular wall, the at least one splice opening having a sharp edge at its intersection with the inner tubular surface, and the sharp edge being flush with the inner tubular surface;   receiving an end of a cable conductor in a cavity of the crimp connector, the inner tubular surface defining the cavity, the proximal and distal ends of the tubular wall defining proximal and distal openings leading to the cavity, the cable conductor having a conductive core and an insulation jacket, the at least one splice opening extending from the outer tubular surface to the inner tubular surface and oriented generally transverse to an axis extending between the proximal and distal openings, and the sharp edge oriented generally transverse to the axis;   wherein, in a post-crimp position, the proximal and distal ends of the inner tubular surface contact the insulation jacket and the sharp edge penetrates the insulation jacket and contacts the conductive core to provide electrical communication between the crimp connector and the cable conductor; and   welding an outer surface of the crimp connector to an edge of the electrode.   
     
     
         2 . The method of  claim 1 , wherein forming the at least one splice opening comprises laser cutting. 
     
     
         3 . The method of  claim 1 , further comprising providing the pre-drawn tubing with an oval cross-section. 
     
     
         4 . The method of  claim 1 , wherein the at least one splice opening is at least one slot opening. 
     
     
         5 . The method of  claim 4 , wherein the at least one slot opening comprises a first side, a second side, a third side, and a fourth side, wherein the first and second sides oppose each other and are oriented generally transverse to the axis extending between the proximal and distal openings, wherein the third and fourth sides oppose each other and are oriented generally parallel to the axis extending between the proximal and distal openings, and wherein the sharp edge is disposed at the first and second sides. 
     
     
         6 . The method of  claim 5 , wherein the lengths of the first side and the second side are substantially the same, and wherein the lengths of the third side and the fourth side are substantially the same. 
     
     
         7 . The method of  claim 1 , wherein in the post-crimp position, the sharp edge remains flush with the inner tubular surface. 
     
     
         8 . The method of  claim 4 , wherein the at least one slot opening comprises three slot opening. 
     
     
         9 . The method of  claim 9 , wherein the three slot openings are in line with one another and are equally spaced. 
     
     
         10 . The method of  claim 1 , further comprising providing a termination ring at a proximal end of the electrode, the termination ring having an arcuate inner surface and a proximal edge. 
     
     
         11 . The method of  claim 10 , further comprising fixedly attaching the outer tubular surface of the tubular wall to the proximal edge of the termination ring. 
     
     
         12 . The method of  claim 10 , further comprising welding the outer tubular surface of the tubular wall to the proximal edge of the termination ring. 
     
     
         13 . The method of  claim 1 , wherein the tubing is a segment of a pre-drawn tubing.