Method of fabricating stimulation lead by fusing connector segment between lead body and electrode portion of the lead

Abstract

In one embodiment, a process, for fabricating a medical lead comprises: providing a splicing tube having a plurality of angularly spaced longitudinal grooves; placing a first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube; placing a second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends; positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends; electrically coupling the proximal ends of the first plurality of electrodes to respective proximal ends of the second plurality of electrodes; molding insulative material about at least the electrode assembly and the splicing tube; and fusing the splicing tube with the insulative material from the molding and the lead body.

1 - 20 . (canceled) 
     
     
         21 . A process for fabricating a medical lead for stimulation of tissue of a patient, the process comprising:
 providing an electrode assembly comprising a plurality of electrodes electrically coupled to a first plurality of conductors;   providing a lead body comprising a second plurality of conductors;   providing a splicing tube having a plurality of angularly spaced longitudinal grooves;   placing proximal ends of the first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube;   placing distal ends of the second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the proximal ends of the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends;   positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends;   electrically coupling the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors;   molding insulative material about at least the electrode assembly and the splicing tube; and   fusing the splicing tube with the insulative material from the molding and the lead body.   
     
     
         22 . The process of  claim 21 , wherein the electrically coupling comprises laser welding the conductive filler material such that the conductive filler material couples the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors. 
     
     
         23 . The process of  claim 21 , further comprising:
 removing insulative material of the lead body to release the second plurality of conductors.   
     
     
         24 . The process of  claim 21 , further comprising:
 providing a center tubing about a mandrel;   positioning the electrode assembly over the center tubing; and   positioning at least one spacer adjacent to the at least one electrode assembly; and   providing a second electrode assembly adjacent to the at least one spacer.   
     
     
         25 . The process of  claim 24 , further comprising:
 positioning a ring electrode over the center tubing; and   positioning a spacer adjacent to the ring electrode.   
     
     
         26 . The process of  claim 21 , further comprising performing centerless grinding after performing the molding. 
     
     
         27 . The process of  claim 21  wherein the plurality of electrodes of the electrode assembly are segmented electrodes. 
     
     
         28 . The process of  claim 27  further comprising:
 attaching the segmented electrodes about a central tubing. 
 
     
     
         29 . The process of  claim 28  further comprising:
 maintaining angular separation between the segmented electrodes using thermoplastic tape. 
 
     
     
         30 . The process of  claim 27  wherein the segmented electrodes have a cross-section being generally crescent shaped. 
     
     
         31 . The process of  claim 30  further comprising:
 crushing each segmented electrode about a respective conductor of the first plurality of conductors. 
 
     
     
         32 . A process for fabricating a medical lead for stimulation of tissue of a patient, the process comprising:
 providing an electrode assembly comprising a plurality of segmented electrodes electrically coupled to a first plurality of conductors;   providing a lead body comprising a second plurality of conductors;   providing a splicing tube having a plurality of angularly spaced longitudinal grooves;   placing proximal ends of the first plurality of conductors within the plurality of angularly spaced grooves defined on an exterior surface of the splicing tube;   placing distal ends of the second plurality of conductors within the plurality of angularly spaced grooves and adjacent to the proximal ends of the first plurality of conductors such that a portion of the distal ends overlap a portion of the proximal ends;   positioning conductive filler material adjacent to the overlapped portions of the distal and proximal ends;   electrically coupling the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors;   molding insulative material about at least the electrode assembly and the splicing tube; and   fusing the splicing tube with the insulative material from the molding and the lead body.   
     
     
         33 . The process of  claim 32 , wherein the electrically coupling comprises laser welding the conductive filler material such that the conductive filler material couples the proximal ends of the first plurality of conductors to respective distal ends of the second plurality of conductors. 
     
     
         34 . The process of  claim 32 , further comprising:
 removing insulative material of the lead body to release the second plurality of conductors.   
     
     
         35 . The process of  claim 32 , further comprising:
 providing a center tubing about a mandrel;   positioning the electrode assembly over the center tubing; and   positioning at least one spacer adjacent to the at least one electrode assembly; and   providing a second electrode assembly adjacent to the at least one spacer.   
     
     
         36 . The process of  claim 35 , further comprising:
 positioning a ring electrode over the center tubing; and   positioning a spacer adjacent to the ring electrode.   
     
     
         37 . The process of  claim 32 , further comprising performing centerless grinding after performing the molding. 
     
     
         38 . The process of  claim 32  further comprising:
 attaching the segmented electrodes about a central tubing. 
 
     
     
         39 . The process of  claim 38  further comprising:
 maintaining angular separation between the segmented electrodes using thermoplastic tape.