METHODS OF MANUFACTURING A CONTACT ARRAY ASSEMBLY AND LEADS AND SYSTEMS CONTAINING THE ASSEMBLY

摘要

A method of making an electrical stimulation lead includes disposing conductive contacts in a spaced-apart longitudinal arrangement within a mold. A portion of a stylet tube is disposed within the mold, and the stylet tube extends through the conductive contacts. Conductive wires are positioned external to the stylet tube and each contact is coupled to at least one of the wires. A non-conductive material is molded between adjacent pairs of the contacts, around the wires, and over the stylet tube, to form a portion of the lead. This portion includes the contacts, the stylet tube, the wires, and one or more non-conductive spacers formed from the non-conductive material. Finally, the portion of the lead is removed from the mold. Another method includes placing a temporary tube around the conductive contacts and forming spacers by introducing flowable, curable, non-conductive material within the tube and between the conductive contacts.

主权项

1. A method of making an electrical stimulation lead, the method comprising:
disposing a plurality of conductive contacts within a mold in a spaced-apart longitudinal arrangement; disposing at least a portion of a stylet tube within the mold and extending longitudinally through the plurality of conductive contacts; coupling a plurality of conductive wires to the plurality of conductive contacts, wherein each conductive contact is coupled to at least one of the conductive wires, wherein the conductive wires are external to the stylet tube; molding a non-conductive material between adjacent pairs of the conductive contacts, around the conductive wires, and over the stylet tube to form a portion of the electrical stimulation lead comprising the plurality of conductive contacts, stylet tube, conductive wire and at least one non-conductive spacer formed from the non-conductive material; and removing the portion of the lead from the mold.