U.S. patent application number 11/167020 was filed with the patent office on 2005-10-20 for terminal connector assembly for a medical device and method therefor.
This patent application is currently assigned to Cardiac Pacemakers, Inc.. Invention is credited to Ley, Gregory R., Rugnetta, Jaime L., Sundberg, Gregory L., Wentorf, Mary S., Zarembo, Paul E., Zerby, Christopher M..
Application Number | 20050234522 11/167020 |
Document ID | / |
Family ID | 35097289 |
Filed Date | 2005-10-20 |
United States Patent
Application |
20050234522 |
Kind Code |
A1 |
Ley, Gregory R. ; et
al. |
October 20, 2005 |
Terminal connector assembly for a medical device and method
therefor
Abstract
A connector assembly of an electrophysiologial device. The
connector assembly includes a substrate forming a tube extending
from a proximal end to a distal end an electrical circuit formed on
the substrate, such as etching or printing, where the substrate is
optionally non-conductive. In another option, the connector
assembly includes clad wires and/or flexible circuits within an
insulated terminal structure.
Inventors: |
Ley, Gregory R.; (Blaine,
MN) ; Sundberg, Gregory L.; (Stillwater, MN) ;
Rugnetta, Jaime L.; (White Bear Lake, MN) ; Wentorf,
Mary S.; (Roseville, MN) ; Zarembo, Paul E.;
(Vadnais Heights, MN) ; Zerby, Christopher M.;
(New Brighton, MN) |
Correspondence
Address: |
Schwegman, Lundberg, Woessner & Kluth, P.A.
P.O. Box 2938
Minneapolis
MN
55402
US
|
Assignee: |
Cardiac Pacemakers, Inc.
|
Family ID: |
35097289 |
Appl. No.: |
11/167020 |
Filed: |
June 24, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11167020 |
Jun 24, 2005 |
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10226374 |
Aug 21, 2002 |
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6912423 |
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11167020 |
Jun 24, 2005 |
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09738401 |
Dec 15, 2000 |
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6643550 |
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60313893 |
Aug 21, 2001 |
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Current U.S.
Class: |
607/37 |
Current CPC
Class: |
H01F 2007/1692 20130101;
A61N 1/056 20130101; A61N 1/3752 20130101; Y10S 439/908
20130101 |
Class at
Publication: |
607/037 |
International
Class: |
A61N 001/375 |
Claims
What is claimed is:
1. A terminal assembly for a medical device, the terminal assembly
comprising: an insulative elongate tube having an outer periphery
and a longitudinal axis; at least three conductors disposed along
the elongate tube; at least three conductive ring members having an
internal surface, each ring disposed over the elongate tube; a
conductive member electrically coupling each conductive ring member
with its respective conductor; a terminal pin extending from a pin
proximal end to a pin distal end, the terminal pin disposed within
the insulative elongate tube; and insulative material disposed over
the insulative elongate tube adjacent to the conductive ring
members.
2. The terminal assembly as recited in claim 1, wherein each ring
member has at least one projection extending from the internal
surface, the insulative elongate tube having a plurality of grooves
within the tube, each projection disposed in its respective
groove.
3. The terminal assembly in claim 2, wherein an outer diameter of a
portion of the insulated conductors are greater than a width of the
grooves.
4. The terminal assembly as recited in claim 1, further comprising
a lead body mechanically coupled with the terminal pin, the lead
body including electrodes disposed therealong, wherein the at least
three conductors extend continuously from the conductive ring
members to the electrodes.
5. The terminal assembly as recited in claim 1, wherein the
conductive member is a feed-through terminal.
6. The terminal assembly as recited in claim 1, wherein the rings
have an insulated portion and a conductive portion.
7. The terminal assembly as recited in claim 1, wherein the at
least three conductors are printed along the elongate tube.
8. The terminal assembly as recited in claim 1, wherein the
terminal pin is snap fittedly coupled with the insulative elongate
tube.
9. The terminal assembly as recited in claim 1, wherein the at
least three conductors are insulated conductors, and the insulated
conductors are electrically coupled with respective conductive ring
members.
10. A method comprising: forming a terminal assembly including
disposing one or more conductors along an outer periphery of an
insulative elongate tube having a longitudinal axis; disposing one
or more conductors along tube includes printing a conductive path
on the elongate tube; placing at least one conductive ring member
having an internal surface over the outer periphery of the
insulative elongate tube; electrically coupling each conductive
ring member with a respective conductive path; disposing a terminal
pin within the insulative elongate tube; and disposing insulative
material over the insulative elongate tube adjacent to the
conductive ring member.
11. The method as recited in claim 10, further comprising disposing
multiple conductive ring members over the tube, and electrically
isolating each ring from each other.
12. The method as recited in claim 10, wherein printing the
conductive path includes etching the conductive path on the
elongate tube.
13. The method as recited in claim 10, further comprising
snap-fittedly coupling the terminal pin with the elongate tube.
14. The method as recited in claim 10, further comprising providing
the rings with an insulated portion and a conductive portion.
15. A terminal assembly comprising: an insulative elongate tube
having one or more conductors printed thereon; at least one
conductive ring member having an internal surface; and the at least
one conductive ring member disposed over the insulative elongate
tube, the at least one conductive ring electrically coupled with
the one or more conductors.
16. The terminal assembly as recited in claim 15, further
comprising a terminal pin disposed within insulative elongate
tube.
17. The terminal assembly as recited in claim 15, further
comprising insulative material disposed over insulative elongate
tube adjacent to the conductive ring member.
18. The terminal assembly as recited in claim 15, further
comprising a feed-through coupled between the ring and the
conductor.
19. The terminal assembly as recited in claim 15, wherein the
terminal pin is snap fittedly coupled with the insulative elongate
tube.
20. The terminal assembly as recited in claim 15, wherein at least
three conductive rings are disposed over the insulative elongate
tube.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a Continuation of U.S. patent
application Ser. No. 10/226,374, filed Aug. 21, 2002, which claims
the benefit of U.S. Provisional Application No. 60/313,893, filed
on Aug. 21, 2001, under 35 U.S.C. 119(e). U.S. patent application
Ser. No. 10/226,374 is also a continuation-in-part of U.S. patent
application Ser. No. 09/738,401, filed on Dec. 15, 2000 and issued
as U.S. Pat. No. 6,643,550, the specifications of which are
incorporated by reference herein.
Technical Field
[0002] The present invention relates generally to connector
assemblies for electrophysiological applications. More
particularly, it pertains to printed circuit and micro terminal
connectors for electrophysiological applications.
BACKGROUND
[0003] Connector assemblies are used to couple electrophysiological
devices with a conductor. For instance, a connector is used to
couple a cardiac stimulator system such as a pacemaker, an
anti-tachycardia device, a cardioverter or a defibrillator with a
lead having an electrode for making contact with a portion of the
heart.
[0004] When leads with multiple conductors are involved, the
conductors are individually, mechanically and electrically coupled
with the pulse generator at a proximal end of the multiple
conductors. The multiple conductors at the proximal end are
electrically insulated from each other to prevent shorts and limit
electrical leakage between conductors. However, conventional
assemblies are bulky and are relatively large for multi-polar
assemblies. Furthermore, conventional assemblies have manufacturing
drawbacks, for example, the assembly process is difficult and time
consuming.
[0005] Accordingly, what is needed is an improved connector
assembly. What is further needed is a multipolar connector having a
reduced outer diamter.
SUMMARY
[0006] A connector assembly of an electrophysiologial device is
provided herein which overcomes the above problems. The connector
assembly includes an insulative elongate tube having an outer
periphery and a longitudinal axis. The tube further includes at
least one groove within the outer periphery of the elongate tube,
and a conductor is disposed in each groove. The assembly further
includes a conductive ring member with a projection extending from
the internal surface. The projection of the ring member is disposed
in the groove and is electrically coupled with the conductor. A
terminal pin is disposed within the elongate tube, and insulative
material is disposed over the insulative elongate tube adjacent to
the conductive ring member.
[0007] In another embodiment, a micro terminal is provided that has
an outer peripheral surface. The micro terminal includes a tube of
insulation, and a first conductor embedded within the tube of
insulation, a second conductor embedded within the tube of
insulation. A first conductive tab and a second conductive tab
extend from the outer peripheral surface to the first conductor and
the second conductor, respectively. The tube of insulation has an
inner lumen therethrough.
[0008] A method is also provided and includes forming a least one
groove within an outer periphery of an insulative elongate tube
having a longitudinal axis, disposing a conductor in each groove,
placing at least one conductive ring member having an internal
surface over the outer periphery of the insulative elongate tube,
and disposing a projection extending from the internal surface of
the conductive ring member within the at least one groove. The
method further includes disposing a terminal pin within the
insulative elongate tube, and disposing insulative material over
the insulative elongate tube adjacent to the conductive ring
member.
[0009] Several options are as follows. For instance, in one option,
the method further includes disposing an insulated conductor in
each groove, wherein a portion of insulation of the insulated
conductor is removed as the insulated conductor is disposed within
the groove. In another option, the method further includes forming
a plurality of elongate grooves within the elongate tube, placing a
plurality of conductive ring members over the outer periphery of
the insulative elongate tube, and positioning the projection of
each conductive ring member in a different groove from one
another.
[0010] In another embodiment, a method includes mechanically and
electrically coupling a plurality of conductors with a plurality of
rings, positioning the rings and conductors around an inner tube,
molding a insulation around the rings, the conductors, and inner
tube, mechanically and electrically coupling a coil to a terminal
pin, and disposing the coil and the terminal pin through the inner
tube.
[0011] Several options for the method are as follows. For instance,
in one option, the method further includes snap-fittedly coupling
the terminal pin with the inner tube. In another option, the method
further includes rotating the terminal pin with the inner tube
after snap-fittedly coupling the terminal pin with the inner tube.
In yet another option, the method further includes stringing an
insulative lead body over the coil. Optionally, mechanically and
electrically coupling the conductors with the rings includes
staking the conductors with the rings.
[0012] The terminal connectors described herein allow for
significantly smaller terminal design. Furthermore, an insulative
non-conductive inner lumen has been provided, which is particularly
suited for an open lumen lead, assisting in the prevention of
electrical shorts due to fluid entry through the open lumen. In
addition, the connectors lend themselves to isodiometric,
over-the-wire lead designs, with multiple high and low voltage
paths. Furthermore, the connector designs allow for the
miniaturization of the connectors while simultaneously providing
for multiple conductive pathways suitable for use in various lead
designs. This further results in increased reliability and
manufacturability of the designs with reduced resistance and
increased isolative properties.
[0013] These and other embodiments, aspects, advantages, and
features of the present invention will be set forth in part in the
description which follows, and in part will become apparent to
those skilled in the art by reference to the following description
of the invention and referenced drawings or by practice of the
invention. The aspects, advantages, and features of the invention
are realized and attained by means of the instrumentalities,
procedures, and combinations particularly pointed out in the
appended claims and their equivalents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a side cut-away view of a connector
assembly constructed in accordance with one embodiment.
[0015] FIG. 2 illustrates an end view of a connector assembly
constructed in accordance with one embodiment.
[0016] FIG. 3 illustrates a cut-away view of a connector assembly
in accordance with another embodiment.
[0017] FIG. 4 illustrates an end view of a connector assembly in
accordance with one embodiment.
[0018] FIG. 5 illustrates a perspective view of a terminal pin in
accordance with one embodiment.
[0019] FIG. 6 illustrates a perspective view of a conductor in
accordance with one embodiment.
[0020] FIG. 7 illustrates a perspective view of a ring constructed
in accordance with one embodiment.
[0021] FIG. 8 illustrates a perspective view of a connector
assembly in accordance with one embodiment. p FIG. 9 illustrates a
perspective view of a connector terminal constructed in accordance
with one embodiment.
[0022] FIG. 10 illustrates a portion of a connector assembly in
accordance with one embodiment.
[0023] FIG. 11 illustrates a side elevational view of a connector
assembly constructed in accordance with one embodiment.
[0024] FIG. 12 illustrates a side-elevational view of a terminal
pin in accordance with one embodiment.
[0025] FIG. 13 illustrates an end view of the terminal pin of FIG.
12.
[0026] FIG. 14 illustrates a perspective view of a portion of a
terminal pin constructed in accordance with one embodiment.
[0027] FIG. 15 illustrates a tube constructed in accordance with
one embodiment.
[0028] FIG. 16 illustrates a portion of cross-sectional view of the
tube in FIG. 15.
[0029] FIG. 17 illustrates a cut-away view of a portion of a
connector assembly constructed in accordance with one
embodiment.
[0030] FIG. 18 illustrates a cross-section view of the connector
assembly.
[0031] FIG. 19 illustrates a cross-section view of the connector
assembly.
[0032] FIG. 20 illustrates a cross-section view of the connector
assembly.
[0033] FIG. 21 illustrates a cross-sectional view of a portion of a
connector assembly constructed in accordance with one
embodiment.
[0034] FIG. 22 illustrates a perspective view of a portion of a
connector assembly constructed in accordance with one
embodiment.
[0035] FIG. 23 illustrates a side view of a micro terminal
constructed in accordance with one embodiment.
[0036] FIG. 24 illustrates a cut-away view of FIG. 23 constructed
in accordance with one embodiment.
[0037] FIG. 25 illustrates a side view of the conductive pathways
of FIG. 23 constructed in accordance with one embodiment.
[0038] FIG. 26 illustrates a side view of a micro terminal assembly
constructed in accordance with one embodiment.
[0039] FIG. 27 illustrates a side view of a micro terminal assembly
constructed in accordance with one embodiment.
[0040] FIG. 28 illustrates a side view of a micro terminal assembly
constructed in accordance with one embodiment.
[0041] FIG. 29 illustrates a side-elevational view of a pin and
ring assembly constructed in accordance with one embodiment.
[0042] FIG. 30 illustrates a cross-sectional view of a portion of
FIG. 29.
[0043] FIG. 31 illustrates a cross-sectional view of a connector
assembly constructed in accordance with one embodiment.
[0044] FIG. 32 illustrates a cross-sectional view of a connector
assembly constructed in accordance with one embodiment.
[0045] FIG. 33 illustrates a cross-sectional view of a connector
assembly constructed in accordance with one embodiment.
[0046] FIG. 34 illustrates a cross-sectional view of a connector
assembly constructed in accordance with one embodiment.
[0047] FIG. 35 illustrates a cross-sectional view of a connector
assembly constructed in accordance with one embodiment.
[0048] FIG. 36 illustrates a cross-section view of a connector
assembly constructed in accordance with one embodiment.
DESCRIPTION OF THE EMBODIMENTS
[0049] In the following detailed description, reference is made to
the accompanying drawings which form a part hereof, and in which is
shown by way of illustration specific embodiments in which the
invention may be practiced. These embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention, and it is to be understood that other embodiments
may be utilized and that structural changes may be made without
departing from the scope of the present invention. Therefore, the
following detailed description is not to be taken in a limiting
sense, and the scope of the present invention is defined by the
appended claims and their equivalents.
[0050] A micro terminal connector assembly and a printed circuit
connector assembly are provided herein. The micro terminal
connector assembly includes small conductive insulated clad wires
and/or flexible circuits which are fed through, or embedded within
an insulated terminal structure. Variations on these designs
include, but are not limited to, inclusion of elements of co-axial
or co-radial lead technology. The printed circuit terminal assembly
includes conductive and insulation layers in a multiple conductive
terminal connector. Each of these in combinations thereof are
described in further detail below.
[0051] FIGS. 1-4 illustrate examples of a feed-through terminal
110. The feed-through terminal 110 includes electrical connections
which are fed from an outer surface of the terminal to the filars
through an insulative material. The feed-through terminal 110
includes one or more metallic tabs 112 that serve to connect an
outer surface 113 of the feed-through terminal 110 to conductor of
the lead. The tabs 112, in one option, have different lengths. The
tabs 112 advantageously provide a small feed-through connection
between an outer peripheral surface and the conductor wire. The
tabs 112 further allow for more insulation to be disposed between
the tabs, as opposed to larger components, such as ring electrodes.
This further allows the feed-through terminal 110 to have a smaller
outer diameter and allows the feed-through terminal 110 to be used
in high voltage applications.
[0052] A conductor wire 114 is electrically coupled with the tabs
112, for example, by welding to an inner side of the tabs 112. The
wires 114 are formed of a conductive material, such as titanium,
Pt-Ta, etc, and optionally the wires 114 are further individually
insulated, in addition to the insulative material 116. The
electrically connected wires 114 and tabs 112 are molded into an
insulative material 116, such as tecothane, through a molding
process, such as insert molding. Filars are welded, swaged, or
connected using other connection processes to the wires 114 which,
in one option, are fed through the terminal 110. The terminal 110
further includes an open lumen 118 therein, which has a wall formed
of insulative material. A distal end of the wires 114, in one
option, is exposed at a distal end of the insulation, as shown in
FIG. 3, and conductive wires are attached thereto. It should be
noted that FIGS. 1 and 2 illustrate a co-radial design. In one
option, a first conductor and a second conductor are embedded
within the tube of insulation, and, optionally, are co-radial with
one another. In another option, a first conductor, second, third,
and fourth conductor are embedded within the tube of insulation,
and are co-radial with one another.
[0053] FIGS. 3 and 4 illustrate a coaxial design. For example, a
first conductor is radially spaced apart from a second conductor,
but they share an axis. In another option, the first conductor is
disposed around the second conductor. The tabs 112, 112' of FIG. 3,
are in one option, longitudinally spaced from one another. In FIGS.
3 and 4, three layers of insulation 116 are incorporated to form
the insulated lumen 118, and to insulate the wires 114 from one
another. It should be further noted that the embodiments shown in
FIG. 1 through FIG. 4 can be combined with the embodiments
discussed above and below.
[0054] FIGS. 5-8 illustrate one example of a bipolar feed-through
terminal assembly 120 and portions thereof, incorporating another
embodiment. The terminal assembly 120 includes a terminal pin 122.
The terminal pin 122 is formed as a single unit of, in one option,
insulative material, including an elongate tube 123. In another
option, the terminal pin 122 and the elongate tube 123 are separate
components coupled together, and optionally are formed of different
materials. The elongate tube 123 is formed of insulative material,
and includes at least one longitudinal groove 126 therein. In one
option, the groove is an elongate longitudinal groove that is
parallel to the longitudinal axis of the tube 123. Disposed within
the longitudinal groove 126 is at least one conductor 124. One
example of a conductor 124 is a flat elongate conductor, as shown
in FIG. 6. Alternatively, other conductors such as wires, coils, or
other shapes can be used as well. In another option, conductive
material is coated within the groove 126 (FIG. 5). Optionally
disposed over portions of the conductor 124 is additional
insulative material, to insulate the conductor 124 from other rings
or electrically conductive components which are slid thereover. In
yet another option, the at least one conductor 124 extends
continuously from the terminal pin to an electrode 145 along the
lead body 148, as shown in FIG. 11.
[0055] FIGS. 9 and 10 illustrate another option for a terminal 100.
The terminal 100 includes a plurality of grooves 102 formed
therein. The grooves 102 are configured to receive an insulated
filar 106 therein. The grooves have a width 104 which is slightly
smaller than an outer diameter 108 of the filar 106. The filars 106
are forced into the groove 102. As the filars 106 are forced into
the groove 102, the insulation of the filar 106 is removed, given
the size of the width 104 for groove 102 relative to the filar 106.
In one option, the terminal 100 is electrically conductive, and as
the insulation of the filar 106 is removed, an electrical
connection is made between the filar 106 and the terminal 100. In
another option, the terminal 100 is formed of non-conductive
material, such as polyetheretherketone (PEEK), and the filar 106 is
electrically coupled with another component, such as a ring, as
further described below.
[0056] In another option, the terminal 100 will consist of multiple
strips of metal which are insert molded, into an insulating
polymer. Alternatively, the multiple strips of metal are disposed
within the insulative polymer in-other manners. Each strip of metal
will have the grooves 102 formed or cut therein which forms the
insulation displacement connector. The strips are placed in
locations to make connections with electrodes or rings, which are
electrically coupled with a pulse generator. The insulation
displacement terminal can be used with the various embodiments
discussed above and below.
[0057] Referring to FIGS. 7 and 8, the terminal assembly 120
further includes one or more electrically conductive rings 128. As
shown in FIG. 7, the ring, in one option, has an interior surface
130 from which a projection 132 extends. The projection 132 of the
ring 128 is received within the groove 126, and is electrically
coupled with the conductor 124. The projection 132 electrically
couples the conductor 124 with the header or other electrical
stimulation device. FIG. 7 illustrates an example where multiple
rings 128 are incorporated within the assembly 120.
[0058] FIGS. 11-13 illustrate alternative embodiments for the
terminal pin 122. The elongate tube 123 of the terminal pin 122
includes a plurality of grooves 126 within the periphery of the
elongate tube 123, for example, four grooves 126 suitable for use
in a quad-polar design, shown in FIGS. 11-13. It should be noted
that any number of grooves can be used, including a single groove.
Alternatively, two grooves 126 are formed in the elongate tube of
the terminal pin 122 (FIG. 14). At least one conductor 124 (FIG. 9)
is inserted into each of the grooves 126. Since the grooves 126 are
disposed within insulative material for the terminal pin 122, each
of the conductors 124 are electrically isolated from one another,
and do not add to the overall outer diameter of the terminal
assembly 120.
[0059] FIG. 11 illustrates a connector assembly 140 formed from a
terminal pin 122 of FIGS. 12 and 13. Four rings 142, each having an
outer diameter of 0.072 inches, are disposed over the terminal pin
122, and each is electrically coupled with a conductor disposed
within the grooves. An outer diameter of 0.072 inches is achievable
due to the construction of the terminal pin 122 and ring 142. The
inner diameter of the lumen is electrically isolated from each of
the four rings 142, and the four rings 142 are electrically
isolated from one another. All of the dielectric paths for this
quad-polar configuration were confirmed to be electrically isolated
at 1,500 volts AC. Previously, it was not possible to have a
bipolar 0.072 inch outer diameter terminal.
[0060] FIGS. 15-20 illustrate another embodiment including a
printed circuit terminal 150. The printed circuit terminal 150
includes one or more printed circuits 152 thereon. The printed
circuits 152 or conductive paths would be printed on a substrate in
the form of a tube 154, where the tube 154 is formed of
non-conductive material. In another option, the tube 154 is formed
of electrically conductive material. In another option, a layer of
insulation 156 is disposed over the tube 154, and the printed
circuits 152 are formed on the layer of insulation 156. In
addition, a layer of insulation 155 is disposed in a layer over the
printed circuits 152. One or more rings 158 are disposed on the
assembly 150. An electrical connection 160 would then be formed in
between the ring 158 and the printed circuits 152, where the
electrical connection 160 is fed through the insulative material.
Each of the individual printed circuits 152 would be electrically
isolated from each other by the spacing on the insulative material
156. The printed circuits can be printed on the pin or substrate
154, alternatively they can be etched or otherwise formed thereon.
One example of material for use with the insulative material is
KAPTON.TM. by Dupont. Examples for the conductive material include,
but are not limited to, gold, platinum, titanium, copper, or
nickel. The connections in between the ring and the printed
circuits are formed, for example, by an exposed pad with
feed-through wires, a wire through hole, or fingers which extend
beyond the flexible circuits, as further discussed above and
below.
[0061] FIG. 21 illustrates one example of connecting the etched
pathways or conductive paths with the terminal by insulated rings
170 which are connected to set screws. The rings 170 have
insulating material 172 such as polyurethane, silicone dioxide,
etc., as the insulative material. The ring 170 further includes a
conductive portion 174, which is formed of conductive material,
such as, but not limited to, titanium, gold, or platinum. A small
section 176 of an inside of a ring 170 is not insulated and can
make an active connection with one of the etched conductive
pathways (see 180, FIG. 22).
[0062] FIG. 22 illustrates another example of a printed circuit
terminal which includes two etched pathways 180 thereon, including
a first pathway 181 and a second pathway 183. The first pathway 181
and the second pathway 183 are electrically isolated from one
another. It should be noted that additional pathways are
contemplated and considered within the scope of this application.
The first and second pathways 181, 183 are electrically coupled
with a first ring 182 and a second ring 184, respectively. Ring 182
is electrically isolated at 186 such that it is isolated from the
second pathway 183. Ring 182 is electrically coupled at 188 with
the first pathway 181 to form the electrical connection
thereto.
[0063] FIG. 23 illustrates another variation of a micro terminal
concept. A printed circuit terminal pin 200 includes a pin 202 and
a layer of insulation 204 with a plurality of electrodes 206
therein. Optionally, pin 202 is formed of metal material The
plurality of electrodes 206 are electrically isolated from one
another within the layer of insulation 204. The plurality of
electrodes 206 are coupled with conductive pathways 180 (FIG. 25)
which are etched on the pin, and insulation 204 is disposed over
the conductive pathways. The conductive pathways extend between the
electrode 206 (A, B, C, and D) and the attachment sites, A', B',
C', and D'. As shown in FIGS. 26 and 27, the rings, are coupled
with their respective electrodes A, B, C, and D. Wires 218 are
electrically coupled with the attachment sites A', B', C', and D'
and extend along the lead body. As shown in FIG. 28, insulation 219
is disposed over insulation 204 and over attachment sites A', B',
C', and D', and the terminal is optionally isodiametric. In another
option, no rings are used, and the electrode 206 is used for
electrical connection, for example, within a header. In another
option, the wires 218 are embedded within the insulation 204, such
that additional insulation 219 is not necessary. Still further, in
another option, the conductive pathways comprise flexible circuits
214 which are disposed within the insulation. Electrical connection
between the pin and the device is made by disposing electrical
connectors 206 within the insulative material 216, where the
electrical connectors 206 extend to various depths to reach the
individual, respective flexible circuits 214. Filars of the lead
are electrically coupled with a circuit trace of the flexible
circuit 214. It should be noted that for this embodiment, as well
as for above and below discussed embodiments, the flexible circuit
214 includes, but is not limited to, electrical paths which are
printed, etched, or embedded within or on insulative material and
formed into the appropriate configuration. In yet another option,
the micro terminal includes a lumen 207.
[0064] FIGS. 30-31 illustrate another option of the printed circuit
terminal. The printed circuit terminal includes, for example, a
substrate 220, with a terminal ring disposed there over. A layer of
insulative material, such as polyimid, i.e., KAPTON.TM. by Dupont,
is disposed over the substrate 220. The layer of insulative
material 222 has a thickness, for example, in the range of 0.0002
inches to 0.0010 inches. Disposed over the insulative material 222,
is a layer for the conductive path 224. The layer 224, in one
embodiment, comprises Pt, for the conductive path. The terminal
ring 226 is slid over the layers of 224 and 222 and is joined with
the outer conductive path 224 with, for example, by conductive
adhesive, welding, or other fixation features which would form the
electrical connection thereto. One or more filars 228 are
electrically coupled with the outer conductive layer or path
224.
[0065] FIGS. 32-35 show one example of various cross-sectional
views of the printed circuit tube for the terminal connector, for
example, of a quad-polar . Each of the cross-section views include
an insulative portion 232, as well as a conductor 234. Each of the
conductors 234 shown individually in FIGS. 32-35 allow for the
multiple rings to be electrically connected with the tube, for
example, forming a quad polar relationship thereto, while also
maintaining an isodiametric shape for the terminal pin. In
addition, the FIGS. 32-35 illustrate how the conductors 234 are
spaced peripherally from one another, for example, at 0, 90, 180,
and 270 degrees around the diameter of the pin. In another option,
the conductors 234 are longitudinally spaced from one another. It
should be noted that other configurations, for example, with more
or fewer electrically conductive portions can be configured and
arranged on the printed circuit tube. It should be further noted
that the embodiments shown in FIGS. 32-35 can be combined with all
of the above discussed embodiments.
[0066] In another embodiment, a method for forming a connector
assembly of an electrophysiological device is provided herein. The
method includes insert molding a first flexible circuit within
tubular insulating material, and electrically coupling a connector
with the first flexible circuit. In one option, the method further
includes molding a second flexible circuit within the tubular
insulating material, where the second flexible circuit forms a
second layer over the first flexible circuit. In another option,
the method includes electrically coupling a second connector with
the second flexible circuit, and the second connector has a
different depth within the tubular insulating material than the
first connector.
[0067] A method is also provided and includes forming a least one
groove within an outer periphery of an insulative elongate tube
having a longitudinal axis, disposing a conductor in each groove,
placing at least one conductive ring member having an internal
surface over the outer periphery of the insulative elongate tube,
and disposing a projection extending from the internal surface of
the conductive ring member within the at least one groove. The
method further includes disposing a terminal pin within the
insulative elongate tube, and disposing insulative material over
the insulative elongate tube adjacent to the conductive ring
member.
[0068] Several options are as follows. For instance, in one option,
the method further includes disposing an insulated conductor in
each groove, wherein a portion of insulation of the insulated
conductor is removed as the insulated conductor is disposed within
the groove. In another option, the method further includes forming
a plurality of elongate grooves within the elongate tube, placing a
plurality of conductive ring members over the outer periphery of
the insulative elongate tube, and positioning the projection of
each conductive ring member in a different groove from one
another.
[0069] In another embodiment, referring to FIG. 36, a method
includes mechanically and electrically coupling a plurality of
conductors 250 with a plurality of rings 252, for example, by
staking the conductors 250 with the rings 252. The method further
includes positioning the rings 252 and conductors 250 around an
inner tube 254, molding an insulation 258 around the rings 252, the
conductors 250, and inner tube 254, for example by injecting an
insulative material to fix the components and place and complete
the assembly except for the pin component. The rings, cables, and
inner tube can be provided in a single overmolded assembly. The
method further includes mechanically and electrically coupling a
coil to a terminal pin 256, and disposing the coil and the terminal
pin through the inner tube 254.
[0070] Several options for the method are as follows. For instance,
in one option, the method further includes snap-fittedly coupling
the terminal pin with the inner tube. In yet another option, the
method further includes stringing an insulative lead body over the
continuously extending conductors. Optionally, mechanically and
electrically coupling the conductors with the rings includes
coupling continuously extending conductors with the rings, and
coupling the continuously extending conductors with an electrode
(see FIG. 11). The method allows for achieving an outer diameter of
approximately 3 mm, and in one option, is designed for a simple
snap-assembly where latches of the pin and tube engage one another.
Other types of snap-fit designs are available as well. The molding
operation distinctly locates components consistently, and reliably
isolates the conductors from one another by providing redundant
insulation between components.
[0071] Advantageously, the above-described terminal connectors
allow for significantly smaller terminal design. Furthermore, an
insulative non-conductive inner lumen has been provided, which is
particularly suited for an open lumen lead, assisting in the
prevention of electrical shorts due to fluid entry through the open
lumen. In addition, the above-described connectors lend themselves
to isodiametric, over-the-wire lead designs, with multiple high and
low voltage paths. Furthermore, the above connector designs allow
for the miniaturization of the connectors while simultaneously
providing for multiple conductive pathways suitable for use in
various lead designs. This further results in increased reliability
and manufacturability of the designs with reduced resistance and
increased insulative properties.
[0072] It is to be understood that the above description is
intended to be illustrative, and not restrictive. Many other
embodiments will be apparent to those of skill in the art upon
reading and understanding the above description. It should be noted
that embodiments discussed in different portions of the description
or referred to in different drawings can be combined to form
additional embodiments of the present invention. The scope of the
invention should, therefore, be determined with reference to the
appended claims, along with the full scope of equivalents to which
such claims are entitled.
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