Abstract: Medical leads included coiled filars that have longitudinally straight ends. The coiled filars may be coiled at a constant pitch until reaching the point where the filars become longitudinally straight. The coiled filars may reside within a central lumen of the lead body, while the longitudinally straight portions may reside in a region where electrical connectors are present and where filar passageways provide a pathway for the filars to exit the central lumen and bond with the electrical connectors. The coiled filars may be created with longitudinally straight ends using a body that includes longitudinally straight holes that receive the filars and maintain the longitudinally straight configuration while the remaining portion of the filars is being coiled.

Abstract: An implantable lead for a medical device with a coplanar coupling for connecting a conductor to a contact reduces conductor bending moments to improve lead reliability. The implantable lead comprises a lead body having a proximal end and a distal end, at least one conductor, at least one contact carried on the proximal end, at least one contact carried on the distal end, and at least one coupling. The lead body has an exterior surface. The conductor is contained in the lead body and extends from the lead proximal end to the distal end. The conductor is also electrically insulated. The contact carried on the proximal end is electrically connected to the conductor. The coupling has a conductor coupling and a contact coupling. The conductor coupling is placed over the conductor and attached to the conductor. The contact coupling exits the lead body and has a weld to connect the contact coupling to the contact.

Abstract: A method for forming a lead body includes contacting a proximal section of the lead body having a lumen and a first lead body characteristic to a distal section of the lead body having a lumen and a second lead body characteristic. The proximal and distal sections are contacted such that their lumens are axially aligned. A lap band is disposed about a portion of the proximal section and a portion of the distal section, and is thermally formed to the proximal and distal sections. Axially compressive pressure is applied to the lap band as the lead body is being thermally formed. The pressure applied is sufficient to result in the lead body having an outer diameter in regions proximally and distally adjacent to the lap band that are substantially the same to an outer diameter in a region formed by the lap band.

Abstract: An implantable lead for a medical device with an improved stylet lumen reduces the potential for damage to a stylet and seals the lead proximal end. The implantable lead comprises a lead body having a distal end and a proximal end, a stylet lumen, at least two conductor lumens, at least two conductors, at least two contacts carried on the proximal end, at least two contacts carried on the distal end, and a proximal flare formed on the lead proximal end. The two conductors are contained in the conductor lumens and extend from the lead proximal end to the distal end. The two contacts carried on the lead distal end are electrically connected to the conductors. The proximal flare has tapering walls that narrow toward a stylet opening to guide insertion of a stylet into the stylet lumen, and the proximal flare seals the conductor lumens proximal end to isolate the conductor lumens.

Abstract: An implantable lead for a medical device with an improved distal tip eliminates the need for a separate component distal tip that can become detached during implantation or use and seals distal tip conductor lumens to maintain lead integrity. The implantable lead comprises a comprising: a lead body having a proximal end and a distal end, at least two conductors, at least two contacts carried on the proximal end, at least two contacts carried on the distal end, and a distal tip. The lead body has a stylet lumen and at least two conductor lumens. The conductors are contained in the conductor lumens and extend from the lead proximal end to the distal end. The two contacts carried on the proximal end are electrically connected to the conductors. The distal tip is formed on the lead body distal end, and the distal tip seals the conductor lumens free from adhesive.

Abstract: An implantable lead for a medical device with a coplanar coupling for connecting a conductor to a contact reduces conductor bending moments to improve lead reliability. The implantable lead comprises a lead body having a proximal end and a distal end, at least one conductor, at least one contact carried on the proximal end, at least one contact carried on the distal end, and at least one coupling. The lead body has an exterior surface. The conductor is contained in the lead body and extends from the lead proximal end to the distal end. The conductor is also electrically insulated. The contact carried on the proximal end is electrically connected to the conductor. The coupling has a conductor coupling and a contact coupling. The conductor coupling is placed over the conductor and attached to the conductor. The contact coupling exits the lead body and has a weld to connect the contact coupling to the contact.

Abstract: An implantable lead for a medical device with an improved stylet lumen reduces the potential for damage to a stylet and seals the lead proximal end. The implantable lead comprises a lead body having a distal end and a proximal end, a stylet lumen, at least two conductor lumens, at least two conductors, at least two contacts carried on the proximal end, at least two contacts carried on the distal end, and a proximal flare formed on the lead proximal end. The two conductors are contained in the conductor lumens and extend from the lead proximal end to the distal end. The two contacts carried on the lead distal end are electrically connected to the conductors. The proximal flare has tapering walls that narrow toward a stylet opening to guide insertion of a stylet into the stylet lumen, and the proximal flare seals the conductor lumens proximal end to isolate the conductor lumens.

Abstract: An implantable lead and an improved method of manufacture is disclosed that is highly automated and simplified over prior art techniques. An implantable lead is disclosed having a flexible tubing member, a central coil member having a first portion having differing pitches, and a least one contact sleeve having a through radial hole for receipt of the wire member. A method for manufacture of the lead is disclosed by providing a coil member having a fixed pitch portion and a variable pitch portion, extending at least one filar member radially from the coil member, placing a lead body over the coil member, providing a contact sleeve over a portion of the lead body, the contact sleeve having a slot for receipt of the filar member, and welding the filar member to the contact sleeve.

Abstract: A novel flexible and highly fatigue resistant neural lead is provided having a body with multiple lumens, one of which may receive a stiffening stylet, and the others of which serve as conduits for bundle stranded wire conductors which make contact with ring electrodes at the distal end of the lead. The ring electrodes will be constructed according to a novel technique in which the body of the lead is etched or milled to provide notches and the ring electrodes are formed by enplacing a C-shaped conductor over the notch and closing it into place to provide an isodiametric lead construction.