Abstract: A method of forming an electrical stimulation lead includes molding an electrically-nonconductive substrate over and between spaced-apart electrically-conductive contacts to form a multi-contact lead assembly. The contacts are disposed along a first face of the substrate with a first face of each of the contacts exposed along the first face of the substrate and an opposing second face of each of the contacts covered by material forming a second face of the substrate. The multi-contact lead assembly is coupled along a first end portion of a lead body with the first face of the multi-contact lead assembly conforming to a shape of an outer surface of the lead body, and with the multi-contact lead assembly wrapping around the outer surface of the lead body. Conductors extending along a length of the lead body are electrically coupled to each of the contacts of the multi-contact lead assembly.

Abstract: An electrical stimulation lead includes a paddle body, at least one lead body having a distal end, a proximal end, and a longitudinal length with the distal end of the lead body coupled to the paddle body. The lead further includes fixation elements and electrodes. The fixation elements are disposed entirely within the paddle body and the electrodes are disposed on the paddle body. Each of the electrodes includes a stimulating element with an exposed stimulation surface, and a piercing element extending from the stimulating element into the paddle body and making contact with at least one of the fixation elements. Further, the lead includes terminals disposed along the proximal end of the lead body and conductor wires electrically coupling the electrodes to the terminals. In addition, methods of making stimulation leads using sacrificial portions of electrodes are presented.

Abstract: A method for implanting an electrical stimulation lead into a patient includes inserting an elongated sheath into a patient. The sheath includes a sheath body with a proximal end and a distal tip. The sheath defines a lumen extending from the proximal end of the sheath to the distal tip. The distal tip of the sheath is advanced to the patient's epidural space. The distal tip of the sheath is positioned at a target implantation location. A lead is advanced along the lumen of the sheath from the proximal end of the sheath body to the distal tip. The lead includes a lead body and a plurality of electrodes disposed along a distal end of the lead body. The sheath is removed from the patient while leaving the distal end of the lead at the target implantation location.

Abstract: An insertion kit for an electrical stimulation system includes a lead with a lead body and a jacket disposed over at least a portion of the lead body. Apertures are defined along an outer surface of the lead body with each of the apertures extending completely through the jacket to an inner surface. The apertures include at least one first aperture. Conductors electrically couple electrodes and terminals disposed along the lead. Conductor insulation is disposed over each of the conductors. At least a portion of the conductor insulation is in fluid communication with the local environment external to the lead via the apertures. A fluid-insertion assembly is configured and arranged for inputting fluid into the lead, via the at least one first aperture, prior to implantation of the lead into the patient.

Abstract: 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.

Abstract: An insertion kit for an electrical stimulation system includes a lead with a lead body and a jacket disposed over at least a portion of the lead body. Apertures are defined along an outer surface of the lead body with each of the apertures extending completely through the jacket to an inner surface. The apertures include at least one first aperture. Conductors electrically couple electrodes and terminals disposed along the lead. Conductor insulation is disposed over each of the conductors. At least a portion of the conductor insulation is in fluid communication with the local environment external to the lead via the apertures. A fluid-insertion assembly is configured and arranged for inputting fluid into the lead, via the at least one first aperture, prior to implantation of the lead into the patient.

Abstract: 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.

Abstract: A method of forming an electrical stimulation lead includes molding an electrically-nonconductive substrate over and between spaced-apart electrically-conductive contacts to form a multi-contact lead assembly. The contacts are disposed along a first face of the substrate with a first face of each of the contacts exposed along the first face of the substrate and an opposing second face of each of the contacts covered by material forming a second face of the substrate. The multi-contact lead assembly is coupled along a first end portion of a lead body with the first face of the multi-contact lead assembly conforming to a shape of an outer surface of the lead body, and with the multi-contact lead assembly wrapping around the outer surface of the lead body. Conductors extending along a length of the lead body are electrically coupled to each of the contacts of the multi-contact lead assembly.

Abstract: An electrical stimulation lead includes a paddle body, at least one lead body having a distal end, a proximal end, and a longitudinal length with the distal end of the lead body coupled to the paddle body. The lead further includes fixation elements and electrodes. The fixation elements are disposed entirely within the paddle body and the electrodes are disposed on the paddle body. Each of the electrodes includes a stimulating element with an exposed stimulation surface, and a piercing element extending from the stimulating element into the paddle body and making contact with at least one of the fixation elements. Further, the lead includes terminals disposed along the proximal end of the lead body and conductor wires electrically coupling the electrodes to the terminals. In addition, methods of making stimulation leads using sacrificial portions of electrodes are presented.

Abstract: A method for implanting an electrical stimulation lead into a patient includes inserting an elongated sheath into a patient. The sheath includes a sheath body with a proximal end and a distal tip. The sheath defines a lumen extending from the proximal end of the sheath to the distal tip. The distal tip of the sheath is advanced to the patient's epidural space. The distal tip of the sheath is positioned at a target implantation location. A lead is advanced along the lumen of the sheath from the proximal end of the sheath body to the distal tip. The lead includes a lead body and a plurality of electrodes disposed along a distal end of the lead body. The sheath is removed from the patient while leaving the distal end of the lead at the target implantation location.