Manufacturing method of a dynamic coil for implantable stimulation leads

1. A method of making a therapy delivery element configured for at least partial insertion in a living body, the method comprising the steps of:

coiling a conductor structure around a mandrel, wherein the conductor structure includes a plurality of conductors, and wherein each conductor of the plurality of conductors contains: an insulator and a plurality of wires located inside the insulator, wherein the plurality of wires inside the insulator include a first wire and a plurality of second wires that surround the first wire, and wherein the first wire has a greater breaking strength than each of the second wires;

securing a segment of the conductor structure to the mandrel;

positioning, after the securing, an outer tubular structure around the conductor structure, wherein portions of the conductor structure that are not secured are free to expand to an inside surface of the outer tubular structure; and

forming a lumen by removing at least a portion of the mandrel.

2. The method of claim 1 , further comprising: releasing a free end of the conductor structure such that the free end of the conductor structure expands beyond the outer tubular structure.

3. The method of claim 2 , further comprising: attaching the conductor structure to an electrode and an electrode contact.

4. The method of claim 1 , wherein the coiling is performed such that a stress on the conductor structure during the coiling is at or below a yield point of the conductor structure.

5. The method of claim 1 , wherein the coiling is performed such that a stress on the conductor structure during the coiling is below an elastic limit of a stress-strain curve for the conductor structure.

6. The method of claim 1 , wherein the conductor structure loosely wraps around the mandrel such that the conductor structure has substantially no memory of a coiled configuration.

7. The method of claim 6 , wherein the mandrel includes a core and an inner tubular structure disposed around the core.

8. The method of claim 7 , wherein the inner tubular structure is elastic in at least a longitudinal direction.

9. The method of claim 7 , wherein the inner tubular structure includes a stylet coil, a braid, or an extruded tube.

10. The method of claim 7 , wherein the securing comprises:

securing a first segment of the conductor structure to distal ends of the core; and

securing a second segment of the conductor structure to distal ends of the inner tubular structure;

wherein portions of the conductor structure that are not secured are free to shift relative to the inner tubular structure.

11. A method of making a therapy delivery element configured for at least partial insertion in a living body, the method comprising the steps of:

coiling a conductor structure around a mandrel, wherein the coiling is performed such that:

a stress on the conductor structure during the coiling is at or below a yield point of the conductor structure; and

the conductor structure loosely wraps around the mandrel and has substantially no memory of a coiled configuration;

securing a segment of the conductor structure to the mandrel, wherein portions of the conductor structure that are not secured are free to shift relative to the mandrel;

positioning, after the securing, an outer tubular structure around the conductor structure, wherein portions of the conductor structure that gaps are not secured are free to expand to an inside surface of the outer tubular structure such that gaps are formed between the conductor structure and the mandrel;

forming a lumen by removing at least a portion of the mandrel; and

releasing a free end of the conductor structure such that the free end of the conductor structure expands beyond the outer tubular structure.

12. The method of claim 11 , wherein the conductor structure includes a plurality of conductors, and wherein each conductor of the plurality of conductors contains: an insulator and a plurality of wires located inside the insulator, wherein the plurality of wires inside the insulator include a first wire and a plurality of second wires that surround the first wire, and wherein the first wire has a greater breaking strength than each of the second wires.

13. The method of claim 11 , further comprising: retaining the conductor structure in the coiled configuration via one or more mechanical restraints.