Methods for fabricating segmented electrodes
A method for fabricating a segmented electrode is provided. The method includes performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, and removing portions of the initial electrode using a centerless grinding process to form a segmented electrode including a plurality of circumferentially spaced contacts.
1. A method for fabricating a segmented electrode, the method comprising:
performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, wherein the initial electrode includes i) a plurality of contact bodies having a first thickness and ii) at least one retaining tab extending axially from each contact body, the at least one retaining tab having a same inner diameter as the plurality of contact bodies and having a second thickness smaller than the first thickness; and
removing portions of the initial electrode using a centerless grinding process to form a segmented electrode including a plurality of circumferentially spaced contacts.
2. The method of claim 1 , wherein performing a series of progressive die stamping operations comprises performing a coining operation to form the at least one retaining tab.
3. The method of claim 2 , wherein the at least one retaining tab includes a first retaining tab extending axially in a proximal direction from an associated contact body and a second retaining tab extending axially in a distal direction from the associated contact body.
4. The method of claim 1 , wherein performing a series of progressive die stamping operations comprises performing a stamping operation to form a plurality of sacrificial tabs on the initial electrode, the plurality of sacrificial tabs extending radially outward.
5. The method of claim 4 , further comprising forming a weld on one of the plurality of sacrificial tabs.
6. The method of claim 4 , wherein removing portions of the initial electrode comprises removing the plurality of sacrificial tabs.
7. The method of claim 1 , wherein performing a series of progressive die stamping operations comprises performing a stamping operation to form a plurality of sacrificial sections on the initial electrode, the sacrificial sections having the same outer diameter as the contact bodies of the initial electrode.
8. The method of claim 7 , wherein removing portions of the initial electrode comprises removing the plurality of sacrificial tabs.
9. The method of claim 1 , wherein the initial electrode includes three sacrificial sections and three retaining tabs.
10. The method of claim 1 , wherein the foil sheet of material is a foil sheet of a platinum-iridium alloy, a different allow, or pure platinum.
11. A method of forming an electrode assembly, the method comprising:
performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, wherein the initial electrode includes i) a plurality of contact bodies having a first thickness and ii) at least one retaining tab extending axially from each contact body, the at least one retaining tab having a same inner diameter as the plurality of contact bodies and having a second thickness smaller than the first thickness;
coupling the initial electrode to a lead body; and
removing portions of the initial electrode using a centerless grinding process to form a segmented electrode on the lead body, the segmented electrode including a plurality of circumferentially spaced contacts.
12. The method of claim 11 , wherein performing a series of progressive die stamping operations comprises performing a coining operation, a traditional machining operation, or an electrical discharge machining operation to form the at least one retaining tab.
13. The method of claim 12 , wherein the at least one retaining tab includes a first retaining tab extending axially in a proximal direction from an associated contact body and a second retaining tab extending axially in a distal direction from the associated contact body.
14. The method of claim 11 , wherein performing a series of progressive die stamping operations comprises performing a stamping operation to form a plurality of sacrificial tabs on the initial electrode, the plurality of sacrificial tabs extending radially outward.
15. The method of claim 14 , further comprising forming a weld on one of the plurality of sacrificial tabs.
16. The method of claim 14 , wherein removing portions of the initial electrode comprises removing the plurality of sacrificial tabs.
17. The method of claim 11 , wherein performing a series of progressive die stamping operations comprises performing a stamping operation to form a plurality of sacrificial sections on the initial electrode, the sacrificial sections having the same outer diameter as the contact bodies of the initial electrode.
18. The method of claim 17 , wherein removing portions of the initial electrode comprises removing the plurality of sacrificial tabs.
19. The method of claim 11 , wherein the initial electrode includes three sacrificial sections and three retaining tabs.
20. The method of claim 11 , wherein coupling the initial electrode to a lead body comprises flowing a polymer of the lead body over the at least one retaining tab.
21. A method of forming an implantable stimulation lead, the method comprising:
performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, wherein the initial electrode includes i) a plurality of contact bodies having a first thickness and ii) at least one retaining tab extending axially from each contact body, the at least one retaining tab having a same inner diameter as the plurality of contact bodies and having a second thickness smaller than the first thickness;
coupling the initial electrode to a lead body;
removing portions of the initial electrode using a centerless grinding process to form a segmented electrode on the lead body, the segmented electrode including a plurality of circumferentially spaced contacts; and
electrically connecting each of the plurality of circumferentially spaced contacts to associated conductors of the lead body to form the implantable stimulation lead.
22. The method of claim 21 , further comprising electrically connecting the plurality of circumferentially spaced contacts to respective terminals of the lead body, each circumferentially spaced contact electrically connected to the respective terminal by the associated conductor.
23. The method of claim 21 , wherein performing a series of progressive die stamping operations comprises performing a coining operation to form the at least one retaining tab.
24. The method of claim 21 , wherein performing a series of progressive die stamping operations comprises performing a stamping operation to form a plurality of sacrificial tabs on the initial electrode, the plurality of sacrificial tabs extending radially outward.