Electrode leads, wire structures and wire interlocking machines

Abstract

The present invention provides an electrode lead, a wire structure and a wire interlocking machine. The electrode lead includes a progression axis from a proximal end to a distal end and at least one electrode contact. The at least one electrode contact is arranged at the distal end of the electrode lead and connected to the proximal end of the electrode lead with at least one conductor, and the electrode contact serves as a connection terminal.

Description

[0001] This application is a divisional application of application number CN 201780042734.8 (PCT application number PCT / IL2017 / 050528), application date May 11, 2017, invention name “Bidirectional interlocking method for electrode lead wires”. Technical Field

[0002] The present invention relates to the field of multiple wire interlocking and multiple electrodes produced therefrom. Background Art

[0003] Electrical stimulation of multiple body parts such as the spinal cord, peripheral nerves, cranial nerves, nerve roots, muscles or brain tissue is used to treat a variety of conditions, including, for example, Parkinson's disease, dystonia, chronic pain, Huntington's disease, bradykinesia, epilepsy and seizures, eating disorders and mood disorders. For those conditions and others, sensing electrodes and / or recording electrodes can be used to monitor the electrical activity of multiple tissues to be treated or studied, and a stimulating electronic signal is often provided to multiple target areas / multiple structures for treatment. Many of the multiple electrodes, whether stimulating or sensing, have multiple similar characteristics.

[0004] The plurality of electrode leads are typically implanted in a specific area for providing treatment and / or monitoring functions, and a plurality of properties and features are required to be present in the plurality of electrode leads for providing appropriate functions while mitigating the risk of a plurality of undesirable effects. Some of the plurality of desired properties and features include: small lead size, a plurality of small contacts, directionality of sensing and stimulation, structural rigidity and flexibility, manufacturing cost, etc. However, due to a plurality of conventional constraints inherent in the common physical structure of the plurality of leads, some trade-offs are typically made between the plurality of properties and features in the electrode leads.

[0005] Therefore, there is a need in the art for multiple electrode lead structures for achieving better trade-offs to facilitate multiple enhanced properties and characteristics.

[0006] There are various wire interlocking techniques for achieving different biological tissue properties and structures, the most common techniques include: breading, braiding and knitting. In knitting, a yarn is manipulated to interlock with itself at various points by forming a plurality of loops arranged in a line or a tube and called a plurality of sutures. The plurality of loops are formed by manipulating the yarn using a plurality of needles, and the plurality of dimensions of the knitted structure are affected by the dimensions of the plurality of needles and the wire (yarn). In knotting, a plurality of wires are interlocked together in an axially traveling manner to form an elongated structure, and the dimensions of the plurality of wires and their number determine the length of the axial travel, and the technology is generally used to manufacture a variety of ropes and a variety of cables. In braiding, two different groups of wires are interlocked to form the structure: a first group of wires and a second group of wires, the first group of wires being called a plurality of warp-vertical wires, usually aligned linearly; the second group of wires being called (a plurality of) wefts, including: a wire, being manipulated horizontally to pass between the plurality of warps. During weaving, the weft thread passes through the plurality of warp threads each time to form a beat, and in each beat, the plurality of warp threads are arranged so that the weft thread passes in front of or behind a warp thread, thereby forming a plurality of desired weaving patterns.

[0007] The use of multiple wire interlocking techniques can facilitate the assembly of some structures and devices, such as multiple contact electrodes, but the number of multiple wires involved in the process and / or the interlocking procedure itself makes the multiple techniques inefficient. Therefore, the present invention provides multiple methods and devices that can use the required number of wires for manufacturing structures of any size required, while using multiple required diameters and materials in each case. Summary of the invention

[0008] The present invention provides a plurality of electrode leads made of a plurality of interlocking filaments having a conductive core coated with a non-conductive coating. The exposed conductive core of the filaments forms at least one three-dimensional (3D) different conductive area at the distal end of the electrode, and a portion of the plurality of filaments having the exposed conductive core is disposed on the circumferential surface of the electrode, and the easy-to-manufacture structure enables control of the size and positioning of a plurality of very small contacts on the electrode lead.

[0009] The present invention also provides methods for manufacturing the plurality of electrode leads by interlocking the plurality of filaments, such as: braiding, knitting, weaving, winding, tangling, netting or any other method or combination of interlocking the plurality of filaments. The plurality of structures of the plurality of electrodes and the plurality of electrode leads are unique and give them a plurality of improved properties, such as: increased charging capacity, improved directionality, and greater contact surface area.

[0010] The present invention also provides a plurality of electrode leads with volume sharing, wherein the volume sharing is used for a plurality of contacts, through which the directionality and functionality of the plurality of contacts can be varied as required.

[0011] In another aspect, the plurality of electrodes of the present invention can be used as a plurality of measuring tools for determining the position or distance of a reference point from the electrode lead based on a predetermined or known spacing. The measuring tools can also be used to measure the distance between multiple layers in a particular cross section, the diameter of a cross section, or the distance of a point in the cross section relative to the reference point in the same cross section. In this way, the width and thickness dimensions of the electrode lead or an area within the electrode lead can be measured.

[0012] In some embodiments, some materials may be incorporated / placed within the electrode lead during manufacturing and may be manipulated / modified after manufacturing to achieve a desired functional and / or structural property, such as: local electrical / thermal isolation, forming a medium with desired functions, etc.

[0013] In some embodiments, the plurality of electrodes of the present invention further include a plurality of connectors, providing a plurality of electrical connection terminals.

[0014] According to other embodiments, the present invention provides a variety of devices, systems and methods for wire interlocking, wherein a plurality of wires in a plurality of interlocking wire structures have a plurality of vertical portions and a plurality of horizontal portions, so that a horizontal portion of a wire is configured to pass between a plurality of vertical portions of other wires and lock the plurality of vertical portions of the other wires. Advantageously, having a plurality of wires that change orientation from vertical to horizontal in the wire interlocking structure can help to generate a plurality of precise structures while using a relatively small amount of wires.

[0015] In one aspect, the present invention provides an interlocking wire structure comprising: (a) a proximal end and a distal end having a progression axis from the proximal end to the distal end; and (b) a plurality of vertically aligned wires parallel to the progression axis at the proximal end and configured to each have a plurality of horizontal portions and a plurality of vertical portions, the plurality of horizontal portions being perpendicular to the progression axis and the plurality of vertical portions being parallel to the progression axis, such that a horizontal portion of one wire is configured to pass between the plurality of vertical portions of the other wires to interlock with the plurality of vertical portions of the other wires, wherein a horizontal portion of one or more wires passing between the plurality of vertical portions of the other wires is a beat, and each bend determines a vertical distance along the progression axis between the proximal end and the distal end.

[0016] In a specific aspect, the present invention provides an interlocking wire structure, comprising: (a) a proximal end and a distal end, having a progression axis from the proximal end to the distal end; and (b) a plurality of vertically aligned wires, parallel to the progression axis at the proximal end, and configured to each have a plurality of horizontal portions and a plurality of vertical portions, the plurality of horizontal portions being perpendicular to the progression axis, and the plurality of vertical portions being parallel to the progression axis, such that a horizontal portion of one wire is configured to pass between the plurality of vertical portions of other wires, thereby forming an interlock with the plurality of vertical portions of the other wires, wherein a horizontal portion of one or more wires passing between the plurality of vertical portions of the other wires is a bend, and each bend determines a vertical distance along the progression axis between the proximal end and the distal end, wherein at least one of the plurality of wires comprises: a conductive filament coated with an electrical insulating layer, and the conductive filament is exposed at a plurality of predetermined positions, and the conductive filament is exposed at a plurality of predetermined positions to achieve a contact at the plurality of predetermined positions.

[0017] In another aspect, the present invention provides a wire interlocking machine for manufacturing an interlocking wire electrode, comprising: (a) a plurality of wire carriers, each wire carrier being configured to hold a desired wire, at least one of the plurality of wire carriers having a conductive core coated with a non-conductive material; and (b) at least two intersecting track sections, each section having: (i) a vertical track defining a vertical range of movement of a wire carrier; and (ii) a horizontal track defining a horizontal range of movement of a wire carrier (shuttle), such that the vertical track and the horizontal track intersect along the longitude of the vertical track and the horizontal track, causing the vertical track to intersect with the horizontal track. a shift in the movement of a wire carrier between the horizontal tracks, and the plurality of cross track segments are horizontally arranged to facilitate movement of a wire carrier from a horizontal track of one cross track segment to a horizontal track of another segment; (c) a wire base configured to hold a plurality of wires at a distal end of the wire base such that the plurality of wires are stretched from the wire carrier to the wire base; (d) at least one actuator for moving the plurality of wire carriers and optionally the wire base; (e) at least one device (laser) for exposing the conductive core of the wire(s) / filament(s); and (f) a control unit.

[0018] On the other hand, the present invention provides a method for manufacturing a wire interlocking electrode using the wire interlocking machine described in the present invention, the method comprising the following steps: (a) inputting a desired structure of an electrode to be manufactured; (b) optionally, compiling the structure of the desired electrode into an interlocking digital structure, and then compiling it into a machine code for controlling the interlocking machine; (c) arranging multiple wire carriers at multiple vertical tracks of multiple sections of the multiple wire interlocking machines according to the desired structure; (d) selecting a carrier as a weft; (e) moving the weft along the horizontal track to pass between other filaments as the multiple warps; (f) optionally, selecting a different wire carrier to be used as a weft and switching between the multiple wire carriers; (g) continuing to move the selected weft along the horizontal track to pass between the multiple warps; (h) pressing the (multiple) wefts against the base to define a bend; and (i) terminating the method when the electrode is ready. The above method also includes at least one of the following steps: functionalizing at least a portion of the weft wire, for example: exposing the conductive material inside the wire by removing the coating material to form a contact; functionalizing at least a portion of the multiple warp portions of the multiple wires, for example: exposing the conductive material inside the wire by removing the coating material to form a contact; and terminating the wire when a wire is no longer needed in the electrode.

[0019] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Schematically illustrates an interlocking wire structure of an exemplary electrode lead of the present invention;

[0021] Figure 2 schematically illustrates an interlocking wire structure having a plurality of terminal wires according to some embodiments;

[0022] Figure 3 Schematically illustrates an interlocking wire structure with vertical wire repositioning according to an embodiment of the present invention;

[0023] Figure 4 Schematically illustrates an interlocking wire structure having a plurality of adjacent horizontal portions of different wires according to an embodiment of the present invention;

[0024] Figures 5a to 5b schematically illustrates a plurality of interlocking planar structures according to some embodiments;

[0025] Figure 6 The diagram schematically shows a method of manufacturing an electrode having a plurality of interlocked wires according to an embodiment of the present invention.

[0026] Figures 7a to 7c schematically illustrates a plurality of horizontal cross-sections of a plurality of exemplary electrodes according to some embodiments;

[0027] Figures 8a to 8d Schematically showing various possible shapes of an electrode according to the present invention;

[0028] Figures 9a to 9e schematically illustrates a plurality of braided layered electrode leads having a plurality of joints according to some embodiments; Figures 10a to 10c A single wire electrode in a lead is schematically shown;

[0029] Figures 10d to 10e Schematically shows Figures 10a to 10b A cross-sectional view and a side view of the plurality of functional filaments after post-processing;

[0030] Figures 11a to 11b shows a plurality of electrode leads with a plurality of markings according to some embodiments;

[0031] Fig.11c is a block diagram of a method that may be performed for placement according to some embodiments;

[0032] Figures 12a to 12g A plurality of electrode leads having a barrier portion and a method for manufacturing the same according to an exemplary embodiment are shown;

[0033] Figures 13a to 13c Shows a plurality of electrical connection terminals according to the present invention;

[0034] Figures 14a to 14d A male mating connector is shown inserted into a female lead connector;

[0035] Figures 15a to 15e Various possibilities of exposing a bundle of wires in a predetermined structure are shown; Fig.15a An electrode made from a single wire is shown, the electrode being divided into a plurality of filaments; and Figures 15b to 15e An electrode made from a bundle of filaments is shown;

[0036] Figures 16a to 16c schematically illustrates a plurality of electrodes having an inner layer and an outer layer according to some embodiments;

[0037] Figures 17a to 17c schematically illustrates an electrode having an opening in its outer layer according to some embodiments; Fig.17cshows a planar electrode lead according to an exemplary embodiment;

[0038] Fig.18 schematically illustrates a multi-segment system for wire interlocking according to some embodiments;

[0039] Fig.19 schematically illustrates a rear view of a fragment according to some embodiments;

[0040] Figures 20a to 20b schematically illustrates a segment with multiple vertical actuators at different locations according to some embodiments;

[0041] Fig.21 shows a segment with multiple vertical actuators at different locations according to some embodiments;

[0042] Figures 22a to 22c Shows the rear side of a section and the movement of a carrier between horizontal and vertical tracks;

[0043] Fig.23 shows the back side of multiple segments with multiple vertical actuators and shuttles according to some embodiments;

[0044] Figures 24a to 24b A plurality of wire interlocking machines are shown: According to some embodiments, Fig.24a For a machine having a lowered base; Figure 24b A machine having a centrally located base;

[0045] Figures 25a to 25b are pictures showing actual fabrication of multiple electrodes according to multiple embodiments of the present invention;

[0046] Fig.26 One possible configuration of a wire interlocking machine of the present invention is shown;

[0047] Fig. 27 schematically illustrates a method for wire interlocking according to some embodiments;

[0048] Fig.28 schematically illustrates an additional method for wire interlocking according to some embodiments; and

[0049] Fig.29 The exposure of the inner conductive core of a wire is shown before it is interlocked to the electrode structure. DETAILED DESCRIPTION

[0050] According to aspects and embodiments of the present invention, a plurality of leads for a plurality of electrodes are provided. The embodiments are intended to construct a plurality of leads, which may be custom made, with a plurality of filaments interlocking to form a lead, the lead being provided with a plurality of electrodes having a plurality of contacts at the distal side of the lead. The plurality of interlocked filaments may be manufactured using, for example, plaiting, knitting, braiding, winding, tangling, netting or any other method or combination of methods for interlocking the plurality of filaments. Any other method that may interlock a plurality of filaments into a structure of a lead is included within the scope of the present invention. The electrode is a portion of the electrode lead having a conductive portion that is electrically connected to an electronic module.

[0051] According to one aspect of the embodiments disclosed herein, there is provided an electrode lead having at least one electrode, the electrode having a contact surface area serving as an electroactive surface, wherein the electrode occupies a volume associated with a distal portion of the electrode lead. The volume occupied by the electrode may be mostly within the volume of the lead hidden in a cavity, hollow portion, chamber, or pocket; the electrode may have a contact that is flush or semi-flush with an outer surface of the lead; or the volume of the electrode may protrude, extend, or extend from the outer surface of the electrode lead; or a combination thereof.

[0052] In the following description, various aspects of the present disclosure will be described. For the purpose of explanation, a number of specific configurations and a number of details are described to provide a thorough understanding of the different aspects of the present disclosure. However, it is obvious that those skilled in the art can practice the present disclosure without the specific details shown in this specification. In addition, in order not to obscure the present disclosure, a number of well-known features can be omitted or simplified.

[0053] Multiple wires are interlocked together to form a structure for various fields to achieve different properties. Examples of the multiple structures include fabrics, wires, ropes, strings / strands, etc., and the manner of interlocking the multiple wires provides multiple unique properties and manufacturing constraints.

[0054] Common methods of interlocking wires include: weaving, knotting and knitting, which have a unique weaving advantage in terms of special selectivity and resolution, and can form multiple precise patterns in textiles. The distance between multiple warps is determined by their thickness and the wefts passing between them, and the distance between the multiple bends is known and determined by the thickness of the (multiple) wefts. The bends are further defined by many other different factors, such as: the tension of the multiple wires / multiple yarns, the warps bent on the multiple wefts, etc. Therefore, in some embodiments, the determination of the structural pattern of the weaving is carried out by any of the above-mentioned multiple mechanisms, and the fineness of the distance determination and resolution can reach microns or even smaller.

[0055] Meanwhile, multiple industries besides textiles rely on a variety of processes to achieve spatial resolution: some expensive and include, for example, photolithography and microfabrication processes, and other cheaper techniques but with limited resolution and finesse.

[0056] One such area is electrodes, particularly invasive multi-contact electrodes, where the exact location and size of the electrical contacts is of very high importance, the number of required contacts is high (tens or hundreds), and the electrode is typically an elongated structure capable of hosting a limited number of wires or support structures to deliver the desired functionality while maintaining mechanical properties above a required threshold.

[0057] Therefore, the present invention provides a variety of devices, systems and methods for manufacturing a plurality of electrodes, wherein the structure of the electrode is manufactured by a plurality of interlocking wires, the plurality of wires having a plurality of vertical portions (parts) and a plurality of horizontal portions, the plurality of vertical portions are carried out along the extension of the electrode, and the plurality of horizontal portions pass between the plurality of vertical portions of other wires, with the plurality of vertical portions interlocking with the plurality of horizontal portions and defining a bend / node (beat). The present invention also provides a variety of electrodes produced by the plurality of devices, systems and methods of the present invention.

[0058] Advantageously, the plurality of wires are changed from a vertical direction to a horizontal direction, so that the vertical support structure can be provided to serve as a plurality of additional delivery channels for delivering the plurality of wires (electrical wires) to their desired effective positions, and at the same time providing electrical contact, so that a plurality of electrical wires can be used to achieve a plurality of electrical contacts. According to some embodiments, the plurality of electrical contacts are produced by exposing an isolation medium on the plurality of wires at a plurality of desired positions. Therefore, the plurality of methods, devices and systems of the present invention facilitate the production of a plurality of electrodes having the plurality of wires, the electrodes serving as both a support (structure) for the electrodes and a conductive path for reaching the electrical contacts of the plurality of targets.

[0059] It should be noted that the term "vertical" as used in this specification and throughout this application also refers to interlocking with multiple horizontal wires.

[0060] According to some embodiments, upon reaching a determined contact position, the associated wires are selected to change the interlocking orientation to form a contact of a desired shape and size within the depth of the electrode structure.

[0061] In some embodiments, the provided structure facilitates accurate determination and / or contact location, and multiple dimensions at a resolution based on the thickness of the multiple conductors. Alternatively, in some embodiments, other methods besides thickness, such as visual control, counting of structural patterns, etc., are used to accurately determine and / or contact location.

[0062] According to some embodiments, the interlocking technology of the present invention is used to manufacture various structured electrodes having a plurality of different desired geometric shapes, such as: planar, sheet-like, or multiple volumetric shapes.

[0063] According to some embodiments of the present invention, the plurality of interlocking wires are configured to construct a two-dimensional (or planar) sheet-like shape. According to alternative embodiments, the plurality of interlocking wires are configured to construct a three-dimensional shape.

[0064] In some embodiments, the electrode prepared according to the present invention is a portion of the electrode lead having a conductive portion, and the conductive portion is electrically connected to an electronic module.

[0065] In some embodiments, an electrode lead prepared according to the present invention comprises at least one electrode having a contact surface area that serves as an electroactive surface, wherein the electrode occupies a volume associated with a distal portion of the electrode lead. The volume occupied by the electrode can be mostly hidden within the volume of the lead in a cavity, hollow portion, chamber or pocket; the electrode can have a contact that is flush or semi-flush with an outer surface of the lead; or the volume of the electrode can protrude, extend or extend from the outer surface of the electrode lead; or a combination thereof.

[0066] The present invention provides an interlocking wire structure, comprising: (a) a proximal end and a distal end, having a progression axis from the proximal end to the distal end; and (b) a plurality of vertically aligned wires, parallel to the progression axis at the proximal end, and configured to each have a plurality of horizontal portions and a plurality of vertical portions, the plurality of horizontal portions being perpendicular to the progression axis, and the plurality of vertical portions being parallel to the progression axis, so that a horizontal portion in one wire is configured to pass between the plurality of vertical portions of the other wires, thereby forming an interlock with the plurality of vertical portions of the other wires, wherein a horizontal portion of one or more wires passing between the plurality of vertical portions of the other wires is a bend, and each bend determines a vertical distance along the progression axis between the proximal end and the distal end.

[0067] In some embodiments of the interlocking wire structure of the present invention, a vertical portion of a wire is a warp portion, a horizontal portion of a wire is a weft portion, and at least some of the plurality of wires are configured to be a plurality of warps at certain positions and a plurality of wefts at other positions.

[0068] In some embodiments of the interlocking wire structure of the present invention, when multiple wires are converted from warp to weft, the multiple wires form a directional contact; the entire time that the wire is in the weft portion, the wire does not need to form a complete wrap around the interlocking core. When a wire changes from a warp to a weft, it can: (i) form a complete circle, that is, wrap around the entire finished interlocking lead or lead core (see, e.g., Figure 7a or (ii) not forming a complete circle, i.e. not winding the entire fabricated interlocking lead or lead core, but only winding a portion of the (multiple) warp wires at a specific region of the fabricated electrode (see, e.g. Figure 7b ), and optionally into a full weft, and then converted back into a warp (see e.g. Figure 1 126 in ).

[0069] In some specific embodiments of the interlocking wire structure of the present invention, the plurality of wires are arranged to form a sheet.

[0070] In specific embodiments of the interlocking wire structure of the present invention, horizontal portions of a plurality of wires pass through a vertical portion of at least one other wire to form a bend.

[0071] In some embodiments of the interlocking wire structure of the present invention, the plurality of vertical portions of the plurality of wires are arranged in a non-linear pattern such that a horizontal cross-section of the structure forms a two-dimensional shape. In a specific embodiment, the plurality of wires are arranged to form an elongated cylindrical shape such that the axis of the elongated tubular shape is the axis of progression between the proximal end and the distal end. In an alternative specific embodiment, the plurality of wires are arranged to form an elongated shape such that the axis of the elongated shape is the axis of progression between the proximal end and the distal end, and a horizontal cross-section of the elongated shape includes a plurality of vertical wire portions arranged at a plurality of different radial distances. In a more specific embodiment, the horizontal cross-section includes a plurality of vertical wire portions arranged at more than one radial distance.

[0072] In some embodiments of the interlocking wire structure of the present invention, the horizontal portions of the wires and the arrangement of the horizontal portions between vertical portions are determined to achieve a desired mechanical / structural / functional property.

[0073] In some embodiments, the interlocking wire structure of the present invention is an electrode, wherein at least one of the plurality of wires comprises a conductive filament coated with an electrical insulating layer, and the conductive filament is exposed at a plurality of predetermined positions to achieve a contact at the plurality of predetermined positions.

[0074] In various specific embodiments, when the interlocking wire structure of the present invention is an electrode, the contact is located at multiple horizontal portions of the at least one filament.

[0075] In some embodiments of the interlocking wire electrodes of the present invention, horizontal portions of multiple wires pass through vertical portions of other wires to form a bend.

[0076] In multiple specific embodiments of the interlocking wire electrodes of the present invention, the multiple vertical portions of the multiple wires are arranged in a non-linear form so that a horizontal cross-section of the structure forms a two-dimensional shape, and a horizontal portion of a wire forms a planar (two-dimensional) structure at a specific bend.

[0077] In specific embodiments of the interlocked wire electrodes of the present invention, the conductive filaments of the at least one wire are exposed at predetermined positions in the horizontal portion, forming a two-dimensional (planar) contact at the predetermined positions.

[0078] In other embodiments of the interlocking wire electrode of the present invention, a horizontal portion of at least one wire at a plurality of bends forms a three-dimensional structure along and within the electrode.

[0079] In some embodiments of the interlocked wire electrodes of the present invention, the conductive filaments of the at least one wire are exposed at a plurality of predetermined positions in a plurality of horizontal portions, forming a three-dimensional (volume) contact.

[0080] In yet another specific embodiment of the interlocking wire electrode of the present invention, the plurality of wires form a porous structure, allowing a plurality of body fluids to flow through the porous structure.

[0081] Reference now Figure 1 , shows an interlocking wire structure 100 according to some embodiments of the present invention. In some embodiments, the structure 100 is made of a plurality of wires: a first wire 110, a second wire 120, a third wire 130, and a fourth wire 140, which are interlocked together to form the structure 100. In some embodiments, at least some of the plurality of wires 110, 120, 130, and 140 include: a plurality of vertical portions and a plurality of horizontal portions, the plurality of vertical portions advancing along the longitude of the structure 100, and the horizontal portions advancing perpendicular to the longitude of the structure 100, interlocking with the plurality of vertical portions of other wires. As shown, the second wire 120 has a first vertical portion 122, and then the second wire 120 changes the advancing direction to obtain a horizontal portion 124, the horizontal portion 124 interlocks with the first wire 140, the third wire 130, and the fourth wire 140, and then switches back to vertical advancement to a second vertical portion 126.

[0082] Generally, multiple wires may have multiple horizontal portions of the same or different longitudes along the structure 100. For example, the fourth wire 140 starts with a vertical portion 142, then changes direction to advance with a horizontal portion 144, interlocks with multiple vertical portions of other wires, and then returns to the original position to advance with a second vertical portion 146 of the fourth wire 140.

[0083] In some embodiments, on each horizontal pass / advancement of a horizontal portion of a wire, multiple vertical portions of other wires are arranged on axes perpendicular to the horizontal and vertical advancement directions to achieve a desired interlocking path / pattern.

[0084] In some embodiments, at least some of the wires may advance along the longitudinal path of the interlocking structure until it ends, while other wires may terminate along the way and not further participate in the structure. This property is advantageous when a wire reaches a contact position, and after the contact is made, the associated wire(s) are no longer needed and may be terminated for various reasons, such as reducing the complexity of the interlocking process, reducing the diameter / cross-sectional area of ​​the electrode, etc.

[0085] Reference now Figure 2 , schematically illustrates an interlocking wire structure with multiple terminal wires according to some embodiments. In some embodiments, the structure 200 includes multiple wires, such as: a first wire 210, a second wire 220, a third wire 230, and a fourth wire 240, having multiple vertical portions and may have multiple horizontal portions, such as: a first vertical portion 222, a second vertical portion 226, and a horizontal portion 224 of the second wire 220. Some wires may not participate in the interlocking of the structure 200 over its entire longitude, as shown in the figure, for example: for the fourth wire 240 having a vertical portion 242, then changing direction through the horizontal portion 224 to interlock with multiple vertical portions of other wires, and then terminating at an end point 246 of the fourth wire 240.

[0086] In order to achieve multiple desired structures (e.g., multiple contact shapes) or moving wire geometries, etc., multiple wires can have multiple vertical sections at one position and then move to another position by changing the direction to horizontal advancement, and when reaching the new position, changing the direction back to vertical advancement.

[0087] Reference now Figure 3 , schematically illustrates an interlocking wire structure 300 with vertical wire repositioning according to some embodiments. In some embodiments, the structure 300 includes: a first wire 340, a second wire 320, a third wire 330, and a fourth wire 340, wherein the fourth wire 340 begins with a vertical portion 342 at a first vertically advanced position, then changes direction to form a horizontal portion 344, and then changes direction back to vertical advancement 346 at a second vertically advanced position. In some embodiments, the interlocking structure according to the present invention can be part of an entire lead, wherein multiple interlocking structures can include a single lead.

[0088] Typically, a horizontal crossing of a horizontal portion of a wire defines a bend that determines the progression of the interlock based on various characteristics (e.g., the thickness of the wires and their plasticity). In some embodiments, multiple horizontal portions of different wires may participate in defining a bend. The characteristics may be useful for a variety of purposes, such as controlling / determining the shape and area of ​​the cross-section of the electrode, forming contacts that share the same longitudinal distance, etc.

[0089] refer to Figure 4, schematically illustrates an interlocking wire structure 400 having multiple adjacent horizontal portions of different wires according to some embodiments of the present invention. In some embodiments, structure 400 has multiple wires 410, 420, 430, 440, 450, 460, 470, and 480, each of which has its own path. For example, wire 410 has a first vertical portion 412, a horizontal portion 414, and a second vertical portion 416, while wire 480 has a first vertical portion 482, a horizontal portion 484, and a second vertical portion 486. As shown, horizontal portion 484 of wire 480 and horizontal portion 414 of wire 410 both participate in forming at least one bend, shown here as two bends.

[0090] refer to Figures 5a to 5b , schematically illustrating a plurality of interlocking planar structures according to some embodiments of the present invention. In some embodiments, the plurality of interlocking wires are arranged to form a volumetric structure, such as an elongated box, a cylinder, etc., wherein the plurality of vertical portions of the plurality of wires are positioned at some positions in space and extend toward a forming end, which is a bend formed by a plurality of horizontal portions of other wires. According to other embodiments, a plurality of electrodes having certain shapes can be manufactured by a plurality of wires interlocked in a plurality of methods described in this specification or in a manner similar to the plurality of methods, and formed to have a plurality of determined characteristics both structurally and functionally.

[0091] refer to Figure 6 , showing an electrode 600 having a plurality of interlocked wires. In some embodiments, the electrode 600 has an elongated shape, made from a plurality of vertical portions of a plurality of wires 610 and a plurality of bends formed from a plurality of horizontal portions of a plurality of wires 620. In some embodiments, the plurality of wires in the electrode 600 can be selected to form a plurality of contacts at certain locations on the surface of the electrode 600, and to be volumetrically shaped within the body / volume of the electrode 600 by interlocking the functionalized wires with other wires in a desired manner.

[0092] The term "functionalized wire" and its abbreviations used in this specification refer to multiple wires at least a portion of which is functionalized, for example: by: (i) removing the coating material to expose the conductive material inside the wire to form a contact; (ii) incorporating / arranging (multiple) specific materials into the lead of the electrode during manufacturing and then manipulating / modifying to obtain a desired functional property and / or structural property.

[0093] Figures 7a to 7c Schematically illustrated are various horizontal cross-sectional configurations of various electrodes of the present invention. Figure 7aA cross section 700 of an electrode is shown in which a single horizontal portion 720 of a wire forms a bend by passing through and interlocking multiple vertical portions of multiple other wires 710 arranged at certain locations in space to define the shape of the electrode. Figure 7b A cross-section 701 of an electrode is schematically shown, wherein two horizontal portions of different wires (e.g., a horizontal portion of wire 730 and a horizontal portion of wire 740) form a bend by passing through and interlocking multiple vertical portions of other wires 712 arranged at certain positions in space to define the shape of the electrode. Figure 7c A cross section 702 of an electrode is shown, in which two horizontal portions of different wires (e.g., a horizontal portion of wire 732 and a horizontal portion of wire 742) form a bend by passing through and interlocking multiple vertical portions of other wires 712 arranged at some positions in space. Specifically, as shown, the horizontal portion of wire 732 is configured to pass through and interlock multiple vertical portions of wires 714 of multiple outer layers, and the horizontal portion of wire 742 is configured to pass through and interlock multiple vertical portions of wires 718 of multiple inner layers.

[0094] It should be noted that the multiple closed circular shapes of the multiple horizontal portions of the multiple wires are brought for illustrative purposes, and typically, each bend or each horizontal portion participating in a bend will have an entry point and an exit point for the bend, the entry point being where the horizontal portion begins to pass through the particular bend, and the exit point being the position of the wire when the formation of the particular bend is completed.

[0095] In some embodiments, the electrodes prepared according to the present invention can have any shape, size and length, and can be manufactured and designed according to a number of specific needs. For example, the electrodes can be rectangular, triangular, circular or star-shaped. Figure 8a and 8c Two possible shapes of the electrodes made according to the teachings of the present invention are schematically shown. Figure 8b and 8d 1 and 2 are cross-sectional views of each electrode, respectively. In other embodiments, the electrode may be planar, have a single tip or multiple tips, have a single electrical contact or multiple electrical contacts, etc.

[0096] According to some embodiments, multiple wires may be interlocked and functionalized at locations on the surface of the electrode structure and / or within the volume of the electrode structure to achieve multiple desired features and functionalities.

[0097] Reference now Figures 9a to 9e, schematically illustrates a plurality of electrodes 1100 with a plurality of contacts according to some embodiments. As shown, an electrode 1100 may include a plurality of contacts having different shapes and sizes, such as a first rectangular contact 1102, a second contact 1104, and a third contact 1106 closely positioned with the same vertical length, and an elliptical contact 1108. In some embodiments, the shapes of the plurality of contacts are random and amorphous 1110, 1112.

[0098] In some embodiments, an electrode lead 1100 is made of a plurality of conductive filaments coated with a non-conductive material, wherein some of the braided filaments have their coating removed and the conductive portions are exposed to serve as a plurality of electrode contacts 1102 to 1114. The plurality of electrodes 1100 have a surface flush with the outer surface of the electrode lead.

[0099] Figures 9c to 9e Several schematic diagrams of distal end portions of several electrode leads at different viewing angles are shown according to several exemplary embodiments. Fig.9c A view of a portion of the distal side of an inner surface of an electrode lead 1111 is shown, wherein an electrode 1114 is disposed within a volume of the electrode lead, the electrode lead being a structure of a plurality of interlocking filaments 1113, which structure may be manufactured using methods such as braiding, knitting, weaving, winding, entanglement, meshing, and combinations thereof.

[0100] exist Figure 9d In FIG. 1 , an electrode lead is depicted. However, the plurality of electrodes 1114 in the distal portion of the lead are designed to have at least one surface flush with the outer surface of the lead. Fig.9e In the illustrated architecture, the electrodes 1114 protrude from the outer surface of the electrode lead. In this way, electrodes with larger exposed surfaces 1114 and different directivities can be manufactured. One of the advantages of this architecture where the electrodes protrude from the electrode lead is increased diffusion of the fluids between the filaments, and therefore, the current capacity can be higher.

[0101] Optionally, the electrode comprises: a plurality of filaments, the plurality of filaments being made of a conductive material coated with a non-conductive material. In order to form a plurality of contact surfaces within the lead of the contact surface capable of transmitting the electrical signal to an electronic module (or vice versa), a portion or a section of the non-conductive coating is removed from the filament to expose the internal conductive material. The plurality of coated conductive filaments are integrated into the braided, knitted or other such structure, while portions of the coating of the structure are removed during the manufacture of the structure. The contact surface area of ​​the electrode is a cumulative electroactive surface made of several adjacent exposed areas of several filaments.

[0102] In some embodiments, the wire used in the methods and wire interlocking machines of the present invention is made of multiple biocompatible materials, such as: multiple non-conductive polymers for the structure; multiple isolated and non-isolated carbon fibers / nanotubes; multiple palladium-iridium (pl-ir) coated wires with polyparaxylene-C or other polymers; coated platinum wires; multiple metal wires with multiple insulating coatings; multiple reinforced wire cores with appropriate surface treatments, such as: titanium nitride (TIN) coating; black platinum; and polydimethylsiloxane (PDMS) coated with an insulating layer.

[0103] In some embodiments, since the electrode lead is made of multiple filaments, the distance between the multiple filaments can be designed so that the multiple body fluids near the electrode lead electrically interact with the contact surface area of ​​the multiple exposed filaments of the electrode located within the lead structure.

[0104] In tissue stimulation or sensing, the interaction between the electrode contact and the tissue occurs at the metal-tissue interface, and the interface is affected by the total contact area. The larger the surface area of ​​the contact, the lower the impedance, and the greater the charge capacity that can be sent to the tissue through the lead. In sensing, the larger the surface area of ​​the contact, the lower the impedance of the multiple contacts, and the better the quality of the multiple recorded signals. In order to shape the electric field and send the electric field to multiple desired brain areas, an electrode lead is required to include as many individually driven tiny electrode contacts as possible, optionally, each tiny contact is preferably oriented in one direction. Multiple tiny contacts have multiple smaller surfaces, so the present invention provides multiple electrodes with many contacts, the multiple contacts have preferred directionality, and at the same time have a very large surface area of ​​the electrode tissue interface, and therefore have a larger charge capacity. This is achieved by forming multiple volume contacts with multiple increased surface areas, which can be formed by various methods as described in this specification.

[0105] Alternatively, the lead may be designed and manufactured to have a volume (e.g., a pocket or a void), and the contacts are inserted / provided into the volume after the lead is manufactured. According to some embodiments, the electrodes may be manufactured separately and may be designed in a similar manner to the lead or using other manufacturing methods.

[0106] According to some embodiments, after inserting the electrode into its designated area / volume, the electrode is integrated with a structure of the lead and electrically connected to the electronic module. Alternatively, the contact is made by at least one conductive filament wound inside the void.

[0107] In some embodiments, the depicted architecture of the multiple electrode contacts of the present invention is a plurality of volumes that are mostly embedded in the lead structure, and a portion of the multiple volume surfaces of the multiple electrodes are in direct contact with the tissue surrounding the electrode lead. The multiple contact surfaces enable the electrode to contact the preferred directionality of the electrode, and the electrode contact volume helps improve the electrode contact performance.

[0108] In some embodiments, the electrode lead of the present invention is specially designed as needed by designing and establishing specific structures of integration and ordering of the plurality of filaments of the body of the electrode established within the electrode lead structure.

[0109] refer to Figures 10a to 10c Schematically shows an example embodiment according to an example ( Fig.10a and 10d ) of a single wire electrode in a lead and its cross-sectional view (respectively Fig.10b and 10e ), showing three separate electrodes across the cross-sectional area of ​​the lead.

[0110] like Fig.10a As shown, the lead 1200 is made of a plurality of interlocking non-conductive filaments 1202 and arranged in an interlocking structure. In a predetermined area, a conductive single wire 1204 is provided with a predetermined outer surface, and the predetermined outer surface is flush with an outer peripheral surface of the electrode lead 1200. In this way, the single wire 1204 establishes a manageable and controllable contact surface. The wire 1204 is folded and entangled on a plurality of vertical filaments 1202 and a plurality of bends, thereby establishing an exposed conductive material area to establish the electrode contact active surface area. As shown in Fig.10b As shown in a cross-sectional view of an electrode lead, more than one electrode may be provided in a particular cross-section: three single wire electrodes 1204, 1206, and 1208 are shown occupying a volume in the same cross-sectional area of ​​the electrode lead. It can be clearly seen that the plurality of wires are folded and wrapped around the plurality of vertical filaments 1202. It should be clear that the folding around the plurality of vertical filaments shown in the illustration is only due to the clarity of the illustrations, and the folding may be around all types of filament entanglements that create the lead structure.

[0111] It should be noted that if Fig.10bAs shown, each of the plurality of electrode contacts is provided with an isolated conductive filament that transmits a plurality of electrical signals to or from an electronic module (not shown). The plurality of single wire electrode contacts can be distributed in the electrode lead in a customized manner as required. In addition, more than one single wire can be used for one electrode or more than one electrode. Thus, an electrode wire can be folded around other filaments (e.g., a plurality of non-conductive filaments and a plurality of conductive filaments that are coated). The entanglement and folding can be around a plurality of other interlocking filaments and form the basic structure of the lead.

[0112] In some embodiments, the wire forming the folded electrode can be made from at least one of the plurality of filaments that establish the base structure of the electrode lead and fold around the structure. When the filaments are made from a coated conductive material, the coated insulating material is removed at the folded area that constructs the electrode contact area to expose the conductive material that forms the contact before the filaments are folded and woven into position.

[0113] In some embodiments, the folding region made of at least one wire can be integrated into an electrode having a conventional structure used in the industry. Alternatively, the folding region is combined with a plurality of other electrode structures.

[0114] In some embodiments, the plurality of electrodes are constructed with one or more coaxial layers. According to some embodiments, some layers are longitudinally movable relative to other layers. According to other embodiments, an electrode comprises two, three, four, or five or more layers. According to some embodiments, the positioning of the plurality of layers can be adjusted to achieve a plurality of different functions, or alternatively, to adjust / modify one or more functions, such as a directionality of an electric field and / or a magnetic field.

[0115] Fig.10cAnother cross-sectional view of an electrode lead according to the present invention is shown, the electrode lead having multiple electrodes with a shared volume. The electrode lead 1200 is provided with a volume 1210, in which one or more contacts are arranged. A first electrode contact 1212 is provided with multiple contact surfaces electrically connected to an electronic module, and a second electrode contact 1214 has multiple contact surfaces also electrically connected to the electronic module. An electrode contact 1216 with multiple contact surfaces is also provided, wherein the multiple metals of the multiple contacts are not necessarily short-circuited. As shown, all three contacts have a shared volume of the volume 1210 that they occupy in the electrode lead. An advantage of using the architecture is that the same volume is used to stimulate a tissue and sense the tissue at the same time, for example: without increasing the size of the lead. It should be noted that the multiple electrodes can be used for sensing, stimulation, or any other combination between the two options. This brings some other possibilities for using the electrode lead. Other electrodes (e.g., electrode 1218) can be provided in their own volume. Another advantage is the ability to change the directionality of the electrode. By using an electrode lead 1200 and using three electrodes as sensing / stimulation electrodes simultaneously, the directionality of the sensing electrode or stimulation electrode can be moved simultaneously by starting with one electrode, then moving to another electrode and continuing to the next electrode. When the multiple electrodes share the same volume, the resolution of the directionality of the multiple electrodes can be fine-tuned.

[0116] It should be noted that if, for example, the architecture of the plurality of electrodes is composed of a plurality of interlocking filaments, the plurality of contacts in the volume may completely overlap, and then the plurality of filaments of the three electrodes may overlap. Any of the structures described in this specification may be combined: for example: the electrodes may be made partly of a plurality of filaments and partly of a spongy or porous material, enabling full control of the directionality of the electrodes.

[0117] According to another aspect, an electrode lead is provided having a plurality of guide marks on a surface of the electrode lead, with a predetermined or known spacing between the plurality of guide marks. The plurality of guide marks can be used as a measuring device and are configured to facilitate measuring a distance from a reference point on the electrode lead to another block.

[0118] Reference now Fig.11a, which shows an electrode lead 1200 according to an exemplary embodiment, with multiple markings on the electrode lead 1200. In multiple specific embodiments, the electrode lead 1200 is provided with multiple markings 1222, the markings 1222 have multiple constant sizes and are separated from each other by a specific predetermined and constant distance 1224; multiple markings 1228 have multiple constant sizes and are separated from each other by a specific predetermined and constant distance 1230; and multiple markings 1232 have multiple constant sizes and are separated from each other by a specific predetermined and constant distance 1234. In this way, a known reference point 1226 on the electrode lead 1200 can be used to measure a distance from the reference point 1226 to another point on the electrode lead or outside the electrode lead. Other uses of the design can be to place the electrode lead at a specific location in a body portion, expose a contact at a customized location, lay masking materials, etc.

[0119] The plurality of guide markers may preferably be a plurality of predetermined filaments forming and designing a plurality of patterns of the material forming the electrode. The plurality of markers may be manufactured on the electrode lead during or after manufacturing the lead as required, and may be placed in the electrode lead using a method that will be explained later in this specification.

[0120] Reference now Fig.11b , shows an electrode lead 1200 according to another embodiment, with multiple markings on the electrode lead 1200. In some embodiments, the electrode lead 1200 is made of multiple layers 1242, some of which are marked as 1244. In this way, multiple measurements can also be made in the internal structure of the electrode lead. It should be noted that the multiple structures can be connected together to form a three-dimensional structure electrode.

[0121] On the other hand, the electrode may include (multiple) materials disposed within the structure of the electrode lead. The (multiple) materials may be inserted into the electrode lead structure during fabrication, construction or manufacture of the electrode lead. The (multiple) disposed materials are positioned within the electrode lead structure at predetermined locations within the electrode lead structure, and optionally at multiple predetermined times during the manufacturing process. Optionally, the (multiple) disposed materials are post-processed to form a change or transformation of the (multiple) disposed materials. Therefore, the disposed materials are processed after manufacturing the electrode lead to form a medium capable of achieving a desired property or function.

[0122] Fig.11cis a block diagram of a method for placement that can be performed in some embodiments: During the manufacture of the electrode lead, multiple functional filaments or multiple blocks can be interlocked within the structure of the lead (I). Optionally, the entire lead can be inserted into an outer protective sheath (II), which can be retained or removed after the lead is prepared. Then, optionally, the composite of the electrode lead and the outer protective sheath can be inserted into a heat shrink, i.e., a structure that shrinks when heated (III), and then the entire composite (optionally, with the heat shrink) is post-processed (IV). As described earlier in this specification with respect to the protective sheath, the heat shrink can also be removed or stripped after the post-processing (V).

[0123] In some embodiments, the electrode lead manufactured by the present invention has a blocking portion. Fig.12a , showing an example of an electrode lead having a barrier portion according to the present invention, and referring to Figures 12a to 12e A method for manufacturing the electrode lead having a barrier portion is shown.

[0124] In some applications, the distal side of the lead is implanted at a location having a different ambient pressure than the proximal side of the lead, where it is desirable that the body of the lead not enter a leakage path that violates this difference between the multiple regions. Alternatively, because the body of the lead is composed of interlocking optical fibers that enable a path for multiple fluids to pass between a distal side and a proximal side of the lead, the body of the electrode lead formed can form a barrier: Figures 12b to 12e As shown, a post-processing is performed using an external heat shrink to melt a plurality of special filaments or an external protective sleeve into the lead structure, thereby filling a plurality of gaps in the structure and forming a barrier to prevent any pressure leakage or fluid leakage between the two sides of the barrier. It is worth noting that the barrier can be produced by any suitable method, for example: injection molding on the plurality of filaments.

[0125] In some embodiments, heat shrink (peelable or permanent) is used and placed around the lead and / or the protective sleeve so that the heat shrink shrinks upon application of heat, forcing the particular filaments or the protective sleeve to melt and create a desired barrier. After this action, the heat shrink may be removed or may remain permanently as part of the body of the lead.

[0126] Fig.12aAn electrode lead 1200 is shown having a barrier region 1262 provided with a protective sheath 1266 and a heat shrink 1264. One possible way in which the barrier structure may be formed is to include a large amount of functional material, such as a polymer 1266, in a state that may be subsequently melted during the manufacturing process. The polymer 1266 is integrated into the structure of the lead adjacent to a plurality of filaments 1268. Alternatively, the polymer 1266 may be a hollow tube of a functional polymer that is inserted around the lead at the desired barrier location. After the manufacture of the electrode lead is completed, the portion to be applied is covered with, for example, a protective sheath of polymer 1266 and optionally a heat shrink 1264 ( Figure 12b ) is covered. Then, the complete structure is constructed ( Fig.12c The electrode lead is then heated to melt the polymer 1266 into a plurality of filaments 1268 ( Fig.12d ), and then remove the heat shrink ( Fig.12e ). Fig.12a An electrode lead having a distal end and a proximal end is shown, an outer protective sheath is wrapped around the lead at a desired location(s), and the composite is then wrapped within a heat shrink 1264; Figures 12b to 12c is an enlarged cross section along the lead axis of the lead region, including the intended barrier, showing an inner guide tube 1270 typically incorporated within multiple electrode leads. Fig.12d It shows how when the composite is exposed to appropriate heat, thermal contraction is induced to begin shrinking over the outer protective sheath. As heat builds, the outer protective sheath begins to melt into the body of the interlocking leads, thereby forming a barrier. Finally, as Fig.12e In some embodiments, the outer protective sleeve is patterned and has various openings / holes / different protective sleeve thicknesses along the axis or circumference, so that when the outer protective sleeve reflows, the pattern updates the lead composition accordingly.

[0127] Fig.12f An electrode lead with multiple electrical connection terminals according to an exemplary embodiment is shown, showing: a lead 1400 having many electrode contacts 1402 at the distal end of the lead 1400, each electrode contact 1402 being connected to at least one conductor 1404 to a lead conductive area 1406 that serves as a proximal end of the multiple connection terminals. Figure 12gAn electrode lead with multiple electrical connection terminals according to another exemplary embodiment is shown, showing that the proximal end of the lead can also be divided into more than one distal end (during manufacturing), thus allowing as many connection terminals as possible to be accommodated. The characteristics also allow the lead to be compatible with multiple mating connectors. The multiple conductive volumes can be in the form of multiple coiled conductive filaments at each connection terminal or any other configuration.

[0128] In some embodiments, the (multiple) disposed materials provide the electrode lead with multiple properties or functions, such as: isolation between multiple contacts, robustness, erection of the electrode structure, masking portions of the electrode lead for multiple further manufacturing steps, forming patterns within the electrode, performing multiple markings as described in this specification, etc.

[0129] In some embodiments, the present invention provides multiple electrode connection terminals, and the method of the present invention is capable of creating and constructing multiple volume conductive areas, and the multiple volume conductive areas can also be used to provide multiple electrical connection terminals, so that a matching connector will connect each conductive area, and the conductive area serves as a connection terminal of a single channel in the multiple electronic sensing circuits or electronic stimulation circuits.

[0130] Fig.13a A selection of multiple connection terminals 1300 is shown, and the multiple connection terminals 1300 are in the form of multiple coiled exposed filaments / wires wrapped around the circumference of the lead, forming multiple independent connection terminals that do not touch each other. The three contacts shown are separated by multiple non-conductive areas 1302, allowing enough space so that no electrical short circuit is formed between the three contacts. Each contact is optionally connected to an electrode at the distal side of the lead by a conductor. The connection terminals can take any conductive mass volume shape, and the mating connector terminals can be female, male, or multiple pins inserted into the conductive terminal volume, etc.

[0131] The connector may be positioned internally as a female connection terminal, or externally as a male connection terminal. Fig.13b A connector terminal in a female configuration is shown, with three internal connecting terminals 1310 serving as connecting terminals which can be connected to a matching male connector on one side and connected to a plurality of electrode contacts via a conductor on the other side, or actually forming part of the electrode contacts, i.e. forming the same wires that form the electrode contacts and the electrode connector. Fig.13cThe lead distal end 1306 is shown, including: a plurality of electrode contacts 1308, and at the proximal end 1305 of the lead, the plurality of connection terminals 1304 present a planar configuration, the plurality of connection terminals 1304 are a plurality of conductive volumes that extend through the thickness of the proximal end of the lead. The plurality of mating connectors may have a plurality of pins or protrusions that will penetrate or penetrate the conductive areas of the plurality of corresponding terminals when the plurality of pins or protrusions clamp the plurality of terminal connections at the proximal side of the lead.

[0132] The mating connector may be a Fig.13a A linear female connector that mates with the described connection terminals, or a female connector that mates with the Fig.13b A linear male connector that mates with the described connecting terminals, or even a Fig.13c A clamp is described that is clamped on the electrode connector terminal. The female connector having the ability to squeeze multiple male mating connectors can be formed by interlocking / braiding / knitting, etc. The single connection terminal area is achieved by multiple special patterns that allow flexibility and elasticity of the structure. When the male connector is inserted, the male connector will force the female contact to expand, and at the same time the female connector becomes more tight, thereby pushing down the multiple male components in the connector. The behavior can also be achieved by interlocking the multiple conductor filaments forming the female contact area with multiple elastic filaments: the electrode will be braided to have an inner diameter smaller than the outer diameter of the male contact, so that when the male connector is inserted into the distal end of the lead containing the female contact, the flexible / elastic structure of the female connector will expand while continuously pushing the male connector.

[0133] Reference now Figures 14a to 14d A male mating connector is shown inserted into the proximal end of a female wire, which accommodates a plurality of elastic filaments 1444 of the plurality of female connection terminals 1442. Other types of filaments not shown may also interlock. As the male connector 1446 advances into the structure of the lead, the lead expands due to the plurality of elastic filaments used. Fig.14d It is shown that each male connecting terminal in the male connector 1446 is connected to the appropriate female terminal 1442, while the structure at the proximal lead remains pressed against the male connector, thereby providing a more reliable electrical connection between the male connector and the female connector.

[0134] In some embodiments, a block of material can form an electrode. Any method can be used to arrange the block of material during electrode manufacturing, such as: braiding, knitting, weaving, winding, tangling, netting or any combination thereof. In some embodiments, the arranged material is a large amount of material containing a second compound, which forms a desired porous material when triggered. In other embodiments, the arranged material is a material isolated by a polymer, and the material can be arranged in multiple areas to establish an end of an electrode line. In a post-processing of the electrode, such as: radiation, temperature change, addition of a cross-linking agent, etc., the polymer is forced to capture multiple exposed conductive wires of the electrode, thereby isolating the multiple exposed conductive wires from the environment. Optionally, the arranged material includes: multiple wires or multiple filaments.

[0135] Reference now Figures 10d to 10e , showing Figures 10a to 10b Cross-sectional view and side view of the multiple functional filaments after post-processing. Figures 10a to 10b The interlocking electrode lead 1200 shown in can be provided with a plurality of electrodes 1204, between which a plurality of functional filaments 1254 are, for example, a plurality of filaments made of a polymer that can be melted. Both types of filaments of the plurality of wires are interlocked within a structure of a plurality of vertical filaments 1202. Other filaments can be incorporated into the structure. After the structure of the electrode lead is completed, the electrode lead is subjected to post-processing (e.g., heat, radiation, etc.), which changes the state of the plurality of functional polymer filaments to become a melt that holds the plurality of components interlocked therewith together. Figures 10d to 10e The formation of multiple insulating regions within the lead or electrode body is depicted, which can, for example, isolate between multiple conductive regions. One of the multiple methods of achieving this is to use multiple polymer filaments arranged and interlocked within the lead body to form an isolation barrier between multiple different lead regions. The multiple holes and multiple spaces formed within the interlocking barrier can be closed by a post-processing on the electrode lead, such as: applying sufficient heat to melt and reflow the multiple filaments to close the multiple gaps formed in the interlocking structure. The multiple filaments can be designed to melt at a temperature below the temperature threshold of reflow or corrosion of all other components and raw materials of the wire.

[0136] In some embodiments, the present invention provides a method of forming a lateral extension of a plurality of exposed conductive filaments that can be used as an electrode in an electrode lead. Fig.15aAn electrode contact made from a single wire or filament divided into several filaments is shown. A single wire or filament 1570 is made from a conductive core coated with a non-conductive material. In a predetermined point 1572 on the wire filament 1570, the conductive material is exposed and divided into a plurality of filaments 1574, which comprise the electrode that can be integrated into an electrode lead.

[0137] In other embodiments, a bundle of filaments may extend and be exposed in a predetermined area to form an electrode contact. Figures 15b to 15e As shown, a filament bundle 1550 is held together, in which the plurality of filaments are made of a conductive core coated with a non-conductive material. In a predetermined area / region of the filament bundle 1552, the filament bundle is allowed to be loosened, and the plurality of filaments are allowed to extend laterally. In the region 1552, the non-conductive coating is removed from the conductive core of the plurality of filaments, so that the plurality of loosened filaments are in contact as electrodes. The filament bundle can be integrated into an electrode lead, which is manufactured using, for example, braiding, knitting, weaving, winding, entanglement, netting or any combination thereof. Integrating at least one of the filament bundles into an electrode lead can be implemented as any possible electrode lead structure, such as an electrode lead structure. Such as those in Figure 9. An example of forming the lateral extension of a plurality of filaments in a filament bundle 1550 is to squeeze the filament bundle toward each other from both sides of the lateral extension, so that the plurality of filaments are forced to extend toward both sides in the loosened region.

[0138] Fig.15c Schematically shows the Fig.15b An electrode lead 1550 is provided for contacting a plurality of integrated electrodes. As shown, the electrode lead 1550 incorporates at least two electrodes 1552, wherein the plurality of electrodes are electrically connected to an electronic module (not shown) through the isolated bundle of wires 1554 or through a single relatively thick isolated wire. The interlocking structure of the electrode lead 1550 is represented by a plurality of filaments 1562. It should be noted that only a few filaments are shown in the figure to clearly show the structure of the electrode lead, however, it should be understood that this is only one representation and the electrode lead is made of a large number of interlocking filaments.

[0139] In some embodiments, the end of the electrode contact 1560 is coated with an isolation material, which can be applied by any suitable method.

[0140] In some embodiments, the electrode provided herein includes a volume contact that occupies a predetermined volume. In alternative embodiments, the volume contact has a porous structure having a plurality of conductive surfaces therein for facilitating the transfer of an electronic signal to or from a fluid environment near the electrode contact through the plurality of conductive surfaces within the volume of the volume contact. Integrating such a volume contact within the electrode lead results in even further increasing the contact surface area of ​​the electrode within the plurality of disclosed architectures or other architectures, thereby increasing the charge capacity.

[0141] Fig.15d and 15e An electrode lead with an integrated sponge-like or porous electrode is shown respectively according to an exemplary embodiment. Fig.15d A sponge-like mass 1552 made of a conductive material integrated into an electrode lead 1550 is shown, wherein the sponge-like mass 1552 acts as an electrode electrically connected to a wire 1554, and the wire 1554 is electrically connected to an electronic module (not shown). The sponge-like mass 1552 can be integrated into an electrode lead by being incorporated into an electrode lead (e.g., incorporated into the plurality of filaments 1556 of the electrode lead structure). The mass 1552 can be integrated into the structure or the electrode lead, or provided independently. Fig.15e An electrode lead with an integrated porous 1560 electrode is shown according to an exemplary embodiment. In a specific embodiment, the porous bulk 1560 has a relatively large surface area that can serve as an effective surface area for transmitting multiple signals.

[0142] According to specific aspects of the present invention, and due to the unique structure of the lead, an electrode lead having a volume with volume sharing can be manufactured. An electrode is provided with a first contact and a second contact, the first contact having a structure occupying a defined space (surface or volume) to form a conductive surface with multiple voids in the first contact, and the second contact having at least one conductive surface that is at least partially interlocked with the first contact to occupy at least one of the multiple voids within the structure of the first contact, so that there is no direct electrical contact between the at least one conductive surface of the second contact and the multiple contact surfaces of the first contact.

[0143] Reference now Fig.16a, schematically illustrates an electrode 1330 having an inner layer 1334 and an outer layer 1332 according to some embodiments. In some embodiments, the outer layer 1332 and the inner layer 1334 are formed together in the same process, or alternatively, are formed and assembled / introduced independently at a later stage. In other embodiments, the inner layer 1334 and the outer layer 1332 can be structurally combined with each other, or structurally independent.

[0144] In some embodiments, an electrode of the present invention has an opening, opened on the surface of the electrode, or a cavity within the volume of the electrode. In other embodiments, an opening on the surface or multiple outer layers of an electrode is used to introduce multiple objects from the structure of the electrode and protrude out of the outer surface to reach a specific location, such as: within the body of a subject, or to achieve specific functionality, such as: a contact shape or positioning, or, for example: to achieve an anchoring of the electrode in a desired position / position after insertion.

[0145] like Figures 16b to 16cAs shown, the plurality of openings can be produced by the same interlocking process and an internal structure, for example: a plurality of microelectrodes can be formed in the internal moving part and protrude in the openings in the outer layer, and in some cases do not protrude outside the outer layer. When necessary, the internal structure can be moved inwardly, forcing the plurality of microelectrodes to move in the openings and enter the tissue in a plurality of tiny steps, so that the plurality of openings form a plurality of guides, and the plurality of guides guide the plurality of protruding internal components through the outer layer and into the tissue. In other cases, other leads built into the plurality of inner layers can protrude and pass through the plurality of openings into the tissue. One of the advantages of the structure is that the structure can control the precise protrusion speed of the plurality of protruding components of the inner layer into the tissue, and in addition, it can also retract all of the plurality of components into the lead structure when necessary, so that the protrusion of the plurality of internal components does not protrude through the outer surface of the lead. Another advantage of using the above structure is that the structure is able to protect the multiple leads of the multiple electrodes during the insertion of the electrode leads into the final implantation position: after the electrode is inserted into a position, the multiple internal components (the multiple internal components are the multiple actual electrodes or other sub-leads with multiple electrodes) are pushed forward into the tissue in multiple fine steps. In addition, the structure provides another method for performing multiple further fine-tuning bends on the internal electrode after the electrode is implanted in the position. For example: in the case where a more ideal stimulation position or monitoring position in the tissue is required. In addition, if the lead needs to be explanted, the internal structure is first adjusted to force the multiple protrusions to retract into the lead structure without leaving any protrusions beyond the outer layer, and then the lead is explanted without damaging the tissue during extraction.

[0146] In some embodiments, the electrode lead of the present invention comprises a plurality of layers, so that when the inner layer is moved, i.e., extended outward from the outer layer, a plurality of electrodes contact or reside in the inner layer (a plurality of) another structure protrudes from the outer layer. Alternatively, moving a layer enables a plurality of electrodes to contact or reside in the inner layer (a plurality of) another structure to protrude from the outer layer through a plurality of predetermined holes in the outer layer, and the characteristic can be used, for example, on the connector of the electrode to connect the connector to another device.

[0147] Reference now Figures 17a to 17b, schematically illustrates an electrode 1470 having an opening 1474 in its outer layer 1472 according to some embodiments. In some embodiments, an opening 1474 can be formed for structural and / or functional purposes, which are determined by the shape of the opening 1474. The multiple functional properties can be a cavity formed within the body of the electrode to increase the flow of body fluids within the body, for example: in the case of a contact within the volume of the electrode. Alternatively, the cavity or opening can be formed to achieve a specific directionality of the electric field and / or magnetic field. In some embodiments, the opening 1474 can be used to introduce multiple objects, multiple tools, multiple structures, etc. into the external environment of the electrode 1470.

[0148] Fig.17b Further shown are examples of how the electrode can create multiple volumetric regions that are compatible with electromagnetic interference (EMI). The multiple conductors within each of the multiple volumetric contacts can present a track that increases the resistance of the electrode region to EMI interference, for example: not winding all the way around the circumference of the electrode, or forming multiple loops, but weaving / braiding / interlocking in a manner that multiple regions of the conductor are configured to cancel other regions in the same conductor. In this manner, when within a magnetic field, multiple opposing currents will cause multiple opposing configurations, thereby canceling each other to help significantly reduce electromagnetic interference. Fig.17b A conductive block is shown, which may be an electrode contact or a connection terminal 1457 with an exposed metal inner layer 1476, due to a specific necessity of folding the filaments, the folding is configured so that the folded filaments do not form a loop in the opposite direction to another folded filament, thereby forming resistance to electromagnetic interference. Fig.17b As shown, the filament 1478 is bent in a clockwise direction and then in a counterclockwise direction 1749 so as to be folded relative to each other. The plurality of configurations may also be present as any portion of the plurality of electrode leads, where and when electromagnetic compatibility is desired, or to eliminate electromagnetically induced currents entering a plurality of filaments having a plurality of metal cores.

[0149] Fig.17c An electrode having a more planar structure according to various aspects of the present invention is shown, wherein the electrode has multiple conductive regions (black) and is incorporated into the electrode. The electrode structure can also be manufactured using the multiple methods described in this specification and has multiple similar properties as described and mentioned in this specification.

[0150] The present invention also provides a wire interlocking machine configured to carry a plurality of wires and interlock the plurality of wires so that a wire can be positioned to act as a warp thread at a plurality of specific times / positions and to act as a weft thread at other times / positions.

[0151] In some embodiments, a wire is held and arranged to be interlocked by a wire carrier, which is configured to hold the associated wires in a specific tension or multiple tensions and to be controllably released to form the interlocking structure. In multiple specific embodiments, the carrier is configured to be movable in at least two directions: a vertical direction: when used to form a warp in the structure, and a horizontal direction: when used to form a weft in the structure and / or for repositioning the horizontal position of the structure to form a warp at a different horizontal position. In other specific embodiments, the vertical movement of multiple carriers is used to determine the interlocking pattern, and the horizontal movement of the (multiple) carriers is used to form a bend in the structure.

[0152] In some embodiments, the wire interlocking machine of the present invention includes a plurality of vertical tracks and at least one horizontal track. The plurality of vertical tracks facilitate the vertical movement of a plurality of carriers, and the at least one horizontal track facilitates the horizontal movement of at least one carrier at a specific time. In a plurality of specific embodiments, the plurality of carriers are configured to controllably change the movement mode of the plurality of carriers by disengaging from a vertical track to move into a horizontal track, and also moving from the horizontal track to a vertical track.

[0153] In some embodiments, the structure is formed by holding and controlling one end of the wires and a base position at another end of the wires by the plurality of carriers, the base position being where the wires form an interlock.

[0154] Thus, the present invention provides a wire interlocking machine for manufacturing an interlocking wire electrode, comprising: (a) a plurality of wire carriers, each wire carrier being configured to hold a desired wire, at least one of the plurality of wire carriers having a conductive core coated with a non-conductive material; and (b) at least two intersecting track sections, each section having: (i) a vertical track defining a vertical range of movement of a wire carrier; and (ii) a horizontal track defining a horizontal range of movement of a wire carrier (shuttle), such that the vertical track and the horizontal track intersect along the longitude of the vertical track and the horizontal track, causing the vertical track to intersect the horizontal track. a shift in the movement of a wire carrier between horizontal tracks, and the plurality of cross track segments are horizontally arranged to facilitate a movement of a wire carrier from a horizontal track of one cross track segment to a horizontal track of another segment; (c) a wire base configured to hold a plurality of wires at a distal end of the wire base so that the plurality of wires are stretched from the wire carrier to the wire base; (d) at least one actuator for moving the plurality of wire carriers and optionally the wire base; (e) at least one device (laser) for exposing the conductive core of the wire(s) / filament(s); and (f) a control unit.

[0155] In some embodiments, the wire interlocking machine of the present invention is a radial braiding machine.

[0156] In some embodiments of the wire interlocking machine of the present invention, the vertical track includes a plurality of predetermined positions for anchoring the wire carrier.

[0157] In other embodiments of the wire interlocking machine of the present invention, the actuator moves each wire carrier (from one position to another) independently of the other wire carriers.

[0158] In some embodiments of the wire interlocking machine of the present invention, the control unit is designed to: (a) receive data about the length of the electrodes and the weaving pattern and the multiple positions of the multiple exposed filaments; (b) control the movement of the multiple wire carriers from one station to another; (c) control the movement of the shuttle; and (d) control the activation of the multiple devices for exposing the conductive core of the (multiple) filaments.

[0159] In various specific embodiments, the electrode manufactured by the wire interlocking machine of the present invention is an interlocked wire electrode of the present invention.

[0160] In some embodiments, the present invention provides a cross-track segment, which is configured to facilitate a controlled movement of a wire carrier in the wire interlocking machine of the present invention, and includes at least two cross-track segments, each segment having: (a) a vertical track, which limits a vertical movement range of the wire carrier, and (b) a horizontal track, which limits a horizontal movement range of the wire carrier, so that the vertical track and the horizontal track intersect along the longitude of the vertical track and the horizontal track, thereby facilitating a change in the movement of the wire carrier between the vertical track and the horizontal track, wherein the cross-track segment is also configured to be horizontally arranged with another cross-track segment, thereby facilitating a movement of the wire carrier from the horizontal track of the cross-track segment to a horizontal track of another cross-track segment.

[0161] Reference now Fig.18 , schematically illustrates a multi-segment system 1500 for wire interlocking according to some embodiments of the present invention. As shown, the system 1500 may include a first section 1510, a second section 1520, a third section 1530, and a fourth section 1540. The first section 1510 has a first vertical track 1512 and a first horizontal track 1514, the second section 1520 has a second vertical track 1522 and a second horizontal track 1524, the third section 1530 has a third vertical track 1532 and a third horizontal track 1534, and the fourth section 1540 has a fourth vertical track 1542 and a fourth horizontal track 1544 (etc.).

[0162] In many specific embodiments, the plurality of sections are configured such that the first horizontal track 1514, the second horizontal track 1524, the third horizontal track 1534, and the fourth horizontal track 1544 are aligned to form a continuous or semi-continuous horizontal track to allow a carrier to move horizontally on the horizontal track. According to some embodiments, a first carrier 1502 is shown to move in the horizontal direction and act as a latitude, while a second carrier 1504, a third carrier 1506, and a fourth carrier 1508 are positioned in the second vertical track 1522, the third vertical track 1532, and the fourth vertical track 1542, respectively, at specific locations above or below the horizontal track, acting as a warp. In many specific embodiments, within each segment, the intersection of the horizontal track and the vertical track is configured to allow a carrier to switch from the vertical track to the horizontal track, and vice versa.

[0163] In some embodiments, a carrier may include a plurality of actuators for moving the carrier within a track or between multiple tracks, or alternatively, the machine may include a plurality of independent actuators, configured to have a mechanical and / or electrical / electromagnetic / magnetic association with a carrier at least occasionally, so as to controllably actuate a movement of a transfer of the carrier within a track or between different tracks. In a plurality of specific embodiments, the wire interlocking machine of the present invention may have one (multiple) horizontal actuators and a plurality of vertical actuators, the one (multiple) horizontal actuators being configured to controllably move a plurality of carriers in the (multiple) horizontal tracks, and the plurality of vertical actuators being configured to controllably move a plurality of carriers in the plurality of vertical tracks. In other specific embodiments, the vertical and horizontal actuators are configured to allow the mechanical / electrical / magnetic connection / association of a plurality of carriers transmitted between the vertical and horizontal actuators. In a plurality of specific embodiments, a horizontal actuator has a form of connection / association with a plurality of carriers, and a vertical actuator has a different form of connection / association with a plurality of carriers. In specific embodiments, the horizontal actuator (interchangeably referred to herein as a shuttle) is configured to form a mechanical connection with the plurality of carriers, and a vertical actuator is configured to form a magnetic connection with the plurality of carriers.

[0164] In some embodiments, each carrier further comprises at least one mechanism to vary the tension of the wire it holds. In one embodiment, the mechanism is an array of springs, each spring producing a different tension, such that when the shuttle reaches and holds a particular carrier, it is mechanically or electronically connected to the particular carrier; the spring forces the carrier to switch between a plurality of different springs, thereby varying the tension of the wire. In another embodiment, the tension mechanism is the motor / servo mechanism actually incorporated into the carrier, the tension mechanism being a variable tension on the wire and controllable by the machine controller. In other embodiments, the plurality of devices may be wireless or other mechanical mechanisms that may be used at the vertical or horizontal tracks or sections to switch the tension of a carrier.

[0165] Fig.19A rear view of a section 1600 according to the present invention is shown, which includes a vertical track 1602 and a horizontal track 1604, wherein a magnetic actuator 1610 is positioned to move along the vertical track 1602, and a shuttle 1620 is configured to move along the horizontal track 1602. In specific embodiments, a vertical track can include one or more stations, which are mechanisms that hold a carrier at a desired vertical position along the vertical track without being associated with a horizontal actuator. Advantageously, holding a carrier at a station can allow the vertical actuator to handle the vertical movement of other carriers while the remaining carriers within the associated vertical track are positioned at determined positions.

[0166] According to some embodiments, a vertical track can be configured to accommodate at least one, at least two, or more carriers at a given time. According to some embodiments, at least some of the multiple carriers can be held in place by multiple stations. In multiple specific embodiments, each vertical track is configured to accommodate one, two, three, four, five, six, seven, eight, nine, ten, or more carriers at a given time. In other specific embodiments, each horizontal track is configured to accommodate one, two, three, four, five, six, seven, eight, nine, ten, or more carriers at a given time.

[0167] Figures 20a to 20b A segment with multiple vertical actuators is shown at different locations in accordance with some embodiments. Fig.20a A section 1700 is shown having a vertical track 1704 and a horizontal track 1702 , with a first carrier 1710 and a second carrier 1712 disposed below the horizontal track 1702 . Fig.20b Another possible configuration of a section 1701 having a vertical track 1704 and a horizontal track 1702 is shown, wherein a first carrier 1710 is disposed above the horizontal track 1702 and a second carrier 1712 is disposed below the horizontal track 1702 .

[0168] Fig.21 A single section 2160 within a wire interlocking machine of the present invention is schematically shown, showing three carriers 2161, 2162, and 2163 deployed on the vertical track, wherein the middle carrier 2162 is set on the vertical track and is ready to be moved vertically by the (multiple) vertical actuators.

[0169] Figures 22a-22c A single section 2160 of a wire interlocking machine of the present invention is shown, wherein a carrier 2161 is connected from the horizontal track ( Fig.22a ) moves to the vertical track ( Figure 22b ), then move vertically ( Fig.22c ). In some embodiments, the movement may be reversed, from a vertical track to a horizontal track and then move horizontally.

[0170] Fig.23 Schematically showing some parallel sections 2160 in a wire interlocking machine of the present invention, showing multiple possible positions of the multiple vertical actuators and shuttle 1620. In some embodiments, the multiple sections 2160 are aligned to form a continuous or semi-continuous circular / closed horizontal track, wherein a carrier can be cyclically moved along the horizontal track. In multiple specific embodiments, in the cyclic configuration, the formation position of the interlocking wire (or leg or base) is set in the center of the circle between the multiple carriers ( Figure 24b ), or along an axis passing through the circle ( Fig.24a ).

[0171] Figures 24a to 24b Two possible configurations of a wire interlocking machine of the present invention are shown: Fig.24a A wire interlocking machine 2100 is shown with a lowered base 2170; Figure 24b A wire interlocking machine with a centrally placed base 2270 is shown. As shown, the wire interlocking machine 2100 includes: a plurality of sections 2110, 2120, 2130, 2140 arranged in a circle, wherein each section holds a carrier 2112, 2122, 2132, 2142, and a single carrier 2152 is used as a shuttle (or is held by the shuttle) when it moves on a horizontal track 2202. As described in this specification, the carrier used as a shuttle can be replaced by any other carrier, thereby enabling multiple complex interlocking structures and horizontal and vertical weaving of the same wire.

[0172] The core stabilization / braiding point of the electrode in the wire interlocking machine of the present invention is where the actual braiding / interlocking occurs, and the core stabilization / braiding point is a point where the braided wires in the electrode meet / come together. In specific embodiments, the point remains at the same height throughout the process of braiding / interlocking the electrode. In an alternative embodiment, the point can be moved up and down to create other patterns during braiding, or to advance or remove the lead from the braided / manufactured structure.

[0173] In some embodiments, the braiding points are held in precise positions by adding multiple new bends of wires to the core and then pulling the entire structure upward with an actuator (eg, a core actuator).

[0174] In some embodiments, the interlocking leads directly above the braiding point are held in a tube, and the electrode core directly below the braiding point is held in another stable tube, thereby stabilizing the braiding point. The wires from all carriers meet at the braiding point between the stabilized upper and lower tubes, helping to form a reaction force to the force applied by the tensioned wires and also contributing to the accuracy of the manufactured structure.

[0175] Fig.25a and 25b 25 shows a plurality of pictures of an electrode 2525 manufactured in real time by a wire interlocking machine according to the present invention, wherein the plurality of pictures are taken during the process of manufacturing an interlocked wire by a wire interlocking machine having a central base, such as Figure 24b shown.

[0176] Fig.26 One possible configuration of a wire interlocking machine of the present invention is shown, with a plurality of circularly arranged sections 2160 .

[0177] The present invention also provides a method for manufacturing an electrode by wire interlocking using the wire interlocking machine of the present invention. The method is mainly based on simultaneously changing multiple warp threads into multiple weft threads, and vice versa, according to a control method of a predetermined electrode structure of the electrode to manufacture a flat electrode structure.

[0178] In some embodiments of the method and wire interlocking machine of the present invention, the change from multiple warps to multiple wefts, and vice versa, is performed by changing the latitudinal and vertical positions of multiple different carriers (multiple wires), thereby converting a carrier from a weft forming wire to a weft forming wire, or vice versa.

[0179] In some embodiments, each carrier includes a roll of filament having multiple desired properties, such as: diameter, material, strength, conductivity, etc.; a wire tension generator for maintaining a desired tension in the wire; and multiple devices for integrating the shuttle, such as: a magnet or an electromagnet.

[0180] An important aspect of the present invention is the ability of the machine to expose / functionalize the wires at precise locations as the braiding proceeds. The exposure of the wire insulation can be done in a laser process to functionalize a specific length of wire required to form an electrode contact. Fig.29As shown, the exposed wire is used before folding / interlocking the exposed wire in three dimensions (3D) to the actual volume contact of the manufacturing electrode. Therefore, in some embodiments, the electrode manufacturing method of the present invention includes a step of exposing the insulation of the wire in a laser process, thereby functionalizing a wire of a specific length required to form an electrode contact before folding / interlocking the exposed wire in 3D to the actual volume contact of the manufacturing electrode.

[0181] like Fig.29 As shown, just before the wire / conductor is interlocked to the probe structure, a laser beam LB exposes multiple small areas 2901 in the wire / conductor (resolution can be as small as about 7 microns (um)) A computer controls when and where the laser ablates the wire / micro-conductor insulation. After interlocking the wire, the exposed area acts as a contact area 2902, for example, as a micro / macro stimulation or recording site. The same method is used to expose larger surfaces for multiple microelectrode contacts, for example, for macro stimulation.

[0182] In some embodiments, during weaving, ideally before the folding of the wire or before interlocking the wire into the structure, the wire carrier is brought by the shuttle actuator or by any other means to a position in the horizontal track where the wire is within the range of the laser beam. The controller then instructs the laser to functionalize a portion of the wire equal to the total length of the same wire required to form the conductive contact.

[0183] In another configuration, the laser functionalizes multiple small sections of a wire at a time, each time the wire is brought into range of the laser. In this way, the laser beam can be fixed at a specific focus and the wire is brought to that specific point. Alternatively, for example: as in the previous configuration, the machine will be able to change the focus / position of the laser to speed up the functionalization process, which change can be achieved, for example, by a galvanometer mirror or XY stage.

[0184] Therefore, in some embodiments, the wire interlocking machine of the present invention further comprises: a plurality of devices for functionalizing a wire, i.e. exposing its inner conductive core, for example: a laser unit / system capable of exposing a portion of the inner conductive core of a wire according to a predetermined design of the electrode. In some embodiments, the laser unit is fixed in place, and the portion of the wire that needs to be functionalized is brought in front of the laser to allow removal of the outer non-conductive coating. Alternatively, the laser unit is movable and can be brought in front of the portion of the wire that needs to be functionalized. In a number of specific embodiments, the laser unit is movable, but the final alignment of the wire portion in front of the laser unit is achieved by a dual movement of the laser unit and the carrier / shuttle that holds the wire that needs to be functionalized.

[0185] In some embodiments, the intensity of the laser can be adjusted as needed, for example, according to the thickness of the non-conductive layer of the wire and / or multiple physical properties of the inner conductive core.

[0186] In another embodiment, functionalization is performed by using a plurality of wires having insulating coatings sensitive to a specific wavelength of light, functionalizing desired portions of the plurality of wires using a laser having the same wavelength of light, and then interlocking the wires into the interlocking leads. A post-processing method (e.g., electrochemical method) may also be used on the interlocking leads to remove portions of the plurality of coatings treated with the laser beam, a process of photolithography using a laser beam.

[0187] After functionalizing the wires, the wires are interlocked into the manufactured electrode, thereby forming a contact / conductive area at a desired location of the electrode. Thus, the process of specifically functionalizing specific wire portions and then interlocking the wires into the final electrode enables isolation from each other by interlocking non-functionalized wires between the wires, forming multiple isolated contact areas, thereby enabling the manufacture of specifically designed electrodes according to specific needs (e.g., multiple desired stimulation locations, a patient's physiology, the strength of the signal passing, etc.).

[0188] In some embodiments, the wire interlocking machine of the present invention further comprises a reed. As will be apparent and explained in this specification, after a horizontal wire is placed in the manufactured electrode structure, a horizontal portion of the wire needs to be pushed upward toward the braiding point by a special mechanism, and the pushing is done when the horizontal wire is tightened. A reed can be made of a plurality of very thin wires / yarns / sheets, and the strength of the reed is sufficient not to bend when pushed relative to the plurality of horizontal wires. In a plurality of specific embodiments, the reed is not part of the final interlocked lead. In a plurality of alternative specific embodiments, the reed is part of the plurality of wires interlocked in the lead. An example of a reed is two wires that are not assembled / interlocked in the structure and are connected to a mechanism in the manufactured structure that can bring the two wires into the plurality of interlocked wires. Thus, a horizontal wire is pushed to the braiding point and toward the braiding point, and then the plurality of wires are lowered so that the plurality of wires do not interfere with other wires when the braiding continues.

[0189] One of the advantages of the wire interlocking machine and system of the present invention is that the wire interlocking machine and system can customize the electrode lead as it is being constructed. Once the machine has completed construction of the electrode, the machine can immediately begin construction of a second electrode. Thus, the finished electrode lead is cut from the fabricated structure while the machine continues to construct the next electrode lead.

[0190] In some embodiments, the setup of the machine of the present invention, including all carriers, wires and materials in the machine, is performed only once before the machine is started, or when the plurality of required wires needs to be replaced / reloaded.

[0191] The present invention also provides a method for manufacturing a wire interlocking electrode using the wire interlocking machine of the present invention, comprising the following steps: (a) inputting a desired structure of an electrode to be manufactured; (b) optionally, compiling the desired electrode structure into an interlocking digital structure, and then compiling it into a machine code for controlling the interlocking machine; (c) arranging multiple wire carriers at multiple vertical tracks of multiple sections of the multiple wire interlocking machines according to the desired structure; (d) selecting a carrier as a weft; (e) moving the weft along the horizontal track to pass between other filaments as the multiple warps; (f) optionally, selecting a different wire carrier to be used as a weft and switching between the multiple wire carriers; (g) continuing to move the selected weft along the horizontal track to pass between the multiple warps; (h) pressing the (multiple) wefts against the base to define a bend; and (i) terminating the method when the electrode is ready.

[0192] In some embodiments, the method of the present invention also includes at least one of the following steps: (i) functionalizing at least a portion of the weft wire, for example: by removing the coating material to expose the conductive material inside the wire to form a contact; (ii) functionalizing at least a portion of the multiple warp portions of the multiple wires, for example: by removing the coating material to expose the conductive material inside the wire to form a contact; and (iii) terminating the wire when a wire is no longer needed in the electrode.

[0193] Fig. 27 A method for performing wire interlocking using the wire interlocking machine of the present invention is schematically shown, the method comprising the following steps: arranging a plurality of carriers according to a predetermined architecture and holding a plurality of desired filaments at a plurality of desired positions along the plurality of vertical rails of the plurality of sections to act as a plurality of warps 2402; selecting a carrier to act as a weft 2404; moving the weft along the horizontal rail / track to pass between other filaments acting as the plurality of warps 2406; optionally, selecting a different carrier to act as a weft and switching between the plurality of wire carriers 2408 to meet the desired structure outlined by the predetermined architecture; continuing to move the selected weft along the horizontal rail / track to pass between the plurality of warps 2410; pressing the weft (s) toward the base to define a bend 2412; and terminating the method when the electrode preparation is complete 2414.

[0194] In other embodiments, the electrode architecture or computer-aided design (CAD) design is input into a special compiler that compiles the electrode structure, thereby converting the electrode structure into a digital form that describes the wire, length, exposure position, material placement, interlocking form, and any other mechanism and capability described in the present invention. The compiler can find the multiple properties of each required contact and then determine the required wire exposure length to form multiple required contacts by exposing the wire / coated wire. For example: the total surface of the tissue facing the original contact can be determined: the compiler determines the length of the wire that needs to be exposed to form a volume contact with the same or better exposed surface. The compiler also determines when to use the appropriate wire to form the contact, when to activate the functionalization on the same contact, where the contact will be interlocked with the vertical or horizontal wire, and how the wire is folded in 3D to form the final volume contact. Alternatively or additionally, in addition to the surface area, the impedance of the original contact is calculated, and then a comparable impedance of a volume contact is calculated to extract the exposure parameters, folding parameters, and interlocking parameters. The compiler may further determine the structural flexibility, length, width, cross-section, connection terminals of the interlock to be formed by the interlocking machine.

[0195] In some embodiments, the compiler or a corresponding computing component receives data about the designated implant destination, for example, from a magnetic resonance imaging (MRI), computerized axial tomography (CAT) or computerized tomography (CT) scan, and multiple required treatments / parameters, to determine the overall structure of the final electrode lead, including the types of multiple wires to be used, the locations of the multiple contact areas, the functionalization of each part of the various wires, etc., so that multiple customized electrode leads can be easily and quickly manufactured.

[0196] In another embodiment, another compiler is used to convert / compile the digital structure into machine code for controlling the weaving process: once the interlocking machine is set up, the machine code will run multiple sensing control signals of the interlocking mechanism to automatically or semi-automatically build multiple required interlocking leads as described in the present invention.

[0197] Fig.28Another alternative method for wire interlocking using the wire interlocking machine of the present invention is schematically shown, the method comprising the following steps: arranging a plurality of carriers and holding a plurality of desired filaments in a plurality of desired positions along the plurality of vertical tracks of the plurality of sections to act as a plurality of warp threads 2502; selecting a carrier to act as a weft thread 2504; moving the weft thread along the horizontal rail / track to pass between other filaments acting as the plurality of warp threads 2506; optionally, functionalizing at least a portion of the weft thread, for example by removing the coating material to expose the internal conductive material to form a contact 2508; optionally, terminating the wire if the electrode no longer requires a wire 2510; optionally, selecting a different carrier to act as a weft and switching between the plurality of wire carriers to meet the desired structure outlined by the predetermined architecture; continuing to move the selected weft along the horizontal rail / track to pass between the plurality of warps; pressing the weft (multiple) toward the base to define a bend 2512; and terminating the method when the electrode is ready 2514.

[0198] It should be noted that, by using the wire interlocking machine of the present invention, the wire interlocking method according to the present invention uses multiple functionalization devices (e.g., thermal systems and laser systems) to functionalize each wire when each wire is interlocked / braided and before finally forming the electrode according to a predetermined electrode architecture. For example: a laser can be used to expose the inner conductive core of a portion of a wire extending from a carrier, which acts as a shuttle and winds other wires at the manufactured electrode. Alternatively, the laser can be used to expose the inner conductive core of a portion of a wire extending from a carrier located at the multiple surrounding segments, which provide multiple wires for the base of the manufactured electrode. In addition, the laser can expose the inner conductive core of any portion of any wire: the weft or the warp or both, depending on the predetermined electrode architecture. The exposure of the inner conductive core or various wires enables the formation of an electrical contact area at the precise desired point, which has the desired shape and electrical properties (e.g., conductivity, electric field, etc.) obtained by the shape and depth of the manufactured contact area.

[0199] In some embodiments of the method of manufacturing an interlocked electrode lead according to the present invention, the setting of the wire interlocking machine, including placing and adjusting the plurality of carriers, the plurality of wires and the plurality of materials, is performed only once before the machine is started. Alternatively, it is performed when the plurality of required wires need to be replaced / reloaded, for example, when a different type of wire is required, or when a wire is torn or reaches the end.

[0200] Therefore, in some embodiments, the method of manufacturing an interlocking electrode lead according to the present invention enables the manufacture of multiple electrodes without stopping the machine, because the interlocking machine of the present invention is able to customize the electrode lead as it is constructed, and is able to cut each electrode when the electrode lead is completed, thus clearing the way for the manufacture of the next electrode. In multiple specific embodiments, the method is used to manufacture multiple identical electrodes. In other specific embodiments, the method is used to manufacture multiple different electrodes. In both cases, there is no need to stop the machine for multiple adjustments or multiple modifications.

[0201] Several additional inventive concepts of the present invention include:

[0202] A-Volume Contact: An electrode has at least one contact, which has "a conductive volume space" that can protrude / stretch out / extend from the electrode, forming a cavity / hollow portion / chamber / pocket or a combination thereof within the electrode.

[0203] B-Volume Sharing: More than one contact is placed within the same volume, more than one contact has a shared volume, or multiple contacts are at least partially spatially interleaved in the same space / volume.

[0204] Placement of C-contact: Based on the number of wires, determine the position / distance from a reference point, where the multiple intervals between multiple wires / multiple bends / multiple weaving patterns are pre-defined / known.

[0205] D-Material placement: placing a support / isolated wire / material within the electrode during the forming / manufacturing / printing / weaving process, and processing / converting the placed wire / material after the forming / manufacturing / printing / weaving process to form a medium with a desired purpose / function.

[0206] The present invention also provides the following multiple structural components:

[0207] Volume Contact:

[0208] A device (electrode) comprises: a volume contact occupying a predetermined volume, the volume contact having a porous structure, the porous structure having a plurality of conductive surfaces therein, for facilitating the transmission of an electronic signal to / receiving an electronic signal from a fluid environment through the volume within the volume contact. :

[0209] The plurality of conductive surfaces of the volume contact have a cumulative conductive surface area greater than a cross-sectional area of ​​the volume contact.

[0210] The volume contact is formed / integrated in the body / shell of the electrode, forming a cavity / hollow portion in the body / shell of the electrode.

[0211] The volume protruding from the surface of the body / casing of the electrode contacts to form a protrusion / bump of the porous structure.

[0212] The volume contact has a protruding portion and an inner portion.

[0213] The porous structure and multiple conductive surfaces are made of various materials and combinations.

[0214] The shape of the volume contact can be any possible shape.

[0215] Each volume has a different capacitive charge value.

[0216] The electrode has multiple volume contacts.

[0217] A system comprising the electrode as described above, having a stimulation signal generator and / or a signal reader / decoder:

[0218] Volume sharing:

[0219] An electrode has a first contact and a second contact, wherein the electrode has a structure occupying a defined space (surface or volume) to form a conductive surface with multiple gaps in the first contact, and the second contact has at least one conductive surface, which is at least partially staggered with the first contact to occupy at least one of the multiple gaps within the structure of the first contact, so that there is no direct electrical contact between the at least one conductive surface of the second contact and the multiple contact surfaces of the first contact.

[0220] The second electrode has a structure occupying a defined space, forming a plurality of conductive surfaces having a plurality of voids, such that at least some of the plurality of conductive surfaces of the first contact are disposed within at least some of the plurality of voids of the structure of the second electrode, and at least some of the plurality of conductive surfaces of the second contact are disposed within at least some of the plurality of voids of the structure of the first contact.

[0221] The first contact and / or the second contact occupies a space defining a volume / space / line / block / point.

[0222] The second contact is completely interlaced with the first contact

[0223] The second contact and the first contact have an interleaved / shared space, and each has an independent space that is not interleaved with another electrode structure.

[0224] At least one of the plurality of contacts is a stimulation contact, and one of the plurality of contacts is a recording contact.

[0225] The plurality of staggered contacts are arranged to form a staggered contact cascade.

[0226] · A plurality of structures of said plurality of interleaved contacts.

[0227] - A plurality of materials of the plurality of structures.

[0228] A system comprises the electrode as described above, wherein the electrode has a stimulation signal generator and / or a signal reader / decoder.

[0229] The system is configured to select between a plurality of staggered contacts for directional modification.

[0230] • The system is configured to intermittently select between interleaving stimulation contacts and recording contacts.

[0231] A method of using a device / system as described above

[0232] Choose between multiple staggered contacts for directional modification.

[0233] Intermittently choose between interleaving stimulation contacts and recording contacts.

[0234] Contact placement:

[0235] An electrode having a plurality of guide marks on the surface of the electrode, the plurality of guide marks having a predefined / known spacing therebetween and configured to facilitate measuring a distance from a reference point on the electrode:

[0236] The plurality of guide marks are patterns of a plurality of wires / a plurality of wire bends / a plurality of weaves of the material forming the electrode.

[0237] A weaving structure and how to measure the distance.

[0238] Multiple alternative configurations and multiple measurement options.

[0239] Perform a function based on the measured distance: place an electrode, expose a contact, lay down masking material.

[0240] A method of measuring the distance to a reference point on an electrode using a plurality of guide marks on the surface of the electrode:

[0241] The method is applied during the formation of a plurality of specific layers in the electrode.

[0242] · The method is applied in a weaving process.

[0243] Placement of Materials:

[0244] A method of manufacturing / constructing / making / fabricating an electrode, comprising: placing a plurality of materials at predetermined locations within the electrode structure at predetermined times during the manufacturing process, and processing / converting the plurality of placed materials at a later stage to form a medium for achieving a desired property / function:

[0245] The disposed material comprises a plurality of wires.

[0246] The desired property / function is robustness.

[0247] The required functionality is isolation between at least two contacts.

[0248] The desired function is to stand up the electrode structure.

[0249] • The desired function is masking for a number of further manufacturing steps.

[0250] • The desired function is to form a pattern in the electrode.

[0251] The placement of the material is integrated into a weaving process for manufacturing the electrode.

[0252] The terms used in this specification are only used for the purpose of describing a plurality of specific embodiments and are not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" as used in this specification are also intended to include the plural forms. It will be further understood that when the terms "comprises" or "comprising" are used in this specification, it means the presence of the stated plurality of properties, integers, steps, operations, components or compositions, but does not exclude or preclude the presence or addition of one or more other properties, integers, steps, operations, components or compositions or multiple groups of their compositions.

Claims

1. A wire structure, characterized in that: include: (a) a proximal end and a distal end, with an axis of progression from the proximal end to the distal end; and (b) a plurality of vertically aligned wires parallel to the progression axis at the proximal end and configured to each have a plurality of horizontal portions and a plurality of vertical portions, the plurality of horizontal portions being perpendicular to the progression axis and the plurality of vertical portions being parallel to the progression axis, such that a horizontal portion of one wire is configured to pass between the plurality of vertical portions of the other wires to interlock with the plurality of vertical portions of the other wires, wherein a horizontal portion of one or more wires passing between a plurality of vertical portions of the other wires is a bend, and each bend defines a vertical distance along the axis of progression between the proximal end and the distal end; and At least one of the plurality of wires comprises a plurality of conductive portions coated with an electrical insulating layer, and the plurality of conductive portions are exposed at a plurality of predetermined positions to achieve contact at the plurality of predetermined positions.

2. The wire structure according to claim 1, characterized in that A vertical portion of a wire is a warp portion, a horizontal portion of a wire is a weft portion, and at least some of the wires are configured to be a plurality of warps at certain positions and a plurality of wefts at other positions.

3. The wire structure according to claim 1, characterized in that: When multiple wires are converted from warp to weft, the multiple wires form a directional contact; during the multiple weft portions of the multiple wires, the bend of a weft: (i) forms a complete circle, that is, wraps around the entire manufactured interlocking lead or lead core; or (ii) does not form a complete circle, that is, does not wrap around the entire manufactured interlocking lead or lead core, but only wraps around a portion of the warp of the manufactured electrode, and becomes a complete weft, and then converts back to a warp.

4. The wire structure according to claim 1, characterized in that A plurality of horizontal portions of a plurality of wires pass through a vertical portion of at least one other wire to form a bend.

5. The wire structure according to claim 1, characterized in that: The plurality of wires are arranged to form an elongated tubular shape such that the axis of the elongated tubular shape is the axis of progression between the proximal end and the distal end.

6. The wire structure according to claim 2, characterized in that: The plurality of wires are arranged to form an elongated shape such that the axis of the elongated shape is the axis of progression between the proximal end and the distal end, and a horizontal cross-section of the elongated shape includes a plurality of vertical wire portions arranged at a plurality of different radial distances, wherein the plurality of vertical wire portions are configured to be formed by braiding or weaving.

7. The wire structure according to claim 1, characterized in that The conductive portion of the at least one wire is exposed at a plurality of predetermined positions in a plurality of horizontal portions, and a two-dimensional contact is formed at the plurality of predetermined positions.

8. The wire structure according to claim 1, characterized in that A horizontal portion of at least one wire at a plurality of bends forms a three-dimensional structure along and within the wire structure.

9. The wire structure according to claim 1, characterized in that: The conductive portion of the at least one wire is exposed at a plurality of predetermined positions in a plurality of horizontal portions, forming a three-dimensional contact.

10. An interlocking electrode lead, characterized in that: include: a proximal end and a distal end with an axis of progression from the proximal end to the distal end; and at least one electrode contact disposed at the distal end of the electrode lead and connected to the proximal end of the electrode lead with at least one conductor, the electrode contact serving as a connection terminal; The wire structure of any one of claims 1 to 9 is the electrode lead, wherein at least one of the multiple wires includes a conductive filament coated with an electrical insulation layer, and the conductive filament is exposed at multiple predetermined positions to achieve a contact at the multiple predetermined positions; the contact is located at multiple horizontal portions of at least one filament.

11. The electrode lead according to claim 10, characterized in that: The proximal end of the electrode lead is divided into a plurality of distal ends, thereby providing a plurality of connection terminals.

12. The electrode lead according to claim 10, characterized in that: The connecting terminal has a planar structure.

13. The electrode lead according to claim 10, characterized in that: The electrode lead has a planar structure.

14. The electrode lead according to claim 10, characterized in that: The at least one electrode contact is volumetric such that a mating connector is configured to connect each conductive region as the connection terminal of a single channel in an electronic sensing circuit or an electronic stimulation circuit.

15. The electrode lead according to claim 10, characterized in that: The connection terminal is in the form of a coiled exposed filament wound around the circumference of the electrode lead, forming a plurality of independent connection terminals that do not contact each other.

16. The electrode lead according to claim 10, characterized in that: A plurality of contacts are disposed at the proximal end of the electrode lead and are separated by a plurality of non-conductive regions to prevent electrical shorts from forming between the plurality of contacts.

17. The electrode lead according to claim 16, characterized in that: Each of the plurality of contacts is connected to an electrode contact at the distal end of the electrode lead by a conductor.

18. The electrode lead according to claim 10, characterized in that: The connection terminal is configured to be connected to a mating connector on one side and to be connected to the electrode contact through an electrode conductor on the other side.

19. The electrode lead according to claim 18, characterized in that The same wire forms the electrode contact and the electrode conductor.

20. The electrode lead according to claim 10, characterized in that The electrode lead is made of a plurality of interlocking non-conductive filaments, and at least one conductive wire is arranged in a predetermined outer surface, thereby providing a directional contact surface.

21. The electrode lead according to claim 10, characterized in that The electrode lead is made of a plurality of interlocking wires having at least one conductive filament exposed at a plurality of predetermined locations in a plurality of horizontal portions and forming at least one three-dimensional contact.

22. The electrode lead according to claim 21, characterized in that At least one conductor within each three-dimensional contact is not wrapped all the way around the circumference of the electrode lead so that multiple regions of the at least one conductor are arranged in a configuration that cancels out other regions of the same conductor, thereby reducing electromagnetic interference.

23. The electrode lead according to claim 21, characterized in that At least some of the plurality of interlocked wires run along the longitudinal direction of the interlocked electrode lead, while others terminate along the way, thereby reducing the diameter of the electrode lead.

24. A wire interlocking machine for manufacturing an interlocking wire electrode, characterized in that: The wire interlocking machine comprises: (a) a plurality of wire carriers, each wire carrier being configured to hold a desired wire, at least one of the plurality of wire carriers having a conductive core coated with a non-conductive material; and (b) at least two intersecting track sections, each section having: (i) a vertical track to limit a vertical movement range of a wire carrier; and (ii) a horizontal track defining a horizontal range of movement of a wire carrier, such that the vertical track and the horizontal track intersect along the longitude of the vertical track and the horizontal track to facilitate a change in movement of the wire carrier between the vertical track and the horizontal track, and the plurality of cross-track segments are arranged horizontally to facilitate movement of the wire carrier from a horizontal track of one cross-track segment to a horizontal track of another segment; (c) a wire base configured to hold a plurality of wires at a distal end of the wire base such that the plurality of wires are stretched from the wire carrier to the wire base; (d) at least one actuator for moving the plurality of wire carriers and moving the wire base; (e) at least one means for exposing the conductive core of the wire; (f) a control unit; and (g) The wire interlocking machine is used to prepare the wire structure described in any one of claims 1 to 9 or the electrode lead described in any one of claims 10 to 23.

25. The wire interlocking machine of claim 24, wherein: The wire interlocking machine is a radial braiding machine.

26. The wire interlocking machine of claim 25, wherein: The vertical track includes a plurality of predetermined locations for anchoring the wire carrier.

27. The wire interlocking machine of claim 24, wherein: The wire material in step (e) comprises filaments.

28. A wire interlocking machine as claimed in any one of claims 24 to 27, characterised in that The actuator moves each wire carrier from one position to another independently of the other wire carriers.

29. A wire interlocking machine as claimed in any one of claims 24 to 27, characterised in that The control unit is designed to: (a) receiving data regarding the length of the electrodes and the braid pattern and the plurality of locations of the plurality of exposed filaments; (b) controlling the movement of the plurality of wire carriers from one station to another; (c) controlling the movement of the shuttle; and (d) controlling activation of the plurality of means for exposing the conductive core of the filament.

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