Braze-Bonded Neural Electrode Array for Stable Tissue Contact
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Solution Overview
Problem
Existing electrode devices for neural interfaces are limited in their ability to establish stable, non-destructive electrical contact with a large number of individual nerve fibers, often causing tissue damage during insertion and experiencing instability due to bulkiness and limited electrode density, which restricts long-term implantation and precise signal targeting.
Innovation Solution
A bed-of-nails electrode array with sharp, conductive needles of varying lengths and spacings, anchored to a substrate via a braze joint, allowing for minimal tissue disruption and stable, focused contact with multiple nerve fibers, while being designed for hermetic sealing to accommodate electronic signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple needle electrodes are employed to contact individual nerve fibers, then the number of electrical contacts increases, but the device complexity and difficulty of implantation increase progressively
Solution Approach 1:
The electrode array is segmented into multiple individual needle electrodes (typically 19-49 needles) arranged in a grid pattern on a substrate, allowing each needle to contact individual nerve fibers independently while maintaining an organized, manageable structure that reduces implantation complexity
Solution Approach 2:
The electrode array transitions from one-dimensional linear arrays to two-dimensional grid patterns, enabling significantly increased electrode density and contact capability while maintaining a compact form factor that simplifies handling and implantation procedures
2Measurement precision
If needle electrodes are used to contact individual nerve fibers, then specific nerve fiber contact is achieved, but long-term stability is compromised due to tissue motion and leverage effects
Solution Approach 1:
Multiple individual needle electrodes are merged into a single integrated array structure mounted on a rigid substrate, providing mechanical stability and preventing individual needle displacement while maintaining precise electrical contact with multiple nerve fibers simultaneously
Solution Approach 2:
The electrode array creates multiple copies of the needle electrode structure in a systematic arrangement, allowing redundant contact points that maintain stable electrical connections even when individual contacts experience minor tissue motion or displacement
3Object-affected harmful factors
If a prong-shaped base with flat electrodes is used, then tissue damage during insertion is reduced, but electrode contact area with neural tissue is limited
Solution Approach 1:
The needle electrodes are designed with curved or beveled tips rather than flat surfaces, enabling penetration into neural tissue with minimal damage while creating point contacts that achieve focused electrical contact with individual nerve fibers, effectively increasing functional contact area despite reduced physical footprint
4Quantity of substance
If electrode density is increased to contact more nerve fibers, then sensing and stimulation capability improves, but device bulkiness increases limiting long-term implantation
Solution Approach 1:
The electrode array utilizes thin substrate materials (such as flexible circuits or thin rigid plates) to support high-density electrode arrangements, minimizing the overall device volume and profile to reduce mechanical burden on implanted tissue while maintaining high electrode density for enhanced neural interface capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The electrode array achieves stable, long-term electrical contact with a large number of nerve fibers with minimal tissue damage, enabling effective sensing and stimulation, and is robust enough to withstand movement, with the hermetic design protecting electronic components.
Implementation Method 1
bonding said electrically conductive electrode to each of said at least two feedthroughs by a brazing process
Data Source
AI summary
The electrode array is a device for making electrical contacts with cellular tissue or organs. The electrode array includes an assembly of electrically conductive electrodes arising from a substrate where the electrodes are hermetically bonded to the substrate. A method of manufacture of an electrode array and associated circuitry is disclosed where the braze preform tab disappears during the braze bonding process and is completely drawn into the substrate feedthrough holes such that the braze perform tab is completely involved in the braze joint and is no longer connecting the adjacent electrodes.