Cochlear Implant Electrode Array Molding Without Acid Etching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods of manufacturing electrode arrays for implantable cochlear stimulation systems are susceptible to issues such as the use of harsh chemicals, production delays, and the creation of uneven contact surfaces that can lead to biofilm growth and varying electrical impedances.
Innovation Solution
A method involving the use of a mold with a truncated circle shape to form a flexible body with electrically conductive contacts, eliminating the need for welded masks and acid etching, and producing a smooth surface that reduces biofilm growth and impedance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded masks and acid etching are used to mask contacts during molding, then contacts can be protected from resilient material, but the process requires harsh chemicals, produces uneven contact surfaces, and causes production delays
Solution Approach 1:
The mold cavity is pre-configured with masking surfaces that automatically protect contact surfaces during the molding process. The maskable surface in the mold cavity serves as a preliminary protective structure, eliminating the need for post-manufacturing masking steps and acid etching processes.
Solution Approach 2:
The invention extracts and eliminates the harmful masking steps (welded masks and acid etching) from the manufacturing process. By integrating the masking function directly into the mold cavity structure, the problematic separate masking and etching operations are removed, reducing production time and eliminating chemical usage.
2Reliability
If welded masks are used to protect contacts, then contacts are masked during molding, but the masks create uneven contact surfaces with granulations that promote biofilm growth
Solution Approach 1:
The mold cavity is pre-configured with masking surfaces that automatically protect contact surfaces during the molding process. The maskable surface in the mold cavity serves as a preliminary protective structure, eliminating the need for post-manufacturing masking steps and acid etching processes.
Solution Approach 2:
The invention uses a disposable or easily replaceable mold cavity with integrated masking surfaces rather than reusable welded masks. This eliminates the need for repeated mask application and removal, ensuring consistent smooth contact surfaces without granulations that would promote biofilm growth.
3Ease of manufacture
If acid etching is used to remove masks, then contact surfaces are exposed, but the process takes approximately 8 hours and requires harsh chemicals
Solution Approach 1:
The invention extracts and eliminates the harmful masking steps (welded masks and acid etching) from the manufacturing process. By integrating the masking function directly into the mold cavity structure, the problematic separate masking and etching operations are removed, reducing production time and eliminating chemical usage.
Solution Approach 2:
The mold cavity's maskable surface automatically performs the masking function during molding, and the design allows for easy removal or reuse of the mold itself. The system serves its own masking and unmasking needs through the integrated mold design, eliminating the need for separate chemical etching processes.
Data Source
AI summary
A method of forming an electrode array includes the steps of positioning a workpiece on a mold part defining an opening and a channel and having undercuts, compressing the workpiece into the mold part to form a contact, and introducing resilient material into the mold part to form a flexible body.