Integrated Wire Carrier for Cochlear Electrode Array
Solution Overview
Problem
Managing the delicate wires in cochlear implant systems is challenging due to their small diameter, which can lead to damage and performance issues during manufacturing and surgical insertion, particularly in maintaining wire organization and preventing kinking.
Innovation Solution
An integrated wire carrier is introduced to manage and protect the wires, providing a structured pathway and markers for precise insertion depth, reducing the risk of wire damage and kinking, and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the wire diameter is reduced to minimize trauma to the patient, then the invasiveness is reduced, but the wires become more susceptible to damage and kinking during manufacturing and insertion
Solution Approach 1:
The wire is nested within a protective carrier structure that provides mechanical support and prevents kinking. The carrier acts as a protective sheath that maintains wire integrity while allowing the thin wire to pass through the cochlea with minimal trauma.
Solution Approach 2:
The carrier serves as an intermediary structure between the wire and the external environment. It provides the necessary mechanical strength and protection during handling and insertion, while the wire itself remains thin to minimize patient trauma.
2Object-affected harmful factors
If the wire diameter is reduced to minimize trauma, then patient comfort is improved, but maintaining wire organization becomes more difficult
Solution Approach 1:
Multiple wires are nested within a common carrier structure that maintains their organization. The carrier provides a structured pathway that keeps wires separated and ordered, preventing tangling and making assembly easier despite the thin wire dimensions.
3Reliability
If a protective structure is added to manage the wires, then wire protection is improved, but the device complexity increases
Solution Approach 1:
The wire carrier is merged with the electrode array structure, creating an integrated assembly. This combination provides wire protection while maintaining a compact, unified device that does not significantly increase overall complexity.
Solution Approach 2:
The carrier structure serves multiple functions: it protects the wire from damage, maintains wire organization, provides structural support, and facilitates controlled insertion. This multi-functionality justifies the added structure by delivering multiple benefits from a single component.
4Measurement precision
If markers are added to indicate insertion depth, then surgical precision is improved, but the device complexity increases
Solution Approach 1:
Radio-opaque markers are incorporated into the carrier structure to provide visual indication of insertion depth during surgery. These markers enable precise positioning while maintaining a relatively simple overall device design.
Data Source
Figure 1
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Figure 4
AI summary
A cochlear lead (190) includes a plurality electrodes (465, 470) to stimulate an auditory nerve (160) from within a cochlea (150) and a plurality of wires (455) configured to connect the plurality of electrodes (465, 470) to an internal processor (185). An integrated wire carrier (605) with a cavity (607) along its longitudinal axis is configured to contain the plurality of wires (455) and shape the plurality of wires (455) into a wire bundle; and a flexible body (475) encapsulating the integrated wire carrier (605) and the plurality of wires (455).