Cochlear Implant Electrode Array Spacing via Silicone Retention

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Solution Overview

Problem

Existing electrode arrays for medical implants, such as cochlear implants, face challenges in maintaining precise longitudinal spacing between electrode contacts, which affects the accuracy and effectiveness of electrical stimulation in the cochlea.

Innovation Solution

A method of forming an elongate comb structure with longitudinally-spaced electrode contacts supported by a spine, where electrically conductive pathways are connected to the contacts, and silicone is used to retain the spacing before severing the spine, ensuring consistent and accurate placement of electrodes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional methods are used to form electrode arrays, then the manufacturing process is simpler, but the longitudinal spacing between electrode contacts cannot be precisely maintained

Engineering Contradiction:

Improvelongitudinal spacing between electrode contactsVSAvoidcomplexity of forming comb structure and severing spine

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The electrode contacts are formed as part of a comb structure with a spine in advance, maintaining precise longitudinal spacing during the forming process. The spine serves as a temporary support structure that preserves the exact spacing between contacts before they are severed and implanted, eliminating the need for complex post-formation alignment procedures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The comb structure is divided into individual electrode contacts by severing the spine after the contacts have been formed and positioned. This segmentation allows each contact to be precisely spaced during the forming process while enabling separation for final implantation, resolving the contradiction between maintaining precision and simplifying the final configuration.

Inventive Principle:

Principle #1Segmentation

2Productivity

If electrode contacts are formed and connected before implantation, then manufacturing is more efficient, but maintaining consistent spacing becomes difficult

Engineering Contradiction:

Improvemanufacturing efficiency of electrode arrayVSAvoidconsistency of longitudinal spacing

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The spine acts as an intermediary structure that maintains the longitudinal spacing between electrode contacts during manufacturing and assembly. By providing a rigid support framework, the spine ensures consistent spacing is preserved throughout the manufacturing process, allowing efficient batch production while maintaining precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The comb structure with precisely spaced contacts is formed in advance as a complete assembly. This preliminary formation of the entire array with all contacts and connections maintains manufacturing efficiency while the rigid spine structure ensures spacing consistency is locked in during the forming process itself.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the spine is removed after forming, then the electrode contacts are ready for implantation, but the spacing may shift during separation

Engineering Contradiction:

Improvereadiness for implantationVSAvoidspacing retention during severing

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The electrode contacts are formed with precise spacing while supported by the spine before any severing occurs. This preliminary formation ensures the exact spacing is established and maintained during the critical forming stage, and the spine remains in place to preserve this spacing until the final implantation stage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spine is severed into segments corresponding to each electrode contact or small groups of contacts. This segmented separation minimizes movement and spacing shifts during the removal process, as each severing action is localized and the rigid spine structure maintains contact positions until the cut is complete.

Inventive Principle:

Principle #1Segmentation

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

This approach allows for the precise retention of longitudinal spacing between electrode contacts, enhancing the accuracy and consistency of electrical stimulation in medical implants like cochlear implants, improving their therapeutic efficacy.

Implementation Method 1

placing silicone over the conductive pathways and contacts; curing the silicone so as to substantially retain the longitudinal spacing between neighboring contacts

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS8955211B2Manufacturing an electrode array for a stimulating medical device

Publication Date: 2015.02.17 COCHLEAR LIMITED

AI summary

A method of forming an electrode array is disclosed, the method comprising: forming an elongate comb structure comprising a plurality of longitudinally-spaced electrode contacts extending from and supported by a spine; electrically connecting each of a plurality of electrically conductive pathways to a respective one of the plurality of electrode contacts; placing the conductive pathways adjacent the contacts; placing silicone over the conductive pathways and contacts; curing the silicone so as to substantially retain the longitudinal spacing between neighboring contacts; and severing the spine from the plurality of electrode contacts.