Electrode Structure with Laser-Structured Contact Paths
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Solution Overview
Problem
Existing methods for producing electrode structures, such as cochlear electrodes, face challenges in creating high-quality structures with distinct electrodes and contact paths that are efficiently connected over a spatial distance, while maintaining mechanical strength and flexibility, and ensuring biocompatibility.
Innovation Solution
A process involving the formation of a longitudinal body with a core and an electrode material layer, where the layer is structured to create separate electrodes and contact paths, which are then embedded in a polymeric material, allowing for seamless integration and enhanced mechanical properties, using techniques like ultra-short pulse lasers for precise removal and polymeric materials for insulation and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrodes and contact paths are created using conventional structuring methods, then basic electrode formation is achieved, but manufacturing precision and quality of distinct electrode separation deteriorates
Solution Approach 1:
A release structure is formed on the core before applying the electrode material layer. This preliminary action creates a predefined pattern that guides subsequent material deposition and structuring, enabling precise electrode separation without complex post-processing steps. The release structure acts as a template that simplifies the overall manufacturing process while achieving high manufacturing precision.
Solution Approach 2:
A release structure serves as an intermediary element between the core and the electrode material layer. This intermediary component enables precise pattern transfer and facilitates clean separation of electrodes during processing. The release structure mediates the interaction between the core geometry and the electrode material, ensuring high manufacturing precision without requiring complex direct structuring methods.
2Reliability
If electrodes are connected over spatial distance, then electrical connectivity is achieved, but mechanical strength and flexibility deteriorates
Solution Approach 1:
The electrode material layer is selectively structured to provide different properties in different regions. Contact paths are designed with optimized geometry and material distribution to balance electrical conductivity and mechanical flexibility. The structuring process creates local variations in material density and composition, allowing long contact paths to maintain both electrical connectivity and mechanical strength through region-specific property optimization.
3Reliability
If electrode material layer is fully applied for coverage, then complete insulation is achieved, but material usage and cost increases
Solution Approach 1:
The electrode material layer is segmented into functionally distinct regions through selective structuring. Instead of applying a continuous uniform layer, the material is deposited and structured to form discrete electrodes and contact paths. This segmentation eliminates unnecessary material in non-functional areas while maintaining complete insulation where required, reducing overall material usage without compromising insulation quality.
Solution Approach 2:
The thickness and distribution of the electrode material layer are varied spatially according to functional requirements. The structuring process creates regions of different material density and thickness, providing adequate insulation in critical areas while minimizing material usage in less demanding regions. This parameter optimization achieves complete insulation quality with reduced total material consumption.
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 process enables the production of high-quality electrode structures with improved mechanical strength, flexibility, and biocompatibility, suitable for applications in the human body, including cochlear implants and deep brain stimulation, with enhanced electrical connectivity and reduced risk of damage or contamination.
Implementation Method 1
selective removal of the electrode material using techniques like ultra-short pulse lasers
Implementation Method 2
selective removal of the electrode material using techniques like ultra-short pulse lasers or photochemical processes
Data Source
AI summary
One aspect relates to a method of producing an electrode structure, including producing a longitudinal body having a core and at least one layer made of an electrode material surrounding the core. A part of the layer made of electrode material is removed while forming a plurality of electrodes that are arranged such as to be distributed in the longitudinal direction and which are separated from each other, and contact paths that extend in the longitudinal direction and adjoin the electrodes, each, as the same part. A layer made of a polymeric material is applied while embedding, at least in part, the electrodes and/or contact paths.