Method of manufacturing nerve electrode
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Solution Overview
Problem
Existing nerve electrodes lack sufficient flexibility and biocompatibility, leading to issues such as tissue damage, inflammation, and mechanical mismatch with nerve tissues, which affect their ability to sense nerve signals effectively over a long period.
Innovation Solution
A manufacturing method involving electrospinning poly(amic acid) to create a fibrous sheet, followed by heat-treating it to form a polyimide sheet, thermal compression, inkjet printing a conductive ink, and heat-treating the printed ink to form a nerve electrode with high porosity and flexibility, optionally incorporating an anti-fibrotic drug.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid substrate (silicon, polymeric substrates) is used for nerve electrode, then structural stability is improved, but flexibility and biocompatibility deteriorate due to mechanical mismatch with nerve tissue
Solution Approach 1:
The patent changes the physical and chemical parameters of the substrate material by using electrospun nanofibers with controlled pore size, fiber diameter, and porosity. This transforms the substrate from a rigid structure to a flexible, porous network that can dynamically adapt to nerve tissue movement while maintaining structural integrity for electrode functionality.
Solution Approach 2:
The patent creates a composite structure combining conductive materials (for electrode functionality) with flexible, porous polymer nanofibers (for mechanical compliance). This composite approach allows the electrode to simultaneously achieve electrical conductivity and mechanical flexibility matching nerve tissue properties.
2Strength
If a dense, non-porous substrate is used for nerve electrode, then structural integrity is improved, but nutrient diffusion and waste removal deteriorate due to blocked mass transport
Solution Approach 1:
The patent employs a porous nanofiber substrate with controlled pore sizes and high porosity. This porous structure enables efficient diffusion of nutrients, oxygen, and metabolic waste products between the electrode and surrounding nerve tissue, preventing ischemia and improving long-term biocompatibility while maintaining structural integrity through the nanofiber network.
3Ease of manufacture
If a smooth, non-porous surface is used for nerve electrode, then manufacturing simplicity is improved, but cell attachment and tissue integration deteriorate due to reduced surface area and poor adhesion
Solution Approach 1:
The patent segments the substrate surface into numerous nanoscale fibers with high surface area to volume ratio. This segmentation creates a three-dimensional nanofiber network that provides abundant attachment sites for cells and tissue ingrowth, significantly improving tissue integration and electrode reliability compared to smooth surfaces.
Solution Approach 2:
The patent transitions from a two-dimensional smooth surface to a three-dimensional nanofiber network structure. This dimensional change dramatically increases the effective surface area available for cell attachment and tissue integration, enhancing biological performance while maintaining manufacturing feasibility through electrospinning technology.
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 resulting nerve electrode is thin, flexible, and biocompatible, with reduced inflammation and tissue damage, allowing stable nerve signal sensing for extended periods with low impedance and signal noise ratio.
Implementation Method 1
manufacturing a poly(amic acid) fibrous sheet by electrospinning poly(amic acid)
Implementation Method 2
manufacturing a polyimide fibrous sheet by heat-treating the poly(amic acid) fibrous sheet
Implementation Method 3
thermally compressing the polyimide fibrous sheet
Implementation Method 4
heat-treating the polyimide fibrous sheet on which the conductive ink is inkjet printed
Data Source
AI summary
The present invention relates to a method of manufacturing a nerve electrode in which a conductive ink is inkjet printed on an electrospun polyimide fibrous sheet; and a nerve electrode manufactured by the manufacturing method.