Tension-Controlled Electrode Winding for Fine Nerve Inserters
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Solution Overview
Problem
There is no efficient and reliable method for fabricating a delivery system for electrodes sized and dimensioned to record, measure, and/or stimulate very fine nerve structures, such as those in the microscale or smaller, for intra-fascicular or deep brain applications.
Innovation Solution
A method involving securing the electrode tip to a proximal portion of an inserter, winding the electrode around it while maintaining tension, and securing it to a distal portion, which can be automated to ensure reproducible and reliable fabrication of electrode delivery systems, including multiple channel interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrodes are sized and dimensioned to microscale or smaller for insertion into very fine neural structures, then the ability to record, measure, and stimulate fine neural structures is improved, but the difficulty of fabricating a delivery system increases
Solution Approach 1:
The delivery system is segmented into distinct functional components: a sharp needle for tissue penetration, a separate electrode assembly with multiple contacts, and a deployment mechanism. This segmentation allows each component to be optimized independently for its specific function while simplifying the overall fabrication process.
Solution Approach 2:
A biodegradable polymer coating serves as an intermediary between the electrode and the neural tissue. This coating provides a controlled interface that protects the electrode during insertion and delivery, then degrades over time to allow direct electrode-tissue contact for optimal recording and stimulation performance.
2Manufacturing precision
If electrodes are made with diameter of 100 μm or less for very fine nerve structures, then the precision for targeting fine structures is improved, but the reliability of delivery system fabrication deteriorates
Solution Approach 1:
Traditional mechanical winding and attachment methods are replaced with a deployment mechanism that uses controlled mechanical expansion or dissolution of a temporary holding structure. This substitution provides more reliable and reproducible electrode positioning without the variability inherent in manual or semi-automated winding processes.
Solution Approach 2:
The fabrication process utilizes parameter changes in the biodegradable polymer coating, transitioning from a solid protective state during delivery to a degraded state after implantation. This parameter change enables automatic electrode deployment and secure positioning, improving fabrication reliability.
3Extent of automation
If electrodes are wound around an inserter during fabrication, then the ease of automated fabrication is improved, but the complexity of maintaining tension and positioning increases
Solution Approach 1:
The electrode is pre-coated with biodegradable polymer material before the winding process. This preliminary action simplifies the winding operation by providing a self-adhering surface that maintains electrode position without requiring complex tension control systems during fabrication.
Solution Approach 2:
The biodegradable polymer coating performs multiple functions automatically: it adheres the electrode to the inserter during fabrication, protects the electrode during insertion, and then degrades to release and position the electrode at the target site. This self-service approach reduces the need for complex external control systems.
Data Source
AI summary
A method for fabricating electrodes sized and dimensioned to record, measure, and/or stimulate very fine nerve structures (e.g., microscale or less) is described herein. The method can include securing a tip of an electrode, comprising a conductor substantially encased by an insulator, to a proximal portion of an inserter. The electrode can be wound around a proximal portion of the inserter and a portion of the electrode can be secured to a distal portion of the inserter. A tension in the electrode can be maintained during the winding to keep the electrode in place during the winding.