Flexible Circuit Lead Body for High-Density Segmented Electrodes
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Solution Overview
Problem
Manufacturing independent connections from multiple discrete electrode segments on a small diameter lead body to independent ring contacts at the proximal end is challenging, particularly when a large number of electrode segments are required for precise stimulation or sensing applications within a human body.
Innovation Solution
A method involving a flexible circuit, such as a liquid crystal polymer (LCP) circuit, is used to couple the distal end assembly with segmented electrodes to the proximal end assembly, utilizing a conducting section that is helically wound over an inner member and then fused at the ends with an outer member, allowing for independent electrical connections and flexibility to prevent kinking or breaking under bodily forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent connections are made from each discrete electrode segment to the proximal end, then electrical connectivity is achieved, but manufacturing difficulty increases significantly
Solution Approach 1:
Multiple electrode segments are connected to a single continuous flexible circuit instead of requiring separate connections to the proximal end. The flexible circuit acts as a common conductor that collects signals from multiple electrodes, merging multiple connection paths into one unified structure, thereby simplifying manufacturing while maintaining electrical connectivity.
Solution Approach 2:
The flexible circuit serves as an intermediary component between the electrode segments and the proximal end connector. Rather than connecting each electrode directly to the proximal end, the flexible circuit mediates these connections, providing a flexible intermediate layer that simplifies the overall connection architecture and manufacturing process.
2Measurement precision
If a large number of electrode segments are provided on a small diameter lead, then sensing and stimulation precision is improved, but manufacturing independent connections becomes more difficult
Solution Approach 1:
The flexible circuit introduces a dimensional solution by using a planar, two-dimensional circuit layout to accommodate multiple electrode connections. Instead of attempting to pack multiple independent connections in a limited three-dimensional space around the small diameter lead, the flexible circuit spreads connections across a flexible plane that can be wrapped around or attached to the lead, enabling high electrode density without proportionally increasing manufacturing complexity.
3Reliability
If the lead is made flexible to accommodate bodily forces, then durability is improved, but structural stability may be compromised
Solution Approach 1:
The flexible circuit is constructed using flexible materials and thin-film technology that inherently provide both flexibility and structural integrity. The flexible nature of the circuit allows it to accommodate bodily forces and movements without breaking, while the continuous circuit design and material selection maintain sufficient structural stability to preserve electrical connections and lead composition throughout implantation and operation.
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 enables the creation of leads with a high number of segmented electrodes and corresponding ring contacts in a small diameter, enhancing precision in applications like deep brain stimulation and other therapies while maintaining flexibility and durability.
Implementation Method 1
The outer member and circuit are fused adjacent the distal end assembly to the proximal end assembly
Data Source
AI summary
One aspect is a method of forming a lead for implantation. The method includes forming a distal end assembly, forming a proximal end assembly, and forming a flexible circuit coupling the distal end assembly to the proximal end assembly. The distal end assembly, the proximal end assembly and the flexible circuit are formed over an inner member. An outer member is placed over the combination of the distal end assembly, the proximal end assembly and the flexible circuit. The outer member and circuit are fused adjacent the distal end assembly to the proximal end assembly.