Flexible Implantable Electrode Array with Embedded Control Modules
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Solution Overview
Problem
Existing implantable electrode arrays face challenges with conductor stress and breakage due to flexing, particularly when embedded with semi-conductor die packages, leading to potential malfunction from mechanical vibrations and tissue movement.
Innovation Solution
The electrode array design incorporates control modules seated in windows within a flexible carrier, with vias and conductors optimized for flexibility, reducing mechanical stress and the likelihood of breakage by using thin, short vias and conductors, and a biocompatible material package for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control modules are embedded in the carrier with traditional conductor configurations, then the array provides functional control capability, but the conductors are subjected to high mechanical stress and breakage from flexing and tissue movement
Solution Approach 1:
The patent employs thin, flexible conductor traces patterned directly onto the carrier substrate, replacing traditional rigid wire conductors. These thin-film conductors flex with the carrier and surrounding tissue, dramatically reducing mechanical stress and breakage while maintaining electrical connectivity to the control modules embedded in the carrier.
Solution Approach 2:
The patent replaces mechanical wire-based conductor connections with integrated circuit traces formed through semiconductor fabrication processes. This substitution eliminates the need for discrete wire bonds that are susceptible to mechanical failure, using instead etched or deposited conductive pathways that are inherently more resistant to flexing and movement-induced stress.
2Reliability
If traditional packaging methods are used for control modules, then the modules are protected, but the conductors remain vulnerable to stress concentration at connection points
Solution Approach 1:
The patent merges the control module packaging with the carrier structure itself, embedding the control modules directly into recesses or windows in the carrier. This integration eliminates separate packaging layers and conductor connection points that would create stress concentrations, allowing conductors to transition smoothly from the control modules to the flexible carrier without sharp bends or rigid interfaces.
3Adaptability or versatility
If numerous conductors are used to connect control modules, then complete control functionality is achieved, but the complexity of the array increases and minimally invasive implantation becomes more difficult
Solution Approach 1:
The patent implements a multi-functional conductor network where a single flexible trace system serves multiple purposes: providing electrical connectivity to numerous control modules, maintaining mechanical flexibility, and enabling minimally invasive implantation. The integrated trace architecture allows one conductor system to fulfill what would traditionally require multiple separate wiring harnesses, thereby reducing overall device complexity while preserving complete control functionality.
Data Source
AI summary
An implantable electrode array is provided that includes a carrier that is flexible. At least one control module is coupled to the carrier. A shell encases the control module. At least one electrode is coupled to the carrier and is electrically connected to the control module.