Flexible Electrode Array with Silicone Notch Carrier for Cochlear Trauma Reduction

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Solution Overview

Problem

Cochlear implant electrode arrays face challenges in minimizing trauma to the cochlea during insertion due to their rigid structure, which does not adapt to the varying curvature of the cochlea, leading to potential damage and inefficiency in stimulating auditory nerve fibers.

Innovation Solution

The electrode array features a silicone notch carrier with varying opening angles and bending radii, allowing for non-uniform flexibility along its length, specifically designed to match the curvature of the cochlea, and includes a micro transducer to adjust these parameters for optimal insertion and reduced trauma, using Electro Active Polymer (EAP) materials for controlled curvature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid electrode array structure is used, then structural strength and stability are improved, but trauma to the cochlea during insertion increases and adaptability to cochlear curvature deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidtrauma to cochlea

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The electrode array employs a flexible carrier made of thin film material that can bend and conform to the curved surface of the cochlea. This flexible structure reduces insertion trauma while maintaining structural integrity through the distributed electrode design and appropriate material selection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The electrode array is divided into multiple discrete electrode contacts along the carrier, allowing each segment to independently adapt to the cochlear curvature. This segmentation enables the structure to flex without compromising the functional integrity of individual electrodes while reducing overall rigidity.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a rigid electrode array structure is used, then manufacturing simplicity is improved, but adaptability to varying cochlear curvature deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidadaptability to cochlear curvature

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The carrier is constructed from flexible thin film material that inherently adapts to the cochlear geometry. This approach maintains manufacturing simplicity through standard flexible substrate fabrication techniques while achieving the required adaptability to varying cochlear curvatures across different patients.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexibility and curvature adaptation of the electrode array are achieved by controlling the physical parameters of the carrier material, such as thickness, elastic modulus, and dimensional specifications. These parameter variations allow customization for different cochlear sizes and curvatures without fundamentally changing the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If uniform flexibility is applied along the electrode array, then manufacturing simplicity is improved, but performance in matching varying cochlear curvature deteriorates

Engineering Contradiction:

Improvemanufacturing uniformityVSAvoidcurvature matching performance

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The electrode array features non-uniform flexibility distribution along its length, with varying degrees of flexibility in different regions to match the changing curvature of the cochlea. This is achieved through localized variations in carrier thickness, material composition, or structural features such as notches or hinges at specific positions along the array.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrode array incorporates dynamic flexibility characteristics that allow different regions to bend at different rates and angles during insertion. This dynamic behavior enables the array to progressively conform to the three-dimensional cochlear structure, with more flexible regions adapting to tighter curvatures while stiffer regions maintain positional stability.

Inventive Principle:

Principle #15Dynamics

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 design reduces the risk of trauma during insertion and improves the flexibility of the electrode array, allowing for better stimulation of auditory nerve fibers by adapting to the cochlear shape, thereby enhancing the effectiveness of cochlear implantation.

Implementation Method 1

using Electro Active Polymer (EAP) materials for controlled curvature

Methodology Applied

Scientific EffectElectro Active Polymer: Electroactive Polymer

Data Source

PatentUS11980754B2Cochlear implant device with a flexible electrode array

Publication Date: 2024.05.14 COCHLEAR LIMITED

AI summary

The disclosure relates to an electrode array that comprises a first region including a first group of electrodes of a plurality of electrodes and a second region including a second group of electrodes of the plurality of electrodes, where a silicone notch carrier is arranged between the electrodes of the second group, and where each of the silicone notch carrier includes a notch that is formed into the silicone notch carrier, and when the electrode array is straighten each notch has an opening angle and/or a bending radius which varies between the silicone notch carriers.