Flexible Circuit Electrode Array with Tack Opening for Retinal Stimulation
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Solution Overview
Problem
Existing electrode arrays for neural stimulation, particularly for retinal prostheses, face challenges in achieving mechanical stability, minimizing pressure on neural tissue, and preventing tissue damage due to their flat design, which can lead to increased electrical resistance and potential retinal ischemia or hemorrhage.
Innovation Solution
A flexible circuit electrode array is designed with a curved shape to match the spherical retina, featuring a tack opening and additional material along the edges for compliance, and a fold or twist at the sclera interface to reduce pressure and promote a secure seal, using thermoplastic polymers and metal layers for improved adhesion and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat electrode array design is used, then the device structure is simple, but the electrical resistance increases and tissue damage risk increases
Solution Approach 1:
The electrode array is designed with a curved configuration that matches the spherical geometry of the retina. This curvature enables the electrodes to conform to the retinal surface, maintaining close contact and reducing electrical resistance while preserving structural simplicity through the use of flexible circuit board materials.
2Ease of manufacture
If a flat electrode array is used, then manufacturing is easier, but pressure on neural tissue increases causing ischemia or hemorrhage
Solution Approach 1:
The electrode array employs a flexible circuit board constructed from thin film materials that can bend and conform to the curved retinal surface. This flexibility distributes the mechanical pressure evenly across the implant site, preventing localized high-pressure zones that could cause retinal ischemia or hemorrhage, while maintaining ease of manufacture through standard flexible PCB fabrication processes.
3Object-affected harmful factors
If additional material is added along the edges for compliance, then tissue damage is prevented, but device complexity increases
Solution Approach 1:
The electrode array integrates regions of varying material compliance within the flexible circuit board structure. Softer, more compliant materials are strategically placed along the edges to cushion and protect the retinal tissue, while the central region maintains standard flexibility for electrical functionality. This composite approach prevents tissue damage without significantly increasing overall device complexity.
Data Source
AI summary
The present invention provides a flexible circuit electrode array adapted for neural stimulation, comprising: a polymer base layer; metal traces deposited on said polymer base layer, including electrodes suitable to stimulate neural tissue; a polymer top layer deposited on said polymer base layer and said metal traces at least one tack opening; wherein said polymer base layer, said metal traces and said polymer top layer are thermoformed in a three dimensional shape.The present invention provides further a method of making a flexible circuit electrode array comprising depositing a polymer base layer; depositing metal on said polymer base layer; patterning said metal to form metal traces; depositing a polymer top layer on said polymer base layer and said metal traces; preparing at least one tack opening; and heating said flexible circuit electrode array in a mold to form a three dimensional shape in said flexible circuit electrode array.