Flexible Electrode Arrays with Spring-like Traces

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Solution Overview

Problem

Conventional electrode arrays are limited in their ability to interface with three-dimensional tissue, fail to penetrate tougher tissues like muscle, and are not adaptable to non-linear biological contours, leading to mechanical failures such as folding, buckling, and loss of contact.

Innovation Solution

A medical electrode array system featuring a thin-film substrate with flexible electrode contacts and spring-like traces that can deform to maintain contact with curvilinear biological tissues, incorporating a flexible ribbon cable for electrical connectivity and mechanical flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional rigid electrode arrays are used, then manufacturing precision and structural stability are improved, but adaptability to non-linear biological contours and reliability under tensile loads deteriorate

Engineering Contradiction:

Improveelectrode contact positioning precisionVSAvoidadaptability to non-linear biological contours

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs a thin-film substrate with integrated flexible traces and electrode contacts that can conform to curved and non-linear biological surfaces. The flexible nature of the thin-film allows the array to adapt to anatomical contours while maintaining precise electrode positioning through controlled flexing, resolving the contradiction between manufacturing precision and adaptability to non-linear contours.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The electrode array is designed with flexible components that can dynamically adjust their shape and position in response to tissue movement and deformation. The flexible traces and thin-film substrate enable the array to move and deform with the underlying tissue, maintaining reliable contact while preserving electrode positioning accuracy through elastic deformation rather than rigid structure.

Inventive Principle:

Principle #15Dynamics

2Stability of the object's composition

If conventional rigid electrode arrays are used, then structural stability is improved, but reliability under tensile loads deteriorates due to folding, buckling, and twisting

Engineering Contradiction:

Improvestructural stabilityVSAvoidreliability under tensile loads

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The thin-film substrate and flexible trace design replace rigid structures with compliant materials that can withstand tensile loads through elastic deformation. The flexible construction prevents folding, buckling, and twisting by allowing the array to stretch and deform with the tissue, maintaining structural integrity and reliable electrical contact under mechanical stress.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the mechanical parameters of the electrode array by using flexible materials with appropriate elastic properties. The thin-film substrate and flexible traces are designed with specific mechanical characteristics that allow them to deform under tensile loads without permanent deformation, folding, or buckling, thereby maintaining reliability while preserving structural stability through controlled elastic behavior.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional electrode arrays are used, then ease of manufacture is improved, but adaptability to three-dimensional tissue arrangement deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthree-dimensional tissue interface capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The thin-film substrate with integrated flexible traces and electrode contacts can be manufactured using standard flexible PCB or thin-film fabrication techniques, maintaining ease of manufacture. The flexible nature of the array allows it to be configured in three-dimensional arrangements that conform to complex tissue geometries, enabling 3D tissue interface capability without significantly complicating the manufacturing process.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The system provides reliable electrical and mechanical contact with moving tissues, maintaining stability under tensile loads and natural anatomical deformations, enabling effective tissue stimulation and sensing.

Implementation Method 1

The plurality of traces may include flexible spring-like portions to add flexibility to the thin-film substrate

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11602630B2Systems and methods for flexible electrode arrays

Publication Date: 2023.03.14 NEURONEXUS TECHNOLOGIES INC

AI summary

A medical electrode array system comprising a thin-film substrate, a plurality of electrode contacts disposed on the thin-film substrate, and a plurality of traces. The plurality of electrode contacts is configured to provide electrical contact points. The plurality of traces is electrically connected to the plurality of electrode contacts. A electrode contact of the plurality of electrode contacts has a dedicated trace of the plurality of traces that provides electrical connectivity to the electrode contact. The thin-film substrate is configured to flex to maintain continuous contact with contours of patient anatomy. The plurality of traces includes flexible spring-like portions to add flexibility to the thin-film substrate.