Folded Electrode Array Structure for Higher Implant Electrode Density
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Solution Overview
Problem
Conventional electrode manufacturing for body-implantable devices, such as cochlear implants, is costly and time-consuming due to manual resistance-welding of platinum electrodes and wires, limiting the number of electrodes that can be effectively integrated per unit length.
Innovation Solution
The development of an electrode array with a structured electrode structure that includes contact electrodes, wires, and connection wires, which are integrally formed and patterned using laser technology, allowing for easier manufacturing and increased electrode density by folding the structure to optimize space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual resistance-welding and silicon molding are used to manufacture electrodes, then manufacturing precision can be maintained, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The patent replaces manual resistance-welding (mechanical process) with laser welding (optical/thermal process). The laser welding system uses a laser beam to join electrodes to wires, eliminating the need for manual mechanical welding operations. This substitution enables automated manufacturing while maintaining precise control over the joining process, thereby improving productivity without sacrificing manufacturing precision.
Solution Approach 2:
The patent implements preliminary positioning and fixation of electrodes on the substrate before the welding process. Electrodes are pre-aligned and secured in their final positions, allowing for efficient batch welding operations. This preliminary action eliminates the need for repeated positioning and adjustment during manufacturing, significantly improving productivity while ensuring consistent manufacturing precision across all electrodes.
2Reliability
If manual resistance-welding is used to connect electrodes and wires, then connection reliability can be achieved, but device complexity increases due to multiple discrete components
Solution Approach 1:
The patent merges the electrode, wire, and connection structure into a single integrated assembly. The laser welding process directly joins the wire to the electrode substrate in one operation, eliminating separate connection components and assembly steps. This merging reduces device complexity by creating a unified structure while maintaining connection reliability through the strong, precise laser weld joints.
Solution Approach 2:
The patent designs a universal electrode substrate structure that can accommodate multiple electrodes and wire connections simultaneously. The substrate serves multiple functions: mechanical support for electrodes, electrical isolation between electrodes, and a platform for laser welding connections. This multi-functional design reduces overall device complexity while ensuring reliable connections across all electrode-wire interfaces.
3Manufacturing precision
If conventional electrode manufacturing methods are used, then manufacturing cost increases, but manufacturing precision can be maintained
Solution Approach 1:
The patent replaces manual mechanical positioning and welding with automated laser-based systems. The laser welding system provides precise, non-contact joining with automated control, eliminating manual operations while maintaining or improving positioning precision. This substitution dramatically improves ease of manufacture by enabling high-volume automated production without sacrificing the precision achieved through manual methods.
Solution Approach 2:
The patent changes the manufacturing parameters from manual mechanical processes to laser-based thermal processes. By controlling laser parameters (power, speed, focal position), the system achieves precise electrode-wire connections with consistent quality. This parameter control enables automated manufacturing with high precision, making the process both easier to execute and more scalable while maintaining the positioning accuracy of conventional methods.
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 simplifies the manufacturing process, increases the number of electrodes per unit length, and enhances the precision and performance of body-implantable devices, such as cochlear implants.
Implementation Method 1
an electrode structure according to an embodiment includes a contact electrode part including a plurality of contact electrodes, a plurality of first wires, and a plurality of connection wires connecting the plurality of contact electrodes and the plurality of first wires; a pad part including a plurality of pads and a plurality of second wires connected to the plurality of pads; and a connection part including a plurality of third wires connecting the plurality of first wires and a plurality of second wires, and disposed between the contact electrode part and the pad part
Data Source
AI summary
The embodiment discloses an electrode array including a housing; a plurality of first contact electrodes exposed to an outside of the housing; a plurality of second contact electrodes exposed to the outside of the housing; a first wire group disposed inside the housing and electrically connected to the first contact electrodes; and a second wire group disposed inside the housing and electrically connected to the second contact electrodes, the plurality of first contact electrodes and the first wire group being disposed on different planes within the housing.