Helically Wrapped Microcircuit Cochlear Electrode Array Manufacturing
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Solution Overview
Problem
Current cochlear electrode manufacturing processes are slow, prone to mechanical stresses, and result in material waste due to manual handling and high operator intervention, leading to inefficiencies and increased breakage.
Innovation Solution
The development of microcircuit cochlear electrode arrays with a compact and robust design, featuring helically wrapped microcircuits and overmolding with polymeric material to reduce operator intervention, minimize waste, and enhance manufacturing efficiency, including specific configurations such as J-style and spiral-style arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and operator intervention are used in electrode manufacturing, then flexibility and adaptability are maintained, but processing speed is slow and mechanical stress and breakage increase
Solution Approach 1:
The electrode array is divided into multiple electrodes formed simultaneously from a single continuous insulating member, allowing automated batch production while maintaining structural integrity and reducing handling of individual components
Solution Approach 2:
The insulating member is prepared in advance with all electrode recesses and structures formed before the electrodes themselves are created, enabling subsequent automated electrode formation without manual intervention
2Productivity
If manual handling is used throughout the manufacturing process, then precise control is possible, but material waste and rework increase
Solution Approach 1:
Multiple electrodes are formed simultaneously from a single insulating member in one automated process run, maximizing material utilization and eliminating waste associated with sequential manual production
Solution Approach 2:
The formation of multiple electrodes, insulation application, and structural creation are merged into a single automated process using one continuous insulating member, reducing material waste and rework
3Reliability
If individual electrode handling is performed, then quality control is possible, but mechanical stress and breakage occur
Solution Approach 1:
The insulating member is pre-formed with all necessary structures and electrode positions before electrodes are created, eliminating the need for complex individual handling and assembly operations that could cause damage
Solution Approach 2:
The insulating member itself provides the structural framework and positioning for all electrodes, making the structure self-supporting and eliminating the need for external handling fixtures or complex assembly procedures
Data Source
AI summary
A microcircuit cochlear electrode array and process for the manufacture thereof, the electrode array comprising first and second flat microcircuits comprising a plurality of laterally spaced longitudinally extending electrical conductors and longitudinally spaced electrode receiving pads extending laterally from the conductors, the first flat microcircuit being helically wrapped in a first direction along an axis with its longitudinally spaced electrode receiving pads exposed on an end of an outer surface hereof and the second flat microcircuit helically being wrapped in an opposite direction on and along an outer surface of the first helically wrapped microcircuit with its longitudinally spaced electrode receiving pads exposed on an outer surface thereof adjacent the exposed longitudinally spaced electrode receiving pads of the first microcircuit, and ring electrodes around and electrically secured to the electrode receiving pads of the first and second microcircuits.