Implantable Electrode Configuration with Polymer Encapsulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing implantable electrode configurations face issues with liquid-induced degradation and mechanical fastening in non-planar structures, leading to separation between the electrode and carrier substrate, which compromises the stability and longevity of medical implants.

Innovation Solution

The electrode configuration features a metallic base plate with orthogonal structural elements, such as columns or ribs, completely surrounded by biocompatible polymer, minimizing exposed interfaces and using adhesion promotion layers like SiC or DLC to enhance bonding between the metal and polymer, thereby reducing the risk of liquid penetration and delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the electrode structure is applied to the carrier substrate surface, then the electrode is freely accessible for electrical contact, but the interface is exposed to capillary fluid penetration causing delamination

Engineering Contradiction:

Improveelectrode accessibilityVSAvoidinterface stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The electrode structure is nested within a recess of the carrier substrate, with the electrode body at least partially receiving the recess. This nesting configuration protects the electrode-carrier substrate interface from direct exposure to capillary fluid while maintaining electrode accessibility through the recess opening.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A connection element is introduced as an intermediary between the electrode and carrier substrate, extending from the electrode top surface into the carrier substrate. This connection element reinforces the interface and prevents delamination caused by fluid penetration, while allowing the electrode to remain accessible.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the electrode structure is completely enclosed by polymer, then mechanical fastening is improved, but electrode surface accessibility is reduced

Engineering Contradiction:

Improvemechanical fasteningVSAvoidelectrode accessibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The electrode is nested within a recess of the carrier substrate, allowing complete or partial enclosure by the polymer material for mechanical reinforcement, while the recess opening provides pathways for electrode surface accessibility. The electrode body receives the recess, creating a protected yet accessible configuration.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The electrode structure employs asymmetric configuration where the electrode body has different properties at different locations - the body portion is enclosed for mechanical strength while the top surface remains accessible through the recess opening. The connection element also creates asymmetric reinforcement extending from the accessible surface into the substrate.

Inventive Principle:

Principle #4Asymmetry

3Reliability

If adhesion promotion layers are applied, then bonding between metal and polymer is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An adhesion promotion layer is applied to the electrode body before the electrode is integrated into the carrier substrate. This preliminary application of adhesion enhancement material ensures strong bonding between the metallic electrode and polymeric carrier substrate, preventing delamination while the subsequent manufacturing steps complete the integration.

Inventive Principle:

Principle #10Preliminary action

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 significantly reduces or prevents the creeping separation between the electrode and carrier substrate, ensuring long-term stability and maintaining the functionality of the medical implant by minimizing interfacial exposure to intracorporeal liquids and enhancing mechanical fastening.

Implementation Method 1

using adhesion promotion layers like SiC or DLC to enhance bonding between the metal and polymer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

intracorporeal liquids, for example, have a tendency to penetrate into extremely small cracks and interspaces on technical-grade surfaces in particular due to their capillary spreading and wetting properties

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS10569085B2Implantable electrode configuration

Publication Date: 2020.02.25 NEUROLOOP

AI summary

The invention is an implantable electrode configuration having a carrier substrate of a biocompatible polymer in at least some areas and a freely accessible electrode surface applied to the carrier substrate or integrated into the carrier substrate on the carrier substrate surface in at least some areas is described and a method for producing the implantable electrode configuration. The electrode has a metallic base plate having a planar top side and bottom side, including at least one structural element protruding orthogonally from the top side. The planar surface of the metallic base plate is oriented parallel to the carrier substrate surface and the metallic base plate is enclosed by the biocompatible polymer, except for a first surface area of the at least one structural element which faces the carrier substrate surface and is the freely accessible electrode surface.