Microscale Electrode Inserter Winding for Reliable Neural Delivery
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Solution Overview
Problem
There is no efficient and reliable method for fabricating a delivery system for electrodes sized and dimensioned to record, measure, and/or stimulate very fine nerve structures, particularly for microscale or smaller applications such as intra-fascicular recording and deep brain stimulation.
Innovation Solution
A method involving securing the electrode tip to a proximal portion of an inserter, winding the electrode around the inserter while maintaining tension, and securing it to a distal portion, which can be partially automated to ensure reproducible and reliable fabrication of a delivery system capable of recording, measuring, and stimulating very fine nerve structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a delivery system is fabricated for microscale electrodes to record, measure, and/or stimulate very fine nerve structures, then the ability to interface with fine neural structures is improved, but the fabrication reliability and efficiency deteriorate due to lack of established methods
Solution Approach 1:
The delivery system is divided into distinct components: an inserter with a sharp tip for tissue penetration, an electrode with conductor and insulator segments, and a fabrication process that sequentially assembles these parts. The electrode itself is segmented into conductor portions and insulator portions along its length, allowing precise control over stimulation/recording zones while maintaining fabrication reliability through standardized component assembly
Solution Approach 2:
The method performs preliminary actions by first forming the conductor and insulator structures on the electrode before final assembly into the delivery system. The insulator is applied to the conductor in advance, and the electrode is prepared with its tip structure beforehand, ensuring that when the electrode is inserted into the nerve, the interface is already optimized for the specific neural structure target
2Manufacturing precision
If electrodes are sized at microscale or smaller for insertion into fascicles and brain structures, then the precision for targeting specific neural structures is improved, but the difficulty of fabrication and delivery increases
Solution Approach 1:
The electrode is nested within the delivery system components: the conductor is nested within the insulator coating, which is then nested within the delivery system assembly during fabrication. This nested structure allows microscale electrodes to be manufactured with high precision while simplifying the overall fabrication process, as each nested layer protects and positions the previous layer during assembly and insertion
Solution Approach 2:
The insulator material serves as an intermediary between the conductor and the neural tissue. It allows the electrode to maintain its microscale dimensions for precise targeting while providing a controlled interface with the nerve structure, reducing direct mechanical interaction that would be difficult to manufacture and deliver at such small scales
3Productivity
If a delivery system is designed for efficient fabrication, then the productivity of electrode delivery system production is improved, but the complexity of the fabrication process increases
Solution Approach 1:
The delivery system fabrication method is designed to be universal, capable of producing electrodes for different neural targets (fascicles, brain structures, peripheral nerves) using the same basic process. The electrode structure with conductor and insulator components can be configured for different applications while maintaining a consistent fabrication approach, increasing productivity without proportionally increasing process complexity
Solution Approach 2:
The fabrication process allows the electrode structure to self-organize during assembly. The conductor and insulator portions are arranged along the electrode length, and the winding around the inserter creates the final configuration automatically. This self-organizing capability reduces the need for complex manual assembly steps, improving productivity while keeping the process manageable in complexity
Data Source
AI summary
A method for fabricating electrodes sized and dimensioned to record, measure, and/or stimulate very fine nerve structures (e.g., microscale or less) is described herein. The method can include securing a tip of an electrode, comprising a conductor substantially encased by an insulator, to a proximal portion of an inserter. The electrode can be wound around a proximal portion of the inserter and a portion of the electrode can be secured to a distal portion of the inserter. A tension in the electrode can be maintained during the winding to keep the electrode in place during the winding.