Modular Electrode Structure for Neural Interfaces
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Solution Overview
Problem
Existing methods for producing high-resolution electrode structures for neural interfaces face limitations due to the constraints of carrier material area and the precision issues at the edges, leading to reduced resolution and increased manufacturing errors.
Innovation Solution
A modular approach where separate electrode modules with different resolutions are produced and assembled, allowing for precise alignment and connection without damaging underlying structures, enabling efficient use of the carrier material area and reducing manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the total area of the carrier material is increased to accommodate more electrode contact areas, then the resolution of the electrode structure is improved, but the manufacturing precision deteriorates due to laser focus issues at the edges
Solution Approach 1:
The electrode structure is divided into multiple segments or layers, each containing a subset of electrode contact areas. This segmentation allows each segment to be manufactured within the optimal laser focus area, maintaining high precision while collectively providing a large number of electrode contacts across multiple segments.
Solution Approach 2:
The patent transitions from a two-dimensional arrangement of electrode contacts on a single carrier material surface to a three-dimensional multi-layer structure. By stacking multiple carrier materials with electrode contacts on different planes, the system achieves high resolution without requiring a single large-area carrier material, thus avoiding edge-related manufacturing precision issues.
2Manufacturing precision
If the number of electrode contact areas is increased to improve resolution, then the resolution is improved, but the area available for conductor tracks decreases
Solution Approach 1:
By arranging electrode contact areas on multiple layers vertically stacked, the patent creates three-dimensional space for both electrode contacts and conductor tracks. Conductor tracks can be routed on different layers or on the sides of the structure, allowing high-density electrode contacts without compromising the area available for conductor routing.
Solution Approach 2:
The patent employs a nested arrangement where conductor tracks and electrode contacts are organized in a hierarchical manner across multiple layers. Conductor tracks on lower layers can be positioned beneath electrode contacts on upper layers, efficiently utilizing the vertical space and allowing both high electrode density and adequate conductor routing area.
3Manufacturing precision
If multilayer electrode structures are produced by applying carrier materials sequentially, then the resolution is improved, but the underlying electrode structures are damaged by the laser
Solution Approach 1:
The patent segments the manufacturing process into independent steps for each layer, where each carrier material and its electrode contacts are produced separately before assembly. This segmentation allows precise control of laser parameters for each layer without affecting previously manufactured layers, as the layers are not present during the laser processing of subsequent layers.
Solution Approach 2:
The patent applies preliminary protective measures by fully manufacturing and stabilizing one layer before applying the next carrier material. The underlying electrode structures are completely formed and protected before the laser is used for subsequent layers, preventing any laser-induced damage to previously created structures.
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 method allows for the creation of high-resolution electrode structures with flexible design options, optimal utilization of the carrier material, and reduced production costs by enabling the use of different resolutions on various parts of the structure.
Implementation Method 1
the electrode contact areas and conductor tracks to be produced with a laser
Data Source
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AI summary
A method for manufacturing an electrode structure for a neural interface is provided, wherein a first electrode module and at least one second electrode module are manufactured, preferably separately from one another, and wherein the second electrode module is arranged on the first electrode module. The arrangement of the second electrode module on the first electrode module is preferably such that the electrode contact surfaces of the lower, i.e., the first, electrode module are not covered by electrode contact surfaces and/or conductor tracks of the upper, i.e., the second, electrode module. Furthermore, the invention provides an electrode structure for neural interfaces that can be manufactured using the method according to the invention.