Implantable Multielectrode Array Manufacturing via Ductile Fracture
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Solution Overview
Problem
The manufacturing of implantable multielectrode arrays is inefficient, as existing methods require separate production and affixing of spike electrodes, which complicates the process and increases costs.
Innovation Solution
A method involving a substrate with conductors having constrictions, where the substrate is split to create electrodes protruding from both sides, allowing for efficient production of biostable multielectrode arrays using biocompatible materials and printed circuit board techniques, with ductile fractures generating electrodes that taper continuously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spike electrodes are separately produced and affixed onto the substrate, then the multielectrode array can be manufactured with existing techniques, but the manufacturing process becomes complex and inefficient
Solution Approach 1:
The invention merges the electrode production and substrate integration into a single unified process. Conductors are deposited directly onto the substrate in a continuous pattern, then selectively removed to form electrodes, eliminating the separate production and affixing steps of prior art.
Solution Approach 2:
The continuous conductor pattern is segmented into individual electrodes through selective removal of conductor portions. This segmentation occurs in-situ on the substrate, transforming a single continuous structure into multiple discrete electrodes that remain integrated with the substrate.
2Productivity
If multiple separate steps are used to produce electrodes and substrate, then existing manufacturing techniques can be utilized, but production time and costs increase
Solution Approach 1:
The conductor pattern is deposited onto the complete substrate in advance, before any electrode formation steps. This preliminary deposition of the entire conductor network allows subsequent selective removal to efficiently create all electrodes in parallel, rather than forming each electrode individually.
Solution Approach 2:
The manufacturing process maintains continuous action by depositing conductors across the entire substrate in a single continuous deposition process, followed by continuous selective removal to form all electrodes simultaneously, maximizing production efficiency.
3Reliability
If conventional manufacturing methods are used, then production can proceed with established processes, but biostable materials and cost-effectiveness are compromised
Solution Approach 1:
The invention changes the material parameters by using biostable conductive materials deposited directly onto biostable substrates. The continuous deposition process allows precise control of conductor thickness and composition, ensuring biostability while maintaining manufacturing simplicity through the unified in-situ process.
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 enables the efficient and cost-effective production of biostable multielectrode arrays with continuously tapering electrodes, suitable for measuring brain waves, allowing for large-scale production with low production costs and the use of biocompatible materials.
Implementation Method 1
exerting a first force on the first substrate part and a second force on the second substrate part and heating said sections, such that a fracture of the respective section is generated at the respective constriction
Implementation Method 2
the respective fracture is a ductile fracture. Thus, particularly, the heated sections of the conductors are torn apart at the respective constriction by said opposite forces such that the respective fracture separating the respective section into the respective two electrodes is a ductile fracture
Data Source
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AI summary
The present invention relates to a method for producing an implantable multielectrode array (1), comprising the steps of: providing a substrate (2) on which a plurality of conductors (10) are arranged, wherein each conductor (10) comprises a section (100) comprising a constriction (101), and wherein said sections (100) extend parallel to one another in a first direction (D1); removing a portion of the substrate (2) such that a first and a separate second substrate part (21, 22) is formed, which substrate parts (21, 22) are separated by a gap (20), and wherein each section (100) extends in the first direction (D1) from the first substrate part (2a) across the gap (20) to the second substrate part (2b), and exerting a first force (F1) on the first substrate part (2a) and a second force (F2) on the second substrate part (2b) and heating said sections (100), such that a fracture (102) of the respective section is generated at the respective constriction (101), which fracture (102) separates the respective section (100) into an electrode (3) protruding from the first substrate part (2a) and an electrode (3) protruding from the second substrate part (2b). Furthermore, the present invention relates to an implantable multielectrode array (1) as well as to a device (1) for manufacturing an implantable multielectrode array (1).