Multielectrode System Manufacturing with Flexible Sheath and Ring Electrodes
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Solution Overview
Problem
Current manufacturing methods for multielectrode systems are complex and result in devices that are not flexible, have poor corrosion resistance, and can act as barriers within the body, leading to inflammatory reactions and injuries during insertion and operation.
Innovation Solution
A manufacturing method involving electrically conductive conductors bundled with a sheath and ring electrodes that can be configured into a longitudinally extended or transversally expanded form, with accessible slits to prevent barrier formation and allow tissue interaction, using materials like shape memory alloys and thermally shaped polymers for flexibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for multielectrode systems, then the structure can be formed, but the device complexity increases and manufacturing becomes complicated
Solution Approach 1:
The multielectrode system is divided into modular components: a flexible lead with multiple conductors and separate ring electrodes that can be independently positioned and connected. This segmentation simplifies manufacturing by allowing each component to be produced separately and assembled, reducing overall device complexity while improving ease of manufacture
Solution Approach 2:
The lead is designed with flexible materials and configurable geometry that allow it to adapt to different anatomical pathways. The lead can be configured in various shapes (straight, curved, branched) and scaled to different sizes, enabling a single manufacturing process to produce multiple device variants, thereby improving manufacturing efficiency without increasing complexity
2Reliability
If conventional multielectrode systems are used, then electrodes can be provided, but they act as barriers within the body causing inflammatory reactions and injuries
Solution Approach 1:
The lead is constructed from flexible materials with a soft, compliant structure that mimics natural tissue mechanics. This flexibility allows the lead to conform to blood vessel walls and surrounding tissues without creating sharp edges or rigid structures that could cause mechanical injury or trigger inflammatory responses, thereby improving reliability by reducing harmful biological reactions
Solution Approach 2:
The ring electrodes are designed with smooth curved geometries rather than sharp edges. The curved surfaces distribute mechanical stress evenly and prevent tissue concentration at sharp points, reducing the risk of mechanical injury and inflammatory reactions while maintaining effective electrical contact with surrounding tissues
3Reliability
If conventional multielectrode systems are used, then electrodes can be provided, but corrosion resistance is poor
Solution Approach 1:
The lead incorporates composite material structures combining biocompatible metals (such as platinum, iridium, or titanium) with corrosion-resistant coatings and flexible polymer matrices. This composite construction provides both the electrical conductivity needed for electrode function and superior corrosion resistance for long-term stability in the physiological environment
Solution Approach 2:
The electrical conductivity and corrosion resistance parameters of the lead materials are optimized through selection of specific alloys and coatings. By carefully controlling material composition and microstructure, the system achieves high electrical conductivity for effective stimulation while simultaneously providing excellent corrosion resistance for long-term reliability
4Quantity of substance
If the multielectrode system is made with larger diameter, then fewer electrodes can be accommodated, but if smaller diameter is used, then manufacturing precision and electrode functionality may be compromised
Solution Approach 1:
Multiple ring electrodes are arranged in a nested or closely packed configuration around the conductors, similar to nested dolls. This efficient spatial arrangement maximizes the number of electrodes that can be accommodated within a compact lead diameter while maintaining adequate spacing for manufacturing precision and electrical isolation between electrodes
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
The method produces more reliable, long-term stable multielectrode systems with improved corrosion resistance and smaller diameters, allowing for higher electrode numbers and reduced risk of injury and inflammatory reactions, while maintaining effective performance.
Implementation Method 1
using materials like shape memory alloys and thermally shaped polymers for flexibility and stability
Implementation Method 2
using materials like shape memory alloys and thermally shaped polymers for flexibility and stability
Data Source
AI summary
One aspect includes a manufacturing method for a multielectrode system including providing several conductors, which are electrically conductive in their longitudinal direction; bundling the conductors at a proximal portion of the multielectrode system by means of a sheath surrounding the conductors to form a conductor bundle configured to be used as a lead of the multielectrode system; and providing several ring electrodes each surrounding one of the conductors at a distal portion of the multielectrode system and electrically connecting the ring electrodes and the conductors to form a multielectrode array of the multielectrode system. The multielectrode array is configured to be in a longitudinally extended or in a transversally expanded configuration.