Implantable Neural Electrode Interface Platform Manufacturing
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Solution Overview
Problem
Current methods for manufacturing implantable neural electrode interfaces face challenges in creating durable, flexible, and efficiently connectable electrodes that can effectively stimulate or record neural activity without causing tissue damage or disintegration over time.
Innovation Solution
A method involving a metal layer sandwiched between adhesive silicone layers, with the metal layer cut to form electrode sites, traces, and contact pads, and exposed through holes in the silicone layers, allowing for secure welding of wires and a detachable needle for insertion into neural tissue, ensuring structural integrity and ease of handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal layer is used to form electrode sites and traces, then electrical conductivity and structural integrity are improved, but the flexibility and ease of handling are worsened
Solution Approach 1:
The patent uses a composite structure combining a flexible polymer substrate with a metal layer deposited on top. The polymer substrate (e.g., silicone or polyimide) provides flexibility and ease of handling, while the metal layer (e.g., platinum, iridium, or aluminum) provides electrical conductivity and structural integrity for electrode sites and traces. This composite approach resolves the contradiction by allowing the device to be both flexible and structurally sound.
2Ease of operation
If the metal layer is made thinner to improve flexibility, then ease of handling is improved, but manufacturing precision and reliability are worsened
Solution Approach 1:
The patent specifies precise thickness parameters for the metal layer (typically 5-50 micrometers) and the polymer substrate to optimize both flexibility and manufacturability. By carefully controlling these dimensional parameters, the invention achieves a balance where the metal layer is thin enough to provide flexibility but thick enough to maintain manufacturing precision, reliability, and electrical performance.
3Reliability
If adhesive silicone layers are used to sandwich the metal layer, then reliability and structural integrity are improved, but the complexity of the manufacturing process is worsened
Solution Approach 1:
The patent combines the metal layer with the polymer substrate through direct deposition or lamination processes, creating an integrated structure where the metal trace pattern is formed directly on the flexible substrate. This merging of layers simplifies the overall device structure and manufacturing process compared to assembling separate components, while maintaining structural integrity and reliability.
4Manufacturing precision
If laser ablation is used to form holes and patterns, then manufacturing precision is improved, but the complexity of the manufacturing process is worsened
Solution Approach 1:
The patent employs laser ablation technology to form precise holes, slots, and patterns in the metal layer and polymer substrate. This replaces traditional mechanical cutting or drilling methods with a non-contact, highly precise laser-based process. While laser equipment adds complexity to the manufacturing setup, it dramatically improves manufacturing precision and can be automated, ultimately simplifying the overall manufacturing workflow through consistent, repeatable results.
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 solution enables the creation of durable, flexible electrodes that maintain structural integrity and facilitate effective neural stimulation and recording, reducing the risk of tissue damage and improving handling and longevity.
Implementation Method 1
laser ablation is used to cut the metal layer and form the first and second sets of holes
Implementation Method 2
the metal layer is cleaned with oxygen plasma before laminating the first silicone layer to the second silicone layer
Implementation Method 3
A first silicone layer is formed by knife-coating a polymer mesh with silicone and cured
Implementation Method 4
Wires are welded to the exposed contact pads
Data Source
AI summary
The present disclosure discusses a method of manufacturing an implantable neural electrode. The method includes cutting a metal layer to form a plurality of electrode sites, contact pads and metal traces connecting the electrode sites to the contact pads. A first silicone layer including a mesh is formed and coupled to the metal layer. A second silicone layer is formed and laminated to the first silicone layer coupled with the metal layer. Holes are formed in the first or second silicone layer exposing the contact pads and electrode sites. Wires are welded to the exposed contact pads and a third layer of silicone is overmolded over the contact pads and wires.