Neuromodulation Probe Electrode Assembly via Spherical Casting
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Solution Overview
Problem
The manufacturing of neuromodulation probes with extremely small electrodes and wires is challenging due to consistency issues, leading to less manufacturing accuracy and higher production costs, while existing methods like planar arrays can cause inflammation and contamination.
Innovation Solution
A manufacturing fixture and process involving a two-layer frame structure with beveled sides, where electrodes and wires are arranged in parallel, and a fluid plastic is used to encase and cure around the components, allowing for precise assembly and removal of the probe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar array is applied to assemble the electrodes, then the electrodes can be assembled, but the surface smoothness deteriorates and gaps cause inflammation and contamination
Solution Approach 1:
The patent transitions from a planar (2D) array arrangement to a three-dimensional spherical arrangement of electrodes. This dimensional change allows the electrodes to be positioned on the surface of a sphere, eliminating gaps and achieving a smooth continuous surface while maintaining ease of assembly through the spherical geometric framework.
Solution Approach 2:
The patent employs a spherical geometry for the electrode arrangement, where electrodes are positioned on the surface of a sphere. This curved surface configuration eliminates the gaps inherent in planar arrays, providing a smooth surface that prevents inflammation and contamination while maintaining manufacturability.
2Manufacturing precision
If semiconductor process is used, then the size of electrodes can be small and the number thereof can be large, but the investment on materials and process equipment would be expensive
Solution Approach 1:
The patent adopts a disposable mold approach where inexpensive molds are used to form the electrodes and insulating coating in a single casting process. The molds are discarded after one use, eliminating the need for expensive semiconductor process equipment while achieving precise electrode dimensions and arrangements. This substitutes capital-intensive reusable equipment with low-cost single-use tools.
Solution Approach 2:
The patent replaces complex semiconductor manufacturing processes with a simple casting process. Instead of using sophisticated semiconductor equipment to fabricate tiny electrodes, the invention uses a mold-based casting method where the electrode array is formed by pouring conductive material into a pre-designed mold, significantly reducing equipment investment while maintaining manufacturing precision.
3Volume of moving object
If electrodes are made extremely small for implantation, then the probe size is reduced, but the consistency and manufacturing accuracy deteriorate
Solution Approach 1:
The patent incorporates the electrode array geometry directly into the mold design before casting. The mold pre-defines the precise positions, sizes, and arrangements of all electrodes, ensuring consistency is established in advance rather than relying on post-manufacturing adjustments. This preliminary structuring maintains manufacturing accuracy even as electrode dimensions are reduced for smaller probe sizes.
Solution Approach 2:
The patent combines multiple manufacturing steps into a single casting process. The electrodes, insulating coatings, and structural support are all formed simultaneously in one operation, ensuring consistent dimensions and precise relative positioning of all components. This merging of processes maintains manufacturing precision while enabling smaller overall probe dimensions.
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 approach reduces the difficulty in fabricating electrodes, improves assembly accuracy, lowers production costs, and ensures a smooth surface finish, minimizing the risk of inflammation and contamination.
Implementation Method 1
having a fluid plastic to surround the cylinder by filling all the spaces between the plurality of wires and the plurality of electrodes, and waiting the fluid plastic to cure
Data Source
AI summary
A manufacturing process for electrode of neuromodulation probe includes the steps of: preparing a plurality of the manufacturing fixtures for electrode of neuromodulation probe; preparing a plurality of the manufacturing fixtures for electrode in a surrounding manner by having the first-layer frames to be externally disposed side by side with the bevels of the two neighboring first-layer frames close to each other, so that the second-layer frames, the plurality of electrodes and the plurality of wires are enclosed thereinside; placing a cylinder amid the plurality of manufacturing fixtures for electrode to have the plurality of wires to surround the cylinder; having a fluid plastic to surround the cylinder by filling all the spaces between the plurality of wires and the plurality of electrodes, and waiting the fluid plastic to cure; removing the plurality of first-layer frames and the plurality of second-layer frames; and, pulling off the cylinder.