Reinforced Cochlear Electrode Leads for Torsion-Resistant Flexibility
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Solution Overview
Problem
Conductive wires in cochlear implant electrode leads are fragile and prone to damage during manufacturing, packaging, handling, and insertion procedures due to their flexibility and the insufficient protection provided by soft silicone tubing.
Innovation Solution
Incorporating a coiled reinforcing element within the electrode lead with a winding direction opposite to the coiled electrode wire, and a larger winding pitch than the electrode wire, to provide resistance against torsion and tensile stress, thereby protecting the electrode wire from kinking and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If soft silicone tubing and thin conductive wires are used to achieve flexibility for cochlear insertion, then the electrode lead can conform to the spiral shape of the cochlea, but the conductive wires become fragile and prone to damage during manufacturing, handling, and insertion
Solution Approach 1:
The patent applies composite materials by combining soft silicone tubing with a reinforcing element (such as a braid or mesh) to create a hybrid structure. The silicone provides flexibility and biocompatibility, while the reinforcing element adds mechanical strength and damage resistance, resolving the contradiction between flexibility and wire strength.
Solution Approach 2:
The reinforcing element is applied locally to the electrode lead body where mechanical strength is needed, rather than making the entire lead rigid. This allows the lead to maintain flexibility in the silicone tubing while having enhanced strength in critical areas where wires are vulnerable during insertion and handling.
2Ease of operation
If the electrode lead body is made softer to protect conductive wires during insertion, then the lead becomes more flexible for cochlear conformability, but the protection against impact and traumatic injury is insufficient
Solution Approach 1:
The electrode lead body uses a composite construction combining soft silicone material with a reinforcing element (braid or mesh). The soft silicone ensures ease of insertion and cochlear conformability, while the reinforcing element provides impact resistance and protection against traumatic injury, resolving the contradiction between insertion ease and impact resistance.
Solution Approach 2:
The reinforcing element acts as a pre-established protective structure within the soft silicone tubing, providing beforehand cushioning and strength reinforcement. This allows the lead to be soft enough for easy insertion while having built-in protection against future impact and traumatic events.
3Adaptability or versatility
If thin conductive wires are used to achieve flexibility, then the electrode lead can be inserted into the cochlea, but the wires are fragile and may break during manufacturing, packaging, and handling
Solution Approach 1:
The patent uses composite materials by embedding thin conductive wires within a reinforced silicone tubing structure. The thin wires maintain flexibility for cochlear insertion, while the composite tubing structure with reinforcing elements provides damage resistance during manufacturing, packaging, and handling operations.
Solution Approach 2:
The electrode lead uses a flexible shell structure (silicone tubing with reinforcing element) that encases and protects the thin conductive wires. This flexible shell maintains the overall flexibility needed for insertion while providing a protective barrier against damage during manufacturing and handling processes.
Data Source
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AI summary
An exemplary electrode lead includes a flexible body formed of a flexible insulating material, an electrode contact disposed on a side of the flexible body, a coiled electrode wire provided within the flexible body so as to extend along a length of the flexible body and electrically connect the electrode contact to a signal source, and a coiled reinforcing element provided within the flexible body so as to extend together with the coiled electrode wire along the length of the flexible body. A winding direction of the coiled electrode wire is opposite a winding direction of the coiled reinforcing element and a winding pitch of the coiled electrode wire is smaller than a winding pitch of the coiled reinforcing element. Corresponding methods of manufacturing an electrode lead are also described.