Method of manufacturing an implantable neural electrode interface platform
Inventors
Burns, IV, John • Grainger, Julianne • McLaughlin, Bryan • Sriram, Tirunelveli S. • LaChapelle, John
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Assignees
Charles Stark Draper Laboratory Inc
Member
DraperDraper is an independent nonprofit engineering innovation company with a legacy spanning over 90 years, dedicated to delivering transformative solutions for national security, prosperity, and global challenges. Renowned for its pioneering work in guidance, navigation, and control (GN&C) systems, Draper partners with government, industry, and academia to engineer advanced technologies in space, defense, biotechnology, and electronic systems. The company leverages multidisciplinary expertise, digital engineering, and a collaborative approach to provide field-ready prototypes, mission-critical systems, and innovative research. Draper’s mission is to ensure the nation's security and prosperity by delivering sustainable, cutting-edge solutions that address the toughest problems of today and tomorrow, while fostering an inclusive and diverse workforce. Draper also invests in the next generation of innovators through robust educational programs, including internships, co-ops, and the Draper Scholars Program, integrating academic research with real-world problem-solving.
Draper is an independent nonprofit engineering innovation company with a legacy spanning over 90 years, dedicated to delivering transformative solutions for national security, prosperity, and global challenges. Renowned for its pioneering work in guidance, navigation, and control (GN&C) systems, Draper partners with government, industry, and academia to engineer advanced technologies in space, defense, biotechnology, and electronic systems. The company leverages multidisciplinary expertise, digital engineering, and a collaborative approach to provide field-ready prototypes, mission-critical systems, and innovative research. Draper’s mission is to ensure the nation's security and prosperity by delivering sustainable, cutting-edge solutions that address the toughest problems of today and tomorrow, while fostering an inclusive and diverse workforce. Draper also invests in the next generation of innovators through robust educational programs, including internships, co-ops, and the Draper Scholars Program, integrating academic research with real-world problem-solving.
Publication Number
US-11938314-B2
Publication Date
2024-03-26
Expiration Date
Abstract
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.
Core Innovation
The present disclosure discusses a method of manufacturing an implantable neural electrode. The method includes forming a metal layer patterned to provide a plurality of electrode sites, contact pads and metal traces, coupling the patterned metal layer to a first silicone layer that incorporates a polymer mesh, laminating a second silicone layer such that the metal layer is positioned between the silicone layers, forming openings to expose electrode sites and contact pads, welding wires to exposed contact pads, and overmolding a further silicone layer over the welded contact pads and portions of the wires. [procedural detail omitted for safety]
Based on the available documentation, information is insufficient.
Claims Coverage
The patent includes one independent claim. The following inventive features are extracted from the independent claim.
Patterned metal layer
cutting a metal layer to form a plurality of electrode sites, contact pads and metal traces, wherein the metal traces connect one or more electrode sites to one or more contact pads. [procedural detail omitted for safety]
First silicone layer formed with polymer mesh
forming a first silicone layer by knife-coating a polymer mesh with silicone and curing the first silicone layer. [procedural detail omitted for safety]
Second silicone layer formed by calendaring
forming a second silicone layer by calendaring silicone to a desired thickness. [procedural detail omitted for safety]
Lamination with metal layer between silicone layers
laminating the first silicone layer to the second silicone layer such that the metal layer is positioned between the first silicone layer and the second silicone layer.
Forming holes to expose electrode sites and contact pads
forming a first set of holes in the first or second silicone layers to expose one or more electrode sites and a second set of holes in the first or second silicone layers to expose one or more contact pads in the metal layer.
Welding wires to exposed contact pads
after exposing the one or more contact pads, welding one or more wires to the one or more exposed contact pads. [procedural detail omitted for safety]
Overmolding third silicone layer over welded contact pads and wires
overmolding a third silicone layer over the one or more welded contact pads and a portion of the wires. [procedural detail omitted for safety]
The independent claim recites a multilayer implantable neural electrode manufacturing method combining a patterned metal layer with silicone layers including a mesh, lamination of the silicone layers with the metal layer sandwiched between, formation of openings to expose electrode sites and contact pads, attachment of wires to exposed contact pads, and overmolding of a silicone layer over the welded contact pads and portions of the wires.
Stated Advantages
The mesh can reinforce the first silicone layer to improve the longevity of the electrode, ease the handling of the electrode, and provide structural integrity to the electrode.
The improved structural integrity reduces the likelihood that the metal layer will separate from the first silicone layer during subsequent steps or handling of the completed electrode.
A primer may be used to increase the adhesion of the metal layer to an additional silicone layer.
A third silicone overmold protects the weld between the wires and the metal layer.
The overmold can achieve a gradual transition that is substantially smooth and does not possess sharp angles or abrupt discontinuities.
Documented Applications
Peripheral nerve stimulation and recording.
Peripheral nerve stimulation for treatment of chronic pain and migraines.
Cortical neural stimulation for treatment of Parkinson's disease and depression.
Electrocorticographic (ECoG) recordings and stimulation, including micro-electrocorticographic electrodes.
Longitudinal intra-fascicular electrodes for implantation through a nerve fascicle to record from and/or stimulate nerve fibers.
Cuff electrodes.
Transverse intra-fascicular electrodes.
Surface electrodes.
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