Method of making a cochlear electrode array with electrode conta

Surgery: light – thermal – and electrical application – Light – thermal – and electrical application – Electrical energy applicator

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29860, 29825, 607137, A61N 105

Patent

active

061448834

ABSTRACT:
A method of making an implantable electrode array, adapted for insertion into a cochlea, provides stability relative to the electrode contact direction. In-line electrodes are spaced-apart along one side of a flexible carrier. The structure of the electrode array facilitates bending of the array with the electrode contacts on the inside of the bend, yet deters flexing or twisting of the array in other directions. The electrode contacts preferably are each made from two strips of metal, arranged in a "T" shape (top view). During assembly, all of the "T" strips are held in position on an iron sheet. Two wire bundles are formed that pass along each side of each "T". The leg of each "T" is folded over to pinch at least one of the wires from one of the wire bundles therebetween. This pinched wire is then resistance welded to the strip. The sides of the "T" are then folded up and touch or nearly touch to form a ".DELTA." shape (side view). The wire bundles going to more distal electrodes pass through the ".DELTA." and are thus engaged by the ".DELTA.". A flexible carrier, made from, e.g., silicone rubber, is molded over and around the wire bundles and folded electrode T's, preferably in a slightly curved shape, The iron sheet is chemically etched away, leaving an array of spaced-apart electrode contact areas along one edge of the flexible carrier, each of which is electrically attached to at least one wire which passes through the carrier. The electrode array may be manufactured using low cost technology.

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