Mid-scalar electrode array

• US 10,016,589 B2
• Filed: 07/07/2016
• Issued: 07/10/2018
• Est. Priority Date: 05/11/2011
• Status: Active Grant

• Current Assignee: Advanced Bionics AG (Sonova Holding AG)
• Original Assignee: Advanced Bionics AG (Sonova Holding AG)
• Inventors: Thenuwara, Chuladatta, Gallegos, Rosa, Vasquez, Lidia, Downing, Mark B.
• Primary Examiner(s): Porter, Jr., Allen
• Application Number:
  US15/204,594
• Publication Number:
  US 20160317801A1
• Time in Patent Office: 733 Days
• CPC Class Codes: A61N 1/0541 Cochlear electrodes
• CPC Class Codes: Y10T 29/49224 with coating

Abstract

In one example, a cochlear lead includes a flexible body, an array of electrodes in the flexible body, and a plurality of wires passing along the array of electrodes. The plurality of wires includes a flexural geometry between each pair of adjacent electrodes and a substantially straight geometry over the electrodes. A method for forming an electrode array with a reduced apical cross section is also provided.

Claims

1. A cochlear lead, the cochlear lead comprising:

a flexible body;

an array of electrodes in the flexible body; and

a plurality of wires passing along the array of electrodes, wherein the plurality of wires comprise a plurality of flexural elements with a single flexural element between each pair of adjacent electrodes, each flexural element consisting of a loop, an arch, or a semicircle formed in the wire, wherein the flexural elements are configured to create a spring force that tends to return the flexible body to a mid-scalar geometry after straightening, and wherein the spring force is partially based on resisting stiffness or curling of the plurality of wires.

2. The lead of claim 1, wherein the plurality of flexural elements is oriented to reduce a stiffness of the wires in a plane orthogonal to an exposed surface of an adjacent electrode.

3. The lead of claim 1, wherein the electrodes of the array have uniform thickness.

4. The lead of claim 1, wherein the plurality of flexural elements contain only curvatures.

5. The lead of claim 1, wherein the plurality of the flexural elements reduce a prevalence of shorts in the lead.

6. The lead of claim 1, wherein the flexural element is in a plane substantially parallel to a plane of curvature of the electrode array.

7. A cochlear lead, the cochlear lead comprising:

a flexible body;

an array of electrodes in the flexible body;

a wire between each electrode and the proximal end of the flexible body, wherein each wire is oriented in a straight line along a length of the lead over each electrode and each wire has a flexural element between each pair of electrodes such that the wire over the electrode is static relative to the electrode and the wire between the electrodes flexes at the flexural element to accommodate bending of the flexible body and creates a spring force that tends to return the flexible body to a mid-scalar geometry after straightening, and wherein the spring force is partially based on resisting stiffness or curling of the plurality of wires.

8. The lead of claim 7, wherein each flexural element is an arch.

9. The lead of claim 7, wherein each flexural element is a semicircle.

10. The lead of claim 7, wherein the flexural element located in the wire between the pair of electrodes reduces a rate of shorts.

11. The lead of claim 7, wherein each flexural element extends beyond a neutral bending axis of the flexible body.

12. The lead of claim 7, further comprising a lumen in the flexible body, wherein a plane in which an entire flexural element lies intersects the lumen.

13. The lead of claim 7, further comprising a lumen in the flexible body and a stiffening element in the lumen, wherein a flexural element opposes straightening of the flexible body by the stiffening element.

14. The lead of claim 7, wherein an electrode comprises a wing folded parallel to an exposed surface of the same electrode.

15. The lead of claim 7, wherein a ratio at a most distal electrode of a cross sectional area of the flexible body to a cross sectional area of the wires is between 90 and 120.

16. The lead of claim 7 wherein the wire between each electrode and the proximal end of the flexible body electrically connects each electrode to a processor.

17. A method of forming a cochlear lead with a reduced apical cross section, the method comprising:

connecting a wire to a first electrode;

forming in the connected wire, a single arch having a radius of curvature between the first electrode and a second electrode adjacent to the first electrode, the wire passing straight over the surface of the second electrode such that the wire occupies a minimum area over the second electrode, wherein the single arch is configured to create a spring force; and

overmolding the wire and electrodes with encapsulation material in a single molding operation to form a completed silicone body, wherein the spring force is partially based on an amount of silicone in the completed silicone body and wherein the spring force tends to return the silicone body to a mid-scalar geometry after straightening.

18. The method of claim 17, wherein a plane comprising all of the arch is perpendicular to an exposed surface of the first electrode.

19. The method of claim 17, further comprising folding a wing on the first or second electrode such that a surface of the wing is parallel to an exposed surface of the first or second electrode.