Percutaneous electrode array

• US 20050043775A1
• Filed: 10/04/2004
• Published: 02/24/2005
• Est. Priority Date: 01/07/2000
• Status: Active Grant

• Current Assignee: Bradford Siff, Carter John
• Original Assignee: Bradford Siff, Carter John
• Inventors: John, Carter, Siff, Bradford
• Granted Patent: US 7,130,696 B2
• Time in Patent Office: Days
• US Class Current: 607/69
• CPC Class Codes: A61N 1/0504 Subcutaneous electrodes
• CPC Class Codes: A61N 1/32 alternating or intermittent currents applying electric fields by inductive or capacitive coupling A61N1/40; microwave apparatus A61N5/02
• CPC Class Codes: A61N 1/36017 with leads or electrodes penetrating the skin
• CPC Class Codes: A61N 1/36021 for treatment of pain
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

Abstract

A method of producing percutaneous electrode array is disclosed for applying therapeutic electrical energy to a treatment site in the body of a patient. The array comprises a plurality of electrode microstructures which are inserted into the epidermis, thereby overcoming the inherent electrical impedance of the outer skin layers and obviating the need to prepare the skin surface prior to an electro-therapy treatment. The array preferably includes an adhesion layer to help keep the electrode microstructures inserted into the epidermis during the duration of the therapeutic treatment, and temperature and condition monitoring devices to ensure proper treatment and enhance patient safety.

Claims

1. A method of producing a percutaneous electrode array comprising:

micromachining a master mold of a perctaneous electrode array having a substrate and a plurality of electrodes from silicon using semiconductor lithographic processing;

creating a replica mold by electroplating thin film silver followed by nickel onto the master mold;

heating, softening, and rolling a polymeric film;

forcing the film into the replica mold using pressure to form an array structure; and

cooling the array structure and removing the structure from the replica mold.

2. The method of claim 1, further comprising:

thermally processing array material to form a carbonized structure; and

depositing an adhesive layer on the structure.

3. The method of claim 1, wherein the polymeric film comprises polymethyl methacrylate.

4. The method of claim 1, further comprising spraying conductive inks onto the structure and heating the structure to form a conductive coating.

5. The method of claim 1, further comprising:

spraying, dipping or spin coating an indium tin oxide precursor onto the array structure; and

heating the structure to form a conductive film coating.

6. The method of claim 1, further comprising forming a conductive film comprising indium tin oxide by evaporation or sputtering processes onto the array structure.

7. A method of introducing therapeutic electrical energy to body tissues in a treatment site beneath the epidermis of a patient, comprising:

providing an electro-therapy apparatus comprising;

a signal generator configured to produce first and second signals; and

a first and second percutaneous electrode array;

positioning the first array on a first portion of the patient'"'"'s body and positioning the second array on a second portion of the patient'"'"'s body such that the first and second arrays are positioned on the tissue of the patient, and the treatment site is located between the first and second arrays;

forming a therapeutic signal from said first and second signals; and

introducing the therapeutic signal through the first and second arrays.