Method for making an intracochlear electrode array
First Claim
1. A method for making an intracochlear multielectrode array, having an apical portion and a basal portion and a spiral shape at least generally conforming to the scala tympani of a cochlea, said array comprising an elastomeric carrier having a plurality of metallic electrodes, each having an associated lead to form a plurality of leads extending from the basal portion into the apical portion of said array, supported in fixed positions by said carrier, said method comprising the steps offabricating each elctrode and associated lead from a flattened metallic wire by forming said electrode on a first end of said wire to have a covex outer surface.
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Accused Products
Abstract
A method is disclosed for making an intracochlear multielectrode array having a spiral configuration, at least generally conforming to the scala tympani of a cochlea. The array is formed in a two-part mold and comprises an elastomeric carrier supporting a plurality of metallic electrodes in fixed positions thereon. Each electrode has an associated lead to provide a plurality of leads and composite rib structure extending from a basal portion of the array to an apical portion thereof. Each electrode and associated lead is formed from a flattened metallic wire. The wire leads are stacked in the mold to permit the wires to flex in the direction of their spiral curvatures, facilitating insertion of the array into a cochlear, but to prevent transverse flexing thereof.
56 Citations
19 Claims
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1. A method for making an intracochlear multielectrode array, having an apical portion and a basal portion and a spiral shape at least generally conforming to the scala tympani of a cochlea, said array comprising an elastomeric carrier having a plurality of metallic electrodes, each having an associated lead to form a plurality of leads extending from the basal portion into the apical portion of said array, supported in fixed positions by said carrier, said method comprising the steps of
fabricating each elctrode and associated lead from a flattened metallic wire by forming said electrode on a first end of said wire to have a covex outer surface.
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10. A method of maufacturing an electrode array for implanting in a human cochliea comprising the following steps:
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providing a plurality of electrodes, each having an associated electrode lead; disposing said plurality of electrodes and associated leads in a mold cavity defined in a mold to position said electrodes at predetemined spaced positions relative to each other to effectively stimulate auditiory nerves when said array is implanted in a human cochlea and to form said leads into a rib structure for said array, securing said electrodes at said predetermined spaced positions in the cavity of said mold utilizing an elastomer material; and after securing said electrodes, casting a resilient carrier within said cavity in encapsulating relationship about said leads to form a rib structure for said array and to position and secure said electrodes at said predetermined positions and to expose outer surface portions thereof on said array.
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11. A method for making an intracochlear multielectrode array, having an apical portion and a basal portion and a spiral shape at least generally conforming to the scala lympani of a cochlea, said array comprising an elastomeric carrler havlng a plurality of metallic electrodes, each having an associated lead to form a plurality of leads extending from the basal portion into the apical portion of said array, supported in fixed positions on said carrier to expose an outer surface of each said electrode on said array, said method comprising the steps of
fabricating each of said electrodes and associated leads, placing said electrodes and associated leads in first cavities, defined in a first mold member, conforming to the shape of said array. positioning said leads to form a central rib structure for said array that is flexible to permit uncurling of said rib structure, but is relative inflexible in a direction transverse to the direction of such uncurling, securing a second mold member, having second cavities at least generally conforming to said first cavities, to said first mold member to superimpose said first and second cavities which jointly conform to the shape of said array, filling said first and second cavities with an uncured elastomer, and curing said elastomer to form said carrier and said array.
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18. A method for making an intracochlear multielectrode array, having an apical portion an a basal portion and a spiral shape at least generally conforming to the scala tympani of a cochlea, said array comprsiing an elastomeric carrier having a plurality of metallic electrodes, each having an associated lead to form a plurality of leads extending from the basal portion into the apical portion of said array, supported in fixed positions on said carrier to expose an outer surface of said electrode on said method comprising the steps of
fabricating each electrode and associated lead from a flattened metallic wire, including fabricating a first group of said leads from wires having a heavier gauge than a second group of said leads, placing said electrodes and associated leads in a mold defining cavities conforming to the shape of said array, including extending only said first group of leads into an apical end of said cavities to form a central rib structure for said array that flexes substantially uniformly throughout the length thereof, filling said cavities with an uncured elastomer, and curing said elastomer to form said carrier and said array.
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19. A method for making an intracochlear multielectrode array, having an apical portion and a basal portion and a spiral shape at least generally conforming to the scala tympani of a cochlea, said array comprising an elastomeric carrier having a plurality of metallic electrodes, each having an associated lead to form a plurality of leads extending from the basal portion into the apical portion of said array, supported in fixed positions on said carrier to expose an outer surface of each of said elctrodes on said array, said method comprising the steps of
fabricating each of said electrodes and associated lead from a flattened wire of rectangular cross-section having a width substantially large than its thickness, placing said electrodes and associated leads in a mold defining cavities conforming to the shape of said array, including stacking substantial portions of at least some of said leads in stacked alignment relative to each other to form a rib structure in said array flexible in a horizontal plane containing the full spiral shape of said array, but relatively inflexible in a vertical plane perpendicular to said horizontal plane, filling said cavities with an uncured elastomer, and curing said elastomer to form said carrier and said array.
Specification