Implantable microelectrode

• US 5,515,848 A
• Filed: 06/07/1995
• Issued: 05/14/1996
• Est. Priority Date: 10/22/1991
• Status: Expired due to Term

• Current Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories)
• Original Assignee: PI Medical Corporation
• Inventors: Loeb, Gerald E., Corbett, Scott S. III, Martyniuk, Jerry, Skiens, W. Eugene, Stobie, John J., Mewes, Klaus, Beck, Doris A.
• Primary Examiner(s): Kamm, William E.
• Application Number:
  US08/482,189
• Time in Patent Office: 342 Days
• Field of Search: 128/897, 128/899, 128/642, 128/673, 128/696, 174/120 R, 174/120 SR, 607/116-138, 607/154, 607/156
• US Class Current: 600/377
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61F 11/04 Methods or devices for enabling ear patients to achieve auditory perception through physiological senses other than hearing sense, e.g. through the touch sense electronic stimulation of auditory nerves A61N1/36036
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: H01R 13/50 formed as an integral body H01R13/514 takes precedence
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A miniature, electrically-insulated multi-conductor electrical cable suitable for implantation in living bodies and readily connected to sensors or electrodes, and implantable microelectrodes attached to such cables. Individual electrical conductors are coated with at least one layer of, insulating material and stranded together, or optionally bound together by an additional layer of insulating material which is compatible with implantation in living bodies. The individual conductors are separated from one another in terminal portions of the cable and are held by a ribbonizing resin at a predetermined pitch to facilitate connection of each of the conductors. The terminal portions may define microelectrodes. Another microelectrode includes an electrically conductive electrode core member sharpened and coated with a thin layer of a dielectric material. An extremely small area of the core at the sharpened point is exposed by ablating the dielectric material by the use of an ultraviolet laser beam scanned over the material. Multiple conductor microelectrodes may also be supported within a hollow needle or in flat ribbon configuration, with openings in dielectric material defining active electrode sites. Multiple active electrode sites may be defined on a microelectrode accompanied by an integrated circuit after connection of the integrated circuit to a multiconductor cable.

Claims

1. A biologically implantable multiconductor microelectrode, comprising:

(a) a plurality of fine wires, all of said fine wires being wrapped helically around a sharp-pointed electrode support core;

(b) a quantity of a dielectric material covering a portion of each of said plurality of fine wires and electrically insulating said fine wires from each other and holding said fine wires together in a predetermined spatial relationship with each other, said quantity of dielectric material having an outer surface and defining a plurality of openings, each of said openings communicating between said outer surface and a respective one of said fine wires and exposing a predetermined area of a respective one of said fine wires therethrough.

2. The biologically implantable multiconductor microelectrode of claim 1 wherein said sharp-pointed core is of metal and wherein said core and said fine wires are held together as an integral structure by said dielectric material, said dielectric material insulating said core from each of said fine wires, said microelectrode including a respective active electrode site defined by each of said openings through said dielectric material.

3. A biologically implantable multi-conductor microelectrode, comprising:

(a) a plurality of fine wires each having a surface, said fine wires of said plurality being arranged in a planar array; and

(b) a thin coating of a dielectric material having a predetermined thickness covering a portion of each of said plurality of fine wires, electrically insulating said fine wires from each other and holding said fine wires together in a predetermined spatial relationship with each other, said coating of dielectric material having an outer surface and defining a plurality of openings, said openings being defined in said dielectric material within said planar array and each of said openings extending inward from said outer surface and communicating between said outer surface and a predetermined area on a surface of a respective one of said fine wires at a location spaced inwardly from said outer surface.

4. The biologically implantable multi-conductor microelectrode of claim 3, including a respective deposit of electrically conductive material different from said fine wires located within each of said openings and electrically connected with said predetermined area on said surface of the respective one of said fine wires within said opening.

5. A biologically implantable multi-conductor microelectrode, comprising:

(a) an integrated circuit substrate including a portion defining a probe tip;

(b) a plurality of active electrode sites each including exposed conductive material located on said probe tip;

(c) a respective electrical interconnect line, located on said substrate and electrically interconnected with each said active electrode site located on said probe tip, and extending away from said active electrode site along said probe tip;

(d) a plurality of terminal pads located on said substrate and spaced apart from said probe tip;

(e) a plurality of conductors each connected electrically to a respective one of said terminal pads; and

(f) a substantially continuous coating of a dielectric material covering said interconnect line, said terminal pads, respective portions of said conductors connected to said terminal pads, and said substrate, a plurality of openings being defined through said coating, and each said opening exposing a predetermined area of said conductive material located on said probe tip and thereby defining a respective one of said active electrode sites, said coating of dielectric material being tightly adhered to said probe tip immediately adjacent and surrounding each of said active electrode sites.

6. In combination, a miniature electrical conductor cable and a biologically implantable microelectrode, comprising:

(a) a pair of opposite ends and an intermediate portion of said cable;

(b) a plurality of very small elongate flexible electrical conductors each having respective opposite ends corresponding with said opposite ends of said cable, each said conductor having a respective intermediate portion extending between said opposite ends thereof, said intermediate portions of said conductors being located closely alongside one another in a predetermined arrangement defining said intermediate portion of said cable;

(c) a first layer of a first electrical insulating material constituting a separate thin substantially continuous coating on each of said plurality of conductors;

(d) at least one of said opposite ends of said cable having a respective ribbonized portion including a respective transition portion in which said plurality of conductors diverge from one another and a terminal portion in which said plurality of conductors are arranged generally parallel with each other and are separated from one another by a predetermined pitch; and

(e) said plurality of conductors in said transition portions and terminal portions of said ribbonized portion included in said one of said opposite ends being covered and surrounded by and supported by a quantity of a ribbonizing material and being held in predetermined relative positions with respect to each other by said ribbonizing material, a plurality of openings being defined through said ribbonizing material and said first layer in said terminal portion, and a predetermined area of each of said conductors being cleanly exposed adjacent said ribbonizing material within each said opening as a respective active electrode site, said active electrode sites together constituting a microelectrode.

7. The combination of claim 6, each of said plurality of flexible electrical conductors including a second layer of a second insulating material constituting a separate thin coating over said first layer of said first electrical insulating material, said plurality of openings extending through said second layer.

8. The combination of claim 7 wherein said second insulating material is biologically compatible with implantation in a living body.

9. The combination of claim 7, including a third layer of a third insulating material, in the form of an overcoating over said second layer of insulating material on each of said plurality of conductors, said third layer of said third insulating material interconnecting adjacent ones of said plurality of elongate conductors, holding all of said elongate conductors closely alongside one another in a predetermined arrangement throughout said intermediate portion of said cable.

10. The combination of claim 9 wherein said third insulating material is biologically compatible with implantation in a living body.

11. The combination of claim 6, including at least a respective outermost layer of insulating material which is biologically compatible with being implanted in a living body, surrounding each of said plurality of conductors.

12. The combination of claim 6, including an outer layer of dielectric material in said intermediate portion of said cable, holding said intermediate portions of each of said conductors parallel with each other in a ribbon-like arrangement in said intermediate portion of said cable.

13. The combination of claim 6 wherein all of said plurality of conductors are arranged in a circular stranded arrangement in said intermediate portion of said cable.

14. The combination of claim 13 including an outer layer of insulating material in said intermediate portion of said cable coating the outside of at least some of said plurality of conductors over said first layer and any additional separate layers of insulating material covering said first layer on any of said plurality of conductors, with said outer layer mechanically interconnecting adjacent ones of said plurality of conductors in said intermediate portion of said cable.

15. A biologically implantable multiconductor microelectrode, comprising:

(a) a plurality of fine wires each having a surface;

(b) a quantity of a dielectric material, including a thin coating having a predetermined thickness, covering a portion of said surface of each of said plurality of fine wires and electrically insulating said fine wires from each other and holding said fine wires together in a predetermined spatial relationship with each other, said fine wires being separated from one another by a distance established by said predetermined thickness of said coating, said quantity of dielectric material having an outer surface and defining a plurality of openings, each of said openings extending inward from said outer surface and communicating between said outer surface and a predetermined area on said surface of a respective one of said fine wires at a location spaced inwardly from said outer surface.

16. The biologically implantable multiconductor microelectrode of claim 15 including a respective deposit of conductive metal different from said fine wires located in each of said plurality of openings in said electric material, each of said deposits of conductive metal being mechanically and electrically interconnected with the respective one of said fine wires in the respective opening.

17. The biologically implantable multiconductor microelectrode of claim 16 wherein each of said plurality of openings defines a space and each said deposit of electrically conductive material fills the space respectively defined by one of said openings.

18. The biologically implantable multiconductor microelectrode of claim 17 wherein each said deposit of electrically conductive material includes a terminal contact surface located flush with an outer surface of said dielectric material surrounding the respective opening in which said electrically conductive material is located.

19. A miniature electrical conductor cable suitable for implantation in a living body, comprising:

(a) a pair of opposite ends and an intermediate portion;

(b) a plurality of very small elongate flexible electrical conductors each having respective opposite ends corresponding with said opposite ends of said cable, each said conductor having a respective intermediate portion extending between said opposite ends thereof, said intermediate portions of said conductors being arranged together with each other in a helical circular strand defining said intermediate portion of said cable;

(c) a respective first layer of a first electrical insulating material, said first layer having a thickness and constituting a separate thin substantially continuous coating, surrounding said intermediate portion of each of said plurality of conductors;

(d) at least one of said opposite ends of said cable having a respective ribbonized portion defined by said plurality of conductors of said cables being substantially covered by and supported by a quantity of a ribbonizing material adhered thereto and having a predetermined thickness greater than that of said first layer, said conductors being held in predetermined relative positions with respect to each other by said ribbonizing material, said ribbonized portion including a respective transition portion adjacent said intermediate portion and said plurality of conductors diverging from one another in a single stratum in said transition portion, and said ribbonized portion also including a respective terminal portion adjacent said transition portion, said plurality of conductors in said terminal portion being parallel with each other and separated from one another by a predetermined pitch; and

(e) an electrically connectable surface portion of each of said conductors being exposed adjacent said ribbonizing material of said terminal portion.

20. The miniature electrical conductor cable of claim 19, each of said plurality of flexible electrical conductors having associated therewith throughout all of said intermediate portion a respective second layer of a second insulating material constituting a separate thin coating over said first layer of said first electrical insulating material.

21. The miniature electrical conductor cable of claim 20 wherein said second insulating material is biologically compatible with implantation in a living body.

22. The miniature electrical conductor cable of claim 21 wherein said second insulating material is a polyesterimide material.

23. The miniature electrical conductor cable of claim 20 wherein said second insulating material has a lower melting temperature than said first insulating material.

24. The miniature electrical conductor cable of claim 20, including a third layer of a third insulating material, in the form of an overcoating over said second layer of insulating material on each of said plurality of conductors, said third layer of said third insulating material interconnecting adjacent ones of said plurality of elongate conductors, holding all of said elongate conductors closely alongside one another in a predetermined arrangement throughout said intermediate portion of said cable.

25. The miniature electrical conductor cable of claim 24 wherein said third insulating material is biologically compatible with implantation in a living body.

26. The miniature electrical conductor cable of claim 25 wherein said third insulating material is a polyesterimide material.

27. The miniature electrical conductor cable of claim 25 wherein said third insulating material is a polyurethane material.

28. The miniature electrical conductor cable of claim 25 wherein said third insulating material is a silicone material.

29. The cable of claim 19 wherein said ribbonized portion includes a portion of each of said conductors substantially free from any of said first layer of said first electrical insulating material.

30. The cable of claim 19 wherein each of said conductors has associated therewith a surrounding outermost layer of an insulating material that is biologically compatible with being implanted within a living body.

31. The cable of claim 19 wherein said thickness of said first layer, measured in a radial direction respectively from a surface of each of said plurality of conductors, is no greater than about 7 microns.

32. The cable of claim 31 wherein said thickness of said first layer is in the range of 3-6 microns.

33. The cable of claim 19 including an outer layer of insulating material coating respective portions of at least some of said conductors, exterior of said first layer and thereby holding together all of said plurality of conductors in said circular stranded arrangement in said intermediate portion of said cable.

34. The miniature electrical conductor cable of claim 19 wherein said first electrical insulating material is a polyimide resin material.

35. The miniature electrical conductor cable of claim 19 wherein said first electrical insulating material is a polyurethane material.

36. The miniature electrical conductor cable of claim 19 wherein said first electrical insulating material is a silicone material.

37. The miniature electrical conductor cable of claim 19 wherein said first electrical insulating material is a polymeric fluorocarbon material.

38. The miniature electrical conductor cable of claim 19 wherein each of said elongate electrical conductors is a single wire no larger than about 0.040 mm in diameter.

39. The miniature electrical conductor cable of claim 19 wherein said intermediate portion of said cable includes a centrally located tube defining a lumen within said helical circular strand of conductors.