Electrode system with rigid-flex circuit

• US 8,463,354 B2
• Filed: 03/23/2012
• Issued: 06/11/2013
• Est. Priority Date: 09/25/2009
• Status: Active Grant

• Current Assignee: Neuronetrix Solutions LLC
• Original Assignee: Neuronetrix Solutions LLC
• Inventors: Fadem, Kalford C.
• Primary Examiner(s): Cohen, Lee S
• Assistant Examiner(s): Cardinal, Erin M
• Application Number:
  US13/428,183
• Publication Number:
  US 20120179019A1
• Time in Patent Office: 445 Days
• Field of Search: 600/383, 600/393, 600/544, 600/545
• US Class Current: 600/383
• CPC Class Codes: A61B 2560/0443 Modular apparatus
• CPC Class Codes: A61B 2562/0215 Silver or silver chloride containing
• CPC Class Codes: A61B 2562/0217 Electrolyte containing
• CPC Class Codes: A61B 2562/046 in a matrix array
• CPC Class Codes: A61B 2562/164 the sensor is mounted in or on a conformable substrate or carrier
• CPC Class Codes: A61B 2562/166 the sensor is mounted on a specially adapted printed circuit board
• CPC Class Codes: A61B 5/291 for electroencephalography [EEG]
• CPC Class Codes: A61B 5/377 using evoked responses
• CPC Class Codes: A61B 5/6814 Head

Abstract

An electrode system comprises a flexible circuit substrate and a plurality of electrode modules. The flexible circuit substrate comprises a flexible material and traces supported by the flexible material. The flexible circuit substrate extends through at least two of the electrode modules such that the electrode modules encompass portions of the flexible circuit substrate. Each electrode module comprises at least one rigid circuit member configured to process ERPs of a test subject. The rigid circuit members are layered against the flexible circuit substrate such that the rigid circuit members and the flexible circuit substrate together form a rigid-flex circuit. A sensor may be removably disposed through a substantially central opening defined by each electrode module.

Claims

1. An electrode system, comprising:

(a) a flexible circuit substrate, wherein the flexible circuit substrate comprises a flexible material and traces supported by the flexible material, wherein the traces are configured to provide communication of signals; and

(b) a plurality of electrode modules, wherein the flexible circuit substrate extends completely through at least two electrode modules of the plurality of electrode modules such that the at least two electrode modules encompass corresponding portions of the flexible circuit substrate, wherein the electrode modules are positionable at different locations on the head of a test subject, wherein each electrode module comprises at least one rigid circuit member having sensing circuitry configured to process evoked response potentials (ERPs) of the test subject sensed at the corresponding location on the head of the test subject, wherein the at least one rigid circuit member comprises a pair of rigid circuit members, wherein the rigid circuit members are layered against the flexible circuit substrate such that the rigid circuit members and the flexible circuit substrate together form a rigid-flex circuit, wherein the flexible circuit substrate comprises an upper surface and a lower surface, wherein each pair of rigid circuit members comprises an upper rigid circuit member layered against the upper surface of the flexible circuit substrate and a lower rigid circuit member layered against the lower surface of the flexible surface substrate.

2. The electrode system of claim 1, wherein the flexible circuit substrate is configured to provide power to the rigid circuit members via the traces.

3. The electrode system of claim 1, wherein the flexible circuit substrate is configured to communicate signals relating to ERPs from the sensing circuitry along the traces.

4. The electrode system of claim 1, wherein the flexible circuit substrate has an elongate shape defining a length, wherein the upper rigid circuit member and the lower rigid circuit member of each pair of rigid circuit members are both positioned along a common portion of the length of the flexible circuit substrate.

5. The electrode system of claim 1, further comprising a plurality of sensors, wherein each sensor of the plurality of sensors is configured to removably couple with a corresponding one of the plurality of electrode modules, wherein each sensor is configured to sense ERPs from the test subject, wherein each sensor is further configured to communicate sensed ERPs to the associated electrode module.

6. The electrode system of claim 5, wherein each sensor of the plurality of sensors comprises an insulating upper portion, an electrolytic hydrogel lower portion, and a conductive portion between the upper and lower portions, wherein the conductive portion comprises a plurality of conductive tabs extending outwardly relative to the upper and lower portions.

7. The electrode system of claim 5, wherein each electrode module of the plurality of electrode modules defines a substantially central opening, wherein each sensor is positioned within the substantially central opening of the associated electrode module.

8. The electrode system of claim 7, wherein each electrode module further comprises a conductive ring, wherein each conductive ring is substantially coaxial with the substantially central opening of the associated electrode module.

9. The electrode system of claim 8, wherein each electrode module further comprises a housing defining the substantially central opening, wherein the conductive ring of each electrode module is at least partially exposed in an inner diameter of the substantially central opening defined by the housing of the associated electrode module.

10. The electrode system of claim 8, wherein each sensor comprises at least one outwardly extending conductive tab, wherein the outwardly extending conductive tab is configured to contact the conductive ring of the associated electrode module.

11. The electrode system of claim 1, wherein each of the electrode modules further comprises an upper clamshell member and a lower clamshell member, wherein the at least one rigid circuit member of each electrode module is positioned between the upper clamshell member and the lower clamshell member of the corresponding electrode module, wherein the upper clamshell member and the lower clamshell member are coupled together.

12. The electrode system of claim 1, wherein the sensing circuitry of each electrode module comprises a corresponding amplifier.

13. The electrode system of claim 1, further comprising a head frame configured to fit on the head of a test subject, wherein the electrode modules are removably coupled with the head frame.

14. The electrode system of claim 1, further comprising a handheld control box in communication with the electrode modules.

15. The electrode system of claim 14, wherein the handheld control box comprises a storage medium storing ERP testing protocols and a processor operable to execute evoked response testing via the electrode modules in accordance with the stored evoked response testing protocols.

16. The electrode system of claim 15, wherein the storage medium of the control box is further operable to store results of the evoked response testing.

17. An electrode system, comprising:

(a) a head frame configured to fit on the head of a test subject;

(b) a plurality of electrode modules removably coupled with the head frame, wherein each of the electrode modules comprises;

(i) circuitry configured to process evoked response potentials (ERPs) of the test subject sensed at different location on the head of the test subject,

(ii) one or more housing members, wherein the one or more housing members defines a substantially central opening, and

(iii) a conductive ring substantially coaxial with the substantially central opening; and

(c) a rigid-flex circuit, wherein the rigid-flex circuit comprises;

(i) a flexible substrate having conductive traces, wherein the flexible substrate passes through each of the electrode modules, wherein the flexible substrate physically couples the electrode modules together, and

(ii) rigid circuit board layers bonded to the flexible substrate in a layered fashion, wherein the rigid circuit board layers are substantially encapsulated by the one or more housing members, wherein at least part of the circuitry of the electrode modules is associated with the rigid circuit board layers.

18. An electrode system, comprising:

(a) a plurality of electrode modules, wherein the electrode modules are positionable at different locations on the head of a test subject, wherein each of the electrode modules comprises;

(i) circuitry configured to process evoked response potentials (ERPs) of the test subject sensed at different location on the head of the test subject, and

(ii) one or more housing members, wherein the one or more housing members define an opening;

(b) a rigid-flex circuit, wherein the rigid-flex circuit comprises;

(i) a flexible substrate having conductive traces, wherein the flexible substrate passes through each of the electrode modules, wherein the flexible substrate physically couples the electrode modules together, and

(ii) rigid circuit board layers bonded to the flexible substrate in a layered fashion, wherein the rigid circuit board layers are substantially encapsulated by the one or more housing members, wherein at least part of the circuitry of the electrode modules is associated with the rigid circuit board layers, wherein at least some of the rigid circuit board layers define openings corresponding with the openings defined by the housing members of the electrode modules; and

(c) a plurality of sensors, wherein each sensor is removably disposed in a corresponding set of openings formed through the one or more housing members and rigid circuit board layers, wherein each sensor is configured to sense ERPs of the test subject, wherein each sensor of the plurality of sensors comprises an insulating upper portion, an electrolytic hydrogel lower portion, and a conductive portion between the upper and lower portions, wherein the conductive portion comprises a plurality of conductive tabs extending outwardly relative to the upper and lower portions.