Neural interface system with an edge array

• US 9,008,747 B2
• Filed: 03/09/2012
• Issued: 04/14/2015
• Est. Priority Date: 03/09/2011
• Status: Active Grant

• Current Assignee: Neuronexus Technologies Incorporated (NEL Group, Inc.)
• Original Assignee: Neuronexus Technologies Incorporated (NEL Group, Inc.)
• Inventors: Seymour, John, Hetke, Jamille, Vetter, Rio, Kipke, Daryl, Pellinen, David, Kong, Kc
• Primary Examiner(s): Cohen, Lee S
• Application Number:
  US13/416,775
• Publication Number:
  US 20130090525A1
• Time in Patent Office: 1,131 Days
• Field of Search: 600/377, 600/378, 607/116
• US Class Current: 600/377
• CPC Class Codes: A61B 1/07 using light-conductive means, e.g. optical fibres
• CPC Class Codes: A61M 25/0009 Making of catheters or other medical or surgical tubes
• CPC Class Codes: A61M 25/0023 by the form of the lumen, e.g. cross-section, variable diameter
• CPC Class Codes: A61N 1/0534 Electrodes for deep brain stimulation
• CPC Class Codes: A61N 1/0553 Paddle shaped electrodes, e.g. for laminotomy
• CPC Class Codes: A61N 2005/0632 Constructional aspects of the apparatus
• CPC Class Codes: A61N 5/0601 Apparatus for use inside the body
• CPC Class Codes: H05K 1/028 Bending or folding regions of flexible printed circuits H05K1/0283 takes precedence
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 2201/051 Rolled
• CPC Class Codes: H05K 3/10 in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

The neural interface system of one embodiment includes a cylindrical shaft, a lateral extension longitudinally coupled to at least a portion of the shaft and having a thickness less than a diameter of the shaft, and an electrode array arranged on the lateral extension and radially offset from the shaft, including electrode sites that electrically interface with their surroundings. The method of one embodiment for making the neural interface system includes forming a planar polymer substrate with at least one metallization layer, patterning on at least one metallization layer an electrode array on a first end of the substrate, patterning conductive traces on at least one metallization layer, rolling a portion of the substrate toward the first end of the substrate, and securing the rolled substrate into a shaft having the first end of the substrate laterally extending from the shaft and the electrode array radially offset from the shaft.

Claims

1. A neural interface system, comprising:

a) a substrate, comprising;

i) a substantially cylindrical shaft formed as a rolled portion of the substrate; and

ii) a lateral extension portion of the substrate, wherein the lateral extension extends longitudinally from at least a portion of the shaft and has a thickness less than a diameter of the shaft; and

b) an electrode array, at least partially arranged on the lateral extension and radially offset from the shaft, wherein the electrode array comprises a plurality of electrode sites that are configured to electrically interface with their surroundings.

2. The neural interface system of claim 1, wherein the lateral extension is a trailing end of the rolled substrate.

3. The neural interface system of claim 1, wherein the lateral extension is tangent to the shaft.

4. The neural interface system of claim 1, wherein the rolled substrate defines a lumen.

5. The neural interface system of claim 4, wherein the lumen is configured to receive and transport a fluid.

6. The neural interface system of claim 4, further comprising a stylet insertable into the lumen.

7. The neural interface system of claim 6, wherein the stylet includes a microwire that functions as a single channel microelectrode.

8. The neural interface system of claim 5, further comprising an optical light source disposed within the lumen.

9. The neural interface system of claim 1, wherein the substrate has conductive traces coupled to the electrode array, and wherein the neural interface system further comprises a first electrical subsystem in electrical communication with the conductive traces.

10. The neural interface system of claim 9, wherein the conductive traces extend from the electrode array to a bond pad region of the substrate, and wherein the first electrical subsystem is coupled to the bond pad region of the substrate.

11. The neural interface system of claim 9, wherein the shaft defines a lumen with the first electrical subsystem being at least partially disposed within the lumen, and wherein the system further comprising a second electrical subsystem disposed outside the lumen and in direct electrical communication with the first electrical subsystem.

12. The neural interface system of claim 11, wherein the first electrical subsystem includes an amplifier at least partially disposed within the lumen.

13. The neural interface system of claim 11, wherein the first electrical subsystem includes a multiplexer at least partially disposed within the lumen.

14. The neural interface system of claim 1, wherein the substrate has conductive traces electrically coupled from the electrode array to a first electrical subsystem, and wherein a wired connector couples the first electrical subsystem to a second electrical subsystem.

15. The neural interface system of claim 1, wherein the substrate has conductive traces electrically coupled from the electrode array to a first electrical subsystem, and wherein the first electrical subsystem is configured to wirelessly communicate with a second electrical subsystem.

16. The neural interface system of claim 1, wherein the lateral extension has a slanted distal edge extending to a sharpened distal end of the shaft.

17. The neural interface system of claim 1, wherein the electrode array is arranged at least partially along a longitudinal edge of the lateral extension.

18. The neural interface system of claim 17, wherein the electrode array comprises at least one of a recording electrode site and a stimulation electrode site.

19. The neural interface system of claim 1, wherein the substrate is a polymer substrate having three metallization layers interspersed with silicon carbide insulation layers.

20. The neural interface system of claim 19, wherein the metallization layers are from about 0.7 μ

m to 1.3 μ

m thick.

21. The neural interface system of claim 1, wherein the lateral extension is coupled to the shaft by at least one rib bridging the lateral extension and shaft.

22. The neural interface system of claim 21, wherein the lateral extension is coupled to the shaft by at least two bridging ribs, thereby forming a perforated framework between the shaft and lateral extension with at least one opening bounded by the ribs.

23. A neural interface system, comprising:

a) a polymer substrate, comprising;

i) a substantially cylindrical shaft formed as a rolled portion of the substrate, wherein the cylindrical shaft defines a lumen; and

ii) a lateral extension portion of the polymer substrate, wherein the lateral extension is tangent to the cylindrical shaft, and wherein the lateral extension has a thickness equal to or less than approximately 5 micrometers; and

b) a high-density electrode array, linearly arranged along a longitudinal edge of the lateral extension and radially offset from the shaft, wherein the electrode array comprises at least one hundred microelectrode sites that are configured to electrically interface with their surroundings.