Electrode system with rigid-flex circuit

• US 9,072,448 B2
• Filed: 05/20/2013
• Issued: 07/07/2015
• 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:
  US13/897,900
• Publication Number:
  US 20130253300A1
• Time in Patent Office: 778 Days
• Field of Search: 600/383, 600/393, 600/544, 600/545
• US Class Current: 1/1
• 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, a plurality of electrode modules, and a plurality of sensors. 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. The sensors may be removably coupled with at least one of the plurality of electrode modules and may sense ERPs from the test subject.

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, wherein the flexible circuit substrate further comprises an upper surface and a lower surface;

(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 a pair of rigid circuit members 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 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 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; and

(c) a plurality of sensors, wherein each sensor of the plurality of sensors is configured to removably couple with at least 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, wherein a portion of each sensor is configured to extend outward from the plurality of electrode modules.

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, wherein each sensor of the plurality of sensors comprises at least one tab.

6. The electrode system of claim 1, wherein each sensor of the plurality of sensors comprises an upper and lower portion layered together.

7. The electrode system of claim 1, 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.

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 pair of rigid circuit members of each electrode module are 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 the 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 EVP 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 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;

(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 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; and

(c) a plurality of sensors, wherein each sensor of the plurality of sensors is configured to removably couple with at least 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, wherein a portion of each sensor is configured to extend outward from the plurality of electrode modules, wherein each sensor of the plurality of sensors comprises at least one tab.

18. 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;

(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 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 each electrode module of the plurality of electrode modules defines a substantially central opening, wherein each electrode module further comprises a conductive ring; and

(c) a plurality of sensors, wherein each sensor is positioned within the substantially central opening of an associated one of the plurality of electrode modules, wherein each sensor of the plurality of sensors is configured to removably couple with the associated electrode module, 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, wherein a portion of each sensor is configured to extend outward from the plurality of electrode modules.