Mid-scalar electrode array

• US 9,415,207 B2
• Filed: 05/11/2011
• Issued: 08/16/2016
• Est. Priority Date: 05/11/2011
• Status: Active Grant

• Current Assignee: Advanced Bionics AG (Sonova Holding AG)
• Original Assignee: Advanced Bionics AG (Sonova Holding AG)
• Inventors: Thenuwara, Chuladatta, Gallegos, Rosa, Vasquez, Lidia, Downing, Mark B.
• Primary Examiner(s): Porter, Jr., Allen
• Application Number:
  US14/116,089
• Publication Number:
  US 20140094892A1
• Time in Patent Office: 1,924 Days
• Field of Search: 607 55- 57
• US Class Current: 1/1
• CPC Class Codes: A61N 1/0541 Cochlear electrodes
• CPC Class Codes: Y10T 29/49224 with coating

Abstract

In one example, a cochlear lead includes a flexible body, an array of electrodes in the flexible body, and a plurality of wires passing along the array of electrodes. The plurality of wires includes a flexural geometry between each pair of adjacent electrodes and a substantially straight geometry over the electrodes. A method for forming an electrode array with a reduced apical cross section is also provided.

Claims

1. A cochlear lead comprising:

a flexible body;

an array of electrodes in the flexible body;

a plurality of wires passing along the array of electrodes, in which the plurality of wires comprises a feature having a flexural geometry between each pair of electrodes, the feature having a radius of curvature having a height, and in which the wires have a different, straight geometry over the electrodes and in which the height of the radius of curvature lies in a plane substantially perpendicular to exposed surfaces of adjacent electrodes of the array.

2. The lead in claim 1, in which the electrodes comprise wings that fold over the plurality of wires passing over the electrodes to form a wire bundle.

3. The lead of claim 1, in which the flexural geometry is an arch comprising a first leg, a second leg and a curved center portion.

4. The lead of claim 1, in which the flexural geometry is a substantially uniform arch between a first electrode and a second electrode.

5. The lead of claim 1, in which the flexural geometry is a loop.

6. The lead of claim 1, in which the cochlear lead is configured to be inserted at least 360 degrees into the cochlea.

7. The lead of claim 1, in which the cochlear lead has a relaxed geometry that corresponds to a mid-scalar position in a cochlear duct.

8. The lead of claim 1, in which the cochlear lead is a precurved lead with a lumen and has a first cross sectional area at a basal electrode and a reduced cross sectional area at an apical electrode, the reduced cross sectional area being at least 50 percent smaller than the first cross sectional area.

9. The lead of claim 1, in which the cochlear lead has a ratio of total cross area to wire cross sectional area that is at most 120.

10. The lead of claim 1, in which the flexible body is one shot molded to form an electrode array with a relaxed geometry that has at least a 360 degree curvature.

11. The lead of claim 1, in which each wire in the plurality of wires has a diameter of 25 microns or less and is formed from a platinum/iridium alloy.

12. The lead of claim 1, in which the flexural geometry extends to a neutral bending axis of the cochlear lead.

13. The lead of claim 1, in which the flexural geometry in the plurality of wires is configured to create a spring force which tends to return the flexible body to a mid-scalar geometry after straightening.

14. The lead of claim 1, in which only a single a single said feature with flexural geometry is disposed between adjacent electrodes.

15. The lead of claim 1, wherein:

the electrode array comprises a linear array of electrodes disposed in the flexible body, a basal portion of the electrode array having a first cross sectional area at a basal electrode; and

an apical portion of the electrode array having a reduced cross sectional area at an apical electrode, the reduced cross sectional area being at least 50 percent smaller than the first cross sectional area; and

a plurality of wires passing along the electrode array has an arched flexural geometry between each of the electrodes in the electrode array such that the stiffness of the plurality of wires is reduced;

the plurality of wires being contained by wings on the electrodes as the plurality of wires pass over the electrodes, the plurality of wires being substantially straight as the plurality of wires passes over the electrodes;

in which the cochlear lead is configured to be inserted into a cochlea at least 360 degrees and be located at a mid-scalar position within a cochlear duct.

16. The lead of claim 1, wherein the electrode array comprises:

a basal portion having a first cross sectional area at a basal electrode; and

an apical portion having a second cross sectional area at an apical electrode, the second cross sectional area being at least 50 percent smaller than the first cross sectional area, the electrode array being configured to be placed in a midscalar position in the cochlea and have an insertion depth of at least 360 degrees.

17. A method for forming an electrode array with a reduced apical cross section comprises:

forming a feature having a single flexural geometry in each portion of a wire that will be located between electrodes, the feature having a radius of curvature having a height, with portions of the wire which pass over the electrodes having a different, straight geometry and the height of the radius of curvature of the feature is in a plane substantially perpendicular to exposed surface of adjacent electrodes of the array;

connecting the wires to the electrodes;

placing the wires and the electrodes in a mold;

injecting an encapsulation material into the mold;

curing the encapsulation material; and

removing the electrode array from the mold.

18. The method of claim 17, in which the method for forming the electrode array comprises a single step molding process which produces an electrode array with a completed silicone body.

19. The method of claim 17, in which injecting the encapsulation material into the mold comprises a single shot liquid injection molding process.

20. The method of claim 17, in which the wire is platinum/iridium wire with a diameter less than 25 microns.

21. The method of claim 17, further comprising selecting a wire which retains the flexural geometry in the portions of the wire located between the electrodes through multiple straightening cycles.

22. The method of claim 17, in which the flexural geometry is oriented in a plane which intersects both the medial and lateral walls of the scala tympani.

23. The method of claim 17, in which forming the flexural geometry in portions of a wire that will he located between electrodes comprises forming an arch which extends into the silicone body at least to a neutral bending axis of the electrode array to minimize stress in the wire when straightening the electrode.