Nerve cuff, method and apparatus for manufacturing same

• US 20080065184A1
• Filed: 06/04/2007
• Published: 03/13/2008
• Est. Priority Date: 06/02/2006
• Status: Active Grant

• Current Assignee: 4491343 Canada Inc.
• Original Assignee: 4491343 Canada Inc.
• Inventors: Vallieres, Jean-Martin, Imbeau, Marc-Olivier, Hoffer, Joaquin
• Granted Patent: US 8,214,056 B2
• Time in Patent Office: Days
• US Class Current: 607/118
• CPC Class Codes: A61N 1/0556 Cuff electrodes
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 45/14426 Coating the end of wire-like or rod-like or cable-like or blade-like or belt-like articles
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A nerve cuff comprising a wall band member having an inner surface defining a lumen when the wall band member is in a closed configuration for receiving a nerve therethrough. At least one longitudinal and contiguous conductor extends within the lumen. The conductor is insulated and has at least one exposed portion thereby providing an electrode. When mounting the nerve cuff to a nerve, each electrode is in electrical communication with the nerve. A multi-channel nerve cuff further comprises a plurality of longitudinal ridges formed on the inner surface with each adjacent pair of ridges defining a longitudinal chamber. Each chamber comprises a respective conductor extending therein. When mounting the multi-channel nerve cuff to the nerve, the ridges abut the nerve providing for each chamber to isolate respective longitudinal portions of the nerve. A method and an apparatus for manufacturing such nerve cuffs are also disclosed.

Claims

1. A nerve cuff comprising:

a wall band member having an inner surface defining a lumen when said wall band member is in a closed configuration for receiving a nerve therethrough; and

at least one longitudinal and contiguous conductor extending within said lumen, said conductor being insulated and having at least one exposed portion thereof, thereby providing an electrode,

wherein, when mounting said nerve cuff to a nerve, each said electrode is in electrical communication with the nerve.

2. A nerve cuff according to claim 1, further comprising a plurality of longitudinal ridges formed on said inner surface, each adjacent pair of said ridges defining a longitudinal chamber, each said chamber comprising a respective said conductor extending therein, wherein, when mounting said nerve cuff to the nerve, said ridges abut the nerve providing for each said chamber to isolate respective longitudinal portions of the nerve.

3. A nerve cuff according to claim 1, wherein said conductor is embedded within said wall band member, said inner surface being apertured so as to expose said at least one portion of said conductor thereby providing said electrode.

4. A nerve cuff according to claim 1, wherein said conductor is mounted on said inner surface.

5. A nerve cuff according to claim 1, wherein said inner surface comprises at least one longitudinal protuberance extending within said lumen, said at least one conductor being mounted to said longitudinal protuberance.

6. A nerve cuff according to claim 5, wherein said at least one conductor is embedded within said longitudinal protuberance.

7. A nerve cuff according to claim 6, wherein said longitudinal protuberance is apertured so as to expose said at least one portion of said conductor thereby providing said electrode.

8. A nerve cuff according to claim 5, wherein said at least one conductor is mounted on said protuberance.

9. A nerve cuff according to claim 2, wherein said inner surface comprises a plurality of longitudinal protuberances, each longitudinal protuberance extending within a respective said chamber, each said longitudinal protuberance having a said conductor mounted thereto.

10. A nerve cuff according to claim 9, wherein each said conductor is embedded within a respective said longitudinal protuberance.

11. A nerve cuff according to claim 9, wherein each said longitudinal protuberance is apertured so as to expose said at least one portion of said conductor thereby providing said electrode.

12. A nerve cuff according to claim 9, wherein each said conductor is mounted on a respective said longitudinal protuberance.

13. A nerve cuff according to claim 12, wherein said conductor is mounted along substantially the full length of said protuberance.

14. A nerve cuff according to claim 9, wherein said longitudinal protuberance provides for positioning said electrode at substantially the same level as said longitudinal ridges relative to said inner surface.

15. A nerve cuff according to claim 5, wherein a said longitudinal protuberance is so configured as to provide for said electrode to be in contact with or at least near the surface of the nerve when said nerve cuff is mounted thereto.

16. A nerve cuff according to claim 1, wherein said conductor comprises a pair of wires.

17. A nerve cuff according to claim 16, wherein said wires are insulated, said insulation being removed at said at least one exposed portion providing said electrode.

18. A nerve cuff according to claim 1, wherein an end of said longitudinal conductor protrudes beyond said wall band member.

19. A nerve cuff according to claim 18, wherein said protruding end of said conductor is capped.

20. A nerve cuff according to claim 1, further comprising a ground wire mounted to said wall band member.

21. A nerve cuff according to claim 20, wherein said ground wire is embedded within said wall band member.

22. A nerve cuff according to claim 20, wherein a ground wire is embedded within said longitudinal ridges.

23. A nerve cuff according to claim 1, wherein said wall band member comprises a closure for maintaining said wall band member in said closed configuration.

24. A nerve cuff according to claim 23, wherein said closure comprises mutually interdigitating members positioned at each lateral side of said wall band member.

25. A nerve cuff according to claim 24, wherein said interdigitating members are combined with a sealing tube.

26. A nerve cuff according to claim 24, wherein a rod-like member is inserted through said mutually interdigitating members when interdigitated thereby closing said interdigitated members together.

27. A nerve cuff according to claim 1, wherein said wall band member comprises ports for connection to an agent delivery system.

28. A nerve cuff comprising:

a wall band member having an inner surface defining a lumen when said wall band member is in a closed configuration for receiving a nerve therethrough;

at least one longitudinal protuberance on said inner surface extending within said lumen; and

at least one electrode mounted to said longitudinal protuberance,

wherein, when mounting said nerve cuff to a nerve, said at least one longitudinal protuberance provides for said electrode to be in contact with or at least near the surface of the nerve.

29. A nerve cuff according to claim 28, further comprising a plurality of longitudinal ridges formed on said inner surface, each adjacent pair of said ridges defining a longitudinal chamber, each chamber comprising a said longitudinal protuberance extending therein, wherein, when mounting said nerve cuff to a nerve, said ridges abut the nerve providing for each said chamber to isolate respective longitudinal portions of the nerve.

30. A nerve cuff according to claim 29, wherein said longitudinal protuberance provides for positioning said electrode at substantially the same level as said longitudinal ridges relative to said inner surface.

31. A nerve cuff according to claim 28, wherein a given said electrode is defined by an exposed portion of an insulated conductor mounted to said longitudinal protuberance.

32. A nerve cuff according to claim 31, wherein said conductor is a longitudinal and contiguous element extending along said longitudinal protuberance.

33. A nerve cuff according to claim 31, wherein said conductor comprises a pair of wires.

34. A nerve cuff according to claim 30, wherein said conductor comprises an end thereof protruding beyond said wall band member, said protruding end being capped.

35. A nerve cuff according to claim 28, further comprising a ground wire mounted to said wall band member.

36. A nerve cuff according to claim 28, wherein said wall band member comprises a closure.

37. A nerve cuff according to claim 28, wherein said wall band member comprises ports for connection to an agent delivery system.

38. A nerve cuff comprising:

a wall band member having an inner surface defining a lumen when said wall band member is in a closed configuration for receiving a nerve therethrough;

a plurality of longitudinal ridges formed on said inner surface, each adjacent pair of said ridges defining a longitudinal chamber;

a longitudinal protuberance extending within each said chamber; and

a longitudinal and contiguous conductor mounted to each said longitudinal protuberance, said conductor being insulated and having at least one exposed portion thereof thereby providing an electrode,

wherein, when mounting said nerve cuff to a nerve, said ridges abut the nerve providing for each said chamber to isolate respective longitudinal portions of the nerve, each said longitudinal protuberance providing for a said electrode to be in contact with or at least near the surface of the nerve.

39. A method of manufacturing a nerve cuff, said method comprising:

(a) providing a mold comprising a plurality of longitudinal grooves;

(b) positioning longitudinal conductors coated with insulation within respective longitudinal grooves;

(c) applying flexible bio-compatible material on the mold with the longitudinal conductors positioned therein;

(d) curing the flexible bio-compatible material so as to provide a wall band member with the longitudinal conductors adhered thereto;

(e) ejecting the wall band member with the adhered longitudinal conductors; and

(f) removing lengths of the insulation on the longitudinal conductors thereby providing electrodes.

40. A method according to claim 39, wherein step (b) further comprises positioning longitudinal tubes within the longitudinal grooves, step (c) comprising applying flexible bio-compatible material on the mold with the longitudinal conductors and the longitudinal tubes positioned therein, curing in step (d) providing for the longitudinal tubes to adhere to the wall band member and step (e) comprising ejecting the wall band member with the adhered longitudinal conductors and longitudinal tubes.

41. A method according to claim 40, wherein the longitudinal tubes are made of silicone.

42. A method according to claim 40, wherein rods are positioned in the longitudinal tubes before step (b).

43. A method according to claim 40, wherein after curing, the longitudinal tubes comprise ridge tubes for providing ridges along the length of the wall band member.

44. A method according to claim 43, wherein the longitudinal grooves having the conductors positioned therein are so configured as to provide the electrodes to be at substantially the same level as the top of the ridges.

45. A method according to claim 40, wherein after curing, the longitudinal tubes comprise closing element tubes for providing closing elements positioned at each lateral sides of the wall band member.

46. A method according to claim 45, wherein portions of the closing elements are removed thereby providing a set of closing elements at each lateral side of the wall band member with a mutually engaging interdigitating pattern.

47. A method according to claim 46, further comprising binding a sealing tube on one set of closing elements and a ridge at one of the lateral sides of the wall band member.

48. A method according to claim 43, wherein after ejecting, a ground wire is inserted through the ridges via their respective proximal and distal ends.

49. A method according to claim 48, wherein after inserting the ground wire, the ridges are sealed at their respective proximal and distal ends.

50. A method according to claim 48, further comprising connecting a connector to the longitudinal conductor and the ground wire so as to provide further interface.

51. A method according to claim 39, wherein the longitudinal conductors protrude beyond the longitudinal grooves when positioned therein, said method further comprising cutting the protruding ends of the conductors to a desired length.

52. A method according to claim 51, further comprising applying flexible bio-compatible material on the remaining protruding ends of the conductors thereby capping the conductors.

53. A method according to claim 39, wherein the conductors comprise respective pairs of insulated wires.

54. A method according to claim 53, wherein before positioning the conductors in the longitudinal grooves, the wires are cut to appropriate length and etched so as to facilitate adherence to a bio-compatible material after curing thereof.

55. A method according to claim 39, wherein after ejecting, the excess material of the wall band member is removed.

56. A method according to claim 39, wherein the flexible bio-compatible material comprises silicone.

57. An apparatus for manufacturing a nerve cuff, said apparatus comprising:

a base;

at least one open mold formed within the top face of said base, said mold comprising longitudinal grooves for positioning longitudinal conductors therein;

end plates positioned near each end of said base, each said end plate comprising alignment holes for aligning the conductors positioned in said grooves; and

first and second conductor clamps for clamping the conductors near each longitudinal end thereof respectively, at least one of said first and second conductor clamps being so moveable as to tighten the clamped conductors,

wherein when the conductors are positioned in said grooves and tightened, a flexible bio-compatible material can be applied to said mould for providing the nerve cuff.

58. An apparatus according to claim 57, wherein said at least one moveable clamp is mounted to a tightening device.

59. An apparatus according to claim 58, wherein said tightening device comprises a main body, said at least one clamp being mounted to said main body, and a tightness adjustment member mounted to said main body, wherein actuation of said tightness adjustment member causes said at least one clamp to move away from base member when clamping conductors.

60. An apparatus according to claim 57, wherein said at least one moveable clamp is positioned between one said end plate and said base.

61. An apparatus according to claim 57, wherein both said first and second conductor clamps are moveable with respect to said base member.

62. An apparatus according to claim 57, further comprising at least one tubing clamp for clamping longitudinal tubes positioned in said longitudinal grooves.

63. An apparatus according to claim 62, wherein said longitudinal grooves comprise conductor grooves for receiving conductors therein and tubing grooves for receiving tubes therein.

64. An apparatus according to claim 63, wherein said conductor grooves and said tubing grooves comprise different configurations.

65. An apparatus according to claim 64, wherein said conductor grooves are deeper than said tubing grooves.

66. An apparatus according to claim 62, wherein said tubing grooves comprise ridge grooves for positioning ridge tubes therein and closure element grooves for receiving closure element tubes therein.

67. An apparatus according to claim 66, wherein said ridge grooves and said closure element grooves comprise different configurations.

68. An apparatus according to claim 66, wherein said ridge grooves are deeper than said closure element grooves.

69. An apparatus according to claim 66, wherein said closure element grooves are positioned at each lateral extremity of said mold.

70. An apparatus according to claim 66, wherein each said conductor groove is positioned between a pair of said ridge grooves.

71. A multi-channel nerve cuff comprising a wall band member having an inner surface defining a lumen when said wall band member is in a closed configuration for receiving a nerve therethrough, said inner surface defining a plurality of channels, each said channel including a plurality of electrodes, each said electrode of a same said channel provided from a same conductor, wherein, when mounting said nerve cuff to a nerve, each said electrode is in electrical communication with the nerve.

72. A multi-channel nerve cuff according to claim 71, wherein said electrodes of a same said conductor comprise indifferent electrodes and recording electrodes.