Method of making implantable microelectrode

• US 5,524,338 A
• Filed: 12/22/1994
• Issued: 06/11/1996
• Est. Priority Date: 10/22/1991
• Status: Expired due to Term

• Current Assignee: Advanced Neuromodulation Systems Incorporated (Abbott Laboratories Incorporated)
• Original Assignee: PI Medical Corporation
• Inventors: Mewes, Klaus, Beck, Doris A., Loeb, Gerald E., Corbett, Scott S. III, Martyniuk, Jerry, Skiens, W. Eugene, Stobie, John J.
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US08/362,806
• Time in Patent Office: 537 Days
• Field of Search: 29/825, 128/642
• US Class Current: 29/825
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61F 11/04 Methods or devices for enabling ear patients to achieve auditory perception through physiological senses other than hearing sense, e.g. through the touch sense electronic stimulation of auditory nerves A61N1/36036
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: H01R 13/50 formed as an integral body H01R13/514 takes precedence
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

Microelectrodes for use in stimulating and detecting activity in neurons of living organisms, and a method of manufacturing such microelectrodes. An electrically conductive electrode core member is sharpened and coated with a thin layer of a dielectric material. An extremely small area of the core at the sharpened point is exposed by ablating the dielectric material by the use of ultraviolet laser beam scanned over the material. Multiconductor microelectrodes include multiple fine wires which may be arranged in helical strands, optionally supported by a central core member of stiffer material. Multiple conductors may also be supported within a tubular support such as a hollow needle whose distal end is cut at a slant to expose the conductors, or in flat ribbon configuration with openings in dielectric material defining active electrode sites. Multiple active electrode sites may be defined on a microelectrode accompanied by an integrated circuit after connection of the integrated circuit to a multiconductor cable.

Claims

1. A method of manufacturing a biologically implantable multiconductor electrode, comprising:

(a) providing a plurality of fine wires;

(b) holding said fine wires in predetermined spatial relationship to each other while applying a coating of a biologically implantable dielectric material thereto, thereby forming a distal end portion of said multiconductor electrode;

(c) arranging respective portions of all of said plurality of fine wires in a helical strand and holding said portions of said wires in a configuration defining said helical strand by said coating of dielectric material on said distal end portion thereof; and

(d) directing a beam of ultraviolet light onto a predetermined location in said distal end portion, thereby ablating a portion of said dielectric material from one of said fine wires, exposing cleanly a surface area of said one of said fine wires as an electrode site while leaving said dielectric material attached securely to said fine wire adjacent said active electrode site.

2. The method of claim 1, including the steps of sharpening said distal end portion and thereafter applying a second coating of dielectric material to said helical strand of conductors before directing said beam of ultraviolet light onto said predetermined area.

3. The method of claim 2, including the step of directing said beam of ultraviolet light onto a plurality of areas of said multiconductor electrode and thereby removing a quantity of said dielectric material from each of said conductors at respective active electrode sites spaced apart from one another longitudinally of said helical strand.

4. The method of claim 1, including the further step of providing and connecting electrically to said surface area of said active electrode site on said fine wire a respective quantity of electrically conductive material and thereby replacing at least a portion of said dielectric material which has been ablated therefrom.

5. The method of claim 1, including the further step of depositing onto said surface area of said active electrode site on said fine wire a respective quantity of electrically conductive material and thereby replacing a portion of said dielectric material which has been ablated therefrom.

6. The method of claim 5 wherein said dielectric material has an outer surface, including the step of depositing said electrically conductive material onto said surface area of said active electrode site on said fine wire to a predetermined height with respect to an outer surface of said dielectric material.

7. The method of claim 1, including the additional step of shaping said dielectric material into a sharp point at said distal end of said multiconductor electrode.

8. The method of claim 1, including the additional step of thermally fusing a part of said dielectric material adjacent said surface area from which said dielectric material has been removed by said beam of ultraviolet light and resolidifying said dielectric material adhered to said wire.

9. The method of claim 1 wherein said dielectric material is a polymer of para-chloroxylylene and said beam of ultraviolet light is a laser beam.

10. The method of claim 1 wherein said step of directing a beam of ultraviolet light includes directing a narrowly focused laser beam successively onto respective portions of said dielectric material and thereby removing said dielectric material progressively.

11. The method of claim 1 wherein said step of holding said fine wires includes placing said fine wires in a support tube, providing an open distal end of said support tube, and separately exposing a respective surface area as an active electrode site on each of said fine wires, at respective locations spaced apart from one another proximate said open distal end.

12. A method of making a miniature multiconductor electrical cable including a microelectrode, comprising:

(a) coating a plurality of fine elongate electrical conductors with a first continuous layer of a first insulating material;

(b) arranging respective intermediate portions of all of said plurality of fine elongate electrical conductors closely adjacent one another;

(c) placing and holding a respective terminal portion of each of said fine elongate electrical conductors in a fixture in a terminal configuration with said terminal portions of said conductors substantially parallel with one another and spaced apart from one another in a planar arrangement at a predetermined pitch;

(d) ribbonizing said terminal portions of said fine elongate electrical conductors by applying and curing a layer of insulating ribbonizing material over said terminal portions, embedding said terminal portions in said material and thereby holding said terminal portions in a terminal configuration; and

(e) stripping away said layers of insulating material from each of said fine elongate electrical conductors in a portion of said ribbonized portion of said cable by use of an ultraviolet laser beam scanned in an appropriate pattern under computer control while holding said conductors arranged with said predetermined pitch therebetween adjacent said terminal portion of each of said conductors to provide an opening cleanly exposing a surface area of each said electrical conductor as an active electrode site with a predetermined configuration in a terminal portion of said cable.