Patent ID: 6757970
Filing Date: 2004-07-06
Classification: A61N,Y10T

Abstract:
A method of making an implantable multicontact electrode array comprising:helically winding a plurality of insulated wires to define a lumen; each of said wires having a distal end; positioning a tube jacket around the helically wound wires, said tube jacket covering all but the distal end of the insulated wires; defining a pattern of marks on a metal foil carrier at a desired spacing and orientation using a positioning tool, which marks are used to define a pattern of spaced-apart distal electrodes to be included at a distal end of the multicontact electrode array; welding respective electrode contacts to the marked locations on the metal foil carrier using a positioning tool and relying on the location marks scribed on the surface of the metal foil carrier; electrically and mechanically attaching the distal end of each wire to a respective electrode contact; forming the metal carrier into a tube, with the electrode contacts and wires residing on the inside of the foil tube; placing heat-shrinkable tubing over the foil tube; causing the heat-shrinkable tubing to shrink tightly around the outside of the foil tube; injecting a liquid polymer into the inside of the foil tube to fill all gaps therein, and allowing said liquid polymer to cure; mechanically removing the heat-shrinkable tubing; and removing the metal foil using an etching process, thereby exposing a surface of the electrode contacts that was previously held against the metal foil, said exposed surface of each electrode contact providing a distal electrode of the multicontact electrode array, wherein the distal electrodes are spaced apart and oriented using spacing tools and the markings on the metal foil.