Patent Description:
Use of electrodes to detect electrical signals and/or deliver stimuli is becoming an increasingly popular diagnostic and/or therapeutic strategy. In some instances, one or more electrodes are included as part of an implant device, such that signals can be recorded and/or delivered chronically over an extended time period. Many traditional approaches for using electrodes in implant devices feature low-density electrode arrays of less than eight channels. However, recent improvements in microfabrication processing has enabled multiple electrodes to be disposed on a portion of the device to be positioned at a target location. For example, multiple electrodes may disposed along a length of a neural probe. One approach for using multiple electrodes is to design a device such that each electrode delivers a same stimulus. Manufacturing a multi-electrode device having independent electrode-associated channels requires constructing the device to ensure that the channels remain separate (to prevent shorting) across an entire length between the electrodes and associated circuitry. Given that intermediate components (e.g., that extend from circuitry outside of a person's scalp, skull and/or body to electrode traces) are frequently at least partly inside a person's body or brain, it is desirable that the intermediate components remain thin. Designing connections that can remain thin while maintaining channel separation can be particularly challenging when the number of electrodes is high.

<CIT> discloses a medical electrical lead that includes a proximal connector, an insulated lead body including at least one electrode, a helically coiled conductor wire, and a helically coiled spacer element interstitially disposed between adjacent turns of the conductor wire.

<CIT> discloses flexible tubing includes a wall provided with a plurality of braided elements forming a braid within the wall of the tube.

Illustrative embodiments of the present disclosure are described in detail below with reference to the following drawing figures:.

In some of the disclosure, an implant device is provided, along with methods for making and using the same. The implant device can include one or more electrodes along with a flexible connection component. The flexible connection component can include a cable (e.g., data cable), one or more leads and/or a catheter that connects the one or more electrodes to circuitry that receives data collected at the electrode(s) and/or that controls stimuli to be delivered at the electrode(s). Each connection that extends from a single channel to the circuitry can be referred to as an electrical channel. The flexible connection component can include a set of filaments, such as a set of microfilaments. The set of filaments can be positioned and/or configured to enable reliable communication across each electrical channel and to prevent shorting across multiple electrical channels. For example, the multiple conductive filaments can be separated from each other by an insulating material or themselves each include an insulating coating.

As one example, the flexible connection component can include a set of conductive filaments - each of which extends across the flexible connection component and being positioned such that there is a space (e.g., an empty space) between each given conductive filament and all surrounding conductive filaments. This approach limits the density of electrical channels, due to the required spacing.

As another example, the flexible connection component can include a set of conductive filaments and a set of non-conductive filaments. The set of non-conductive can be positioned to separate, straddle or space adjacent conductive filaments. In some instances, the set of filaments are arranged in a braid, woven or grid pattern, with the set of conductive filaments running in a first direction different than a second direction in which the set of non-conductive filaments are running. For example, the set of non-conductive filaments can be positioned to extend in a direction that has a first angular offset from a central axis of the flexible connection component, and the set of conductive filaments can be positioned to extend in a different direction that has a second angular offset from the central axis. The set of conductive filaments and the set of non-conductive filaments may nonetheless be positioned within a same surface, such that each of the set of non-conductive filaments intersects with one, more or all of the set of conductive filaments.

As yet another example, the flexible connection component can include a set of coated conductive filaments. Each of the coated conductive filaments can include a conductive central filament and an insulating and/or dielectric thin coating. The set of coated conductive filaments can be arranged in a braid, woven or grid pattern. The coating can prevent or inhibit shorting between filaments.

In some instances, each filament of the set of filaments include a set of vias disposed across a length of filaments. Each via can be shaped and/or of a material to facilitate joining another via of another filament in a manner that restricts relative movement of the filaments thereafter. For example, the vias can be positioned to overlap or lock together, and then a bonding process can be performed.

Manufacturing the flexible connection component can include (for example) positioning the set of filaments on a flexible substrate. For example, conductive filaments may first be pulled from a first spool and non-conductive filaments may then be pulled from a second spool. The substrate and/or spools may be moved throughout the pulling process (e.g., and potentially between pulling the conductive and non-conductive filaments). A coating layer (e.g., that includes a thermoplastic or thermoset material) may be deposited over the filaments, and the substrate may then be rolled or folded into a target shape (e.g., a cylinder).

In some instances, the implant device includes a fixture that is positioned at or near an end of the flexible connection component. The fixture can include one or more engagement structures (e.g., holes, grooves or attachments) - each of which can be configured (e.g., shaped) to engage (e.g., partly or entirely surround or attach to) a filament to restrict movement of the conductive filament with respect to one or more dimensions. The fixture can thus help fix relative spacing of filaments and/or restrict relative movement between filaments, each of which can help avoid shorts between electrical channels. The fixture may further facilitate aligning ends of filaments with electrode traces to facilitate forming electrical connections. For example, each conductive filament can be electrically connected to an electrical trace that corresponds to an electrode at the fixture or at a position beyond the fixture. Each electrode can be connected to a corresponding trace by using ultrasonic welding, an epoxy, solder or crimping to attach the electrode to a bond patch connected to the trace. The fixture's engagement structures can thus provide precise relative locations of conductive filaments, such that bond pads can similar be precisely located (e.g., at or near the fixture). The location precision can allow bond pads to be more densely packed while still avoiding shorting between the electrical channels, which can allow devices to include higher numbers of electrodes and/or to include smaller dimensions relative to comparable devices that do not include features of the flexible connection component (and/or fixture(s)) as disclosed herein.

Some embodiments disclose herein refer to conductive filaments that extend across a length of a flexible connection component. It will be appreciated that alternative configurations are contemplated. For example, a single electrical channel can include multiple conductive filaments - each extending across a portion of the flexible connection filament.

<FIG> illustrate an implant device that can be used to record electrical signals and/or deliver electrical stimuli according to an embodiment. The depicted implant device includes a probe that includes one or more electrodes. The probe may (for example) have a median diameter that is greater than <NUM>, <NUM>, <NUM> or <NUM> and/or less than <NUM>, <NUM>, <NUM> or <NUM>. The probe may have a length that is (for example) greater than <NUM>, <NUM> or <NUM> and/or less than <NUM> or <NUM>. The probe can include a substrate that includes (for example) polyurethane and/or epoxy backfill. The probe can include, on one or more surfaces, one or more electrodes. Each of the one or more electrodes can include (for example) platinum or platinum iridium (e.g., with or without a TiN, iridium-oxide coating) The one or more electrodes can include (for example) a single electrode. The one or more electrodes can include (for example) more than: <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM> electrodes. The one or more electrodes can include (for example) less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM> electrodes. The electrodes may be arranged along one or more circumferential, vertical and/or horizontal lines and/or in a spiral configuration.

Probe <NUM> can further include one or more traces. In some instances, each of the one or more traces connects (physically and/or electrically) to a single electrode of the one or more electrodes and runs up (e.g., is positioned along a long axis of) the probe to terminate at a proximal end. Each trace can include a suitable conductor such as stainless steel, silver, copper or other conductive materials. Each trace may further include a coating or sheathing for anticorrosive, insulative and/or protective reasons.

Each of the traces can be (e.g., electrically and/or physically) connected to an interface <NUM> that is also connected to a flexible connection component <NUM>. Interface <NUM> can include (for example) a structure that includes one or more engagement features configured electrically and physically connect probe <NUM> with flexible connection component <NUM>.

Flexible connection component <NUM> can include a substrate (e.g., a dielectric substrate and/or a substrate comprising or composed of a polyurethane, polycarbonate, silicone, polyethylene, fluoropolymer and/or other medical polymers, copolymers and combinations or blends) and one or more electrical connections that connect the one or more electrodes to circuitry <NUM>. For example, a pattern <NUM> of filaments can be formed on a planar substrate. Pattern <NUM> can include a set of conductive filaments - each at least partly connecting an electrode to circuitry <NUM>. Pattern <NUM> can be subsequently shaped (e.g., rolled or wrapped) into a three-dimensional configuration. It will be appreciated that <FIG> shows an illustration where one portion of pattern <NUM> is unwrapped from to show its pattern, though pattern <NUM> can uniformly extend in a wrapped configuration across a length of flexible connection component <NUM>.

Each conductive filament can have a length that is at least <NUM>, <NUM>, <NUM> or <NUM> and/or that is less than <NUM>, <NUM>, <NUM> or <NUM>. Each of the one or more electrical connections can include a conductive filament (e.g., a conductive microfilament). Pattern <NUM> can further include one or more non-conductive filaments, which may separate and/or space adjacent conductive filaments. In some instances, the (conductive and non-conductive) are braided, wound or disposed to form a pattern (e.g., a grid pattern). This type of configuration may result in individual non-conductive filaments intersecting with and/or contacting one or more conductive filaments while maintaining space between conductive filaments. Flexible connection component <NUM> can include one or more coating layers that further constrain the relative positions of the filaments.

Flexible connection component <NUM> may be flexible along its long axis. In some instances, flexible connection component <NUM> is rigid or has a degree of rigidity along a cross section perpendicular to its long axis such that at least a threshold amount of spacing between filaments (in particular, spacing between conductive filaments) is maintained to prevent shorting.

In some instances, each of the filaments in flexible connection component <NUM> includes a same material. For example, in some instances, each conductive filament and each non-conductive filament includes LCP, a dielectric material and/or an insulator. Conductive filaments may further include (for example) a top layer, pattern and/or sputtering that includes or is a conductive material. The conductive material can include or can be stainless steel, silver, copper or other conductive materials, which may have separate coatings or sheathing for anticorrosive, insulative and/or protective reasons.

Circuitry <NUM> can be configured to receive signals detected at the electrode(s) on probe <NUM> and/or to deliver electrical signals corresponding to stimuli to be delivered by the electrode(s) on probe <NUM>. Circuitry <NUM> can include (for example) one or more circuits, chips, integrated circuits, wires, processors and/or computing devices. <FIG> shows circuitry <NUM> as being located outside of a person from in the implant device is implanted. It will be appreciated that, in some instances, circuitry <NUM> may be positioned inside a person (e.g., underneath a scalp) of a person in which the implant device is implanted. Circuitry <NUM> can include (for example) neurostimulation circuitry and/or a pulse generator, which can control a temporal pattern, duration and/or intensity of stimulation to be delivered at probe <NUM>. In some instances, circuitry <NUM> identifies one or more stimulation parameters based on measured data (e.g., to operate in a closed-loop manner), such as signals recording by one or more sensing electrodes of probe <NUM> and/or other sensors measuring biological data.

In an implanted instance, probe <NUM> may be positioned such that the electrodes are positioned at or in (for example) the cortex, subcortex, thalamus (e.g., anterior nucleus of the thalamus, posterior thalamic region or ventrointermediate nucleus of the thalamus), hippocampus, zona incerta, pallidofugal fibers, globus pallidus internus, subthalmic nucleus, periaqueductal gray, and/or pons (e.g., tegmental nucleus of the pons). In the implanted instance, probe <NUM> may be fully or partly implanted into a person's brain, such that interface <NUM> may be outside or inside the person's brain and such that flexible connection component <NUM> may be fully or partly outside of a person's brain. Some or all of the part or entirety of flexible connection component <NUM> may nonetheless remain implanted (e.g., under the person's scalp but outside of the skull).

In some instances, each component of the implant device can be biocompatible. In some instances, all or part of flexible connection component <NUM> and all of probe <NUM> can be biocompatible.

It will be appreciated that the implant device can further include one or more additional components (e.g., a housing, feedthrough assembly and/or power source) and can have one or more additional properties, such as one described in <CIT>, entitled "Monolithic Lead Assembly and Methods of Microfabricating a Monolithic Lead Assembly", which is hereby incorporated by reference in its entirety for all purposes.

It will be further appreciated that, while <FIG> depict a device that includes a neural probe, other configurations are contemplated. For example, as opposed to or in additional to including a probe, the implant device can include other types of stimulating and/or recording components, such as other types of neural interfaces. For example, the implant device may include a probe configuration and/or other electrode component that includes a planar, round or cylindrical substrate attached to one or more book electrodes, split cuff electrodes, spiral cuff electrodes, epidural electrodes, helical electrodes, probe electrodes, linear electrodes, neural probe, paddle electrodes, intraneural electrodes.

<FIG> illustrates a portion of a flexible connection component <NUM> that can be included as part of an implant device according to an embodiment. Flexible connection component <NUM> includes a set of conductive filaments <NUM> and a set of non-conductive filaments <NUM> on or near a surface of flexible connection component <NUM>. In the depicted instance, an orientation of each of set of conductive filaments <NUM> is the same within the set but different than an orientation of each of set of non-conductive filaments <NUM>.

The differential orientation can be achieved based on (for example) different orientation of source spools corresponding to material for set of conductive filaments <NUM> and set of non-conductive filaments <NUM> and/or different orientation of a substrate during times at which set of conductive filaments <NUM> and set of non-conductive filaments <NUM> are pulled.

Flexible connection component <NUM> can be manufactured to preserve relative orientation of set of conductive filaments <NUM> relative to each other, relative orientation of set of non-conductive filaments <NUM> relative to each other and/or relative orientation of set of conductive filaments <NUM> relative to each other (e.g., to prevent or inhibit shorting between conductive filaments). For example, each filament may be affixed and/or attached to a substrate to inhibit subsequent movement. As another example, a layer may be deposited on top of the filaments to inhibit subsequent movement. The layer may include (for example) a thermoplastic or thermoset material. As yet another example, a geometry of the conductive filaments and/or non-conductive filaments can be configured to inhibit movement (e.g., the conductive filaments and/or non-conductive filaments can include grooves to receive the other type of filament). As yet another example, each conductive filament can be bonded to a set of non-conductive filaments (or the reverse). (Select types of material bonds may be particular strong, such as bonds between two filaments, each including LCP at a connection site. ) As yet another example, conductive vias and/or a bonding agent can be formed on positions of overlap between conductive filaments and non-conductive filaments, and the filaments can be connected through (for example) an electrical connection (e.g., welding or crimping) or bonding process. The use of conductive vias can facilitate using non-conductive filaments to restrict movement of conductive filaments without relying upon braiding or winding techniques. For example, the most or all of set of conductive filaments <NUM> (e.g., between any ends, fixtures and/or interfaces) may be positioned on top of each underlying non-conductive filament (or the converse).

In the depicted instance, flexible connection component <NUM> has a cylindrical (albeit curved) shape, in that cross sections perpendicular to the long axis are generally circular. In some instances, set of conductive filaments <NUM> and set of non-conductive filaments <NUM> are first deposited on a flat substrate. A coating layer may be applied and potentially the substrate may be dissolved. Set of conductive filaments <NUM> and set of non-conductive filaments <NUM> (e.g., and any other attached substrate and/or layer(s)) can then be shaped into a target shape (e.g., a cylindrical shape). For example, set of conductive filaments <NUM> and set of non-conductive filaments <NUM> (e.g., and any other attached substrate and/or layer(s)) can be rolled around a shaping structure. While around the shaping structure, a shape-fixation process may be performed, such as a curing process and/or a coating process. In some instances, the shaping structure may then be removed or dissolved.

In this instance, flexible connection component <NUM> is hollow in that includes space along the long axis of flexible connection component <NUM> under its surface. The hollowness may improve the flexibility of flexible connection component <NUM>.

The configuration shown in <FIG> can provide advantages over (for example) traditional techniques not utilizing non-conductive filaments and/or manufacturing techniques that produce patterns of a sea of conductive filaments and/or a set of non-conductive filaments. For example, an alternative technique is to separate leads corresponding to different channels using insulation materials. However, this approach can add to the width of the device. Thus, a decision may be made as to whether to restrict a number of channels/electrodes or whether to risk potential damage to implant-associated tissue. Further, use of channel-separating insulation can risk occurrence of flex-fatigue after extended use of the device. However, configurations utilizing multi-fiber arrangement (e.g., disclosed herein) can support high numbers of channels while maintaining flexibility of the connection component and reducing the probability of and/or extent of flex fatigue.

<FIG> illustrates a thin-film structure <NUM> that includes filaments and electrodes according to an embodiment. Thin-film structure <NUM> includes a neural-interface thin-film component <NUM> and a connection thin-film component <NUM>. Thin-film structure <NUM> can have an average or maximum thickness that is (for example) less than <NUM>, <NUM> or <NUM>.

Neural-interface thin-film component <NUM> includes a set of electrodes <NUM>. Each electrode <NUM> of the set can (for example) be conductive and/or include a metal or metal alloy. Each electrode <NUM> of the set can include (for example) platinum (Pt), platinum/ iridium (Pt/Ir), copper (Cu), gold (Au), silver (Ag), gold/chromium (Au/Cr), titanium (Ti), gold/titanium (Au/Ti), or any alloy thereof. Each electrode <NUM> of the set may have a thickness (z) of from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or from <NUM> to <NUM>. The set of electrodes <NUM> may be formed directly or indirectly on a substrate (e.g., supporting structure), which can include an insulator and/or dielectric and may be non-conductive. Alternatively, the set of electrodes <NUM> may be formed indirectly on the substrate. The substrate can include (for example) polyurethane, polycarbonate, silicone, polyethylene, fluoropolymer, or another polymer, copolymer or blend.

Neural-interface thin-film component <NUM> may include a set of traces --- each configured to communicate electrical signals between (e.g., in a uni-directional or bi-directional manner) an electrode and a conductive fiber in connection thin-film component. Each electrode may be connected to a trace directly or via an electrical contact and/or wiring layer. Each trace can include a conductive material and/or can be conductive. Each trace can include a pure metal, metal alloy, combination of metals (and/or of metal alloys), combination of metals and dielectrics, and so on. For example, each trace can include stainless steel, silver, gold, copper or gold/chromium. Each trace can further include a coating or sheathing for anticorrosive, insulative and/or protective purposes.

In some instances, neural interface thin-film component <NUM> includes a first portion 305a on which the set of electrodes <NUM> are positioned and a second portion 305b that lacks electrodes. A width of first portion 305a (corresponding to a vertical dimension in <FIG>) may be larger than a width of second portion 305b. Traces connected to each electrode can extend across part of first portion 305a and across all of second portion 305b.

Each trace can connect to a bond pad <NUM>. In some instances, one, more or all bond pads <NUM> can be conductive and can include (for example) copper, silver or gold. Connecting the trace to bond pad <NUM> can include (for example) welding the trace to bond pad <NUM> (e.g., using ultrasonic welding), using a conductive epoxy to connect the trace to bond pad <NUM>, soldering the trace to bond pad <NUM>, or welding the trace to bond pad <NUM>.

Connection thin-film component <NUM> can include a set of conductive filaments <NUM>. Each conductive filament <NUM> can include (for example) a metal, metal alloy or other conductive material. In one instance, each conductive filament <NUM> includes a nickel alloy (e.g., MP35N). Each conductive filament <NUM> can have a size corresponding to a French gauge of less than <NUM> French, less than <NUM> French or less than <NUM> French.

Each conductive filament <NUM> can be connected to a corresponding bond pad <NUM>. Connecting conductive filament <NUM> to bond pad <NUM> can include (for example) welding conductive filament <NUM> to bond pad <NUM> (e.g., using ultrasonic welding), using a conductive epoxy to connect conductive filament <NUM> to bond pad <NUM>, soldering conductive filament <NUM> to bond pad <NUM>, or welding conductive filament <NUM> to bond pad <NUM>.

In some instances, an insulating material (e.g., LCP) is disposed between bond pads <NUM>, which can reinforce connection thin-film component. Conductive filaments <NUM> may include a same and/or different insulating material. For example, an insulating material can coat an entire flexible connection component with an insulating material (e.g., a same insulating material as that disposed between bond pads <NUM>). Disposing the insulating material between bond pads <NUM> can result in bonding between the insulating material and conductive filaments <NUM> connected to bond pads. This bonding can increase stability of the position of conductive filaments <NUM>. For example, each of the insulating material and conductive filaments <NUM> can include LCP, which can result in LCP-LCP bonding, which has very strong bond strength.

In the depicted instance, each conductive filament <NUM> is disposed to extend in a substantially straight line parallel to what will be the central axis of the device. Thus, in instances in which connection thin-film component <NUM> is rolled or wrapped to form a cylindrical shape, each conductive filament <NUM> can be at a substantially same angular position within any cross section taken along the central axis.

Part or all of thin-film structure <NUM> can be manufactured on one or more thin-film substrates and (in some instances) subsequently shaped into a three-dimensional shape. In one instance each of neural-interface thin-film component <NUM> and connection thin-film component <NUM> are manufactured on a separate substrate and separately shaped into a three dimensional shape (e.g., such that first portion 305a of neural-interface thin-film component <NUM> forms a first cylinder and connection thin-film component <NUM> forms a second cylinder). Bonding can then be performed to connect the two shaped components.

For example, the traces may be connected to bond pads <NUM> while in a planar configuration, neural-interface thin-film component <NUM> can then be spatially configured (e.g., wrapped around a cylindrical support), and conductive filaments <NUM> (e.g., which may also be configured in a three-dimensional shape) can then be bonded to bond pads <NUM>. As another example, conductive filaments <NUM> may be connected to bond pads <NUM> while in a planar configuration, connection thin-film component <NUM> can then be spatially configured (e.g., wrapped around a cylindrical support), and the traces can then be bonded to bond pads <NUM> (e.g., while neural-interface thin-film component <NUM> is configured in a three-dimensional shape). As yet another example, each of neural-interface thin-film component <NUM> and connection thin-film component <NUM> can be configured to include a three-dimensional (e.g., cylindrical) shape, and the traces and conductive filaments <NUM> may then be connected to bond pads <NUM>.

An implant device can include a fixture to facilitate forming bondings between the traces and conductive filaments. For example, a fixture can have a shape corresponding to a strip, gear-shape or having a circular shape (or oval, square or rectangular shape). The fixture can include a set of grooves around a circumference or perimeter. As another example, a fixture can include a set of holes. The fixture can include a single planar configuration (e.g., that includes the grooves and/or holes) or may include two or more parallel surfaces (e.g., each including a set of grooves and/or holes). In the latter instance, the fixture may include channels (e.g., extended grooves along a distance or an extended tube-shaped hole) extending between spatially corresponding grooves and/or holes, of the parallel surfaces may primarily be separated by empty space (e.g., aside from one or more small mechanically connecting structures). A shape, size and/or diameter of each groove and/or hole can be configured to receive a conductive filament and/or trace.

In some instances, each of neural-interface thin-film component <NUM> and connection thin-film component <NUM> can be rolled or wrapped to form a cylindrical shape. Connection thin-film component <NUM> can be positioned such that each conductive filament <NUM> is positioned to be engaged with (e.g., within) a groove or hole in a fixture. Neural-interface thin-film component can include bond pads <NUM> and can be positioned such that bond pads <NUM> align with the grooves or holes in the fixture. Conductive filaments <NUM> can then be bonded to bond pads <NUM>, thereby electrically connecting traces to conductive filaments <NUM>. In some instances, an insulating material (e.g., LCP monofilament) is then disposed between bond pads <NUM>.

The connection can be further reinforced with (for example) or silicone. In some instances, a tube (e.g., polyurethane tube) is positioned over bond pads <NUM> and the tube is then backfilled with an insulating or adhesive material or silicone.

It will be appreciated that opposite ends of conductive filaments can be connected with circuitry. The connection may further include use of bond pads and/or a fixture to facilitate alignment and/or stabilization of conductive filaments <NUM>.

<FIG> illustrates a thin-film structure <NUM> that includes filaments and electrodes according to an embodiment. Thin-film structure <NUM> includes many features that parallel corresponding features shown in <FIG>. However, thin-film structure <NUM> includes a connection thin-film component <NUM> that includes conductive filaments <NUM> that are oriented in a direction that is not parallel to a center long access of the implant device. Further, connection thin-film component <NUM> includes a set of non-conductive filaments <NUM>. Each conductive filament <NUM> can cross multiple non-conductive filaments <NUM>.

In some instances, each of the set of conductive filaments <NUM> and each of the set of non-conductive filaments <NUM> includes a same material, such as a same polymer. For example, each conductive filament and non-conductive element can include an insulating material. The conductive filaments can further include conductive material (e.g., sputtered or coats onto the insulating material). Using a same material in the conductive and non-conductive filaments can facilitate fixing relative positions of the filaments. For example, each conductive filament and each non-conductive filament can include LCP. The filaments can then be bonded together at their intersecting positions, which - due to the shared LCP material - can result in strong bonding between the filaments.

Each conductive filament <NUM> and/or each non-conductive filament <NUM> can have a size corresponding to a French gauge of less than <NUM> French, less than <NUM> French or less than <NUM> French and/or approximately <NUM>. Each conductive filament <NUM> may, but need not, have a diameter that is substantially the same as the diameter of the non-conductive filaments <NUM>.

In some instances, conductive filaments <NUM> and non-conductive filaments <NUM> are disposed while the substrate is in a three-dimensional shape. For example, the filaments may be disposed on a cylindrical substrate.

The filaments can be disposed such that (for example), at each cross-section of the device portion that includes connection thin-film component <NUM> and along a center axis of the device, each conductive filament is either intersecting with a non-conductive filament or is situated such that the closest filament on each side of the conductive filament is a non-conductive filament. In some instances, connection thin-film component <NUM> includes a cross section (e.g., which can include a cross-section associated with an end of the filaments) at which adjacent filaments are equally spaced and in an alternating pattern between conductive and non-conductive filaments exists.

Conductive filaments <NUM> and non-conductive filaments <NUM> can be positioned in a braid or wound configuration. The positioned filaments can be disposed across, rolled or wrapped to partly surround or form a surface of a cylindrical or tubular component (e.g., similar to a catheter or lead).

In some instances, a preliminary connection component can be provided that includes a fixture (e.g., that includes a set of grooves and/or holes for engaging filaments) and a set of non-conductive filaments <NUM> engaged within a first subset of grooves and/or holes of the fixture. Bond pads <NUM> can be positioned at, within or near a second subset of the grooves and/or holes, and conductive filaments <NUM> can then be pulled to contact the bond pads and become engaged within a second subset of the grooves and/or holes.

Conductive filaments <NUM> can be bonded to (e.g., conductive) bond pads <NUM> using (for example) ultrasonic welding, epoxy, solder or crimping. Non-conductive filaments <NUM> can be bonded to (e.g., non-conductive) bond pads <NUM> using thermosetting and/or epoxy. Thus, bond pads <NUM> in <FIG> may include a subset that are non-conductive bond pads and a subset that are conductive bond pads.

The incorporation of non-conductive filaments can support a more dense spacing of filaments. In some instances, a maximum spacing between adjacent filaments (which can correspond to spacing between conductive filaments and/or spacing between parallel filaments) can be less than <NUM>, less than <NUM> or less than <NUM> and/or can be approximately <NUM>. Thus, in some instances, the filament configuration can facilitate manufacturing an implantable device that includes at least <NUM>, at least <NUM> or at least <NUM> electrodes but nonetheless has a maximum width across probe <NUM> and connection thin-film component <NUM> (when in its final shape, such as being rolled into a cylindrical shape) of <NUM>. In some instances, the filament configuration can facilitating manufacturing an implantable device that includes less than or equal to <NUM>, <NUM>, <NUM> or <NUM> electrode(s) but has a maximum width across probe <NUM> and connection thin-film component <NUM> (when in its final shape, such as being rolled into a cylindrical shape) of <NUM> or <NUM>.

<FIG> shows a flowchart of a process <NUM> for manufacturing an implant device according to an embodiment. Process <NUM> can begin at block <NUM> where a thin-film material is sputtered or coated with a conductive material. For example, the thin-film material can include an LCP monofilament fiber. The conductive material can include (for example) stainless steel, silver or copper. In some instances, subsequent to (e.g., immediately following) the sputtering or coating, the conductive fiber is wound onto a spool.

At block <NUM>, a set of filaments are pulled and positioned on a substrate. The set of filaments can include multiple conductive filaments (e.g., pulled from the conductive fiber) and multiple non-conductive filaments. The conductive filaments and non-conductive filaments may be pulled at separate times. In some instances, the substrate is moved while the filaments are being pulled, so as to control a direction along which the filaments run. The conductive filaments can be pulled to orient at a first angle relative to a long axis of the substrate and the non-conductive filaments can be pulled to orient at a second angle relative to the long axis of the substrate. In some instances an orientation angle of the conductive filaments is opposite to an orientation angle of the non-conductive filaments (e.g., <NUM>° versus -<NUM>°). An absolute value of the angle of orientation of the conductive filaments and/or the non-conductive filaments may be less than (for example) <NUM>°, <NUM>° or <NUM>°. The filaments can be pulled such that the non-conductive filaments are parallel to each other and such that the conductive filaments are parallel to each other.

The filaments can be pulled such that each of the set of filaments extends from a first end of the substrate to a second end of the substrate (e.g., where the first end and second end are at different positions with respect to a long axis of the substrate). The filaments can be pulled such that conductive filaments are not in electrical contact with each other. The filaments can be pulled such that each conductive filament intersects with one or more non-conductive filaments (e.g., where the intersection positions are different when intersecting with multiple non-conductive filaments). In some instances, with respect to each conductive filament, the conductive filament intersects a non-conductive filament at at least <NUM>, <NUM> or <NUM> positions along its length. It will be appreciated that, in some instances, a conductive filament and non-conductive filament can intersect multiple times.

At block <NUM>, one or more fixtures can be used to at least partly fix or restrict movement of filament positions. For example, a fixture can be positioned at or next to each end of the substrate. The fixture can include a set of holes and/or grooves - each shaped to receive a filament (e.g., having a width or diameter that is larger than a width of a corresponding filament and/or having a width or diameter that is less than about <NUM>%, less than <NUM>% or less than <NUM>% a width of a correspond filament). Each filament can be positioned within a groove or hole. Each groove or hole can further support or be adjacent to a structure to which the filament is to be attached (e.g., a bonding pad). Ends of filaments can be attached to grooves and/or holes within the fixture via (for example) bonding, welding, thermosetting, an adhesive, etc..

At block <NUM>, for each conductive filament, an electrical connection is formed between a first end of the conductive filament and an electrode. In some instances, block <NUM> includes bonding the filament with a bonding pad positioned at or near a groove of the fixture (e.g., in which case, the bonding may both fix the filament position and form the electrical connection). In some instances, block <NUM> includes bonding electrode traces with a bonding pad and/or otherwise connecting them with the conductive filaments. In some instances, an end of a conductive filament may extend through a groove or hole of the fixture, and block <NUM> can then include bonding the end with a bonding pad.

At block <NUM>, for each conductive filament, an electrical connection is formed between a second end of the conductive filament and circuitry. In some instances, block <NUM> includes bonding the filament with a bonding pad positioned at or near a groove of the fixture (e.g., in which case, the bonding may both fix the filament position and form the electrical connection). In some instances, block <NUM> includes bonding connections to circuitry with a bonding pad and/or otherwise connecting them with the conductive filaments. In some instances, an end of a conductive filament may extend through a groove or hole of the fixture, and block <NUM> can then include bonding the end with a bonding pad.

In some instances, the substrate is flat and planar when the filaments are pulled. In some instances, the substrate is non-planar and/or supported by a three-dimensional supporting structure. For example, the substrate may be positioned around a cylindrical support, which may be rotated and/or moved along a long and/or horizontal axis as fibers are being pulled. In instances where the substrate is flat and planar when the filaments are pulled, the substrate can subsequently be wrapped or shaped to form a three-dimensional shape (e.g., wrapped around a cylindrical support). In instances in which a support is used while or after filaments are being pulled, the support may remain under the substrate or may be subsequently removed (e.g., after a coating layer is applied on the filaments and/or various intersections are bonded, such as intersections between conductive and non-conductive filaments and/or intersections with a non-conductive or conductive filament and a bond pad).

However, it is understood that the embodiments can be practiced without these specific details. For example, circuits can be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques can be shown without unnecessary detail in order to avoid obscuring the embodiments.

Claim 1:
An implantable medical device (<NUM>) comprising:
one or more electrodes;
a flexible connection component (<NUM>, <NUM>) that includes a surface comprised of a set of filaments (<NUM>; <NUM>, <NUM>), wherein:
each of the set of filaments includes a set of vias extending across a length of the filament;
the set of filaments are positioned such that, for each of the set of filaments, a via of the filament engages a via of at least one other filament of the set of filaments in a manner that restricts movement of the filaments relative to each other;
the set of filaments includes multiple non-conductive filaments (<NUM>);
the surface includes a set of conductive elements; and
a set of electrical channels extend across the flexible connection component, each of the set of electrical channels extending across at least one of the set of conductive elements and electrically connected with an electrode of the one or more electrodes;
circuitry (<NUM>) configured to process recorded data transmitted over one or more of the set of electrical channels and/or to output control signals that identify stimulation parameters to be communicated over at least one of the set of electrical channels; and
one or more electrical interfaces, wherein each electrical interface of the one or more electrical interfaces is configured to connect an end of an electrical channel of the set of electrical channels with the circuitry.