Patent ID: 8524311

Claim:
A method for manufacturing a flexible electrode array, comprising: a) depositing and curing an insulator polymer base layer; b) depositing a metal trace layer on a surface of said insulator polymer base layer; c) applying a layer of photoresist on said metal trace layer and patterning said metal trace layer and forming metal traces on said insulator polymer base layer; and d) activating said surface of said insulator polymer base layer and depositing a top insulator polymer layer and forming one single insulating polymer layer with said base insulator polymer layer; wherein the insulator polymer layers were treated at a temperature from 80-150° C. and then at a temperature from 230-350° C., and e) imparting a permanent approximately semispherical curve into the resulting structure molding the structure in the desired shape, which approximates the shape of the target neural tissue, and heating the structure to a temperature of 230-400° C., so that the pressure of the precurved surface against the neural tissue is uniform across the surface of the array.