Patent ID: 8332052

Claim:
A process for manufacturing a microcircuit cochlear electrode array, comprising: providing a metallic ribbon secured to a nonconductive film substrate; machining first and second flat multiconductor microcircuits from the metallic ribbon each including a flat elongated longitudinally extending multiconductor tail portion with longitudinally spaced outwardly exposed electrode receiving pads, and a flat multiconductor head portion connected to the tail portion and having spaced outwardly exposed attachment pads; laminating the first and second flat microcircuits between the film substrate and an insulating cover; excising the first and second laminated microcircuits from the film substrate and metallic ribbon with the electrode receiving pads; helically wrapping the tail portion of the excised first laminated microcircuit in a first direction with its exposed electrode receiving pads wrapped around its insulating cover; helically wrapping the tail portion of the excised second laminated microcircuit over and along the helically wrapped excised first laminated microcircuit in a second direction with its exposed electrode receiving pads wrapped around its insulating cover; mounting and electrically connecting electrodes on and to the exposed electrode receiving pads; and overmolding the helically wrapped tail portions with a polymeric material.