US7240416B2
Expired / Lapsed
US
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Process for manufacturing electrically conductive components
Assignee: Cochlear Ltd
•
Filing: 2002-05-07
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Granted: 2007-07-10
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Expires: 2022-05-07
Abstract
Abstract A method of forming a device, such as an electrode array for a cochlear implant. The method comprises a step of forming a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions in a sheet of biocompatible electrically conductive material, such as platinum foil. The method can comprise a step of working on the sheet to remove predetermined portions therefrom to form the one or more discrete relatively conducting regions. The step of working on the sheet can comprise embossing the sheet, cutting or slicing the sheet, or using electrical discharge machining (EDM) to remove unwanted portions of the sheet, the EDM equipment having a cutting tool comprising an electrode.
Inventors
- 👤 Dusan Milojevic
- 👤 John Parker
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 10:57
CPC Classifications
A; A61; A61N; A61N1/00; A61N1/02; A61N1/04; A61N1/05; A61N1/0526; A61N1/0541; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49004; Y10T29/49005; Y10T29/4902; Y10T29/4908; Y10T29/49117; Y10T29/49124; Y10T29/49128; Y10T29/49147; Y10T29/49151; Y10T29/49155; Y10T29/49174; Y10T29/49176; Y10T29/49462; Y10T29/49467; Y10T29/49476; Y10T29/49481; Y10T29/49492; Y10T29/49524; Y10T29/49529
Claims Analysis
Total Claims: 49
Claim 1
Independent Claim
187 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means, wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means, wherein the embossing tool with the embossed sheet and layer of backing material positioned thereon, are relatively removable from within the pressing means.
Claim 2
Independent Claim
187 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means, wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means, wherein the embossing tool with the embossed sheet and layer of backing material positioned thereon, are relatively removable from within the pressing means.
Claim 3
Independent Claim
185 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means, wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means, wherein following pressing of the sheet of electrically conducting material, the layer of backing material is removable from the embossed sheet.
Claim 4
Independent Claim
185 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means, wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means, wherein following pressing of the sheet of electrically conducting material, the layer of backing material is removable from the embossed sheet.
Claim 5
Independent Claim
145 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material to form an embossed sheet having a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein an abrading means is used in an abrading step to remove unwanted portions from the embossed sheet, wherein prior to the abrading step the embossed sheet is adhered by a layer of an adhesive to a support base.
Claim 6
Independent Claim
145 words
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of: working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns, wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material to form an embossed sheet having a predetermined pattern of raised portions therein, wherein the working step comprises using an embossing tool, wherein an abrading means is used in an abrading step to remove unwanted portions from the embossed sheet, wherein prior to the abrading step the embossed sheet is adhered by a layer of an adhesive to a support base.
Claim 7
Dependent Claim
30 words
The method of forming a device of claim 3 wherein the embossed sheet is placed on the adhesive layer such that the raised pattern extends outwardly away from the adhesive.
Claim 8
Dependent Claim
35 words
The method of forming a device of claim 4 wherein after the abrading step the method further includes a step of encapsulating at least one surface of the embossed sheet in an electrically insulating encapsulant.
Claim 9
Dependent Claim
48 words
The method of forming a device of claim 5 wherein after the step of encapsulating said at least one surface, the device is removed from the support base so providing a plurality of separate electrically independent conductive portions having a layer of encapsulant encapsulated on one side thereof.
Claim 10
Independent Claim
112 words
A method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of: (i) coating at least a first surface of a sheet of electrically conductive material with a first layer of another electrically conductive material; (ii) forming a predetermined pattern in the sheet of electrically conductive material by removing portions of the sheet therefrom such that at least the pattern of electrically conductive regions remain; (iii) coating a second surface of the sheet of electrically conductive material with a layer of resiliently flexible material; and (iv) removing the first layer from the first surface of said sheet.
Claim 11
Independent Claim
112 words
A method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of: (i) coating at least a first surface of a sheet of electrically conductive material with a first layer of another electrically conductive material; (ii) forming a predetermined pattern in the sheet of electrically conductive material by removing portions of the sheet therefrom such that at least the pattern of electrically conductive regions remain; (iii) coating a second surface of the sheet of electrically conductive material with a layer of resiliently flexible material; and (iv) removing the first layer from the first surface of said sheet.
Claim 12
Dependent Claim
29 words
The method of forming a device of claim 7 wherein the device is an electrode array and step (ii) comprises forming a predetermined electrode array pattern in the sheet.
Claim 13
Dependent Claim
21 words
The method of forming a device of claim 7 wherein the sheet of electrically conductive material is a biocompatible metallic material.
Claim 14
Dependent Claim
25 words
The method of forming a device of claim 9 wherein the sheet is a platinum foil having a thickness no greater than about 50 microns.
Claim 15
Dependent Claim
23 words
The method of forming a device of claim 10 wherein the thickness of the platinum foil is no greater than about 20 microns.
Claim 16
Dependent Claim
20 words
The method of forming a device of claim 7 wherein the first layer of electrically conductive material comprises a metal.
Claim 17
Dependent Claim
20 words
The method of forming a device of claim 12 wherein the first layer of metal is a layer of copper.
Claim 18
Dependent Claim
35 words
The method of forming a device of claim 7 wherein step (ii) comprises using electrical discharge machining (EDM) to remove unwanted portions of the sheet, the EDM equipment having a cutting tool comprising an electrode.
Claim 19
Dependent Claim
48 words
The method of forming a device of claim 14 wherein the cutting tool has a size and shape that at least substantially matches the size and shape of the portion of the sheet to be removed from the sheet during the electrical discharge machining step comprising step (ii).
Claim 20
Dependent Claim
46 words
The method of forming a device of claim 15 wherein the tool is brought adjacent the sheet at a number of different locations so as to remove differing portions of the sheet, the multiple use of the tool serving to gradually build up the predetermined pattern.
Claim 21
Dependent Claim
47 words
The method of forming a device of claim 16 wherein the cutting tool is used to form at least one linear array of discrete stimulating pads or electrodes in the sheet, each pad preferably having a conducting portion extending away therefrom to a location distal the pad.
Claim 22
Dependent Claim
29 words
The method of forming a device of claim 17 wherein each conducting portion extends linearly away from its pad, the linear conducting portions being aligned in a parallel arrangement.
Claim 23
Dependent Claim
23 words
The method of forming a device of claim 18 wherein each pad has an areal dimension of less than 0.5 mm 2 .
Claim 24
Dependent Claim
30 words
The method of forming a device of claim 18 wherein each conducting portion has a width of between about 1 and 100 microns, more preferably between 1 and 70 microns.
Claim 25
Dependent Claim
33 words
The method of forming a device of claim 18 wherein each conductive portion is electrically insulated from its neighbouring conductive wire, the spacing between neighbouring wires being between about 10 and 100 microns.
Claim 26
Dependent Claim
28 words
The method of forming a device of claim 14 wherein the cutting tool removes the platinum where desired and at least a portion of the first layer therebeneath.
Claim 27
Dependent Claim
24 words
The method of forming a device of claim 7 wherein step (iii) comprises coating the second surface with a layer of parylene and/or silicone.
Claim 28
Dependent Claim
49 words
The method of forming a device of claim 23 wherein prior to the coating of the second surface with the layer of resiliently flexible material, the method comprises an additional step in which the areas of sheet removed in step (ii) are filled with a relatively electrically insulating material.
Claim 29
Dependent Claim
33 words
The method of forming a device of claim 7 wherein the method further comprises the following step: (v) coating the exposed first surface of the sheet with a layer of resiliently flexible material.
Claim 30
Dependent Claim
33 words
The method of forming a device of claim 25 wherein the layer of material coated to the sheet in step (v) comprises the same material coated to the second surface in step (iii).
Claim 31
Dependent Claim
52 words
The method of forming a device of claim 26 wherein during step (v), the electrically conductive regions formed in step (ii) are masked to ensure they remain uncovered with the layer of resiliently flexible material and the conducting portions are not masked and so coated by this layer of resiliently flexible material.
Claim 32
Dependent Claim
35 words
The method of forming a device of claim 26 wherein following step (v), the sheet is trimmed to remove the remaining portions of the sheet that do not comprise the pattern of electrically conductive regions.
Claim 33
Independent Claim
30 words
The method of forming a device 28 wherein all of the required number of electrically conductive regions for a device are formed in different regions of a single platinum sheet.
Claim 34
Independent Claim
30 words
The method of forming a device 28 wherein all of the required number of electrically conductive regions for a device are formed in different regions of a single platinum sheet.
Claim 35
Dependent Claim
34 words
The method of forming a device of claim 29 wherein each sheet has a plurality of respective sets of electrically conductive regions formed therein, the sets being adapted to form a single electrode array.
Claim 36
Dependent Claim
37 words
The method of forming a device of claim 30 wherein once each of the sets are formed on the sheet, each trimmed set is stacked one above the other to form an aligned array of stimulating pads.
Claim 37
Dependent Claim
45 words
The method of forming a device of claim 31 wherein the electrode array comprises 30 stimulating pads, with the electrode array comprising 5 different sets of pads that have been formed in a single sheet, trimmed, and then stacked to form a single electrode array.
Claim 38
Dependent Claim
66 words
The method of forming a device of claim 32 wherein the electrode array comprises 3 sets of 7 pads, 1 set of five pads and 1 set of 4 pads, the 3 sets of 7 pads being stacked one on top of the other, the set of five pads being stacked on these sets, and with the set of 4 pads on top of the stack.
Claim 39
Dependent Claim
37 words
The method of forming a device of claim 33 wherein once the stack is formed, the hitherto at least substantially planar pads are curved out of the plane of the conducting portions for each set of pads.
Claim 40
Dependent Claim
36 words
The method of forming a device of claim 34 wherein once the stimulating pads have been deformed to have a curvature, each of the stimulating pads are further folded about a longitudinal axis of the array.
Claim 41
Dependent Claim
33 words
The method of forming a device of claim 34 wherein once the electrode array is complete it is encapsulated in a further layer of a biocompatible material to form an electrode carrier member.
Claim 42
Independent Claim
84 words
The method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of: (i) mounting a sheet of electrically conductive material in an electrical discharge machining (EDM) device, the device having a discharge electrode of a predetermined shape; (ii) programming the EDM device to bring the electrode adjacent the sheet; and (iii) operating the EDM device to remove a portion of the sheet corresponding to the shape of the electrode.
Claim 43
Independent Claim
84 words
The method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of: (i) mounting a sheet of electrically conductive material in an electrical discharge machining (EDM) device, the device having a discharge electrode of a predetermined shape; (ii) programming the EDM device to bring the electrode adjacent the sheet; and (iii) operating the EDM device to remove a portion of the sheet corresponding to the shape of the electrode.
Claim 44
Dependent Claim
36 words
The method of forming a device of claim 37 wherein the sheet prior to mounting in the EDM device is firstly coated on at least a first surface thereof with a layer of electrically conductive material.
Claim 45
Dependent Claim
24 words
The method of forming a device of claim 38 wherein the layer of electrically conductive material comprises a layer of metal, such as copper.
Claim 46
Dependent Claim
39 words
The method of forming a device of claim 38 wherein once the pattern has been formed in the sheet, a second surface of the sheet of electrically conductive material can be coated with a layer of resiliently flexible material.
Claim 47
Dependent Claim
43 words
The method of forming a device of claim 40 wherein once the second surface of the sheet has been coated with the layer of resiliently flexible material, the layer of electrically conductive material can be removed from the first surface of said sheet.
Claim 48
Dependent Claim
16 words
The method of forming a device of claim 37 wherein the device is an electrode array.
Claim 49
Dependent Claim
28 words
The method of forming a device of claim 37 wherein the sheet of electrically conductive material is a platinum sheet having a thickness no greater than 50 microns.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2010-07-09 | 2011-01-08 | 2011-07-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2014-07-09 | 2015-01-08 | 2015-07-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2018-07-09 | 2019-01-08 | 2019-07-10 | $7700.00 | Window Closed / Lapsed |