Flexible sheet for neuromuscular stimulation

Patent metadata

Field	Value
Publication number	US-12370360-B2
Application number	US-202318093415-A
Country	US
Kind code	B2
Filing date	Jan 5, 2023
Priority date	Jun 2, 2016
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

A flexible sheet for neurostimulation is described having a flexible non-conductive substrate matrix in which electrodes are embedded along a lower surface. Electrically conductive wires extend from the electrodes through the flexible substrate to another exterior surface of the substrate. Methods of making the flexible sheet and making a device using the flexible sheet are also disclosed.

First claim

The invention claimed is:

1. A method of making a flexible sheet, comprising:
in a mold, placing conductive wires in connection with electrodes or in connection with contacts for electrodes;
adding an elastomer precursor into the mold to encase the conductive wires and the electrodes or to encase the conductive wires and the contacts for electrodes;
wherein a release liner is disposed between the mold and the elastic precursor; and
curing the elastomer precursor to create the flexible sheet with embedded wires and electrodes or contacts for electrodes.

2. The method of claim 1 wherein contacts for electrodes that are individually connected to conductive wires are placed in the mold; and
after the elastomer precursor is added to the mold; further comprising a step of making electrodes by placing a conductive polymer in contact with the contacts for electrodes.

3. The method of claim 2 wherein the step of making electrodes comprises adding conductive particles to the uncured elastomer precursor to make the electrodes.

4. The method of claim 2 wherein the step of making electrodes comprises depositing a precursor for a conductive polymer in contact with the contacts for electrodes.

5. The method of claim 4 wherein the conductive polymer is colored differently from the elastomer that makes the sheet.

6. The method of claim 1 wherein a sensor is placed in the mold prior to adding the elastomer precursor.

7. The method of claim 6 further comprising a fastener embedded in the elastomer precursor for forming a sleeve.

8. The method of claim 7 wherein the fastener comprises a snap button, a hook and loop fastener, a zipper, or a magnet.

9. The method of claim 6 wherein the sensor comprises an accelerometer.

10. The method of claim 1 wherein the electrodes are made with polymers comprising conductive carbon or metal particles.

11. The method of claim 1 wherein the elastomer has a Shore A Hardness of 60 or less.

12. A method of making a flexible sheet, comprising:
in a mold, placing conductive wires in connection with electrodes or in connection with contacts for electrodes;
adding an elastomer precursor into the mold to encase the conductive wires and the electrodes or to encase the conductive wires and the contacts for electrodes; and
curing the elastomer precursor to create the flexible sheet with embedded wires and electrodes or contacts for electrodes; and
wherein holes are created in the flexible sheet by using rods or pins around which the elastomer precursor would at least partially cure and removing the rods or pins to leave the holes; and
wherein the electrodes are made with polymers comprising conductive carbon or metal particles.

13. The method of claim 12 wherein a release liner is disposed between the mold and the elastic precursor.

14. The method of claim 12 wherein the mold is a nonstick mold.

15. A method of making a flexible sheet, comprising:
in a mold, placing conductive wires in connection with electrodes or in connection with contacts for electrodes;
adding an elastomer precursor into the mold to encase the conductive wires and the electrodes or to encase the conductive wires and the contacts for electrodes; and
curing the elastomer precursor to create the flexible sheet with embedded wires and electrodes or contacts for electrodes; and
wherein an uncured or partly cured polymer layer is injected with a conductive material.

16. A method of making a flexible sheet, comprising:
in a mold, placing conductive wires in connection with electrodes or in connection with contacts for electrodes;
adding an elastomer precursor into the mold to encase the conductive wires and the electrodes or to encase the conductive wires and the contacts for electrodes; and
curing the elastomer precursor to create the flexible sheet with embedded wires and electrodes or contacts for electrodes; and
wherein the sheet comprises at least 50 mass % elastomer;
wherein an elastic fabric or a flexible fabric is coated by the elastomer.

17. The method of claim 16 wherein the elastic or flexible fabric is a mesh.

Assignees

• Battelle Memorial Institute

Inventors

• Bartholomew John
• Friend Jeffrey

Classifications

• A61N1/36031

  using physiological parameters for adjustment · CPC title

• A61B5/296

  for electromyography [EMG] · CPC title

• B29C39/10

  incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)} · CPC title

• B29L2031/753

  Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008) · CPC title

• A61N1/0476

  Array electrodes (including any electrode arrangement with more than one electrode for at least one of the polarities) · CPC title