Implantable electrode array assembly including a carrier with embedded control modules contained in packages, the packages extending outwardly so as to extend over the carrier

Patent metadata

Field	Value
Publication number	US-9770582-B2
Application number	US-201314045914-A
Country	US
Kind code	B2
Filing date	Oct 4, 2013
Priority date	Aug 5, 2009
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

An implantable electrode array that includes a carrier on which multiple spaced apart electrodes are disposed. Embedded in the module are control modules. The control modules are contained in packages. Portions of the packages extend outwardly from the carrier so as to be disposed against adjacent surfaces of the carrier. The packages contain conductive tracts that provide conductive links from the conductors internal to the carrier to the packaged control modules.

First claim

What is claimed is:

1. An electrode array, said electrode array including:
a flexible carrier having first and second surfaces that are opposite each other;
at least one electrode disposed over at least one of the first or second surfaces of said carrier;
a control module disposed in said flexible carrier, said control module configured to control the operation of said at least one electrode or monitor the electrical potential present at said electrode, said control module having at least one conductive pad through which signals are input and output from said control module;
a package formed from electrically insulating material that surrounds said control module so as to separate said control module from said carrier, said package including:
a rigid substrate located adjacent said at least one conductive pad of said control module, said substrate formed so that a section thereof is located outside of said carrier and extends over a surface of said carrier; and
at least one conductive path integral with said substrate that extends from the control module conductive pad to the section of substrate that extends over the surface of the flexible carrier; and

a conductor disposed in said flexible carrier that extends to said conductive path of said substrate.

2. The electrode array of claim 1 , wherein:
said package further includes: a ring that extends upwardly from said substrate so as to surround said control module, said ring having an outer perimeter; and a lid attached to said ring that extends over said control module; and
said package substrate section that is located outside of said carrier and that extends over the surface of said carrier extends outwardly from the outer perimeter of said ring.

3. The electrode array of claim 1 , wherein:
said package further includes: a ring that extends upwardly from said substrate so as to surround said control module; a lid that is attached to said ring that extends over said control module wherein, at least one of said substrate, said ring or said lid is spaced away from said control module; and
a non-porous material is disposed in the package between said control module and at least one of said substrate, said ring or said lid.

4. The electrode array of claim 1 , wherein said conductive path integral with said substrate includes: a first via that extends inwardly from said control module into said substrate; a conductor disposed within said substrate, where said first via extends to said conductor; and a second via that extends outwardly from said conductor to a surface of the section of said substrate that extends over the surface of said flexible carrier.

5. The electrode array of claim 1 , wherein said conductor disposed in said flexible carrier that extends to said conductive path integral with said substrate is a post formed from conductive material, said post being bonded to said substrate and extending into said flexible carrier.

6. The electrode array of claim 1 , wherein:
said at least one electrode is disposed in or on the first surface of said flexible carrier; and
said package is mounted to said flexible carrier so that the section of said package substrate that is located outside of said carrier and extends over a surface of said carrier extends over the second surface of said carrier.

7. The electrode array of claim 1 , wherein said flexible carrier includes at least one structural member formed from elastic material.

8. The electrode array of claim 1 , wherein:
said flexible carrier includes: at least one structural member formed from elastic material; and a layer of electrically insulating material disposed between said structural member formed from elastic material and said package substrate, said layer of electrically insulating material forming the surface of said carrier over which said package substrate extends; and
said conductor disposed in said flexible carrier is disposed in said layer of electrically insulating material.

9. The electrode array of claim 1 , further including:
a plurality of said electrodes are disposed over at least one of the first or second surfaces of said flexible carrier;
a plurality of said control modules disposed in said flexible carrier;
a plurality of separate said packages are mounted to said flexible carrier; each said package surrounding at least one said control module, said packages each having a substrate with a section that is located outside of said carrier and that extends over a surface of said flexible carrier, said substrates being spaced from each other so that, between said substrates, said flexible carrier can bend;
plural said conductors disposed in said flexible carrier; and
conductive paths on said substrates that extend from the said conductive pads of the said control modules contained within the said packages with which said substrates are associated to the sections of said substrates that extend over the surface of said flexible carrier, said conductive paths providing conductive links between said conductors disposed in said flexible carrier and the conductive pads of said control modules.

10. The electrode array of claim 1 , wherein:
a superstrate is disposed over the first surface of said flexible carrier, said superstrate having an exposed face;
said at least one electrode is disposed over the exposed face of said superstrate; and
said package is mounted to said flexible carrier so that the section of said package substrate that located outside of said carrier and that extends over a surface of said carrier extends over the second surface of said carrier.

11. The electrode array of claim 1 , wherein said at least one electrode is mounted to said package substrate.

12. The electrode array of claim 1 , wherein said package includes a shell formed from non-porous material disposed on said substrate and that encases said control module.

13. An electrode array, said electrode array including:
a carrier formed from flexible material, said carrier having first and second surfaces that are opposite each other;
at least one electrode disposed over at least one of the first or second surfaces of said carrier;
a plurality of control modules disposed in said carrier, said control modules configured to control the operation of said electrode or monitor the electrical potential present at said electrode, said control modules having conductive pads through which signals are input and output from said control modules;
a plurality of packages formed from electrically insulating material disposed in said carrier, each said package containing at least one said control module so as to separate the said at least one control module contained therein from said carrier, each said package including:
a rigid substrate located adjacent said at least one conductive pad of the said at least control module, said substrate formed so that a section thereof located outside of said carrier and extends over a surface of said carrier; and
at least one conductive path integral with said substrate that extends from the control module conductive pad to the section of substrate that extends over the surface of the flexible carrier
wherein said rigid substrates of at least two adjacent said packages are spaced apart so that said flexible carrier can bend between said packages; and

conductors disposed in said flexible carrier that extend to said conductive paths of said package substrates.

14. The electrode array of claim 13 , wherein at least one said package includes:
a ring that extends upwardly from said substrate so as to surround said control module, said ring having an outer perimeter; and a lid attached to sa

Assignees

• Stryker Corp

Inventors

• Brindley Robert
• Janik John
• Tang Edward Chia-Ning
• Dunlop James Bernard
• Spangler Joseph Leland

Classifications

• A61N1/05 Primary

  for implantation or insertion into the body, e.g. heart electrode (A61N1/06 takes precedence) · CPC title

• H05K1/185

  associated with components encapsulated in the insulating substrate of the PCBs; associated with components incorporated in internal layers of multilayer circuit boards · CPC title

• H05K1/118

  specially for flexible printed circuits, e.g. using folded portions · CPC title

• A61N1/0553

  Paddle shaped electrodes, e.g. for laminotomy · CPC title

• H10W90/00

  Package configurations · CPC title