Implantable Neural Interface Device with a Deformable Carrier

Abstract

An improved deformable carrier or connector for an implantable neural interface device is described. The neural interface device comprises a carrier supporting at least one electrode array. The carrier comprises a tubular sidewall extending from a proximal carrier portion to a distal carrier portion. At least one deformable segment is provided in the carrier sidewall.. The deformable segment is more pliable than the remainder of the carrier sidewall to preferably move in response to forces imparted on the carrier and the electrode array by the shifting forces in body tissue. The deformable segment takes the form of a thinned sidewall segment or a slitted wall segment.

Description

FIELD OF THE INVENTION

This invention relates generally to the implantable medical devices and, more specifically, to an improved implantable neural interface device with a deformable carrier or connector.

BACKGROUND OF THE INVENTION

Conventional carriers or connectors for neural interface devices, such as those with electrode arrays for deep brain and central nervous system applications, have a tendency to “drift” after implantation in targeted tissue. This is due, in part, to the mechanical mismatch between the relatively stiff carrier for the neural interface device and the target body tissue and, in part, to tissue regrowth around the neural interface device. Any relative movement between the neural interface device and body tissue can result in the electrode array moving away from the targeted tissue. Thus, there is a need in the implantable medical device field for an improved carrier or connector for an implantable neural interface device. The present invention provides such an improved deformable carrier or connector for an implantable neural interface device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 1A to 1DC are schematics of a neural interface device 10 according to the present invention including a carrier 12, an electrical conductor 20, and a stylet 32.

FIG. 2 is a schematic of the implanted neural interface device 10 having been implanted into body tissue.

FIG. 3 is a schematic of a prior art neural interface device 10A after having been implanted in shifted body tissue.

FIGS. 4 and 4A to 4C are schematics of a first embodiment of the carrier 12 for the neural interface device 10 including deformable segments 18.

FIG. 4D is an enlarged view of the area indicted in FIG. 4C.

FIGS. 5A and 5B are schematics of the neural interface device 10 of the present invention after having been implanted in shifted body tissue.

FIG. 6 is a schematic of another embodiment of tapered deformable segments 46 for the carrier 12 of an implantable neural interface device 10 according to the present invention.

FIG. 6A is a cross-section along line 6A-6A of FIG. 6.

FIG. 7 is a schematic of anchoring features such as etched recesses 48 and through-holes 50 in the carrier sidewall 16.

FIG. 8 is a schematic of an electrode array 14.

FIGS. 9A to 9B are schematics of another embodiment of a deformable connector 102 for a neural interface device 100 according to the present invention.

FIGS. 10A to 10D are schematics of a method of manufacturing the neural interface device 100 illustrated in FIGS. 9A and 9B.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, FIGS. 1 and 1A to 1C illustrate a preferred embodiment of an implantable neural interface device 10 according to the present invention. The neural interface device 10 is implantable into a wide variety of body tissue including the brain, spinal cord, peripheral nerve, muscle, and/or any suitable neural tissue and comprises a carrier 12 supporting at least one electrode array 14.

The electrode array 14 may be made from a thin-film polymer substrate such that there is a high density of electrode sites at a first end of the array (e.g., the distal end) and bonding regions at a second end of the array (e.g., the proximal end). The polymer substrate is preferably parylene, polyimide, silicone or a suitable combination of organic and inorganic dielectrics, but may additionally and/or alternatively be made of any suitable material. The substrate can also include a dielectric layer comprised of silicon nitride, silicon dioxide, silicon carbide, and mixtures thereof.

The carrier 12 is preferably of silicone or polyurethane and comprises a tubular sidewall 16 having a length extending from a proximal carrier portion 12A to a distal carrier portion 12B. The distal carrier portion 12B has a step 12C transition to a thin-walled distal end 12D. The step 12C has a height that substantially matches the thickness of the thin film substrate comprising the electrode array 14. That way, the electrode assay 14 is wrapped and otherwise supported at least part way around the circumference of the distal carrier end 12D to provide a smooth transition to the distal carrier portion 12B. To facilitate adhesion between the carrier 12 and electrode array 14, small non-homogenous perforations may be micromachined into the thin-film substrate to allow for the material of the carrier 12 to form a robust anchor with the electrode array 14.

At least one deformable segment 18 is provided along the length of the carrier 12 intermediate a first carrier sidewall portion 16A and a second carrier sidewall portion 16B. As will be described in greater detail, hereinafter, the deformable segment 18 is a portion or location along the carrier 12 that is compressible, tensile, articulatable, and/or rotatable along an axis thereof, such as a longitudinal axis of the carrier. Compression or extension of the deformable segment 18 results in translation of the carrier sidewall portions 16A, 16B relative to one another along an axis of insertion (e.g., longitudinal axis along the carrier). However, the deformable segment 18 may additionally and/or alternatively bend or rotate or deform in any other suitable manner along any suitable axis. For instance, the deformable segment 18 may bend or curve to enable the sidewall portions 16A, 16B to become axially misaligned or curved along the length of the carrier 12. In an alternative embodiment, the entire length of the carrier 12 is substantially equivalent to a deformable segment 18 such that the carrier is adapted to deform in compression, extension, and/or any other suitable manner.

An electrical conductor 20 extends from the proximal carrier portion 12A to the distal carrier portion 12B where the conductor electrically connects to at least one electrode site 22 of the electrode array 14 supported by the distal carrier end 12D. As will be described in greater detail hereinafter, the electrode site 22 is exemplary of a stimulation electrode configured for electrical stimulation of body tissue or a recording electrode for recording of physiological data from body tissue. In that respect, the novel carrier 12 facilitates insertion or implantation of the electrode array 14 into body tissue and, once implanted, helps mitigate or eliminate drift (movement) of the implanted electrode array 14 within the tissue.

The conductor 20 preferably has coiled or otherwise stretchable or deformable sections 20A that coincide with the deformable segments 18 in the carrier 12 of the neural interface device 10. The conductor 20 is preferably a thin-film structure containing multiple individually conductive traces, but may be a wire or any suitable conductive material. The conductor 20 may be wound around the external surface of the carrier 12, wound within a wall of the carrier, or wound around an internal surface of the carrier. The coiling or winding density is preferably selectively varied along the length of the carrier 12 to modulate the flexibility of the conductor 20. In a preferred embodiment, the conductor 20 include at least one section of lower coiling density corresponding to or aligned with a deformable segment. 18 and at least one section of higher coiling density corresponding to or aligned with one of the carrier sidewall section 16A, 16B. In that manner, the carrier 12 and coiled conductor 20 may be deformable in tandem in compression, tension or extension, articulation, rotation and/or any suitable manner.

FIG. 2 is a schematic illustration of the neural interface device 10 according to the present invention extending through the cranium 24 and into brain tissue. This drawing shows that brain tissue is not necessarily homogenous. For example, the brain tissue is depicted as comprising tissue layers or regions 26A, 26B and 26C. The neural interface device 10 has been implanted into the brain tissue with the electrode array 14 residing at a target tissue site 28.

Over time, regions of brain matter can become compressed or expanded through tissue changes. A tethered connection of the neural interface device to the cranium or other proximal structures may induce displacement as well. Such non-specific movement of body tissue can displace an implanted electrode array away from the targeted tissue 28. FIG. 3 shows that relative shifting has occurred between the various tissue layers or regions 26A, 26B and 26C. This shifting results in the electrode array 14A of a prior art neural interface device 10A no longer residing at the target tissue site 28. The consequence can be diminished or even completely ineffective neural stimulation, which is undesirable.

The carrier 12 of the present neural interface device 10 is preferably at least partially made of a flexible material, such as an elastomer. Nitinol is another preferred material for the carrier 12. The carrier 12 is preferably tubular with a substantially cylindrical inner surface and includes one or more lumens 30 (FIG. 1A), such as for receiving a stylet 32 (FIG. 1C) therein. The stylet 32 has a pointed tip at its distal end 32A that helps facilitate insertion of the neural interface device 10 into tissue. If desired, the stylet 32 can have a lumen 34 for transporting fluids or serving as a passage for moving other devices (not shown) through the stylet/carrier assembly from the proximal carrier portion 12A to the distal carrier portion 12B and out the stylet end 32A thereof.

The stylet 32 may be adapted to remain in the tissue coupled to the carrier 12 and include deformable segments 36 similar to those 18 of the carrier 12 that enable compression and/or extension. If provided, the deformable segments 36 of the stylet 32 are preferably aligned with those of the carrier 12. That is so compression and extension of the stylet. 32 and carrier 12 correspond to each other. Alternatively, the stylet 32 may be adapted for removal from the carrier 12 after implantation of the neural interface device 10 into body tissue.

FIGS. 4 and 4A to 4C illustrate a first embodiment of a carrier 12 according to the present invention. As previously described, the carrier 12 comprises the tubular sidewall 16 with a substantially cylindrical inner surface having one or more deformable segments 18 provided at spaced locations along its length. More specifically, the tubular sidewall 16 comprises a plurality of relatively less deformable carrier sidewall portions 16A, 16B, 16C, 16D and 16E, etc. spaced apart from each other by deformable segments 18. The less deformable sidewall portions 16A to 16E each have a first wall thickness that is substantially uniform around the annular extent thereof. This is illustrated in the cross-sections of FIGS. 4A and 4C.

As shown in the cross-sections of FIGS. 4B and 4C, the deformable segments 18 are provided by an annular thinning of the wall thickness. As shown in FIG. 4D, the exemplary deformable segment 18 shown in FIG. 4C has a radiused curvature 38 from where it connects to proximal sidewall segment 16A and to distal sidewall segment 16B. That is the radiused curvature of the deformable segment has a cross-section along a plane aligned perpendicular to a longitudinal axis of the carrier 16 that meets the proximal carrier portion 16A of the first wall thickness and curves to a trough having a second wall thickness at about a mid-point to a distal carrier portion 16B of the first wall thickness. In other words, the carrier segments 16A to 16E, etc. generally have a first wall thickness and the deformable segments 18 generally have a second wall thickness that is less than the first wall thickness.

According to the first embodiment, the carrier 12 is of a continuous molded tubular construction with the thinned deformable segments 18 characterized as a mechanically thinning of the sidewall 16. Thinning of the sidewall can be done by any one of a number of methods including turning the carrier 12 on a lathe, by selective heat pressing the sidewall 16, and the like. Moreover, the carrier sidewall segments 16A to 16E and the deformable segments 18 can be separately manufactured and then serially connected together by thermal sealing, epoxy, or any suitable sealing or coupling method.

As shown in FIG. 5A, the deformable segments 18 enable the carrier 12 and the supported electrode array 14 to remain in the correct position and orientation with respect to the targeted tissue 28. The deformable segments 18 are more pliable than the remainder of the carrier sidewall 16 to preferably move in response to forces imparted on the carrier 12 and the electrode array 14 by the tissue. As shown in FIG. 5A, the deformable segments 18 enable the carrier 12 to more in compression and extension 40. FIG. 5B shows that the deformable segment 18 enables the carrier 12 to undergo both bending 42 and rotational 44 movement. As used herein, the term pliable in reference to the deformable segments 18 means easily bent, relatively more flexible, or relatively suppler.

FIG. 6 illustrates that a deformable segment 46 does not necessarily require the radiused curvature 38 shown for deformable segment 18 in FIGS. 4C and 4D. Instead, the deformable segment 46 can have an irregular or graduated cross-sectional shape that is thinnest at a proximal end 46A and gradually thickens as the segment extends to a distal segment end 46B connected to the next carrier sidewall segment 16B. There can also be a number of deformable segments 46 connected end-to-end intermediate the carrier sidewall segments 16A and 16B. Moreover, the irregularly-shaped deformable segment 46 can be reversed to that shown in FIG. 6. That would be where the segment 46 is thickest at the proximal carrier sidewall segment 16A and thins as it extends to the next, more distal carrier sidewall segment 16B.

In another embodiment, the deformable segments 18 are made of a more flexible material or overall composite of materials having a lower elastic modulus than the carrier segments 16A to 16E, etc. For example, the carrier sidewall segments are of a polymeric material having a durometer ranging from about 75 A to about 60 A, more preferably of a polymeric material having a durometer ranging from about 70 A to about 55 A. Then, the deformable segments 18, 46 are of a more flexible polymeric material having a durometer ranging from about 50 A to about 25 A, more preferably from about 45 A to about 30 A.

In one embodiment, the carrier sidewall 16 is of a first polymeric material having a durometer ranging from about 75 A to about 60 A and the deformable segment 18 is of a second polymeric material having a durometer ranging from about 50 A to 25 A. Moreover, the carrier sidewall 16 of the first polymeric material and the deformable segment 18 of the second polymeric material have similar thicknesses.

In some embodiments, as shown in FIG. 7, the carrier may include one or more anchoring features, such as an etched recess 48 or a through-hole 50 in the carrier sidewall 16. The anchoring features 48, 50 may help promote tissue regrowth into the carrier structure, thereby improving anchoring of the carrier and/or first electrical subsystem in tissue. The carrier sidewall 16 may also be selectively coated with adhesion promoting factors, such as laminin, fibronectin, L1 molecule (Azemi, Gui. 2011, Biomaterials), etc., to promote tissue adhesion.

The electrode array 14 is adapted to provide dynamic tunable electrical interaction with body tissue, and preferably includes a plurality of recording (e.g., sampling or mapping) and/or stimulation electrode sites. For example, the neural interface electrode array may be configured to provide stimulation ranging from macroscale specificity to microscale directional patterning.

As shown in FIG. 8, one embodiment of the electrode array 14 includes sixty-four stimulation electrodes 52 and thirty-two recording electrodes 54 positioned axially along and circumferentially around the carrier 12. Each stimulation site 52 has a surface area of approximately 0.196 mm² (diameter approximately 500 μm), but may alternatively have any suitable surface area. Each recording site 54 has a surface area of approximately 0.00196 mm² (diameter approximately 50 μm), but may alternatively have any suitable surface area. The stimulation sites 52 are positioned such that four sites are equally distributed around the carrier circumference with a center-to-center spacing of approximately 750 μm, and distributed in 16 successive rows equally distributed along the longitudinal or axial direction of the carrier with a row-to-row spacing of approximately 750 μm. A pair of recording sites 54 is positioned on opposite sides of the carrier 12 between each row of stimulation sites 52. Each pair of recording sites 54 is rotated 90 degrees around the carrier with respect to an adjacent pair of recording sites. In alternative embodiments, the electrode array 14 may include any suitable number of stimulation electrode sites 52 and recording sites 54 arranged in any suitable manner.

In another embodiment, the electrode array 14 includes a plurality of cylindrical electrodes (not shown) spaced apart from each other axially along the length of the carrier 12. The cylindrical electrodes can be used in monopolar or bipolar modes to deliver approximately spherical potential fields from separate locations along the cylindrical carrier. Furthermore, although the carrier 12 is preferably a single tube, alternative embodiments may have any suitable shape, such as with branches or forks.

FIGS. 9 and 10 illustrate another preferred embodiment of a neural interface device 100 according to the present invention. The implantable neural interface device 100 comprises a flexible ribbon-type connector 102 having a length extending from a first, proximal connector end 102A to a second, distal connector end 102B, and a width extending between a third, right edge 102C and a fourth, left edge 102D. Further, the connector has a fifth, upper surface 102E spaced from a sixth, lower surface 102F by a thickness 102G (FIGS. 10A to 10C). The ribbon-type connector 102 is preferably of a flexible polymer-based cable, such as of silicone or polyurethane, but may alternatively be any other suitable planar material. Preferably, the connector 102 is encased in silicone or another suitable biocompatible material.

The connector 102 includes at least one deformable segment 104 that functions in a similar manner as previously described with respect to the deformable segments 18, 46 of the carrier 12. The deformable segment 104 comprises at least one split 106 that extends from a proximal slitted end 106A to a distal slitted end 106B. The slit 106 is where the material of the ribbon-type connector 102 has been cut completely through its thickness 102G so that open space exists between adjacent strands 108 of the connector material. The slit 106 and, consequently, the open space extends from a proximal end 104A of the deformable segment to a distal end 104B thereof. More preferably, a plurality of slits 106 form a plurality of strands 108 along the length of the deformable segment 104. Each strand 108 is narrower and consequently more flexible than the unslit connector 102 and includes at least one conducting trace (not shown), and the like, extending from the first, proximal connector end 102A to the second, distal connector end 102B where the traces electrically connect to at least one electrode cite 22 of the previously described electrode array 14.

In this embodiment, the connector 102 with the deformable segment 104 may be fabricated using MEMS or a roll-to-roll technique, and a lithographic technique may be used to pattern the conductive traces. For instance, masking and etching techniques may be used to etch through specific regions of the planar connector 102 to form the one or more split 106. The number of splits 106 and their individual widths may be dependent on various factors, such as intended tissue anatomy of a specific application and manufacturing cost.

FIGS. 10A to 10D illustrate the connector 102 including the deformable segment 104 may include an undulating or three-dimensional shape 110. Undulations 110 facilitate an additional amount of linear expansion or contraction before the connector 102 reaches the tension or compression limits inherent in its material. The undulations 110 may be formed in both a slit and unslit portion. In that respect, the undulations 110 in the connector 102 may be formed by placing the planar structure connector 102 shown in FIG. 10A between complementary undulating top and bottom molds 112A and 112B, and applying heat 114 to anneal the structure. As shown in the side view of FIG. 10C and top plan view of FIG, 10D, the thusly conditioned connector 102 has undulations 110 mirroring those of the molds 112A, 112B. Although FIGS. 10A to 10D primarily show undulations 110 along the axial direction of the connector 102, the connector may additionally and/or alternatively have undulations along the lateral direction or across the width extending from right edge 102C to left edge 102D thereof, or any suitable direction.

If desired, the planar connector 102 can be formed into a tubular shape.

The deformable segments 18, 46 of the neural interface device 10 and the deformable segment 104 of the neural interface device 100 preferably have lengths of from about 0.5 mm to about 2 mm. Moreover, when there is more than one of them in a neural interface device, they are spaced about 1 mm to about 5 mm from each other.

The proximal ends of the implantable neural interface devices 10, 100 are connectable to a second electrical subsystem (not shown) that functions to operate with the electrode array 14. For example, the second electrical, subsystem may be a printed circuit board with or without on-board integrated circuits, comprise an on-chip circuitry for signal conditioning, filtering, or stimulus generation, be an Application Specific Integrated Circuit (ASIC), a multiplexer chip, a buffer amplifier, an electronics interface, an implantable pulse generator, an implantable rechargeable battery, integrated electronics for real-time signal processing of the commands sent to the stimulation electrodes 52 or received from the recording electrodes 54, integrated electronics for control of any fluidic components, and any other suitable electrical subsystem.

In one embodiment, the neural interface devices 10, 100 second may be coupled to a fixation point within the cranium of a patient. For example, a cranial chamber may be attached to the skull, preferably in a cranial burr hole, of a patient, and one or more of the neural interface devices 10, 100 may be coupled to the cranial chamber. One embodiment of such a cranial chamber may be similar to that described in U.S. Pat. No. 7,548,775, which is incorporated in its entirety by this reference. The neural interface devices 10, 100 may further include one or more fluidic channels that provide for delivery of a fluid (e.g., therapeutic drugs) to inhibit biologic response to the implant or to elicit a therapeutic response.

Some embodiments of the neural interface devices 10, 100 of the present invention may include any combination of any of them. One portion of a neural interface device may comprise features of neural interface device 10 while other portions may include features of the neural interface device 100. Moreover, the deformable segments 18, 46 and 104 may be regularly or irregularly spaced along the length of a neural interface device. For example, it may be desirable to impart greater flexibility to selected regions of the carrier, such as spacing the deformable segments progressively closer together towards a distal end or a proximal end of the carrier. Some of the deformable segments may additionally and/or alternatively be more easily deformed than other deformable segments, which may further provide greater flexibility to selected regions of the neural interface device.

A person skilled in the art will recognize from the previous detailed description including the drawing figures, that modifications and changes can be made to the preferred embodiments of the present invention without departing from the scope of the invention defined in the following claims.

Claims

1. A neural interface device, which comprises: a) a carrier having a carrier sidewall extending along a first length from a carrier proximal end to a carrier distal portion having a distal end, wherein the carrier proximal end is electrically connectable to a medical device;b) at least one electrode supported on the distal carrier portion, wherein the electrode is configured for at least one of electrical stimulation of body tissue and sensing of physiological characteristics of the body tissue;c) an electrical conductor that extends along the carrier from the carrier proximal end to the carrier distal portion where it is electrically connected to the electrode; andd) a deformable segment of the carrier sidewall at an intermediate location between the carrier proximal end and the carrier distal end, wherein the deformable segment is relatively more pliable than the remainder of the carrier sidewall.

2. The neural interface device of claim 1 wherein the carrier is of a polymeric material.

3. The neural interface device of claim 1 wherein the carrier has a tubular structure.

4. The neural interface device of claim 1 wherein the carrier sidewall has a first wall thickness and the deformable segment has a second wall thickness that is less than the first wall thickness.

5. The neural interface device of claim 4 wherein the deformable segment is a radiused curvature recessed into the first wall thickness of the carrier.

6. The neural interface device of claim 5 wherein the radiused curvature of the deformable segment extends around the annular extent of the carrier sidewall.

7. The neural interface device of claim 1 wherein the radiused curvature of the deformable segment has a cross-section along a plane aligned perpendicular to a longitudinal axis of the carrier that meets a proximal carrier portion of the first wall thickness and curves to a trough having a second wall thickness at about a mid-point to a distal carrier portion of the first wall thickness.

8. The neural interface device of claim 1 wherein the deformable segment has a graduated thickness that is thinnest at a proximal end of the segment and thickens as the deformable segment extends distally.

9. The neural interface device of claim 8 wherein the graduated thickness of the deformable segment extends around the annular extent of the carrier sidewall.

10. The neural interface device of claim 1 wherein the deformable segment has a graduated thickness that is thinnest at a distal end of the segment and thickness as the deformable segment extends proximally.

11. The neural interface device of claim 10 wherein the graduated thickness of the deformable segment extends around the annular extent of the carrier sidewall.

12. The neural interface device of claim 1 wherein there are at least two deformable segments at spaced locations along the first length of the carrier.

13. The neural interface device of claim 1 wherein the electrical conductor is relatively more stretchable at a location coinciding with the deformable segment of the carrier.

14. The neural interface device of claim 1 wherein the carrier sidewall has a substantially cylindrical inner surface.

15. The neural interface device of claim 1 wherein the at least one electrode is supported on a substrate of a material selected from the group consisting of parylene, polyimide, silicone, silicon nitride, silicon dioxide, silicon carbide, and mixtures thereof.

16. The neural interface device of claim 1 wherein the distal portion of the carrier has a step transition to a thinner carrier sidewall portion that is sized to support the electrode supported on the polymeric substrate,

17. The neural interface device of claim 1 wherein the deformable segment is compressible, tensile, articulatable, and rotatable.

18. The neural interface device of claim 1 wherein the carrier sidewall of the first wall thickness is of a first polymeric material, having a durometer ranging from about 75 to about 60 and the deformable segment of the second wall, thickness is of a second polymeric material having a durometer ranging from about 50 to about 30.

19. The neural interface device of claim 18 wherein the first and second polymeric materials are the same or different.

20. The neural interface device of claim 1 wherein the carrier sidewall is of a first polymeric material having a durometer ranging from about 75 to about 60 and the deformable segment is of a second polymeric material having a durometer ranging from about 50 to 30.

21. The neural interface device of claim 20 wherein the carrier sidewall of the first polymeric material and the deformable segment of the second polymeric material have similar sidewall thicknesses.

22. The neural interface device of claim 1 wherein the carrier is of silicone or polyurethane.

23. The neural interface device of claim 1 wherein the deformable segment has a length of from about 0.5 mm to about 2 mm.

24. The neural interface device of claim 1 wherein there at least two deformable segments spaced apart along the first length of the carrier and the deformable segments are from about 1 mm to about 5 mm from each other.