Method and apparatus for using flex circuit technology to create an electrode

Abstract

A method of creating an active electrode that may include providing a flex circuit having an electrode made of a first material and providing a first mask over the flex circuit, the first mask having an offset region and an opening that exposes the electrode. The method may also include depositing a second material over the offset region and the opening, the second material being different from the first material and providing a second mask over the second material, the second mask having an opening over a portion of the second material that is over the offset region.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The features, objects, and advantages of the invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, wherein:

FIG. 1 is a cross-section view of an active electrode that is created using a flex circuit according to an embodiment of the invention.

FIG. 2 is a top view of a flex circuit according to an embodiment of the invention.

FIG. 3 is a top view of a mask that is used to cover the flex circuit of FIG. 1 according to an embodiment of the invention.

FIG. 4 is a top view showing one or more materials of interest deposited into and above the openings in the mask according to an embodiment of the invention.

FIG. 5 is a top view of a mask that is used to cover the material of interest shown in FIG. 4 according to an embodiment of the invention.

FIGS. 6A and 6B are top views showing vertical and horizontal offsets according to various embodiments of the invention.

FIG. 7 is a flow chart showing a method of creating the electrode of FIG. 1 according to an embodiment of the invention.

Claims

1. A method of creating an active electrode, comprising: providing a flex circuit having an electrode made of a first material;providing a first mask over the flex circuit, the first mask having an offset region and an opening that exposes the electrode;depositing a second material over the offset region and the opening, the second material being different from the first material; andproviding a second mask over the second material, the second mask having an opening over a portion of the second material that is over the offset region.

2. The method of claim 1, further comprising providing a membrane in the opening of the second mask.

3. The method of claim 1, wherein the offset region is adjacent to the opening of the first mask.

4. The method of claim 1, wherein the first material is a copper material and the second material is selected from a group consisting of a carbon, gold, graphite, platinum, silver-silver chloride, rodium, and palladium material.

5. The method of claim 1, wherein one of the plurality of electrodes is positioned along a first axis and the offset region is positioned along a second axis that is not coincident with the first axis.

6. The method of claim 1, wherein one of the plurality of electrodes is positioned along a first plane and the offset region is positioned along a second plane that is not coincident with the first plane.

7. The method of claim 1, wherein the first material is copper and the second material is not copper.

8. A method of creating an electrode, comprising: providing a substrate having a conductive trace thereon;applying a first mask over the conductive trace, the first mask having a first opening over a portion of the conductive trace;applying a material of interest over a portion of the conductive trace and over a portion of the first mask; andapplying a second mask over the material of interest, the second mask having a second opening over a portion of the material of interest, the second opening being offset from the first opening.

9. The method of claim 8, wherein the conductive trace is made of a copper material and the material of interest is made of a material that is not copper.

10. The method of claim 8, wherein the first opening is positioned along a first axis and the second opening is positioned along a second axis that is not coincident with the first axis.

11. The method of claim 8, wherein the first opening is positioned along a first plane and the second opening is positioned along a second plane that is not coincident with the first plane.

12. The method of claim 8, wherein the offset is in a direction that is along a length of the substrate.

13. The method of claim 8, wherein the offset is in a direction that is along a width of the substrate.

14. The method of claim 8, wherein the conductive trace is made of a copper material and the material of interest is selected from a group consisting of a carbon, gold, graphite, platinum, silver-silver chloride, rodium, and palladium material.

15. An electrode, comprising: a substrate having a conductive trace made of a first material;a first mask positioned over the conductive trace, the first mask having a first opening over a portion of the conductive trace;a material of interest made of a second material and positioned over a portion of the conductive trace and over a portion of the first mask; anda second mask over the material of interest, the second mask having a second opening over a portion of the material of interest, the second opening being offset from the first opening.

16. The electrode of claim 15, wherein the first opening is positioned along a first axis and the second opening is positioned along a second axis that is not coincident with the first axis.

17. The electrode of claim 15, wherein the first opening is positioned along a first plane and the second opening is positioned along a second plane that is not coincident with the first plane.

18. The electrode of claim 15, wherein the offset is in a direction that is along a length of the substrate.

19. The electrode of claim 15, wherein the offset is in a direction that is along a width of the substrate.

20. The electrode of claim 15, wherein the conductive trace is made of a copper material and the material of interest is made of a material that is not copper.