Reinforced electrode leads and methods for manufacturing the same

An electrode lead adapted for insertion into a human cochlea, comprising:

• a flexible body formed of a flexible insulating material and that comprises a fantail region that connects to a cochlear implant configured to be implanted within a recipient and that extends to a ground electrode located toward a proximal end of the electrode lead;
• a plurality of electrode contacts disposed on a side of the flexible body;
• a plurality of coiled electrode wires provided within the flexible body and that electrically connect the plurality of electrode contacts to a signal source, each coiled electrode wire included in the plurality of coiled electrode wires being bundled together so as to form a plurality of helically formed groups of windings extending along a length of the flexible body;
• and
• a coiled reinforcing element provided within the flexible body and including a plurality of helically formed windings extending along the length of the flexible body together with the plurality of helically formed groups of windings of the plurality of coiled electrode wires,
• wherein:
• the coiled reinforcing element is only provided in the fantail region of the flexible body;
• a winding direction of the plurality of coiled electrode wires is opposite a winding direction of the coiled reinforcing element;
• a winding pitch of the plurality of coiled electrode wires is smaller than a winding pitch of the coiled reinforcing element;
• and
• the coiled reinforcing element does not electrically connect to any electrode contact included in the plurality of electrode contacts.

A method of manufacturing an electrode lead adapted for insertion into a human body, the method comprising:

• winding an electrode wire in a first winding direction to form a coiled electrode wire;
• attaching the electrode wire to an electrode contact;
• winding a reinforcing element in a second winding direction to form a coiled reinforcing element;
• placing the coiled electrode wire, the electrode contact, and the coiled reinforcing element in an electrode lead mold such that the coiled reinforcing element extends longitudinally together with the coiled electrode wire;
• and
• providing, after placing the coiled electrode wire, the electrode contact, and the coiled reinforcing element in an electrode lead mold, the electrode lead mold with a flexible insulating material such that the coiled electrode wire, the electrode contact, and the reinforcing element are embedded within the flexible insulating material,
• wherein:
• the electrode lead includes a fantail region that connects to a cochlear implant configured to be implanted within a recipient and that extends to a ground electrode located toward a proximal end of the electrode lead;
• the coiled reinforcing element is only provided in the fantail region of the electrode lead;
• the first winding direction is opposite the second winding direction;
• the electrode wire and the reinforcing element are wound such that a winding pitch of the coiled electrode wire is smaller than a winding pitch of the coiled reinforcing element;
• and
• the coiled reinforcing element does not electrically connect to the electrode contact.