# US 2012/0239126 A1 · Visual Prosthesis Including a Flexible Circuit Electrode Array

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- Number: US 2012/0239126 A1
- Document ID: US20120239126A1
- Status: Published application
- Kind: A1
- Application number: 13/460,495
- Filed: 2012-04-30
- Published: 2012-09-20
- Earliest claimed: 2007-06-27
- Assignees: Second Sight Medical Products, Inc.
- Inventors: David Daomin Zhou; Robert J. Greenberg; Jordan Matthew Nevsmith; Boon-Khai Ng; James Singleton Little; Neil Hamilton Talbot; Satinderpall Singh Pannu; James Courtney Davidson; Phillipe John Tabada
- Web page: https://patentgrep.com/patent/US20120239126A1

## CPC

- A61N 1/0543: {Retinal electrodes}
- H05K 3/28: Applying non-metallic protective coatings {(H05K3/0091 takes precedence; methods for intermediate insulating layers for build-up multilayer circuits H05K3/4673)}
- A61N 1/0541: {Cochlear electrodes}
- H05K 1/036: {Multilayers with layers of different types}
- H05K 1/0393: {Flexible materials (H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups)}
- H05K 1/118: {specially for flexible printed circuits, e.g. using folded portions}
- H05K 2201/0133: Elastomeric or compliant polymer
- H05K 2201/0195: Dielectric or adhesive layers comprising a plurality of layers, e.g. in a multilayer structure
- Y10T 156/1002: with permanent bending or reshaping or surface deformation of self sustaining lamina
- A61N: ELECTROTHERAPY; MAGNETOTHERAPY; RADIATION THERAPY; ULTRASOUND THERAPY (measurement of bioelectric currents A61B; surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body A61B18/00; anaesthetic apparatus in general A61M; incandescent lamps H01K; infrared radiators for heating H05B)
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A visual prosthesis which includes a hermetic package and flexible circuit electrode array is disclosed. The hermetic package includes electrode drivers and contacts. The flexible circuit electrode array includes a polymer base layer, metal traces, including electrodes suitable to stimulate visual neural tissue and bond pads bonded to contacts on the hermetic package, all deposited on the polymer base layer, a polymer top layer deposited on the polymer base layer and deposited on the metal traces, a partial or an entire coating of the polymer base layer and of the polymer top layer by a soft polymer that is softer than the polymer base layer; and the polymer base layer and the polymer top layer contain a plurality of aligned holes to facilitate bonding of the soft polymer.

## Claims

### Claim 1

A visual prosthesis comprising:
a hermetic package including electrode drivers;
a flexible circuit electrode array including:
a polymer base layer having a first edge,
metal traces, including electrodes suitable to stimulate visual neural tissue and bond pads bonded to contacts on the hermetic package, deposited on said polymer base layer,
a polymer top layer, having a second edge, deposited on said polymer base layer and deposited on said metal traces,
a partial or an entire coating of said polymer base layer and of said polymer top layer by a soft polymer that is softer than said polymer base layer; and
said polymer base layer and said polymer top layer of said flexible circuit electrode array contain a plurality of aligned holes to facilitate said soft polymer bonding, said holes not aligned to said electrodes.

### Claim 2 (depends on 1)

The visual prosthesis according to claim 1, wherein said first edge of said polymer base layer and said second edge of said polymer top layer are covered by said soft polymer.

### Claim 3 (depends on 1)

The visual prosthesis according to claim 1, wherein said polymer base layer and said polymer top layer are completely coated with said soft polymer.

### Claim 4 (depends on 1)

The visual prosthesis according to claim 1, wherein said polymer base layer and/or said polymer top layer of said flexible circuit electrode array contain said plurality of holes on said edge or on said second edge or over an entire area.

### Claim 5 (depends on 4)

The visual prosthesis according to claim 4, wherein said plurality of holes have a diameter of 1 micrometer to 1000 micrometers, preferably 10 micrometers to 100 micrometers.

### Claim 6 (depends on 4)

The visual prosthesis according to claim 4, wherein the distance between said holes is 1 micrometer to 1000 micrometers preferably 10 micrometers to 100 micrometers.

### Claim 7 (depends on 1)

The visual prosthesis according to claim 1, wherein said polymer base layer and said polymer top layer of said flexible circuit electrode array have a thickness of 2 micrometers to 4 micrometers.

### Claim 8 (depends on 1)

The visual prosthesis according to claim 1, wherein said soft polymer has a thickness of 5 micrometers to 20 micrometers.

### Claim 9 (depends on 1)

The visual prosthesis according to claim 1, wherein said polymer base layer and said polymer top layer are polyimide, polyamide, LCP, Peek, polypropylene, polyethylene, parylene, mixtures, copolymers, or block copolymer thereof.

### Claim 10 (depends on 1)

The visual prosthesis according to claim 1, wherein said soft polymer is polymer, copolymer, block copolymer, or polymer layer structure of at least one of the following polymers: polyimide, silicone, polyurethane, parylene, polyethylene, polypropylene, polyamide, polyester, PEEK, other soft polymers, or mixtures thereof.

### Claim 11 (depends on 1)

The visual prosthesis according to claim 1, wherein said electrodes are platinum gray, platinum, iridium, iridium oxide, palladium, gold, nickel, ruthenium, titanium, alloys, conducting polymers, or layers thereof.

### Claim 12

A method of making a visual prosthesis comprising the steps of:
depositing a polymer base layer;
depositing metal on said polymer base layer;
patterning said metal to form metal traces;
depositing a polymer top layer on said polymer base layer and on said metal traces creating a flexible circuit electrode array;
heating said flexible circuit electrode array in a mold to form a three dimensional shape in said flexible circuit electrode array;
bonding a polymer skirt, comprising a softer polymer than said polymer base layer, to said flexible circuit electrode array;
said polymer base layer and/or said polymer top layer of said flexible circuit electrode array contain a plurality of holes to facilitate bonding; and
bonding said flexible circuit electrode array to a hermetic package including electrode drivers.

### Claim 13 (depends on 12)

The method according to claim 12, wherein bonding said polymer skirt, comprising a softer polymer than said polymer base layer, is bonding said polymer skirt comprising a silicone having a hardness of about 50 or less on the Shore A scale as measured with a durometer.

### Claim 14 (depends on 12)

The method according to claim 12, wherein said flexible circuit electrode array defines a void suitable to accommodate a tack.

### Claim 15 (depends on 12)

The method according to claim 12, further comprising forming at least one bend in a cable portion of said flexible circuit electrode array.

### Claim 16 (depends on 15)

The method according to claim 15, wherein said at least one bend in a cable portion of said flexible circuit electrode array is between 60° and 120°.

### Claim 17 (depends on 12)

The method according to claim 12, wherein said three dimensional shape is an approximately spherical shape.

### Claim 18 (depends on 17)

The method according to claim 17, wherein said approximately spherical shape approximates the shape of a retina.

### Claim 19 (depends on 12)

The method according to claim 12, wherein said step of heating said flexible circuit electrode array in a mold to form a three dimensional shape in said flexible circuit electrode array is selecting a flexible circuit electrode array comprised of a thermoplastic material and heating said thermoplastic material in a single mold.

### Claim 20 (depends on 12)

The method according to claim 12, wherein said step of heating said flexible circuit electrode array in a mold to form a three dimensional shape in said flexible circuit electrode array is selecting a flexible circuit electrode array comprised of a thermoset material and heating said thermoset material in a succession of molds.