Process for manufacturing electrically conductive components
AssigneeCochlear Limited
InventorsDusan Milojevic, John Parker
Life of this patent
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Abstract
A method of forming a device, such as an electrode array for a cochlear implant. The method comprises a step of forming a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions in a sheet of biocompatible electrically conductive material, such as platinum foil. The method can comprise a step of working on the sheet to remove predetermined portions therefrom to form the one or more discrete relatively conducting regions. The step of working on the sheet can comprise embossing the sheet, cutting or slicing the sheet, or using electrical discharge machining (EDM) to remove unwanted portions of the sheet, the EDM equipment having a cutting tool comprising an electrode.
Claims43
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of:
- working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns,
- wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein,
- wherein the working step comprises using an embossing tool,
- wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means,
- wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means,
- wherein the embossing tool with the embossed sheet and layer of backing material positioned thereon, are relatively removable from within the pressing means.
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of:
- working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns,
- wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material using a pressing means to form a predetermined pattern of raised portions therein,
- wherein the working step comprises using an embossing tool,
- wherein the sheet of electrically conductive material is a planar sheet that is mountable relative to the embossing tool in the pressing means,
- wherein during the working step the sheet is placed above and on the embossing tool and a layer of backing material is then placed on top of the sheet before operation of the pressing means,
- wherein following pressing of the sheet of electrically conducting material, the layer of backing material is removable from the embossed sheet.
A method of forming a device comprised of a predetermined pattern of discrete relatively electrically conductive regions and relatively electrically resistive regions, the method comprising a step of:
- working a sheet of electrically conductive material to remove predetermined portions therefrom to form said one or more discrete relatively conducting regions, wherein said sheet of electrically conductive material has a thickness no greater than about 100 microns,
- wherein the step of working the sheet includes a step of pressing the sheet of electrically conductive material to form an embossed sheet having a predetermined pattern of raised portions therein,
- wherein the working step comprises using an embossing tool,
- wherein an abrading means is used in an abrading step to remove unwanted portions from the embossed sheet,
- wherein prior to the abrading step the embossed sheet is adhered by a layer of an adhesive to a support base.
A method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of:
- (i) coating at least a first surface of a sheet of electrically conductive material with a first layer of another electrically conductive material;
- (ii) forming a predetermined pattern in the sheet of electrically conductive material by removing portions of the sheet therefrom such that at least the pattern of electrically conductive regions remain;
- (iii) coating a second surface of the sheet of electrically conductive material with a layer of resiliently flexible material;
- and
- (iv) removing the first layer from the first surface of said sheet.
The method of forming a device 28 wherein all of the required number of electrically conductive regions for a device are formed in different regions of a single platinum sheet.
The method of forming a device comprised of a predetermined pattern of relatively electrically conductive regions and relatively electrically resistive regions, the method comprising the steps of:
- (i) mounting a sheet of electrically conductive material in an electrical discharge machining (EDM) device, the device having a discharge electrode of a predetermined shape;
- (ii) programming the EDM device to bring the electrode adjacent the sheet;
- and
- (iii) operating the EDM device to remove a portion of the sheet corresponding to the shape of the electrode.
Dependencies are inferred from the claim text.