# US 8,782,884 B2 · Manufacturing an electrode assembly having contoured electrode contact surfaces > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,782,884 B2 - Document ID: US8782884B2 - Status: Granted - Kind: B2 - Application number: 12/628,848 - Filed: 2009-12-01 - Published: 2011-06-02 - Granted: 2014-07-22 - Earliest claimed: 2009-12-01 - Assignees: Cochlear Limited - Applicants: Edmond D. Capcelea; Peter Gibson; Fysh Dadd - Inventors: Edmond D. Capcelea; Peter Gibson; Fysh Dadd - Web page: https://patentgrep.com/patent/US8782884B2 ## CPC - B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components} - B29C 45/0055: {Shaping} - A61N 1/0541: {Cochlear electrodes} - B29C 2045/0058: {removing material} - B29L 2031/753: {Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008)} - Y10T 29/49128: Assembling formed circuit to base - Y10T 29/49158: with molding of insulated base - Y10T 29/4916: Simultaneous circuit manufacturing - Y10T 29/49222: forming array of contacts or terminals - Y10T 29/49224: with coating - Y10T 29/53204: Electrode - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - 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) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method for manufacturing an electrode assembly. The method comprises: forming a comb having a plurality of electrode contacts, wherein the surface of at least one of the electrode contacts comprises a plurality of indentations such that the effective surface area per area unit of a center region of the at least one electrode contact is larger than the effective surface area per area unit of the of the region of the surface outside the center region; assembling an array of electrode contacts from the comb; molding a carrier member about the assembled array of electrode contacts, wherein a surface of the at least one electrode contact is covered by a layer of the carrier member material; and removing the layer of carrier member material on the surface of the at least one electrode contact. ## Claims ### Claim 1 A method for manufacturing an electrode assembly, the method comprising: contouring the surface of at least one electrode contact, so as to increase an effective surface area of the electrode contact surface without increasing the geometric surface area of the electrode contact comprising contouring a biocompatible substrate to form at least one designated electrode contact area having indentations formed therein; depositing a protective coating on the contoured surface; molding a carrier member about the at least one electrode contact, wherein the surface of the at least one electrode contact is covered by a layer of the carrier member material; cutting the coating around each designated electrode contact area; and removing the protective coating and the layer of carrier member material from the surface of the at least one electrode contact, comprising removing the coating from the regions of the substrate outside each designated electrode contact area. ### Claim 2 (depends on 1) The method of claim 1, further comprising: punching a comb from the substrate, the comb comprising at least one comb tooth comprising a designated electrode contact area; and shaping the comb to form at least one u-shaped electrode contact, each u-shaped electrode contact comprising one at least one designated electrode contact area. ### Claim 3 (depends on 1) The method of claim 1: wherein the depositing comprises depositing a dissolvable layer of material on the contoured substrate. ### Claim 4 (depends on 3) The method of claim 3, further comprising: punching a comb from the substrate, the comb comprising at least one comb tooth comprising a designated electrode contact area; and shaping the comb to form at least one u-shaped electrode contact, each u-shaped electrode contact comprising one at least one contoured designated electrode contact area. ### Claim 5 (depends on 1) The method of claim 1, wherein depositing a protective coating on the contoured surface comprises: depositing a parylene layer on the contoured surface. ### Claim 6 (depends on 1) The method of claim 1, wherein contouring comprises: contouring the surface of at least one electrode contact such that the effective surface area per area unit of a center region of the at least one electrode contact is larger than the effective surface area per area unit of the of the region of the surface outside the center region. ### Claim 7 (depends on 6) The method of claim 6, wherein contouring the surface comprises: forming a pattern of indentations such that the effective surface area per area unit of a region of the surface outside the center region decreases from the center region towards edges of the at least one electrode contact. ### Claim 8 (depends on 6) The method of claim 6, wherein contouring the surface comprises: modifying one or more portions of the surface outside of the center region such that each portion has a different effective surface area per area unit, wherein the portion adjacent the center region has a greater effective surface area per area unit than any other of the one or more portions. ### Claim 9 (depends on 1) The method of claim 1, wherein contouring the surface of the at least one electrode contact comprises: laser ablating the surface of at least one electrode contact. ### Claim 10 (depends on 9) The method of claim 9, wherein laser ablating the surface of the at least one electrode contact comprises: impacting the surface with a laser beam from an excimer laser. ### Claim 11 (depends on 1) The method of claim 1, wherein contouring the surface of the at least one electrode contact comprises: chemically etching the at least one electrode contact. ### Claim 12 (depends on 1) The method of claim 1, wherein contouring the surface of the at least one electrode contact comprises: applying electric discharges between an electrode discharge machine (EDM) cutting tool and the at least one electrode contact. ### Claim 13 (depends on 1) The method of claim 1, wherein contouring the surface of the at least one electrode contact comprises: applying an acidic wash to the at least one electrode surface. ### Claim 14 (depends on 3) The method of claim 3, wherein removing the protective coating from the at least one electrode contact, comprises: dissolving the protective coating. ### Claim 15 A system for manufacturing an electrode assembly comprising: means for contouring the surface of at least one electrode contact, so as to increase an effective surface area of the electrode contact surface without increasing the geometric surface area of the electrode contact comprising means for contouring a biocompatible substrate to form at least one designated electrode contact area having indentations formed therein; means for depositing a protective coating on the contoured surface; means for molding a carrier member about the at least one electrode contact, wherein the surface of the at least one electrode contact is covered by a layer of the carrier member material; means for cutting the coating around each designated electrode contact area; and means for removing the protective coating and the layer of carrier member material from the surface of the at least one electrode contact, comprising means for removing the coating from the regions of the substrate outside each designated electrode contact area. ### Claim 16 (depends on 15) The system of claim 15, further comprising: means for punching a comb from the substrate, the comb comprising at least one comb tooth comprising a designated electrode contact area; and means for shaping the comb to form at least one u-shaped electrode contact, each u-shaped electrode contact comprising one at least one contoured designated electrode contact area. ### Claim 17 (depends on 15) The system of claim 15: wherein means for contouring comprises means for contouring a biocompatible substrate to form at least one designated electrode contact area, each designated electrode contact area having a plurality of indentations formed therein; and wherein means for depositing comprises means for depositing a dissolvable layer of material on the contoured substrate; the system further comprising: means for cutting the layer around each designated electrode contact area; and means for removing the layer from the regions of the substrate outside each designated electrode contact area. ### Claim 18 (depends on 17) The system of claim 17, further comprising: means for punching a comb from the substrate, the comb comprising at least one comb tooth comprising a designated electrode contact area; and means for shaping the comb to form at least one u-shaped electrode contact, each u-shaped electrode contact comprising one at least one contoured designated electrode contact area. ### Claim 19 (depends on 15) The system of claim 15, wherein the means for depositing a protective coating on the contoured surface comprises: means for depositing a parylene layer on the contoured surface. ### Claim 20 (depends on 15) The system of claim 15, wherein the means for contouring the surface comprises: means for forming a pattern of indentations such that the effective surface area per area unit of a region of the surface outside the center region decreases from the center region towards edges of the at least one electrode contact. ### Claim 21 (depends on 15) The system of claim 15, wherein the means for contouring the surface comprises: means for modifying one or more portions of the surface outside of the center region such that each portion has a different effective surface area per area unit, wherein the portion adjacent the center region has a greater effective surface area per area unit than any other of the one or more portions. ### Claim 22 (depends on 15) The system of claim 15, wherein the means for contouring the surface of the at least one electrode contact comprises: means for laser ablating the surface of at least one electrode contact. ### Claim 23 (depends on 22) The system of claim 22, wherein the means for laser ablating the surface of the at least one electrode contact comprises: means for impacting the surface with a laser beam from an excimer laser. ### Claim 24 (depends on 15) The system of claim 15, wherein the means for contouring the surface of the at least one electrode contact comprises: chemically etching the at least one electrode contact. ### Claim 25 (depends on 15) The system of claim 15, wherein the means for contouring the surface of the at least one electrode contact comprises: means for applying electric discharges between an electrode discharge machine (EDM) cutting tool and the at least one electrode contact. ### Claim 26 (depends on 15) The system of claim 15, wherein the means for contouring the surface of the at least one electrode contact comprises: means for applying an acidic wash to the at least one electrode surface. ### Claim 27 (depends on 17) The system of claim 17, wherein the means for removing the protective coating from the at least one electrode contact, comprises: means for dissolving the protective coating. ### Claim 28 A method for manufacturing an electrode assembly, the method comprising: contouring the surface of at least one electrode contact, so as to increase an effective surface area of the electrode contact surface without increasing the geometric surface area of the electrode contact; depositing a protective coating on the contoured surface; molding a carrier member about the at least one electrode contact, wherein the surface of the at least one electrode contact is covered by a layer of the carrier member material; and removing the protective coating and the layer of carrier member material from the surface of the at least one electrode contact, wherein the contouring comprises: contouring the surface of at least one electrode contact such that the effective surface area per area unit of a center region of the at least one electrode contact is larger than the effective surface area per area unit of the of the region of the surface outside the center region. ### Claim 29 A method for manufacturing an electrode assembly, the method comprising: contouring the surface of at least one electrode contact, so as to increase an effective surface area of the electrode contact surface without increasing the geometric surface area of the electrode contact; depositing a protective coating on the contoured surface; molding a carrier member about the at least one electrode contact, wherein the surface of the at least one electrode contact is covered by a layer of the carrier member material; and removing the protective coating and the layer of carrier member material from the surface of the at least one electrode contact, wherein the contouring the surface of the at least one electrode contact comprises one of the following: laser ablating the surface of at least one electrode contact, chemically etching the at least one electrode contact, applying electric discharges between an electrode discharge machine (EDM) cutting tool and the at least one electrode contact, and applying an acidic wash to the at least one electrode surface. ### Claim 30 A system for manufacturing an electrode assembly comprising: means for contouring the surface of at least one electrode contact, so as to increase an effective surface area of the electrode contact surface without increasing the geometric surface area of the electrode contact; means for depositing a protective coating on the contoured surface; means for molding a carrier member about the at least one electrode contact, wherein the surface of the at least one electrode contact is covered by a layer of the carrier member material; and means for removing the protective coating and the layer of carrier member material from the surface of the at least one electrode contact, wherein the means for contouring comprises means for contouring a biocompatible substrate to form at least one designated electrode contact area, each designated electrode contact area having a plurality of indentations formed therein; the system further comprising: means for removing the coating from the regions of the substrate outside each designated electrode contact area.