Systems and methods for flexible electrodes

Abstract

Disclosed herein are systems and methods for producing and using electrodes, which may be flexible and/or stretchable, and interconnection structures that can be used both externally and/or implanted within the body. Electrodes according to various embodiments disclosed herein may be produced by depositing patterned layers of insulating and conductive polymers to form multi-layer circuits. The conductive materials and layers in the structure can be exposed on the surface of the structures for use as electrodes. A plurality of electrodes may be formed into an electrode array. In various embodiments, electrode arrays may be associated with telemetry modules configured to wirelessly transmit data collected by the electrode array to a receiver module.

1 . A method of forming a flexible electrode, comprising:
 depositing a first layer along a length of the flexible electrode, the first layer comprising a first polymer, the first polymer comprising an insulating polymer;   depositing a second layer on the first layer and along at least a portion of the length of the flexible electrode, the second layer comprising a second polymer and a conductive trace, the conductive trace comprising a plurality of distinct conductive particles, at least a plurality of the distinct conductive particles being separated by the second polymer;   forming an electrode interface in electrical communication with the conductive polymer trace; and   depositing a third layer, the third layer comprising the insulating polymer, such that the first layer and the third layer encompass the conductive trace along at least a portion of the length.   
     
     
         2 . The method of  claim 1 , wherein each of the first layer, the second layer, and the third layer are directly deposited. 
     
     
         3 . The method of  claim 1 , wherein each of the first layer, the second layer, and the third layer are deposited using an ink jet process. 
     
     
         4 . The method of  claim 1 , wherein each of the first layer, the second layer, and the third layer are deposited using a screen printing process. 
     
     
         5 . The method of  claim 1 , wherein each of the first layer, the second layer, and the third layer comprise a bio stable polymer. 
     
     
         6 . The method of  claim 1 , wherein the plurality of distinct conductive particles comprises at least one of: conductive forms of carbon, metal particles, and composite materials comprising an interior particle coated with metal. 
     
     
         7 . The method of  claim 1 , wherein the conductive trace comprises a plurality of distinct conductive micro-particles. 
     
     
         8 . The method of  claim 1 , wherein the second layer exhibits a compressive force upon the plurality of distinct conductive particles. 
     
     
         9 . The method of  claim 1 , wherein the second polymer comprises an intrinsically conductive polymer. 
     
     
         10 . The method of  claim 9 , wherein the intrinsically conductive polymer comprises one of polypyrrole, polyacetylene, polyaniline, and polydioctyl-bithiophene. 
     
     
         11 . The method of  claim 1 , further comprising associating a plurality of electrical components with the conductive trace. 
     
     
         12 . The method of  claim 11 , further comprising:
 providing a printed circuit board to interconnect the plurality of electrical components and the conductive trace; and   depositing the first layer and the third layer encompass the printed circuit board.   
     
     
         13 . The method of  claim 1 , further comprising:
 depositing a fourth layer, the fourth layer comprising a conductive trace, wherein the third layer at least partially insulates the third layer from the fourth layer along at least a portion of the length.   
     
     
         14 . The method of  claim 1 , further comprising depositing at least one of the first layer, the second layer, and the third layer in a mold. 
     
     
         15 . The method of  claim 1 , further comprising curing at least one of the first layer, the second layer, and the third layer. 
     
     
         16 . The method of  claim 1 , further comprising:
 generating an electrical signal using a stimulator in electrical communication with the conductive trace to be transmitted to the electrode interface.   
     
     
         17 . A method of forming a flexible electrode, comprising:
 depositing a first layer comprising an insulating polymer along a length of the flexible electrode;   depositing at least a second layer on the insulating polymer, the second layer comprising a second polymer, the second layer forming a plurality of conductive traces, each of the plurality of conductive traces comprising a plurality of distinct conductive particles, and each of the conductive traces being insulated from each of the other conductive traces by the insulating polymer;   forming a plurality of electrode interfaces, each of the plurality of electrode interfaces being in electrical communication with at least one of the plurality of conductive traces; and   depositing a third layer comprising the insulating polymer over the second layer, the third layer comprising the insulating polymer, such that the first layer and the third layer encompass the plurality of conductive traces along at least a portion of the length.   
     
     
         18 . The method of  claim 17 , wherein at least one of the first layer, the second layer, and the third layer are formed using one of a direct deposition process, an ink jet process, a screen printing process. 
     
     
         19 . The method of  claim 17 , further comprising depositing at least one of the first layer, the second layer, and the third layer in a mold. 
     
     
         20 . The method of  claim 17 , wherein the plurality of electrode interfaces are disposed in a grid pattern.