Electrode devices and methods of manufacturing

Abstract

An extravascular of intravascular neural interface is disclosed containing electrodes for neurostimulation of the vessel. The devices are housed in flexible substrates formed from a multilumen tubing housing conductors for electrodes positioned in a distal serpentine shaped end of the device. The distal serpentine shaped end includes rows or strips of electrodes or coil electrodes.

1 . A method of manufacturing a neural interface, the method comprising:
 (a) laser ablating a plurality of cavities in an outer diameter of a tube including a plurality of lumina;   (b) inserting a conductor into each lumen among the plurality of lumina;   (c) connecting an electrode to an end of a conductor and positioning the electrode over a cavity among a plurality of cavities, wherein a first cavity among the plurality of cavities is near an end of a length of the tube;   (d) placing a spacer over the tube and positioning the spacer against an edge of the electrode;   (e) repeating (c) and (d) until a last electrode among the plurality of electrodes is positioned in a corresponding last cavity;   (f) melting the plurality of spacers and filling the plurality of cavities;   (g) inserting an overlay over the length of the tube; and   (h) thermoshaping the length of the tube in a helical shape.   
     
     
         2 . The method of  claim 1 , wherein the plurality of electrodes are coil electrodes. 
     
     
         3 . The method of  claim 1 , wherein the tube is a polyurethane multilumen tube, and wherein melting includes reflowing the tube. 
     
     
         4 . The method of  claim 3 , wherein reflowing creates an end of the tube. 
     
     
         5 . The method of  claim 4 , further comprising centerless grinding the end of the tube. 
     
     
         6 . The method of  claim 1 , wherein the overlay is a silicone-based material and the method further comprises at least one of:
 doping the silicone-based material with a steroid drug; or   coating the silicone-based material with a hydrophilic polymer.   
     
     
         7 . The method of  claim 1  wherein (g) includes solvent-swelling the overlay prior to inserting. 
     
     
         8 . The method of  claim 1 , further comprising exposing the plurality of electrodes under the overlay by laser ablating openings in the overlay at a plurality of locations. 
     
     
         9 . The method of  claim 1 , wherein the helical shape is formed by a mandrel of a diameter and at a helix angle for an intended application.