Cochlear implantation using thin-film array electrodes

Manufacturable 32-Channel Cochlear Electrode Array and Preliminary Assessment of Its Feasibility for Clinical Use

(1) Background: In this study, we introduce a manufacturable 32-channel cochlear electrode array. In contrast to conventional cochlear electrode arrays manufactured by manual processes that consist of electrode-wire welding, the placement of each electrode, and silicone molding over wired structures, the proposed cochlear electrode array is manufactured by semi-automated laser micro-structuring and a mass-produced layer-by-layer silicone deposition scheme similar to the semiconductor fabrication process. (2) Methods: The proposed 32-channel electrode array has 32 electrode contacts with a length of 24 mm and 0.75 mm spacing between contacts. The width of the electrode array is 0.45 mm at its apex and 0.8 mm at its base, and it has a three-layered arrangement consisting of a 32-channel electrode layer and two 16-lead wire layers. To assess its feasibility, we conducted an electrochemical evaluation, stiffness measurements, and insertion force measurements. (3) Results: The electrochemical impedance and charge storage capacity are 3.11 ± 0.89 kOhm at 1 kHz and 5.09 mC/cm2, respectively. The V/H ratio, which indicates how large the vertical stiffness is compared to the horizontal stiffness, is 1.26. The insertion force is 17.4 mN at 8 mm from the round window, and the maximum extraction force is 61.4 mN. (4) Conclusions: The results of the preliminary feasibility assessment of the proposed 32-channel cochlear electrode array are presented. After further assessments are performed, a 32-channel cochlear implant system consisting of the proposed 32-channel electrode array, 32-channel neural stimulation and recording IC, titanium-based hermetic package, and sound processor with wireless power and signal transmission coil will be completed.

Characterization and Miniaturization of Silver-Nanoparticle Microcoil via Aerosol Jet Printing Techniques for Micromagnetic Cochlear Stimulation

According to the National Institute of Deafness and other Communication Disorders 2012 report, the number of cochlear implant (CI) users is steadily increasing from 324,000 CI users worldwide. The cochlea, located in the inner ear, is a snail-like structure that exhibits a tonotopic geometry where acoustic waves are filtered spatially according to frequency. Throughout the cochlea, there exist hair cells that transduce sensed acoustic waves into an electrical signal that is carried by the auditory nerve to ultimately reach the auditory cortex of the brain. A cochlear implant bridges the gap if non-functional hair cells are present. Conventional CIs directly inject an electrical current into surrounding tissue via an implanted electrode array and exploit the frequency-to-place mapping of the cochlea. However, the current is dispersed in perilymph, a conductive bodily fluid within the cochlea, causing a spread of excitation. Magnetic fields are more impervious to the effects of the cochlear environment due to the material properties of perilymph and surrounding tissue, demonstrating potential to improve precision. As an alternative to conventional CI electrodes, the development and miniaturization of microcoils intended for micromagnetic stimulation of intracochlear neural elements is described. As a step toward realizing a microcoil array sized for cochlear implantation, human-sized coils were prototyped via aerosol jet printing. The batch reproducible aerosol jet printed microcoils have a diameter of 1800 μm, trace width and trace spacing of 112.5 μm, 12 μm thickness, and inductance values of approximately 15.5 nH. Modelling results indicate that the coils have a combined depolarization–hyperpolarization region that spans 1.5 mm and produce a more restrictive spread of activation when compared with conventional CI.

Study of the Carrier-Aided Thin Film Electrode Array Design for Cochlear Insertion

The micro-fabricated thin film electrode array (TFEA) has been a promising design for cochlear implants (CIs) because of its cost-effectiveness and fabrication precision. The latest polymer-based cochlear TFEAs have faced difficulties for cochlear insertion due to the lack of structural stiffness. To stiffen the TFEA, dissolvable stiffening materials, TFEAs with different structures, and TFEAs with commercial CIs as carriers have been invested. In this work, the concept of enhancing a Parylene TFEA with Kapton tape as a simpler carrier for cochlear insertion has been proved to be feasible. The bending stiffness of the Kapton-aided TFEA was characterized with an analytical model, a finite element model, and a cantilever bending experiment, respectively. While the Kapton tape increased the bending stiffness of the Parylene TFEA by 10³ times, the 6-μm-thick TFEA with a similar Young's modulus, as a polyimide, in turn significantly increased the bending stiffness of the 170-μm-thick Kapton carrier by 60%. This result indicated that even the TFEA is ultra-flexible and that its bending stiffness should not be neglected in the design or selection of its carrier.

Patterned semiconductor structures modulate neuronal outgrowth: Implication for the development of a neurobionic interface

Auditory implants stimulate the neurons by broad electrical fields, which leads to a low number of spectral channels. A reduction in the distance between the electrode and the neuronal structures might lead to better electrical transduction. The use of microstructured semiconductors offers a large number of contacts, which could attract neurons and stimulate them individually. To investigate the interaction between neurons and semiconductors, differentiated neuronal precursor cells were cultured on silicon wafers. Different structures were added on the wafers by electron beam lithography, and deep reactive ion etching in different depths (2 and 7 µm). Grooved surfaces guided the neurons and resulted in straight oriented axons, but neuronal outgrowth was impaired by the 7 µm grooves. Within the 7 µm structures, the neuronal cell body was totally encased and the nuclei were deformed from a round to an elliptical shape. On both square and cylindrical structures neuronal bridging could be detected in different forms, either between the tops of the structures or between the bottom and the top. Furthermore, neuronal bridges were established on the lateral part of the structures, and change in direction of neuronal growth was induced by the structure. Finally, it could be shown that neuronal growth cones were particularly attracted by the top of the cylinders, which might allow for the stimulation of neurons via this structure. In conclusion, study results indicate that structured semiconductors can modulate neuronal growth and its direction, offering a novel method for the development of new implants with improved neuronal stimulation. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 106A: 65-72, 2018.

Highly Flexible Silicone Coated Neural Array for Intracochlear Electrical Stimulation

We present an effective method for tailoring the flexibility of a commercial thin-film polymer electrode array for intracochlear electrical stimulation. Using a pneumatically driven dispensing system, an average 232 ± 64 μm (mean ± SD) thickness layer of silicone adhesive coating was applied to stiffen the underside of polyimide multisite arrays. Additional silicone was applied to the tip to protect neural tissue during insertion and along the array to improve surgical handling. Each array supported 20 platinum sites (180 μm dia., 250 μm pitch), spanning nearly 28 mm in length and 400 μm in width. We report an average intracochlear stimulating current threshold of 170 ± 93 μA to evoke an auditory brainstem response in 7 acutely deafened felines. A total of 10 arrays were each inserted through a round window approach into the cochlea's basal turn of eight felines with one delamination occurring upon insertion (preliminary results of the in vivo data presented at the 48th Annual Meeting American Neurotology Society, Orlando, FL, April 2013, and reported in Van Beek-King 2014). Using microcomputed tomography imaging (50 μm resolution), distances ranging from 100 to 565 μm from the cochlea's central modiolus were measured. Our method combines the utility of readily available commercial devices with a straightforward postprocessing step on the order of 24 hours.

Silicone-coated thin film array cochlear implantation in a feline model

OBJECTIVES

Some limitations of cochlear implants can be attributed to a restricted spectral representation of sound provided by contemporary electrode arrays. Microfabricated high-density thin film array (TFA) technology enables a greater density of stimulating sites and, thus, a more complete spectral representation. Previous pilot cadaveric studies have documented insertion characteristics, although not electrical characteristics.

STUDY DESIGN

Electrode evoked auditory brainstem response (ABR) testing in a feline model.

METHODS

Six healthy, normal hearing cats were unilaterally deafened and implanted with a silicone coated TFA, measuring 27.8 × 0.4 × 80μm (L × W × H). Monopolar stimulation of single electrodes was used to evoke a triple peaked ABR. Thresholds to evoke a minimal ABR were determined.

RESULTS

All 6 cats underwent successful full insertion and activation. Thresholds to evoke minimal ABR's varied among implants ranging from 75 to 450 μA. Over the basal portion of the array, thresholds were either larger or unable to evoke an ABR.

CONCLUSION

Two-thirds of the implants showed ABR's along the entire array, whereas the others evoked ABR's at the apical end and less robustly more basally. This may reflect increased distance of the electrodes from the modiolus, as the basal half of the array is narrower relative to the width of the scala. A tapered design to ensure array distance to modiolus is minimized may enable the basal half of the arrays to stimulate more consistently.

Low-power sensing for vestibular prostheses

This paper describes a novel sensing approach for reducing power requirements of implantable vestibular prostheses. A passive, microfabricated polymeric inertial sensor for detecting angular head rotations based on the biomechanics of the human semicircular canal is described. Angular head motion is coded by deflection of a highly compliant capacitor plate placed in parallel with a rigid reference electrode. This capacitance change serves to detect instantaneous angular velocity along a given axis of rotation. Designed for integration with a microelectromechanical systems-based fully implantable vestibular prosthesis, this sensing method can provide substantial power savings when compared with contemporary gyroscopes.

Current steering and current focusing with a high-density intracochlear electrode array

Creating high-resolution or high-density, intra-cochlear electrode arrays may significantly improve quality of hearing for cochlear implant recipients. Through focused activation of neural populations such arrays may better exploit the cochlea's frequency-to-place mapping, thereby improving sound perception. Contemporary electrode arrays approach high-density stimulation by employing multi-polar stimulation techniques such as current steering and current focusing. In our procedure we compared an advanced high-density array with contemporary arrays employing these strategies. We examined focused stimulation of auditory neurons using an activating function and a neural firing probability model that together enable a first-order estimation of an auditory nerve fiber's response to electrical stimulation. The results revealed that simple monopolar stimulation with a high-density array is more localized than current steering with a contemporary array and requires 25-30% less current. Current focusing with high-density electrodes is more localized than current focusing with a contemporary array; however, a greater amount of current is required. This work illustrates that advanced high-density electrode arrays may provide a low-power, high-resolution alternative to current steering with contemporary cochlear arrays.