Apparatus and methods for making cochlear implant electrode arrays

1. A method, comprising the steps of:

positioning a contact assembly, including a plurality of electrically conductive contacts that are respectively connected to a plurality of lead wires, on a shell formed from a first resilient material to form an electrode array sub-assembly that includes the contacts, the lead wires, and the shell;

after the electrode array sub-assembly has been formed, positioning the electrode array subassembly in a cochlear implant electrode array mold; and

introducing a second resilient material into the mold to form a cochlear implant electrode array flexible body, on which the contacts are located, that is defined by the first and second resilient materials.

2. The method as claimed in claim 1 , wherein

the first and second resilient materials are the same material.

3. The method as claimed in claim 1 , wherein

the first and second resilient materials are not the same material.

4. The method as claimed in claim 1 , wherein

the contact assembly includes a plurality of wire carriers respectively located on the plurality of electrically conductive contacts.

5. The method as claimed in claim 4 , wherein

the contact assembly includes a plurality of rod holders respectively located on the plurality of wire carriers.

6. The method as claimed in claim 5 , wherein

the contact assembly includes a removable rod held by the rod holders.

7. The method as claimed in claim 6 , further comprising the steps of:

removing the cochlear implant electrode array flexible body from the mold; and

removing the rod from the cochlear implant electrode array flexible body after removal from the mold.

8. The method as claimed in claim 1 , wherein

the shell includes an elongate channel.

9. A method, comprising the steps of:

positioning a contact assembly, including a plurality of electrically conductive contacts that are respectively connected to a plurality of lead wires, on a shell that includes an elongate channel and a plurality of strain relief protrusions within the elongate channel, and that is formed from a first resilient material, to form an electrode array sub-assembly;

positioning the electrode array subassembly in a cochlear implant electrode array mold; and

introducing a second resilient material into the mold to form a cochlear implant electrode array flexible body, on which the contacts are located, that is defined by the first and second resilient materials.

10. The method as claimed in claim 9 , wherein

a portion of at least some of the lead wires are deflected by the strain relief protrusions.

11. The method as claimed in claim 1 , wherein

the shell defines first and second longitudinal ends; and

the shell is attached to a malleable strip having first and second portions and first and second longitudinal ends, at least the first longitudinal end of the malleable strip extending beyond the first longitudinal end of the shell.

12. The method as claimed in claim 11 , wherein

the second longitudinal end of the malleable strip extends beyond the second longitudinal end of the shell.

13. A method, comprising the steps of:

positioning a contact assembly, including a plurality of electrically conductive contacts that are respectively connected to a plurality of lead wires, on a shell formed from a first resilient material to form an electrode array sub-assembly, wherein the shell defines first and second longitudinal ends and is attached to a malleable strip having first and second portions and first and second longitudinal ends, and at least the first longitudinal end of the malleable strip extends beyond the first longitudinal end of the shell;

positioning the electrode array subassembly in a cochlear implant electrode array mold that defines a mold cavity with a curved shape;

securing the first portion of the malleable strip to the mold and bending the malleable strip into the curved shape; and

introducing a second resilient material into the mold to form a cochlear implant electrode array flexible body, on which the contacts are located, that is defined by the first and second resilient materials.

14. A method, comprising the steps of:

positioning a contact assembly, including a plurality of electrically conductive contacts that are respectively connected to a plurality of lead wires, on a shell formed from a first resilient material to form an electrode array sub-assembly, wherein the shell defines first and second longitudinal ends and is attached to a malleable strip having first and second portions and first and second longitudinal ends, and at least the first longitudinal end of the malleable strip extends beyond the first longitudinal end of the shell;

positioning the electrode array subassembly in a cochlear implant electrode array mold;

introducing a second resilient material into the mold to form a cochlear implant electrode array flexible body, on which the contacts are located, that is defined by the first and second resilient materials;

removing the cochlear implant electrode array flexible body from the mold; and

separating the malleable strip from the cochlear implant electrode array flexible body after removal from the mold.

15. The method as claimed in claim 14 , further comprising the step of:

removing portions of the flexible body to expose the contacts after separating the malleable strip.

16. The method as claimed in claim 1 , further comprising the step of:

removing the cochlear implant electrode array flexible body from the mold.

17. A cochlear implant electrode array made by the process of claim 1 .