Manufacturing an electrode assembly having contoured electrode contact surfaces

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.

2. 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.

3. The method of claim 1 :

wherein the depositing comprises depositing a dissolvable layer of material on the contoured substrate.

4. 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.

5. The method of claim 1 , wherein depositing a protective coating on the contoured surface comprises:

depositing a parylene layer on the contoured surface.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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.

13. 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.

14. The method of claim 3 , wherein removing the protective coating from the at least one electrode contact, comprises:

dissolving the protective coating.

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.

16. 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.

17. 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.

18. 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.

19. 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.

20. 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.

21. 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.

22. 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.

23. 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.

24. 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.

25. 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.

26. 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.

27. 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.

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.

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.

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.