Method for producing an electrode, and corresponding electrode

Abstract

The invention relates to a method for producing an electrode (1) to be attached to human skin, comprising the following steps: - providing a conductive element (2), preferably a composite conductor foil, comprising at least one electrically non-conductive substrate (3) and a conductor (4) arranged on the substrate (3) and covering at least regions of the substrate (3), - removing the conductor (4) in at least one defined region (5) of the conductive element (2) by means of a machining method, preferably by means of milling, such that at least one conductor portion (4a), formed by non-removed parts of the conductor (4) and having a defined geometry, remains on the substrate (3).

Description

[0001] LEARN HOW TO MANUFACTURE AN ELECTRODE AND CORRESPONDING ELECTRODE

[0002] The present invention relates to a method for producing an electrode for application to human skin, an electrode for application to human skin and a computer program product for controlling and / or regulating a machine tool with a tool for machining a workpiece.

[0003] The electrodes mentioned above are generally medical electrodes. Such medical electrodes can be used as measuring electrodes to derive electrical signals from the human body. However, they can also be used as therapy electrodes to supply currents to the human body. For this purpose, the electrodes are adhered to the skin and generally have an electrically conductive gel or other electrical contact medium on their underside that is in electrically conductive contact with a connection element of the electrode. A cable can be connected to this connection element, via which currents can be derived from the electrode or supplied to the electrode.

[0004] With such electrodes, it is desirable that all edges of a conductor that potentially come into contact with human skin are covered in an overlapping manner by the contact medium, for example a conductive gel or a conductive adhesive, in order to avoid the risk of burns due to a reduced contact resistance between the conductor and the skin.

[0005] This cannot be achieved if the leader and the

[0006] The contact medium can be punched at the same time, as is the case with conventional manufacturing processes. To achieve the required overlap, the conductor must first be formed into the desired shape and the contact medium must then be applied in an overlapping manner.

[0007] The prior art proposes a manufacturing process in which a conductor is attached to a carrier, the conductor is subsequently punched, and a residual grid is removed. The contact medium can then be applied in an overlapping manner. Such a manufacturing process is illustrated in Figs. 1a to 1f and explained in more detail in the description of the figures.

[0008] However, such a process is associated with several disadvantages. On the one hand, the material expenditure is quite high, since an additional support must usually be provided on which the support, along with the conductor and the contact medium, is then arranged.

[0009] In addition, the carrier is notched during the conductor punching process, resulting in structural weakening of the carrier. The carrier therefore exhibits mechanical damage in the form of notches.

[0010] In addition, die cuts that are not connected to a punch grid are difficult to transport.

[0011] Ultimately, the punching process can only punch out the conductor or not. Variable hole depths are not possible.

[0012] The object of the invention is to provide an improved method as well as an electrode and a computer program product in which the disadvantages of the prior art are at least partially avoided.

[0013] This object is achieved by a method according to claim 1, an electrode according to claim 10 and a computer program product according to claim 15.

[0014] According to the invention, the following process steps are provided for a method as mentioned above for producing an electrode for application to human skin:

[0015] Providing a conductive element, preferably a composite conductor film, comprising at least one electrically non-conductive carrier and a conductor arranged on the carrier and covering the carrier at least in part, removing the conductor in at least one defined region of the conductive element by means of a machining process, preferably by means of milling, so that at least one conductor section formed by non-removed parts of the conductor remains on the carrier with a defined geometry.

[0016] By removing the conductor in at least one defined area by means of a machining process, the conductor can be removed in said areas, whereby the carrier remains intact, i.e. for example, no notching of the carrier occurs.

[0017] This makes it possible to insert the electrode directly without providing an additional support, resulting in material savings compared to a state-of-the-art process. In particular, even small material savings can result in significant cost reductions, since medical electrodes are mass-produced products manufactured in very large quantities. Furthermore, removing the conductor does not produce any punched pieces, but rather only chips, which can be easily removed, for example, by vacuuming.

[0018] It is also possible to remove only part of the conductor, allowing variable hole depths to be achieved. This can be achieved, for example, by adjusting a tool, such as a milling cutter, to machine the conductor in a direction orthogonal to the conductor.

[0019] The at least one defined area to be removed can also have a variety of shapes, since the tool can usually be moved in a plane parallel to the conductor. This allows electrodes with a wide variety of conductor geometries to be produced.

[0020] In particular, electrodes with a wide variety of conductor geometries can be manufactured using the same device for producing an electrode, since the tool simply has to perform different movements. In any case, it is not necessary to provide a separate tool for each conductor geometry, as would be the case with punching, for example.

[0021] Overall, the result is a simpler and more flexible manufacturing process compared to the state of the art.

[0022] It can also be provided that a cable, which can preferably be connected to a connecting element, can be manufactured using a method according to the invention.

[0023] With regard to an electrode according to the invention, it is provided that it comprises at least one carrier and at least one conductor section arranged on the carrier with a defined geometry, wherein the carrier is free from mechanical damage, preferably notch-free.

[0024] Thus, no additional carrier is necessary for an electrode according to the invention, since the carrier is free from mechanical damage and thus has sufficient stability.

[0025] In a computer program product according to the invention for controlling and / or regulating a machine tool with a tool for machining a workpiece, preferably a milling cutter, it is provided that the computer program product can receive a defined geometry for conductor sections as input and then controls the machine tool in such a way that the conductor is removed in at least one defined area by means of the tool, so that at least one conductor section formed by non-removed parts of the conductor remains on the carrier with the defined geometry.

[0026] A machine tool can, for example, be a station in an electrode production line. Other embodiments are also conceivable.

[0027] The conductor section is the part or parts of the conductor which remain in at least one defined area on the carrier after the conductor has been removed by machining.

[0028] Advantageously, both the carrier and the conductor are designed as foil, whereby the conducting element serves as

[0029] A conductor composite film is present. The conductor is electrically conductive and can be made of metal, carbon fiber, or a conductive plastic, for example.

[0030] The carrier consists of an electrically non-conductive, i.e., electrically insulating, material, for example, a plastic such as polyester or polystyrene. Other electrically insulating materials are also conceivable.

[0031] Further advantageous embodiments of the invention are defined in the dependent claims.

[0032] It can be provided that the conductor is connected to the carrier by means of a bonding agent, preferably an adhesive or a thermoplastic, wherein a bonding agent layer formed by the bonding agent between the conductor and the carrier is removed when the carrier is removed by means of the machining process or wherein the bonding agent layer remains intact when the conductor is removed.

[0033] A bonding agent provides a simple way to connect the conductor to the carrier. In this case, the conductor is bonded to the carrier in a materially bonded manner.

[0034] The composite mediator layer can also serve as a buffer when removing the conductor, so that a cutting tool can easily remove the conductor completely in the defined areas without damaging the carrier.

[0035] In one embodiment of the invention, it can be provided that the conductive element has an impedance layer arranged on the conductor, wherein the impedance layer is removed in the at least one region and / or in at least one region different from the at least one region by means of the machining process.

[0036] The impedance layer is also electrically conductive. By removing the impedance layer in certain areas, a change in the current output at the surface of the electrode can be achieved. For example, the impedance layer can be removed around at least one defined area (see also Fig. 4b).

[0037] It may be provided that chips produced during the removal of the conductor and / or the composite layer and / or the impedance layer are vacuumed away.

[0038] The resulting chips can be easily removed this way. No additional equipment is required, as would be the case with the removal of punched pieces.

[0039] Preferably, it can be provided that in a further step an electrically conductive contact medium is applied to the conducting element, and accordingly to the carrier and / or the conductor.

[0040] For this purpose, the contact medium can either be provided in the form of a prefabricated sheet and applied, for example, laid on, the conductor and / or the carrier. It is also possible for the contact medium to be in liquid form and poured onto the conductor and / or the carrier and then cured. The contact medium can still have a gel-like consistency, for example, even after curing.

[0041] Furthermore, it can be provided that, in a further step, a cover element is applied to the contact medium. The cover element can again be designed as a film.

[0042] Advantageously, it can be provided that in a further step the carrier and / or the contact medium and / or the cover element is severed, preferably by means of a punching process.

[0043] This allows the electrode to be finally formed. In a preferred embodiment, the carrier and the contact medium are severed together. In this case, the cover element remains intact, so that the individual electrodes are arranged together on the cover element.

[0044] In a further step, it can be provided that a residual grid resulting from the cutting through of the carrier and / or the contact medium and / or the cover element is removed.

[0045] In particular, the residual grid can comprise parts of the carrier and the contact medium. In a further step, the cover element can then be severed to separate the electrodes.

[0046] Preferably, it can also be provided that in a further step a connection element for connecting a cable is electrically conductively connected to the conductor and / or the at least one conductor section.

[0047] The connecting element serves to provide a connection point for a cable, wherein the connecting element is electrically connected to the conductor or to the at least one conductor section. With regard to an electrode according to the invention, it can be provided that an electrically conductive contact medium is arranged on the carrier and / or at least one conductor section, preferably wherein the contact medium covers the at least one conductor section on at least two sides.

[0048] The contact medium serves to establish electrical contact with the skin. The contact medium can be, for example, a conductive gel or a conductive adhesive.

[0049] It can also be provided that the contact medium has a

[0050] cover element is arranged.

[0051] This protects the contact medium from damage and contamination.

[0052] The cover element can, for example, be designed as an abhesive film.

[0053] It can further be provided that the electrode has a connecting element for connecting a cable, wherein the connecting element is electrically conductively connected to the at least one conductor section, preferably wherein the connecting element is mechanically connected to the at least one conductor section and / or the carrier.

[0054] The connecting element can be used in various

[0055] Various embodiments are available. Examples include a two-piece or a one-piece design. Possible materials include various metals, carbon fiber, conductive plastics, or electrically non-conductive materials coated with a conductive layer. The connecting element can form or have a connection point via which conventional cables can be connected to the connecting element.

[0056] In a further embodiment, it can be provided that an impedance layer is arranged at least in some areas on at least one conductor section.

[0057] It may also be provided that a plaster layer extending beyond the support is arranged on the support. The plaster layer is arranged on a side of the support on which no conductor is arranged.

[0058] The adhesive layer allows the electrode to be held more securely to the skin.

[0059] Further details and advantages of preferred embodiments of the invention are explained in more detail below with reference to the description of the figures and the drawings.

[0060] Fig. 1a-f schematic representations of process steps of a method for producing an electrode according to the prior art,

[0061] Fig. 2a-e schematic representations of process steps of a process according to the invention for producing an electrode,

[0062] Fig. 3a-b schematic representations of a punching process according to the prior art,

[0063] Fig. 4a-b schematic representations of an impedance layer in an electrode according to the invention.

[0064] Figures 1a to 1f show schematic representations of method steps of a method for producing an electrode according to the prior art. In a manufacturing method according to the prior art, a conductive element 2, here in the form of a composite conductor film, is provided. The conductive element 2 comprises a conductor 2 which is arranged on and connected to a carrier 3 by means of a composite mediator layer 6.

[0065] The conductor 4 can be designed essentially congruent with the carrier 3. However, it is also conceivable that the conductor 4 covers the carrier 3 only in certain areas.

[0066] In a further step, the guide element 2 is then arranged on an additional carrier 3a via an additional bonding layer 6a and bonded to the carrier. The additional bonding layer 6 can be, for example, a pressure- or heat-activated adhesive.

[0067] Subsequently, the conductive element 2 and the second composite mediator layer 6a are punched using first punching tools 11. This creates conductor sections 4a that have a defined geometry. This geometry is determined by the shape of the punching tools 11.

[0068] The residual grid created by the punching process, i.e. the negative of the conductor sections 4a, is subsequently removed.

[0069] In a next step, the additional bonding layer 6a can then be activated, for example, by pressure or thermal activation, and the connection to the additional carrier 3a can be made permanent. However, it is also conceivable that the desired conductor sections 4a are produced before the conductive element 2 is anchored to the additional carrier 3a and only then applied to the additional carrier 3a. However, with increasing complexity of the geometry of the conductor sections 4a, this can lead to significant disadvantages in the manufacturing process, such as handling problems or increased scrap.

[0070] In both cases, the contact medium 8, for example electrically conductive gel or the electrically conductive adhesive, is then applied in an overlapping manner and covered with a covering element 9, for example an adhesive film.

[0071] In a further punching process, the additional carrier 3a and the contact medium 8 are then severed using second punching tools 12, thus producing individual electrodes 1 on the cover element 9. The resulting residual grid is then removed.

[0072] Finally, the cover element 9 can also be cut through and the individual electrodes 1 can be separated.

[0073] Figures 2a to 2e show schematic representations of process steps of a process according to the invention for producing an electrode 1.

[0074] Again, the starting point is a guide element 2 , as is also used in a method according to the state of the art.

[0075] In contrast, however, no additional carrier 3a is required. Instead, the conductor 4 is removed in defined areas 5 by means of a machining process. In this exemplary embodiment, this is done using a tool 10, which is designed, for example, as a milling cutter. This allows conductor sections 4a with a defined geometry to be produced on the carrier 3 without mechanically damaging the carrier 3.

[0076] The geometry of the conductor sections 4a is defined by the movements performed by the tool 10. Thus, by specifying a movement of the tool 10, it is possible to create a wide variety of geometries with one and the same tool 10.

[0077] In the state of the art, however, a separate punching tool 11 must be provided for each desired geometry, which of course involves high effort and costs.

[0078] The further steps for producing the electrode 1 essentially correspond to those which were also carried out in a method according to the prior art and which were described with reference to Figs. 1a to 1f.

[0079] The method according to the invention therefore requires fewer steps and less material to produce an electrode and is also more flexible with regard to the desired geometries.

[0080] Figures 3a and 3b show schematic representations of a punching process according to the prior art. They show how the additional carrier 3a is notched, i.e., mechanically damaged, by the punching process. Thus, mechanical damage in the form of notches 3b is visible on the finished electrode 1.

[0081] If the additional carrier 3a were omitted and only the conductor 4 were punched, the carrier 3 would be mechanically damaged. The carrier 3 would then no longer be stable enough to be used in an electrode.

[0082] As already explained, this problem does not occur in a method according to the invention.

[0083] Figures 4a and 4b show schematic representations of an impedance layer 7 in an electrode 1 according to the invention. The impedance layer 7 is an electrically conductive layer which is arranged on the conductor 4 and covers it at least in part.

[0084] In this exemplary embodiment, the impedance layer 7 is removed by means of the machining process both in the defined region 5 and in a region 5a different from the defined region 5. In the present exemplary embodiment, the region 5a lies around the region 5.

[0085] This can result in a change in the current output at the surface of the electrode 1 .

[0086] Reference symbol list:

[0087] 1 electrode

[0088] 2 Guide element

[0089] 3 carriers

[0090] 3a additional carrier

[0091] 3b notch

[0092] 4 conductors

[0093] 4a ladder section

[0094] 5 Defined area

[0095] 5a different area

[0096] 6 network mediator layer

[0097] 6a additional interconnection layer

[0098] 7 Impedance layer

[0099] 8 Contact medium

[0100] 9 Cover element

[0101] 10 tools

[0102] 11 First punching tools

[0103] 12 Second punching tools

Claims

Patent claims 1. A method for producing an electrode (1) for application to human skin, characterized by the following steps: Providing a conductive element (2), preferably a conductor composite film, comprising at least one electrically non-conductive carrier (3) and a conductor (4) arranged on the carrier (3) and covering the carrier (3) at least in part, removing the conductor (4) in at least one defined region (5) of the conductive element (2) by means of a machining process, preferably by means of milling, so that at least one conductor section (4a) formed by non-removed parts of the conductor (4) remains on the carrier (3) with a defined geometry.

2. Method according to claim 1, wherein the conductor (4) is connected to the carrier (2) by means of a bonding agent, preferably an adhesive or a thermoplastic, wherein a bonding agent layer (6) formed by the bonding agent is arranged between the conductor (4) and the carrier (3) is removed by means of the machining process when the conductor (4) is removed or wherein the composite mediator layer (6) remains intact when the conductor (4) is removed.

3. Method according to one of claims 1 or 2, wherein the conducting element (2) has an impedance layer (7) arranged on the conductor (4), wherein the impedance layer (7) in the at least one defined region (5) and / or in at least one of the at least one defined region (5) different area (5a) is removed by means of the machining process.

4. Method according to one of claims 1 to 3, wherein chips produced during the removal of the conductor (4) and / or the composite layer (6) and / or the impedance layer (7) are sucked off.

5. Method according to one of claims 1 to 4, wherein in a further step an electrically conductive contact medium (8) is applied to the conducting element (2).

6. The method according to claim 5, wherein in a further step a cover element (9) is applied to the contact medium (8).

7. Method according to one of claims 1 to 6, wherein in a further step the carrier (3) and / or the contact medium (8) and / or the cover layer (9) is severed, preferably by means of a punching process.

8. The method according to claim 7, wherein a residual grid resulting from the severing of the carrier (3) and / or the contact medium (8) and / or the cover layer (9) is removed.

9. Method according to one of claims 1 to 8, wherein in a further step a connection element for connecting a cable is electrically conductively connected to the conductor (4) and / or the at least one conductor section (4a).

10. Electrode (1) for application to human skin, preferably produced by a method according to one of the preceding claims, comprising at least one Carrier (3) and at least one conductor section (4a) arranged on the carrier (3) with a defined geometry, wherein the carrier (3) is free from mechanical damage, preferably notch-free.

11. Electrode (1) according to claim 10, wherein an electrically conductive contact medium (8) is arranged on the carrier (3) and / or the at least one conductor section (4a), preferably wherein the contact medium (8) covers the at least one conductor section (4a) on at least two sides.

12. Electrode according to claim 11, wherein on the contact medium (8) a cover element (9) is arranged.

13. Electrode (1) according to one of claims 10 to 12, wherein the electrode (1) has a connection element for connecting a cable, wherein the connection element is electrically conductively connected to the at least one conductor section (4a), preferably wherein the connection element is mechanically connected to the at least one conductor section (4a) and / or the carrier (3).

14. Electrode (1) according to one of claims 10 to 13, wherein an impedance layer (7) is arranged at least in regions on the at least one conductor section (4a).

15. Computer program product for controlling and / or regulating a machine tool with a tool (10) for machining a workpiece, preferably a milling cutter, wherein the computer program product can receive a defined geometry for the at least one conductor section (4a) as input and subsequently controls the machine tool in such a way that by means of the tool (10) the conductor (4) is removed in at least one defined region (5), so that at least one conductor section (4a) formed by non-removed parts of the conductor (4) remains on the carrier (3) with the defined geometry.

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