Bioelectrode Cable Welding for Reliable Connection
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Solution Overview
Problem
Existing bioelectrodes face issues with poor mechanical hold and electrical connection at the electrode-side end of the connection cable, leading to inadequate current distribution and removal from the skin or body.
Innovation Solution
The electrode-side end of the connection cable is thermally or ultrasonically welded between two electrically conductive thermoplastic layers, ensuring a strong mechanical hold and excellent electrical contact, with the option to incorporate a resistance profile for targeted current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive tapes are used to connect the connection cable, then the connection can be made simply at room temperature, but the mechanical hold and electrical connection are poor
Solution Approach 1:
The patent changes the connection method from adhesive bonding to thermal welding, transforming the physical state and bonding mechanism. The thermoplastic layers are heated to melt and fuse together, creating a permanent bond that simultaneously provides mechanical strength and electrical conductivity, resolving the contradiction between ease of manufacture and connection reliability.
Solution Approach 2:
The patent uses composite thermoplastic layers that combine multiple properties: electrical conductivity through conductive fillers (such as carbon or metal particles), mechanical strength through the thermoplastic matrix, and weldability through the thermoplastic nature. This composite structure allows a single material system to satisfy multiple requirements simultaneously.
2Ease of manufacture
If conductive adhesive films are used, then bonding can be done at room temperature under low pressure, but the connection is detachable and only the adhesive film is electrically conductive
Solution Approach 1:
The patent merges the functions of mechanical bonding and electrical conduction into a single integrated thermoplastic layer system. Both layers are electrically conductive and are bonded together through thermal welding, eliminating the need for separate adhesive films and creating a permanent, strong connection that maintains electrical conductivity throughout the bond interface.
Solution Approach 2:
The patent replaces the mechanical adhesive bonding system with a thermal welding system. Instead of relying on adhesive chemistry and mechanical interlocking, the thermoplastic layers are melted and fused together through heat, creating a monolithic structure that is as strong as the material itself and provides inherent electrical conductivity throughout the connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a reliable mechanical and electrical connection, allowing for even current distribution over a larger area and enabling a targeted areal current profile, enhancing the performance of bioelectrodes in applications such as defibrillation and stimulation.
Implementation Method 1
the two thermoplastic layers including the electrode-side connection cable being welded together thermally or by means of ultrasound
Implementation Method 2
the two thermoplastic layers including the electrode-side connection cable being welded together thermally or by means of ultrasound
Implementation Method 3
The electrically conductive, thermoplastic layers allow the current supplied via the electrical connection cable to be evenly distributed over a larger area
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3b
AI summary
Bioelectrode, with a skin-side, electrically conductive adhesive layer (7) and with a flexible electrical connecting cable (4) which comprises at least one electrical conductor (6), preferably in the form of a strand consisting of several individual wires or conductive individual fibers, in an electrically insulating cable sheath (5), wherein the electrode-side end (4a) of the connecting cable (4) is arranged between two thermoplastic layers (2, 3) which are at least partially welded together, wherein both thermoplastic layers (2, 3) are electrically conductive and are electrically connected to the electrical conductor (6) of the connecting cable (4).