Cavity-Backed Electrode Structure for Simpler Gel Containment
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Solution Overview
Problem
Existing electrodes, such as ECG electrodes, face challenges with thick foam backings that require additional materials and steps, limit backing options, and complicate fabrication, while porous sponges restrict gel viscosity and necessitate extra components like liners.
Innovation Solution
An electrode design featuring a non-conductive backing with a raised and indented section forming a cavity, containing a scrim-reinforced electrically conductive gel, and a detachable stud for lead wire connection, fabricated through cold plastic deformation without additional heat, eliminating the need for punching and extra materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick foam backing is used with a punched hole and separate covering, then the electrode structure is stable, but the fabrication process becomes complex and productivity decreases
Solution Approach 1:
The patent combines the backing, cavity formation, and gel containment functions into a single integrated component. The foam backing itself is molded to include an integrated cavity that contains the gel, eliminating the need for separate coverings or patches. This merging of components simplifies the fabrication process while maintaining structural stability.
Solution Approach 2:
The foam backing is segmented into functional zones: an adhesive layer for skin attachment, a raised section for positioning, and an integrated cavity for gel containment. This segmentation allows each zone to perform its specific function efficiently while being part of a unified structure.
2Reliability
If a thick foam backing is used, then the electrode structure is stable, but material usage increases and waste is generated
Solution Approach 1:
The backing and gel containment structure are merged into a single molded piece. The cavity is formed directly in the foam backing through molding, eliminating the need for separate gel-containing components and reducing overall material usage.
Solution Approach 2:
The foam backing uses a lower density foam material that provides sufficient structural stability with less material thickness. The integrated cavity design optimizes material distribution, using foam only where structural support is needed while minimizing material in the gel containment area.
3Reliability
If porous sponge material is used over the sensor, then the gel can be contained, but the gel viscosity must be high and additional liner components are required
Solution Approach 1:
The cavity structure merges the containment function directly into the backing. The raised section and integrated cavity work together to contain the gel without requiring porous sponges or additional liner components, simplifying the overall device structure.
Solution Approach 2:
The gel can have lower viscosity because the integrated cavity provides physical containment through its molded structure rather than relying on porous material retention. This parameter change in gel viscosity enables better spreadability and contact while maintaining containment.
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 design simplifies fabrication, reduces waste, enhances gel adhesion, and offers flexibility in customization, while minimizing material usage and assembly steps, thus improving productivity and performance.
Implementation Method 1
fabricated through cold plastic deformation without additional heat
Implementation Method 2
The scrim is a reinforcing textile material that physically reinforces the electrically conductive gel and facilitates adhesion of the electrically conductive gel to the backing
Data Source
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AI summary
An electrode includes a backing. The backing includes a first backing side and a second backing side. The backing has a planar surface and a portion of the backing forms a raised section on the first backing side and an indented section on the second backing side opposite the raised section. The indented section forms a cavity therein. Further, the backing is not electrically conductive. The electrode also includes an electrically conductive gel disposed at least partially within the cavity. The electrode further includes an eyelet penetrating the backing and electrically coupled with the electrically conductive gel. The electrode includes a stud adapted to detachably couple the electrode to a lead wire and configured to attach to the eyelet.