Raised-Protrusion Conductive Transfer for Gel-Free Skin Contact
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Solution Overview
Problem
Existing wearable medical devices with sensors cause skin irritation due to wet electrodes, require precise positioning by trained clinicians, and are uncomfortable for extended wear, limiting monitoring periods and data capture.
Innovation Solution
A conductive transfer with a conductive layer between encapsulating layers, featuring raised protrusions on the contact surface, which is attached to a wearable item using an adhesive layer, allowing for improved skin contact without gel irritation, and a method for improved skin contact without gel irritation, and a method for manufacturing this transfer with embossing to create the protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet electrodes with gel material are used to contact the skin, then adequate electrical contact is achieved, but skin irritation occurs and body hair removal is required
Solution Approach 1:
The patent changes the physical state and composition of the contact interface by using a raised protrusion structure on the conductive electrode surface. This structural parameter change allows the electrode to make intimate contact with skin contours and hair follicles without requiring gel material, thereby maintaining electrical contact reliability while eliminating skin irritation caused by wet electrodes
Solution Approach 2:
The invention extracts and removes the gel material component from the electrode system. By eliminating the gel layer while introducing a raised protrusion structure on the conductive surface, the patent achieves adequate skin contact without the harmful gel substance that causes irritation and requires hair removal
2Loss of information
If multiple sensors are applied to the patient's skin for data recording, then comprehensive medical data is obtained, but the positioning requires highly trained clinicians and is time-consuming
Solution Approach 1:
The wearable item is divided into multiple discrete sensor regions or zones, each capable of recording specific physiological parameters. This segmentation allows sensors to be distributed across the wearable fabric at predetermined locations, enabling comprehensive data collection without requiring complex manual positioning by clinicians
Solution Approach 2:
The sensor positions and configurations are pre-determined and pre-positioned within the wearable item structure during manufacturing. This preliminary action eliminates the need for clinicians to perform time-consuming positioning procedures, as the sensors are already optimally located for comprehensive medical data recording
3Reliability
If electrodes are removed for patient washing, then skin hygiene is maintained, but the monitoring period is limited to a day or two
Solution Approach 1:
The electrode and wearable item are constructed from flexible, washable materials that can withstand repeated washing cycles. The raised protrusion structure and encapsulating layers are designed to maintain their functional properties after washing, allowing the monitoring system to remain in place for extended periods without removal for skin hygiene purposes
Solution Approach 2:
The wearable item enables continuous monitoring without interruption for electrode removal or replacement. The washable design allows the monitoring system to remain continuously in place on the patient, eliminating gaps in data collection that would occur during electrode removal and reapplication
4Loss of information
If a large number of electronic wires and an electronic box are carried around the neck, then sensor data can be transmitted, but the device becomes restrictive and uncomfortable for extended wear
Solution Approach 1:
The patent merges the sensor array, signal processing electronics, power source, and data storage into a single integrated wearable item. This consolidation eliminates the need for separate electronic boxes and multiple wires, as all components are embedded within the flexible wearable structure, thereby maintaining full data transmission capability while dramatically improving comfort for extended wear
Solution Approach 2:
The wearable item serves multiple functions simultaneously: it acts as both the sensor array for data collection and the electronic processing unit for data management. This multi-functionality eliminates the need for separate dedicated electronic equipment, reducing the overall bulk and complexity of the system while maintaining complete data transmission capabilities
Data Source
AI summary
A conductive transfer (400, FIG. 4) comprises a conductive layer (404, FIG. 4) positioned between a first encapsulating layer (402, FIG. 4) and a second encapsulating layer (403, FIG. 4) forming at least one electrode (501) having a contact surface (503). The conductive transfer further comprises an adhesive layer (405, FIG. 4) for attaching the conductive transfer to a wearable item (102, FIG. 1). The at least one electrode comprises at least one raised protrusion (502) on the contact surface.