Disposable Electrode Module for Body-Worn Physiological Sensor

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Solution Overview

Problem

Existing portable physiological monitors face issues such as tangled wires causing discomfort, increased ECG noise due to muscle movement, high power consumption for transmitting full waveforms, lack of intelligence to adjust data transmission based on patient condition, and inability to perform arrhythmia analysis efficiently.

Innovation Solution

A body-worn monitoring device with a disposable electrode module and a communication-computation module that includes a microprocessor for real-time analysis and radio transmission, featuring resistive traces for high voltage circuit protection and intelligent data transmission, allowing for non-permanent affixation to the patient's skin and capable of performing arrhythmia analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wires are used to connect sensors to the portable monitor, then electrical connection is achieved, but wire tangling and discomfort occur

Engineering Contradiction:

ImprovecomfortVSAvoidwire connections

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the wire connections from the system by integrating the sensor electrodes directly into the portable monitor housing. The electrodes are embedded in the housing surface, allowing direct contact with the patient's skin without requiring external wires, thereby eliminating tangling and discomfort issues.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the sensor electrode function with the portable monitor housing structure. The housing serves dual purposes as both the protective enclosure and the mounting substrate for the electrodes, combining what were previously separate components (housing + wire-connected sensors) into an integrated unit.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If wires connect sensors to the monitor, then signal transmission is enabled, but ECG noise increases due to muscle movement

Engineering Contradiction:

ImproveECG signal qualityVSAvoidECG noise

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the wire transmission path that caused triboelectric noise and muscle movement interference. By embedding electrodes directly in the housing, the signal transmission occurs through fixed internal connections rather than moving external wires, eliminating the source of motion-induced ECG noise.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential harm of rigid fixed electrodes into a benefit by using flexible printed circuit boards that maintain stable electrical contact while accommodating patient movement, thereby achieving both signal stability and patient comfort.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of information

If full waveforms are transmitted continuously, then complete physiological data is provided, but power consumption increases

Engineering Contradiction:

Improvephysiological data completenessVSAvoidpower consumption

Core Design Contradiction:

Loss of informationVSUse of energy by moving object

Solution Approach 1:

The patent applies partial action by selectively transmitting only the most relevant physiological parameters (such as heart rate and arrhythmia detection data) rather than continuously transmitting complete ECG waveforms. This reduces data transmission volume and power consumption while maintaining clinical utility for monitoring purposes.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent implements feedback mechanisms where the monitor analyzes local physiological data and intelligently determines what information needs to be transmitted based on detected events or anomalies, optimizing power usage by transmitting data only when clinically relevant.

Inventive Principle:

Principle #23Feedback

4Volume of moving object

If the monitor is made compact, then portability is improved, but battery maintenance becomes more difficult

Engineering Contradiction:

Improvedevice sizeVSAvoidbattery maintenance

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent employs a disposable electrode module that can be easily replaced without affecting the main monitor unit. The compact monitor housing serves as a reusable platform while the consumable electrode modules are discarded after use, simplifying maintenance and eliminating complex battery replacement procedures in the compact device.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS10939839B2Body worn physiological sensor device having a disposable electrode module

Publication Date: 2021.03.09 WELCH ALLYN INC

AI summary

A body worn patient monitoring device includes a flexible substrate having a plurality of electrical connections adapted to be coupled to a skin surface to measure physiological signals. The flexible substrate is adapted to be directly and non-permanently affixed to a skin surface of a patient and configured for single patient use. A communication-computation module, removably attached to an upper surface of the flexible substrate, is configured to receive physiological signals from the flexible substrate and includes a microprocessor that is configured to process and analyze the physiological signals. A series of resistive traces screened onto the flexible substrate are configured as at least one series current-limiting resistor to protect the communication-computation module.