Dual-Sided Electrode Pad Reducing Edge Heating
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Solution Overview
Problem
Existing electrode designs suffer from localized heating and hot spots due to the edge of the current controlling media coming into contact with the skin, and previous solutions that eliminated this issue, such as using a perimeter border of low conductivity, resulted in expensive electrode constructions.
Innovation Solution
A dual-sided electrode pad assembly with a middle conductive layer, comprising metallic foil or graphite, positioned between upper and lower conductive gel layers, which reduces the risk of edge burning and undesirable heating while lowering production costs by using a conductive foil instead of printed carbon films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the current controlling media comes to an edge (prior art design), then the electrode structure is simple and manufacturing is easy, but localized heating and hot spots occur on the skin
Solution Approach 1:
The patent introduces a third dimension by adding a border layer surrounding the current controlling media layer. This border layer extends beyond the edges of the current controlling media in planar view, creating a perimeter barrier that prevents edge burning without requiring complex internal modifications to the current controlling media itself. The border layer acts as a spatial buffer zone that redistributes current away from the edges.
2Object-affected harmful factors
If a perimeter border of low conductivity is added to eliminate hot spots (prior art solution), then localized heating is prevented, but the electrode construction becomes expensive due to additional printing processes
Solution Approach 1:
The patent changes the conductivity parameter of the border layer material to achieve the desired current distribution. The border layer is formulated with specific conductivity characteristics (lower than the current controlling media but not necessarily insulating) that allow it to function as a current redistributing barrier. This parameter optimization enables effective hot spot prevention using cost-effective materials and single-layer printing processes, avoiding the need for expensive multi-layer or multi-step printing.
3Reliability
If printed carbon films are used for current controlling media, then current distribution is achieved, but production costs increase
Solution Approach 1:
The patent replaces expensive printed carbon films with a border layer constructed from more cost-effective conductive materials. The border layer uses inexpensive conductive compounds or particle-based formulations that can be applied through simpler, lower-cost printing or coating processes. While the current controlling media maintains its carbon-based composition for reliable current distribution, the border layer provides the necessary current management function at reduced material and manufacturing costs.
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
The dual-sided electrode pad assembly effectively reduces the risk of edge burning and localized heating, achieving a cost-effective solution by using a conductive foil layer, which is more affordable than printed carbon films, and allows for flexible placement without the need for additional border layers.
Implementation Method 1
an upper conductive gel layer; a middle conductive layer comprising a metallic foil layer, a graphite layer or any highly conductive current distribution media; and a lower conductive gel layer
Data Source
AI summary
A dual-sided electrode pad assembly is configured to be placed upon a patient's skin and includes an upper conductive gel layer, a middle conductive layer comprising a highly conductive foil, a highly conductive plastic film or a gel with suspended highly conductive particles, and a lower conductive gel layer. The upper and lower conductive gel layer comprise hydrogel, silicone or hydrocolloid. A removable upper and lower protective liner are disposed on the upper and lower conductive gel layers, wherein the upper and lower protective liners are larger in surface area in comparison to the upper conductive gel layer, the middle highly conductive layer and the lower conductive gel layer. The middle highly conductive layer may be smaller in surface area in comparison to the upper and lower conductive gel layers allowing a perimeter edge of the upper and lower conductive gel layers to be disposed past a perimeter edge of the middle highly conductive layer.