Biomedical Electrode Assembly Without Alignment
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Solution Overview
Problem
Conventional EKG electrodes require precise alignment of the stud and eyelet during assembly, which is inefficient, increases manufacturing costs, and limits design freedom, especially when integrating multiple electrodes into compact wearable devices.
Innovation Solution
A biomedical electrode design that includes a hydrogel layer, a trace layer with conductive traces, a conductive adhesive layer, and a terminal array, allowing for assembly without the need for precise alignment, enabling tolerance to minor misalignments and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise alignment of stud and eyelet is required during assembly, then reliable electrical connection is achieved, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The patent removes the eyelet component from the electrode structure, replacing it with a conductive adhesive layer that directly bonds the stud to the trace layer. This extraction of the eyelet eliminates the alignment complexity between two separate components while maintaining reliable electrical connection through the adhesive's conformal bonding capability.
Solution Approach 2:
The patent merges the functions of the eyelet and conductive adhesive into a single integrated layer. The conductive adhesive layer simultaneously provides mechanical bonding and electrical conductivity, eliminating the need for separate eyelet and stud components and their associated alignment requirements during assembly.
2Strength
If eyelet and stud are precisely aligned and pressed together, then mechanical and electrical connection is established, but assembly time increases
Solution Approach 1:
The eyelet component is removed from the assembly, eliminating the time-consuming alignment and pressing operations between eyelet and stud. The conductive adhesive layer is applied directly to bond the stud to the trace layer in a single step, dramatically reducing assembly time while maintaining connection strength.
Solution Approach 2:
The conductive adhesive layer performs self-alignment by conformally bonding to the trace layer and stud, eliminating the need for external alignment fixtures or precision positioning equipment. The adhesive's viscoelastic properties allow it to self-adjust during curing, ensuring strong mechanical connection without precise initial alignment.
3Adaptability or versatility
If multiple electrodes are integrated into a single wearable device, then device functionality increases, but design freedom is limited by component constraints
Solution Approach 1:
The eyelet component is extracted from each electrode, removing a significant spatial constraint. This allows electrodes to be positioned more flexibly within the wearable device, as the reduced component footprint and simplified structure enable closer spacing and more adaptable layouts for integrating multiple electrodes.
Solution Approach 2:
The electrode structure is segmented into discrete functional layers (hydrogel layer, trace layer, conductive adhesive layer, terminal) that can be independently designed and positioned. This layering approach allows flexible arrangement of multiple electrodes within the wearable device, as each layer can be optimized independently without the constraint of rigid eyelet-stud alignment requirements.
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 design ensures electrical continuity and compactness, reducing manufacturing complexity and costs while allowing for more flexible design options in wearable devices.
Implementation Method 1
a conductive adhesive layer above the trace layer... the conductive adhesive layer having a first conductive portion in electrical contact with the first trace
Data Source
AI summary
A biomedical electrode includes a hydrogel layer, a trace layer above the hydrogel layer, the trace layer having a conductive trace, a conductive adhesive layer above the trace layer, and a terminal above the conductive adhesive layer. The hydrogel layer, trace layer, conductive adhesive layer, and terminal are assembled together without requiring a piloting effect to overcome misalignment between these components.