Biomedical Electrode Grid Cutting for Versatile Configurations
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Solution Overview
Problem
Current methods for producing biomedical multiple electrodes are technologically complex and expensive, requiring separate manufacturing for different numbers of electrode bodies and being limited to specific applications, with a need for cost-effective and versatile production.
Innovation Solution
A method for continuous production of self-adhesive, flexible multiple electrodes with symmetrically structured electrode bodies on a carrier material, allowing for cutting to desired numbers and configurations within a single production line, using a grid dimension and spacing that enables versatile application and precise alignment for clinical use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printed circuit board technology is used to manufacture multiple electrodes, then the electrodes can be produced with precise circuitry and structure, but the production becomes technologically complex and expensive
Solution Approach 1:
The electrode array is segmented into modular units that can be independently configured. The carrier material is divided into multiple electrode bodies arranged in rows and columns, allowing the array to be cut into different configurations (e.g., 4x1, 2x2, 1x8) from the same continuous web, simplifying production while maintaining precision
Solution Approach 2:
A single continuous web material serves multiple functions: it acts as the carrier, provides the adhesive layer, supports the electrode bodies, and enables various cutting configurations. This universal approach eliminates the need for separate manufacturing processes for different electrode numbers and applications
2Manufacturing precision
If separate manufacturing processes are used for different numbers of electrode bodies, then each electrode configuration can be optimized, but the production cost and time increase
Solution Approach 1:
The electrode bodies are pre-arranged in a standardized grid pattern on the continuous web with defined spacing and alignment. This preliminary arrangement allows any desired configuration to be obtained simply by cutting the web at appropriate positions, eliminating the need for separate manufacturing processes for different electrode numbers
Solution Approach 2:
The electrode array configuration is changed by varying the cutting position and pattern rather than changing the manufacturing process itself. The same continuous web can be cut into different numbers and arrangements of electrode bodies, allowing flexible adaptation to different applications without retooling
3Adaptability or versatility
If multiple electrode configurations are manufactured separately, then each application can have specialized electrodes, but the versatility and cost-effectiveness decrease
Solution Approach 1:
The continuous web with pre-arranged electrode bodies serves as a universal platform that can produce any electrode configuration needed. By changing only the cutting pattern, the same manufacturing system can produce electrodes for different applications (e.g., nerve identification, muscle stimulation, signal recording), achieving versatility without increasing production complexity or cost
Solution Approach 2:
The electrode array is designed as a segmented modular system where electrode bodies are independently positioned on the web. This segmentation allows the array to be divided into different configurations suitable for various applications, while the standardized modular design keeps manufacturing simple and cost-effective
Data Source
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AI summary
The method involves forming symmetrically and identically designed electrode bodies (6) on a polyethylene foam sheet (1) that is conveyed as an endless sheet article in grid dimension (A). The article is cut at its longitudinal sides so that a distance between longitudinal edges and central axes of the bodies amounts to half of the grid dimension. A cutting- or separating line is laid centrally between the bodies so that a distance from an edge to a geometric middle axis of the adjacent electrode body at three side edges of polyelectrodes (7) amounts to the half of the grid dimension. An independent claim is also included for an electrode system comprising polyelectrodes.