Electrode Patch With Hydrophobic Barrier and Fuse
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Solution Overview
Problem
Existing electrical stimulation systems for medical applications are cumbersome, prone to short circuits due to exposed wires, and require frequent battery replacements, with electrodes losing mechanical and electrical properties quickly, leading to inefficiencies and discomfort for patients.
Innovation Solution
A compact medical device with a substrate, power source, connector, and electrode assembly that minimizes mechanical connections, uses a hydrophobic barrier to prevent short circuits, and incorporates a fuse to protect against excessive electrical loads, ensuring prolonged battery life and electrode durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a large battery is used to provide enough energy for a desired treatment period, then the power supply duration is extended, but the device becomes obtrusive and burdensome for the patient to wear
Solution Approach 1:
The device is divided into two separate components: a reusable external stimulator containing the battery and a disposable electrode patch containing minimal electronics. This segmentation allows the heavy battery to be housed in the permanent stimulator while the lightweight patch can be comfortably worn on the body for extended periods without burdening the patient.
2Reliability
If wires are used to connect the stimulator to the electrodes, then electrical connection is established, but the wires are exposed to moisture resulting in unintended current loss or shorting
Solution Approach 1:
The vulnerable wire connections are extracted from the wearable electrode patch and relocated to the protected external stimulator. The patch now uses integrated dry contacts that mate with the stimulator only during charging/connection moments, eliminating continuous wire exposure to moisture and sweat during the treatment period.
Solution Approach 2:
A hydrophobic barrier layer is introduced as an intermediary between the electrical contacts and the external environment (moisture, sweat). This barrier prevents moisture from reaching the electrical contacts while allowing electrical connection to be maintained when the stimulator is properly connected to the patch.
3Reliability
If multiple connections are made between the electrode patch and stimulator, then complete electrical circuit is established, but the risk of short circuit increases due to exposed connectors
Solution Approach 1:
Multiple electrical connections are merged into a single integrated connector interface. The electrode patch contains integrated circuitry that combines multiple signal paths (stimulation output, sensing inputs, charging contacts) into one unified connection point that mates with the stimulator, reducing the number of separate exposed connectors from three or four to essentially one protected interface.
4Duration of action of moving object
If the electrode is designed for long-term use, then patient comfort is improved, but the electrode loses electrical and mechanical properties within several days requiring regular replacement
Solution Approach 1:
The electrode patch is designed as a disposable component with a planned limited lifespan. Rather than attempting to create a permanently durable patch, the system uses affordable, replaceable patches that are discarded after several days of use. This approach maintains reliable performance during the active treatment period while avoiding the complexity and cost of creating indefinitely durable electrodes.
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 solution provides a compact, reliable, and efficient electrical stimulation system that reduces the risk of short circuits and extends battery and electrode lifespan, enhancing patient comfort and treatment efficacy.
Implementation Method 1
The power source is configured to provide power to an external stimulator coupled to the apparatus
Implementation Method 2
the electrode assembly being coupled to the second surface of the substrate and being configured to facilitate transmission of an electrical current from an external stimulator through a bodily tissue
Data Source
Figure 1
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Figure 5~6
AI summary
In some embodiments, an apparatus includes a substrate, a power source, a connector, electrical circuitry, and an electrode assembly. The substrate has a first surface and a second surface different than the first surface. The power source has a positive terminal and a negative terminal Each of the positive terminal and the negative terminal are coupled to the substrate. The power source is configured to provide power to an external stimulator coupled to the apparatus. The connector is disposed proximate to the first surface of the substrate and is electrically coupled to at least one of the positive terminal and the negative terminal of the power source. The connector is configured to electrically couple the external stimulator to the power source. The electrical circuitry is coupled to the substrate. The electrical circuitry is configured to electrically couple the connector to at least one of the positive terminal and the negative terminal of the power source. At least one of the connector or the electrical circuitry is configured to prevent a short circuit of the electrical circuit. The electrode assembly is coupled to the second surface of the substrate. At least one electrode of the electrode assembly is configured to contact bodily tissue and to facilitate transmission of an electrical current through the bodily tissue.