Electrode Segment Perforated Adhesive Design for Peel Stress Reduction
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Solution Overview
Problem
Existing electrode systems for electrocardiographic and bioimpedance measurements face challenges such as peel stress, inadequate adhesion to varying body shapes, and limited scalability and structural versatility, leading to detachment and signal distortion.
Innovation Solution
The electrode segment and array feature a measuring electrode surrounded by a perforated area free from adhesive, with the perforated area surrounded by a surface-continuous adhesive area. This design reduces peel stress and ensures better contact with the skin, while allowing for flexible adaptation to different body shapes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flexible sheet with larger surface area is used to attach electrodes to the patient's body, then the adhesion area is increased, but the electrode array cannot be easily applied to non-planar surfaces and requires the patient to be in a recumbent position
Solution Approach 1:
The electrode array is divided into multiple electrode segments that can be independently positioned and adapted to the patient's body contours. Each segment contains electrodes arranged in specific patterns, allowing the array to conform to non-planar surfaces such as the chest wall while maintaining adequate adhesion area through the distributed segments
Solution Approach 2:
The electrode array incorporates three-dimensional positioning capabilities with electrodes arranged at different heights and angles relative to the support layer. This dimensional flexibility allows the array to adapt to the curved surfaces of the body while maintaining sufficient contact area through the combined effect of multiple segments in spatial distribution
2Reliability
If electrodes are arranged on flat areas of the body in recumbent position, then proper adhesion is ensured, but the measurement cannot be performed under different patient positions and on diverse anatomical surfaces
Solution Approach 1:
The electrode array is designed with dynamic adaptability features including flexible support layers and adjustable electrode segment positions that allow the array to maintain proper contact with the skin regardless of patient position. The segments can be independently positioned to accommodate supine, seated, or lateral positions while ensuring reliable adhesion through the flexible mounting mechanism
3Ease of manufacture
If adhesive layer is applied immediately surrounding the electrode, then localized adhesion is achieved, but peel stresses cause electrode detachment and the adhesive ring thickness creates manufacturing problems
Solution Approach 1:
The adhesive layer is strategically positioned in specific zones rather than uniformly surrounding each electrode. Adhesive regions are placed at the periphery of the electrode array segments where mechanical stresses are lowest, while central regions remain adhesive-free to prevent interference with electrode-skin contact. This localized adhesive placement reduces peel stresses on electrodes while maintaining secure array attachment
Solution Approach 2:
A mounting layer is introduced as an intermediary between the electrodes and the adhesive layer. This mounting layer provides mechanical support to the electrodes, distributes stresses away from the electrode edges, and allows the adhesive to bond to the mounting layer rather than directly to the electrode, thereby reducing peel stresses that cause detachment while simplifying manufacturing
4Strength
If the adhesive layer thickness is increased, then adhesion strength is improved, but electrode contact with the patient's skin is compromised
Solution Approach 1:
The adhesive layer is applied only in specific peripheral zones of the electrode array segments rather than uniformly across the entire array. This localized application ensures strong adhesion at the boundaries where mechanical stresses occur, while the central electrode regions remain thin and flexible to maintain precise contact with the skin surface, thereby simultaneously achieving adhesion strength and contact precision
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4B
AI summary
The object of the present invention is an electrode segment (100) for electrocardiographic and/or bioimpedance measurements and an electrode array (200) comprising at least two electrode segments (100). The electrode segment (100) for electrocardiographic and/or bioimpedance measurements comprises a measuring electrode (110) comprising a connector element (190) for connecting an electrical signal wire and a sensor element (195) for collecting measurement signals from the patient's body, the measuring electrode (110) being situated in a mounting layer (220) covered with an adhesive layer (230). Moreover, the measuring electrode (110) situated in the mounting layer (220) is surrounded by a perforated area (145) which is free from the adhesive layer (230), and the perforated area (145) is in turn surrounded by a surface-continuous area (160) which is covered with the adhesive layer (230).