Disposable Electrode Thin Silver Coating Low Consumption
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Solution Overview
Problem
Existing disposable skin electrodes face challenges with stable adhesion, skin irritation, and high silver consumption, which affect signal quality and cost-effectiveness, especially for small-format electrodes used in applications like EMG and EOG measurements.
Innovation Solution
A small-format disposable electrode design featuring a self-adhesive carrier with a thin silver-silver chloride coating, a flexible and absorbent gel carrier made of textile material, and a detachable cover, optimized for low silver usage and improved adhesion, allowing for efficient signal transmission and reduced skin irritation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If reticulated polyurethane foam is used as gel carrier, then absorption capacity for liquid gel is improved, but mechanical irritation and skin itching occur due to open sharp cell edges
Solution Approach 1:
The patent uses a fleece-like planar base with controlled porosity instead of reticulated foam. This porous structure provides adequate absorption capacity while having smoother surfaces that do not mechanically irritate the skin, thus resolving the contradiction between absorption and skin comfort.
Solution Approach 2:
The patent combines multiple materials including a fleece-like base, hydrogel, and adhesive layers to create a composite electrode structure. This composite approach allows the fleece to provide gentle absorption while other layers contribute adhesion and signal transmission, avoiding the skin irritation problem of pure foam structures.
2Reliability
If thick silver coating is applied to sensor, then electrical conductivity and signal quality are improved, but cost increases due to high silver consumption
Solution Approach 1:
The patent optimizes the silver coating thickness to a specific range that provides sufficient electrical conductivity for reliable signal transmission while minimizing silver consumption. This parameter optimization resolves the contradiction between signal quality and cost-effectiveness.
Solution Approach 2:
The patent uses a thin silver/silver chloride layer that replicates the essential conductive properties of thicker silver coatings. This thin coating copy provides adequate signal transmission quality at reduced material cost, addressing the contradiction between reliability and silver consumption.
3Stability of the object's composition
If hydrogel is made more adhesive to electrode body, then signal transmission stability is improved, but adhesion to skin and painless removability deteriorate
Solution Approach 1:
The patent applies adhesive properties selectively at specific locations and interfaces within the electrode structure, rather than uniformly throughout. This localized adhesion provides stable signal transmission at the sensor-gel interface while maintaining easy and painless removal from the skin, resolving the contradiction between stability and ease of operation.
4Adaptability or versatility
If electrode format is reduced for small-format applications, then adaptability to sensitive areas is improved, but available adhesive surface area decreases
Solution Approach 1:
The patent optimizes the electrode dimensions and adhesive layer parameters to achieve reliable adhesion despite the reduced size. By carefully controlling the adhesive properties and distribution, the patent maintains sufficient bonding strength in small-format electrodes, resolving the contradiction between adaptability and adhesive surface area.
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 electrode achieves stable adhesion for short and long-term applications, high signal quality, and low silver consumption, meeting ANSI/AAMI EC-12 standards, while ensuring patient comfort and environmental sustainability.
Implementation Method 1
an absorbent body (gel pad) that is soaked with an ionically conductive liquid (the liquid gel) that is at least thickened to prevent it from flowing out under the normal influence of gravity
Implementation Method 2
the contact surface of the sensor pointing in the direction of the skin being coated with a thin silver/silver chloride layer
Implementation Method 3
The self-adhesive carrier (1) has an adhesive area (13) surrounding the gel body (9) for fixing the electrode to the skin
Data Source
Figure 1~3
AI summary
The electrode has a conductive sensor (5) fixedly connected with a carrier material (1) and provided with a contact surface (5') that is coated with a thin silver and/or silver chloride layer. Ratio of the contact surface of the sensor to a contact surface (7') of a gel carrier (7) ranges up to 1:2.5. The carrier is saturated with conductive hydrogel (8) in such a manner that a gel body with thickness of 0.2 mm to 3.5 mm is formed. A removable cover (10) with a trough-shaped opening (11) accommodates the body. The carrier consists of a structure made of woven or non-woven textile material. The carrier material consists of a flexible material based on a polymer foam, a compact polymer foil, fibrous web or fabric. An independent claim is also included for a method for manufacturing a single-use electrode.