Flexible Bioelectrode Structure to Prevent Delamination and Breakage
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Solution Overview
Problem
Existing bioelectrodes face challenges with delamination and breakage due to movement, discomfort, and mechanical mismatch with body tissues, particularly in flexible and implantable applications.
Innovation Solution
A flexible bioelectrode device is manufactured by embedding conductive wires in a polymer matrix using rapid prototyping, with electrodes and connectors integrated in a cohesive structure, allowing for enhanced flexibility and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid electrodes are used to ensure good skin contact, then electrical contact quality is improved, but comfort deteriorates and pressure sores occur
Solution Approach 1:
The patent applies this principle by replacing rigid electrodes with flexible printed circuit board (FPC) electrodes that can conform to the contours of the body part. The FPC substrate allows the electrode to maintain intimate skin contact without exerting excessive pressure, thereby ensuring good electrical contact while preventing discomfort and pressure sores.
Solution Approach 2:
The patent changes the mechanical parameters of the electrode from rigid to flexible by using a flexible PCB substrate. This parameter change allows the electrode to adapt its shape and pressure distribution to match the body surface, improving comfort while maintaining electrical contact quality.
2Ease of manufacture
If layered electrode configuration is used for fabrication, then manufacturing ease is improved, but delamination occurs during bending and flexing
Solution Approach 1:
The patent merges the electrode layers into a single integrated FPC structure where the conductive traces are printed directly onto the flexible substrate. This integration eliminates the separate layers that would otherwise delaminate during bending, while still allowing for standardized manufacturing processes.
3Reliability
If wires are connected to electrodes and connectors, then electrical connectivity is improved, but breakage occurs at discontinuities
Solution Approach 1:
The patent merges the wire connections into the FPC structure itself, where conductive traces are continuously printed from the electrode contact points through the substrate to the connector contacts. This eliminates discrete wire connections and their associated discontinuities, preventing breakage at connection points while maintaining electrical connectivity.
4Adaptability or versatility
If implantable electrodes are used for long-term monitoring, then diagnostic capability is improved, but foreign body reaction occurs due to mechanical mismatch
Solution Approach 1:
The patent applies this principle by using a flexible FPC substrate for implantable electrodes, allowing the electrode to conform to the soft tissue and move with it. This mechanical compatibility reduces the foreign body reaction while enabling long-term monitoring capability.
Solution Approach 2:
The patent changes the mechanical properties of the electrode from rigid to flexible, matching the mechanical parameters of the surrounding biological tissue. This parameter change reduces mechanical mismatch and minimizes foreign body reaction, enabling long-term implantable monitoring.
Data Source
AI summary
The invention has been developed primarily for use in/with sensing biological signals and/or stimulating a body part of a subject. The invention relates to flexible bioelectrode(s) device and a method of manufacturing such a flexible bioelectrode device. The flexible bioelectrode device comprises a moulded body, a wire array of conductive wires at least partially embedded in the moulded body; the wire array defining terminal ends and distal ends; wherein each of the terminal ends of the wire array are connected to an electrode; and at least one or more connector terminals connected to the distal ends of the wire array.