Flexible Biomedical Electrode with Masking Layer for Current Distribution
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Solution Overview
Problem
Biomedical surface electrodes face issues of complexity in assembly, rigidity leading to skin abrasion and irritation, and uneven current density distribution causing localized high current density 'hot spots' which can result in skin burns and pain, especially in high current applications.
Innovation Solution
A flexible biomedical surface electrode comprising a heat-stabilized polyester substrate with a conductive silver polymer ink electrode layer, an insulating masking layer with apertures to control current flow, and a conductive hydrogel adhesive layer for improved skin contact and current distribution, along with a snap fastener stud for external connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electrode design with plastic housing, sponge, and adhesive disc is used, then reliable electrical connection is achieved, but the electrode becomes complex in assembly and expensive to manufacture
Solution Approach 1:
The patent combines multiple separate components (electrode sensor, connection element, adhesive means) into a single integrated metal foil structure. The metal foil simultaneously serves as the electrode sensor, contains the connection element, and provides the adhesive backing, eliminating the need for separate plastic housing, sponge, and adhesive disc components.
Solution Approach 2:
The metal foil performs multiple functions: it acts as the conductive electrode sensor, provides mechanical connection through the integrated connection element, and serves as the adhesive substrate. This multi-functionality reduces the overall component count and simplifies assembly while maintaining reliable electrical connection.
2Stability of the object's composition
If a rigid plastic housing electrode is used, then structural stability is achieved, but skin abrasion and irritation occur
Solution Approach 1:
The patent replaces the rigid plastic housing with a flexible metal foil structure that can conform to skin contours. This flexible construction eliminates the rigidity that causes skin abrasion and irritation while maintaining adequate structural stability for electrode function.
3Use of energy by moving object
If current flows through a gelled biomedical surface electrode, then electrical conduction is achieved, but localized high current density hot spots occur at peripheral areas causing skin burns
Solution Approach 1:
The patent applies a dielectric layer selectively at specific locations on the metal foil electrode. This creates non-uniform current distribution by blocking current flow at particular peripheral areas, thereby redistributing the current density to eliminate hot spots and prevent skin burns while maintaining overall electrical conduction function.
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 flexible, cost-effective electrode with reduced risk of skin irritation and improved current distribution, minimizing the occurrence of high current density hot spots and enhancing patient comfort and safety.
Implementation Method 1
a conductive hydrogel adhesive layer for improved skin contact and current distribution
Implementation Method 2
an insulating masking layer with apertures to control current flow
Data Source
Figure 1
Figure 2(a)~2(f)
AI summary
A flexible biomedical surface electrode comprises an insulating substrate (10), a conductive electrode layer (12) screen-printed on the substrate, and an insulating masking layer (14) on the electrode layer. The masking layer is configured to expose selected regions (16) of the electrode layer. An electrically conductive adhesive gel layer (18) on the masking layer makes electrical contact with the exposed regions of the electrode layer.