Seamless Knitted Electrode Structure for Chafe-Free Skin Contact

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Solution Overview

Problem

Conventional textile-based electrode systems cause discomfort due to stitched or sewn electrodes that can lead to chafing and wear, limiting user comfort and system longevity, while also increasing costs and requiring precise electrode alignment.

Innovation Solution

A textile-based electrode system with knitted electrodes and conductive pathways integrated seamlessly within fabric layers, eliminating the need for stitching and allowing multiple electrodes to be positioned freely, enhancing comfort and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If electrodes are stitched or sewn into the textile system, then the electrodes can be securely attached to the fabric, but this causes chafing and rashes on the user's skin leading to discomfort

Engineering Contradiction:
Improveelectrode attachment securityVSAvoidskin chafing and discomfort
Core Design Contradiction:
StrengthVSObject-affected harmful factors

Solution Approach 1:

The electrode is merged with the conductive yarn during the knitting process itself, creating a seamless integrated structure where the electrode material becomes an intrinsic part of the textile fabric rather than being attached as a separate component. This eliminates stitching while maintaining secure attachment.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The knitted textile structure provides a flexible, conforming interface between the electrode and skin that adapts to body contours, eliminating rigid stitching elements that cause chafing while maintaining secure contact through the flexible knit pattern.

Inventive Principle:
Principle #30Flexible shells and thin films

2Strength

If electrodes are stitched or sewn into the system, then they can be securely attached, but this increases susceptibility to wear and tear reducing system life

Engineering Contradiction:
Improveelectrode attachment securityVSAvoidsystem longevity
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The electrode is merged with the conductive yarn during the knitting process itself, creating a seamless integrated structure where the electrode material becomes an intrinsic part of the textile fabric rather than being attached as a separate component. This eliminates stitching while maintaining secure attachment.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The system uses composite conductive yarns that combine conductive materials with textile fibers, creating a durable integrated structure where the electrode function is embedded within the fabric matrix, improving resistance to wear and tear.

Inventive Principle:
Principle #40Composite materials

3Strength

If electrodes are stitched or sewn into the system, then they can be securely attached, but this increases the overall cost of the system

Engineering Contradiction:
Improveelectrode attachment securityVSAvoidsystem cost
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The electrode is merged with the conductive yarn during the knitting process itself, creating a seamless integrated structure where the electrode material becomes an intrinsic part of the textile fabric rather than being attached as a separate component. This eliminates stitching while maintaining secure attachment.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The knitting machine automatically integrates the conductive yarn into the fabric structure during normal operation, eliminating the need for separate stitching operations and reducing manufacturing steps, time, and cost.

Inventive Principle:
Principle #25Self-service

4Device complexity

If the system is configured to work with only two electrodes, then the structure is simpler, but the electrodes must be located and aligned proximate to each other requiring precise alignment

Engineering Contradiction:
Improvesystem structureVSAvoidelectrode alignment
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The knitted textile structure provides a universal platform where multiple electrodes can be positioned at various locations and orientations within the same fabric, allowing the system to accommodate different electrode configurations and applications without requiring precise alignment procedures.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The flexible knitted fabric allows electrodes to be positioned dynamically at optimal locations on the user's body, adapting to different measurement requirements and body contours rather than being fixed in predetermined positions requiring precise alignment.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS12507343B2Textile blank with seamless knitted electrode system
Publication Date: 2025.12.23 HONEYWELL SAFETY PRODUCTS USA INC
  • US12507343B2 patent drawing
  • US12507343B2 patent drawing
  • US12507343B2 patent drawing

AI summary

A textile-based electrode system includes a first fabric layer having an inner and an outer surface. The inner surface includes a knitted electrode configured to be placed in contact with the skin of a user. A second fabric layer is disposed and configured to contact the outer surface of the first fabric layer. The second fabric layer includes a knitted conductive pathway configured to be electrically coupled to the knitted electrode. Furthermore, a third fabric layer is configured and disposed to contact the second fabric layer. A connector is disposed on the third fabric layer and is configured to be electrically coupled to the knitted conductive pathway. The second fabric layer can be folded about a first fold axis and the third fabric layer can be folded about a second fold axis to place the second fabric layer in contact with the first fabric layer and the third fabric layer.