Multifunction Electrode Pad with Optimized Metal/Metal Chloride Coating
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Solution Overview
Problem
Current multifunction electrode (MFE) pads fail to meet the ANSI/AAMI DF2:1996 standard for low DC offset potential, leading to energy buildup and masking of cardiac signals, while being expensive due to thick metal/metal chloride coatings required for compliance.
Innovation Solution
A multifunction electrode pad design featuring a conductive substrate with a metal/metal chloride coating containing 25-45% metal chloride by weight, a conductive hydrogel layer, and a multi-strand conductor with a carbon fiber tow for efficient energy transfer and dissipation, reducing costs by using a thinner metal/metal chloride coating and optimizing the metal/metal chloride ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick metal/metal chloride coating is used to meet ANSI/AAMI DF2:1996 standard for low DC offset potential, then DC offset potential is reduced, but manufacturing cost increases
Solution Approach 1:
The patent changes the chemical composition parameters of the metal/metal chloride coating, specifically optimizing the ratio of metal to metal chloride and controlling the thickness within a specific range (0.5-2.0 mils). By adjusting these parameters, the coating achieves compliance with ANSI/AAMI DF2:1996 standards for DC offset potential while reducing material usage and manufacturing cost compared to conventional thick coatings.
Solution Approach 2:
The patent employs a composite metal/metal chloride coating structure that combines different materials in specific proportions. The coating contains metal particles (such as silver) and metal chloride particles (such as silver chloride) in an optimized ratio, creating a composite material that provides both the electrical conductivity needed for low DC offset potential and cost effectiveness through reduced precious metal content.
2Power
If a thick metal/metal chloride coating is used to ensure energy transfer capability, then energy transfer is improved, but the pad becomes more expensive
Solution Approach 1:
The patent optimizes the thickness parameter of the metal/metal chloride coating to fall within the range of 0.5-2.0 mils, which is sufficient to maintain effective energy transfer capability for defibrillation and pacing functions. This parameter optimization reduces the amount of expensive metal materials required while preserving the necessary electrical conductivity and power transfer performance.
Solution Approach 2:
The patent applies the metal/metal chloride coating with specific local properties - the coating is distributed across the electrode surface with optimized thickness and composition in different regions. This local quality approach ensures adequate energy transfer capability where needed while reducing overall material usage and cost in areas where full thickness is not required.
3Ease of manufacture
If the metal/metal chloride coating is made thinner to reduce cost, then manufacturing cost decreases, but DC offset potential increases
Solution Approach 1:
The patent uses a composite metal/metal chloride coating where metal chloride particles (such as silver chloride) play a critical role in maintaining low DC offset potential. The metal chloride component has specific electrochemical properties that facilitate ion exchange and reduce charge accumulation. By incorporating metal chloride in optimized proportions within the thinner coating structure, the patent achieves both cost reduction and DC offset potential control.
Solution Approach 2:
The patent adjusts the chemical composition parameters of the coating, specifically increasing the proportion of metal chloride relative to metal in the coating formulation. This parameter change compensates for the reduced coating thickness by enhancing the electrochemical activity at the electrode-solution interface, thereby maintaining low DC offset potential despite the thinner overall coating structure.
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 design effectively meets the ANSI/AAMI standard for DC offset potential, ensuring safe energy transfer and monitoring while being cost-effective, as demonstrated by reduced DC voltage offset and compliance with pacing requirements.
Implementation Method 1
the chloride of the metal allows for the conduction of electrical energy from the electrode to the gel
Implementation Method 2
The conductive gel ensures contact between the electrode layer and the patient's body. The gel functions to wet the patient's skin making it more accepting to the flow of electrical energy
Implementation Method 3
Electrode pairs store energy by effectively forming a capacitor with the metal layer forming one plate of the capacitor, the human body forming another plate of the capacitor, and the hydrogel forming the dielectric material between the plates
Implementation Method 4
A conductive substrate is in electrical communication with one end of the multi-strand conductor
Data Source
AI summary
A multifunction electrode (MFE) pad, which includes a multi-strand conductor having one end in the form of dispersed carbon fibers, and another end adapted for connection to a defibrillation unit. A conductive substrate is in electrical communication with one end of the multi-strand conductor. The conductive substrate includes a conductive back side, an intermediate conductive polymer layer, and a conductive front side, the front side being a metal/metal chloride coating containing at least 25% by weight of metal chloride. The MFE pad further includes a conductive hydrogel layer covering said front side of the conductive substrate and a backing layer covering one end of the multi-strand conductor and the back side of the conductive substrate. The backing layer has a surface area that is greater than the surface area of the conductive hydrogel layer.