Single-Part Skin Electrode Connector for Lower-Cost Anchoring
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Solution Overview
Problem
Existing medical skin electrodes with a two-part connecting element structure are expensive due to the use of costly materials for both the stud and eyelet, which also complicates the manufacturing process.
Innovation Solution
A single-part connecting element is designed with a spherical head, reduced-diameter neck, and flange-shaped holding region, securely anchored to the carrier using a support layer and transverse conductor, allowing for cost-effective production by using less expensive materials for mechanical stability and reserving expensive materials for the electrical contact region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part connecting element structure (stud and eyelet) is used, then mechanical anchoring and electrical properties are improved, but production cost increases
Solution Approach 1:
The patent combines the stud and eyelet into a single integrated connecting element. The spherical head serves as the contact point for signal conductors, while the flange-shaped holding region directly anchors to the carrier without requiring a separate eyelet component. This merging eliminates the need for riveting two parts together, reducing manufacturing complexity and cost while maintaining mechanical anchoring reliability.
Solution Approach 2:
The single connecting element performs multiple functions that were previously distributed across two separate components. The spherical head provides electrical contact and mechanical anchoring, while the flange-shaped holding region provides additional mechanical support and anchoring. This multi-functional design reduces the number of components needed and simplifies the overall structure.
2Reliability
If expensive materials are used for both stud and eyelet, then electrical properties are improved, but production cost increases significantly
Solution Approach 1:
The patent applies expensive conductive materials (such as silver or silver/silver chloride) only in the specific region where electrical contact with the gel is needed, rather than throughout the entire connecting element. The flange-shaped holding region can be made from less expensive materials since it primarily provides mechanical support, while only the contact area requires high-conductivity materials. This localized application of expensive materials maintains electrical performance while reducing overall production cost.
3Strength
If a two-part structure with riveting is used, then mechanical hold is improved, but device complexity increases
Solution Approach 1:
The patent eliminates the need for riveting by integrating the anchoring function directly into the single connecting element. The flange-shaped holding region is formed as an integral part of the connecting element itself, providing mechanical hold through its geometry rather than through assembly operations. This reduces structural complexity while maintaining mechanical strength.
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 single-part connecting element design reduces production costs while maintaining mechanical stability and electrical performance, particularly at the transition to the electrical contact medium, enabling noise-free signal transmission and depolarization effects.
Implementation Method 1
the support layer which diverts those forces laterally into the carrier
Implementation Method 2
The enlarged-diameter flange-shaped laterally projecting holding region is connected, preferably glued, to the underside of the carrier
Implementation Method 3
a transverse conductor is provided in these so-called off-centre signal electrodes, which connects the eyelet to the gel
Data Source
AI summary
An electrode for application to the human skin, includes an electrically non-conductive support which on its upper side, facing away from the skin, has a protruding, electrically conductive connecting element with a terminal for removable connection of a signal conductor. A transverse conductor is provided which extends at least partially on the opposite, lower side of the support and is electrically coupled to the connecting element and to a contact medium facing the skin. The connecting element is made of a single piece, which on the one hand is connected to the transverse electrical conductor, and on the other hand has the terminal for releasable connection of a separate signal conductor.