Surface Electrode with Conductive Epoxy Barrier for Corrosion Protection
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Solution Overview
Problem
Current surface electrodes, particularly those with high concentration electrolytic gels, suffer from short shelf life due to gel corrosiveness, leading to erosion and open circuits, especially in applications requiring high signal-to-noise ratios like maternal-fetal monitoring.
Innovation Solution
Incorporating a conductive epoxy, such as silver-based epoxy, between the dry and silver/silver chloride wet electrodes to act as a barrier against corrosive gels, ensuring electrical connectivity while preventing gel penetration and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high concentration electrolytic gel is used in wet electrodes, then signal-to-noise ratio is improved, but shelf life deteriorates due to gel corrosiveness
Solution Approach 1:
A conductive epoxy layer is introduced as an intermediary barrier between the electrolytic gel and the dry electrode. This epoxy layer allows electrical current to pass through while blocking the corrosive gel from contacting and damaging the electrode, thus resolving the contradiction between maintaining high signal quality and extending shelf life
Solution Approach 2:
The harmful corrosive gel is extracted or removed from direct contact with the electrode structure. The gel is contained within a sponge matrix that is electrically isolated from the dry electrode by the conductive epoxy barrier, allowing the gel to fulfill its electrical function without causing corrosion
2Reliability
If conductive epoxy is added between dry and wet electrodes, then shelf life is extended, but device complexity increases
Solution Approach 1:
The conductive epoxy serves multiple functions simultaneously: it acts as a corrosion barrier, maintains electrical conductivity, and provides structural adhesion between the dry electrode and wet electrode components. By combining these functions into a single material layer, the overall device complexity is minimized while achieving extended shelf life
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 conductive epoxy extends the shelf life of surface electrodes by protecting against corrosion, maintaining signal integrity and enabling prolonged use in physiological monitoring.
Implementation Method 1
the conductive epoxy may be configured to protect the dry electrode from corrosion and transfer electrical potentials from the wet electrode to the dry electrode
Implementation Method 2
Wet electrodes are electrodes, typically made of silver/silver chloride material (Ag/AgCl) or another metal, and configured to use an electrolytic gel material as a conductor between the skin and the electrode
Data Source
AI summary
A surface electrode for patient monitoring includes a flexible substrate, a dry electrode on the substrate, and a wet electrode configured to contact an electrode gel in contact with a patient's skin. A conductive epoxy is arranged between the dry electrode and the wet electrode. The conductive epoxy is configured to protect the dry electrode from corrosion and transfer electrical potentials from the wet electrode to the printed dry electrode.