Waterproof ECG Electrode Assembly for Continuous Wet-Wear Monitoring

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Solution Overview

Problem

Existing cardiac monitoring and treatment devices are not designed to withstand moisture and humidity, limiting their use during activities like bathing or showering, and require frequent maintenance due to potential damage from ingress of water and particulate matter.

Innovation Solution

A waterproof modular electrocardiogram (ECG) electrode assembly with active ECG processing circuitry encapsulated in a moldable dielectric polymer, allowing continuous monitoring and easy replacement of damaged components in high humidity and wet environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If existing cardiac monitoring devices are used in wet environments, then continuous monitoring capability is improved, but device reliability deteriorates due to water and particulate matter ingress

Engineering Contradiction:

Improvecontinuous monitoring capabilityVSAvoiddevice reliability

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The device is divided into modular components including a replaceable electrode module and a main device body. The electrode module can be independently replaced when contaminated, allowing the main device to continue functioning. This segmentation enables continuous monitoring while maintaining reliability through component replacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode module is encapsulated in a waterproof moldable dielectric polymer that forms a protective shell. This flexible polymer coating protects internal circuitry from water and particulate ingress while allowing the electrode to maintain electrical contact with the patient's skin in wet environments.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of operation

If cardiac monitoring devices are designed for waterproofing, then ease of operation in wet environments is improved, but device complexity increases

Engineering Contradiction:

Improveease of operation in wet environmentsVSAvoiddevice complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The device separates waterproofing requirements into the replaceable electrode module, which contains the electronics needing protection. The main device body remains simpler in design. This segmentation allows waterproof functionality where needed without complicating the entire device.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode module is designed as a disposable or easily replaceable component with integrated waterproofing. Rather than making the entire expensive device waterproof, only the low-cost electrode module receives the waterproof polymer coating, simplifying the overall device complexity while enabling wet environment operation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of time

If cardiac monitoring devices are made reusable in wet environments, then loss of time for maintenance is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemaintenance timeVSAvoidmanufacturing precision

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The electrode module is designed as a self-contained unit with pre-integrated waterproofing. This modular design allows rapid replacement without complex reassembly procedures, reducing maintenance time while the precision waterproofing is achieved during automated manufacturing of the sealed module.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The waterproof polymer is applied in a moldable state and then cured to form a precise seal. This parameter change from liquid to solid state allows the polymer to conform exactly to the internal components and sealing surfaces, achieving high sealing precision through the material's own properties rather than requiring ultra-precise mechanical tolerances.

Inventive Principle:

Principle #35Parameter changes

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

Enables continuous cardiac monitoring and treatment in wet conditions, reducing maintenance frequency and costs by allowing reuse of functional components, and ensuring reliable operation during extended wear periods.

Implementation Method 1

active ECG processing circuitry encapsulated in a moldable dielectric polymer

Methodology Applied

Scientific EffectDielectric: Dielectric

Implementation Method 2

encapsulated in a waterproof moldable dielectric polymer

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250360327A1Water-resistant electrocardiogram sensor assembly for a wearable medical device

Publication Date: 2025.11.27 ZOLL MEDICAL CORPORATION

AI summary

A waterproof modular electrocardiogram (ECG) electrode assembly for use in a wearable cardiac monitoring device comprises a first, main circuit board comprising active ECG processing circuitry encapsulated in a waterproof moldable dielectric polymer, and an ECG electrode mechanically coupled to the waterproof moldable dielectric polymer, the ECG electrode configured to be electrically coupled to a portion of the main circuit board.