One-piece sensor for a bioelectrode and processes for production

• US 10,800,079 B2
• Filed: 12/29/2016
• Issued: 10/13/2020
• Est. Priority Date: 12/22/2015
• Status: Active Grant

• Current Assignee: Solventum Intellectual Properties Company (Solventum Corp.)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Derry, Cameron E., Tryphonopoulos, John P.
• Primary Examiner(s): Daniels, Matthew J
• Assistant Examiner(s): Page, Hana C
• Application Number:
  US16/063,559
• Publication Number:
  US 20190047192A1
• Time in Patent Office: 1,384 Days
• CPC Class Codes: A61B 2562/0209 Special features of electrodes classified in A61B5/24, A61B5/25, A61B5/283, A61B5/291, A61B5/296, A61B5/053
• CPC Class Codes: A61B 2562/125 characterised by the manufacture of electrodes
• CPC Class Codes: A61B 5/0006 ECG or EEG signals
• CPC Class Codes: A61B 5/25 Bioelectric electrodes therefor
• CPC Class Codes: A61B 5/259 using conductive adhesive means, e.g. gels
• CPC Class Codes: A61B 5/265 containing silver or silver chloride
• CPC Class Codes: A61B 5/266 containing electrolytes, conductive gels or pastes
• CPC Class Codes: A61B 5/268 containing conductive polymers, e.g. PEDOT:PSS polymers
• CPC Class Codes: B29C 2045/0079 applying a coating or covering
• CPC Class Codes: B29C 45/0053 combined with a final operation, e.g. shaping injection-compression moulding B29C45/561
• CPC Class Codes: B29C 45/14016 Intermittently feeding endless articles, e.g. transfer films, to the mould B29C45/14262 takes precedence
• CPC Class Codes: B29C 45/14336 Coating a portion of the article, e.g. the edge of the article B29C45/14573 and B29C45/14598 take precedence
• CPC Class Codes: B29C 45/14344 Moulding in or through a hole in the article, e.g. outsert moulding
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2031/752 Measuring equipment
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008

Abstract

A process for producing a sensor for a biomedical electrode (e.g. an ECG electrode) involves injection molding an electrically conductive resin through a film of a backing material to form the sensor directly in the backing material and coating the contact face of the sensor with a non-polarizable conductive material (e.g. silver-containing material). Additional steps of applying an electrolyte over the non-polarizable conductive material coated on the contact face and applying a liner over the electrolyte results in the biomedical electrode. Biomedical electrode produced thereby have the sensor secured in a film of the backing material with a contact face of the sensor disposed on a first side of the film and a post of the sensor protruding from a second side of the film opposite the first side. The process permits production of one-piece sensors for bioelectrodes in a continuous fashion without the need for studs to retain sensors in a film of the backing material.

Claims

1. A process for producing a sensor for a biomedical electrode, comprising:

injection molding an electrically conductive resin through a film of a backing material at a resin temperature range of 230-275 degrees Celsius to form the sensor directly in and thermally bonded to the backing material, the sensor comprising a contact face disposed on a first side of the film and a post protruding from a second side of the film opposite the first side; and

, coating the contact face with a non-polarizable conductive material, wherein the backing material comprises polyethylene terephthalate or polypropylene.

13. The process according to claim 1, wherein the resin comprises polypropylene.

14. The process according to claim 13, wherein the backing material comprises polypropylene, wherein the sensor does not have a film-retaining feature.

15. The process according to claim 14, wherein the conductive resin is injected at a resin temperature of 500 degrees Fahrenheit.

16. The process according to claim 13, the backing material comprises polyethylene terephthalate film with a polypropylene layer disposed on the first side.

2. A process for producing a biomedical electrode, comprising:

forming a sensor directly in a backing material by injection molding an electrically conductive resin through a film of the backing material at a resin temperature range of 230-275 degrees Celsius to form a thermal bond between the sensor and the backing, the sensor comprising a contact face disposed on a first side of the film and a post protruding from a second side of the film opposite the first side, wherein the backing material comprises polyethylene terephthalate or polypropylene;

coating the contact face with a non-polarizable conductive material;

applying an electrolyte over the non-polarizable conductive material coated on the contact face; and

,

applying a liner over the electrolyte.

3. The process according to claim 2, wherein the backing material secures the sensor in the film when the conductive resin is injection molded through the film.

4. The process according to claim 3, wherein securing the sensor in the film comprises adhering the conductive resin of the sensor to an adhesive coated on the film.

5. The process according to claim 2, wherein forming the sensor directly in the backing material comprises injection molding a plurality of sensors in a single film to form a web of the sensors in the single film.

6. The process according to claim 2, wherein the sensor comprises a flange disposed on the first side of the film, the contact face is a surface of the flange facing outwardly from the film, and the sensor is coated with the non-polarizable conductive material only on the contact face.

7. The process according to claim 2, wherein the backing material is a solid foam.

8. The process according to claim 2, wherein the conductive resin comprises a thermoplastic polymer matrix having conductive particles dispersed therein.

9. The process according to claim 2, wherein sensor comprises an integrally formed film-retaining feature.

10. The process according to claim 9, wherein the backing material comprises polyethylene terephthalate.

11. The process according to claim 10, further comprising:

processing the backing material to reduce water vapor transmission between the film and the sensor.

12. The process according to claim 11, wherein the backing material comprises polyethylene terephthalate film with a polypropylene layer disposed on the first side.

17. The process according to claim 2, wherein the resin comprises polypropylene, wherein the conductive resin is injected at a resin temperature of 500 degrees Fahrenheit.

18. The process according to claim 17, wherein the backing material is a polypropylene film, wherein the sensor does not have a film-retaining feature.