Sensor for electrode and processes for production
An electrode sensor involves a solid conductive polymeric substrate shaped as an electrode sensor or portion of an electrode sensor having a layer of silver-coated particles distributed on and embedded into a surface of the substrate. The electrode sensor is particularly useful for ECG electrodes and utilizes less silver without unduly sacrificing performance. A process for producing the electrode sensor involves distributing a layer of silver-coated particles on a surface of a solid conductive polymeric substrate shaped as an electrode sensor or portion of an electrode sensor and thermally embedding the silver-coated particles into the surface. The process is simpler and less costly than existing processes for producing electrode sensors.
1. An electrode sensor comprising:
a solid conductive polymeric substrate comprising electrically conductive polymers and/or an electrically conductive filler and having a contact surface; and,
a plurality of silver-coated particles thermally embedded into the contact surface of the solid conductive polymeric substrate,
wherein a portion of each of the plurality of silver-coated particles are sufficiently anchored into the contact surface and surrounded by the solid conductive polymeric substrate while another portion of each of the plurality of silver-coated particles is exposed such that the plurality of silver-coated particles are not dispersed throughout the bulk of the solid conductive polymeric substrate.
2. The electrode sensor according to claim 1 , wherein the plurality of silver-coated particles have an average size in a range of 1-300 um.
3. The electrode sensor according to claim 1 , wherein an amount of silver of the plurality of silver-coated particles distributed on the contact surface is 10 mg Ag/sq. in. or less.
4. The electrode sensor according to claim 1 , wherein an amount of silver of the plurality of silver-coated particles distributed on the surface is 8 mg Ag/sq. in. or less.
5. The electrode sensor according to claim 1 , wherein an amount of silver of the plurality of silver-coated particles distributed on the surface is an amount in a range of 1-6 mg Ag/sq. in.
6. The electrode sensor according to claim 2 , wherein an amount of silver of the plurality of silver-coated particles provides the electrode sensor with a pre-determined recovery time from charge accumulated by the electrode sensor in a defibrillation event during heart fail.
7. The electrode sensor according to claim 1 , wherein surface roughness as measured by the arithmetic average of the absolute values (Ra) is in a range of 1-15 micron.
8. The electrode sensor according to claim 1 , wherein the particles comprise glass.
9. The electrode sensor according to claim 1 , wherein the particles are fibers.
10. The electrode sensor according to claim 1 wherein the plurality of silver-coated particles are distributed non-continuously on the contact surface providing a plurality of conductive channels rather than a single conductive channel as provided by the continuous layer of silver resulting from ink printing or electroplating processes.
11. An electrode assembly comprising:
the electrode sensor as defined in claim 1 ;
a conductive stud for attaching a backing to the electrode sensor;
a conductive gel on a surface of the electrode sensor; and
a removable cover attached to the conductive gel.
12. The electrode assembly according to claim 11 which is an electrocardiogram electrode.
13. The electrode assembly according to claim 11 which is a resting electrode.
14. The electrode assembly according to claim 11 which is a monitoring electrode.
15. A process for producing the electrode sensor of claim 1 comprising: distributing the plurality of silver-coated particles only on the contact surface of the solid conductive polymeric substrate comprising the electrically conductive polymers and/or the electrically conductive filler, and thermally embedding the plurality silver-coated particles into the contact surface.
16. The process according to claim 15 , wherein the plurality of silver-coated particles comprise glass.
17. The process according to claim 15 , wherein the plurality of silver-coated particles have an average size in a range of 1-300 μm.
18. The process according to claim 15 , wherein the plurality of silver-coated particles are distributed on the contact surface to provide an amount of 10 mg Ag/sq. in. or less on the contact surface.
19. The process according to claim 15 , wherein the plurality of silver-coated particles are distributed on the contact surface to provide an amount of 8 mg Ag/sq. in. or less on the contact surface.
20. The process according to claim 15 , wherein the thermal embedding comprises calendering or compression pressing.