MEDICAL ELECTRODE

Abstract: A medical electrode comprises a support (10) coated on each face with an adhesive and formed with a through hole. A conductive gel pad (14) is adhered to a first face of the support (10) beneath the through hole and a contact pad (12) of inert electrically conductive liquid impervious material such as silver is adhered to the first face of the support (10) between the support (10) and the gel pad (14) beneath the through hole. A connector (16) is adhered to the second face of the support, is electrically connected through the through hole to the contact pad (12), and leads from the contact pad (12) to the edge of the electrode. A method of making the electrode is also claimed.

Description: MEDICAL ELECTRODE FIELD OF THE INVENTION The present invention relates to a medical electrode and to a method for making it. BACKGROUND TO THE INVENTION Disposable medical electrodes are used in cardiac monitoring by ECG. A disposable medical electrode for deriving electrical signals from a patient's skin is described in Patent Specification US-A-3977392 (Eastprint Inc). The Eastprint electrode is intended to conform to the contour of the patient's body and to provide a good conductive path between a skin area underlying the electrode and an electrical contact in the form of a male snap fastener element projecting from the top of the electrode. A support layer in the form of a soft compliant layer of polyurethane foam has an aperture in which a gel pad is a compression fit. The lower face of the support layer is adhesive coated. The contact element and the foil strip are offset on the support layer with a flexible conductive foil strip connecting them so that movement of the contact element does not disturb the conductive path between that element and the skin area to which the electrode is adhered. The foil strip both makes the contact with the gel pad and provides the connection to the remotely located contact element, and for the former purpose it has to be unattacked by the gel material and to be electrically compatible with the gel pad, and so silver or other relatively expensive materials have to be used. Furthermore the Eastprint electrode is complex and inherently expensive to make, so that it would not be attractive for use in routine diagnostic procedures. Recently 3M Health Care have introduced the so- called Littmann diagnostic ECG electrode which uses a solid gel electrolyte on the lower face of aluminium foil. But a solid gel presents problems where it is necessary to make contact through the skin on a hairy chest, and requires a 20-30 second delay before the skin is penetrated and contact is established. SUMMARY OF THE INVENTION It is an object of the invention to provide a disposable ECG electrode that can provide an electrical signal comparable with the best existing electrodes, but which employs a conventional soft gel for rapid penetration of the skin's horny outer layer and which can be made very inexpensively. The invention is based on the realisation that if the support is an impermeable material the contact pad can be located on the lower or concealed face of the support and can be contacted through the support, in which case it performs the dual function of making the contact with the gel pad and physically separating the gel pad from a connector on the top or exposed face. The invention therefore provides a medical electrode comprising: (a) a support coated on each face with an adhesive and formed with a through hole; (b) a conductive gel pad adhered to a first face of the support beneath the through hole; (c) a contact pad of inert electrically conductive liquid impervious, material adhered to the first face of the support between the support and the gel pad beneath the through holes; and (d) a connector adhered to the second face of the support, electrically connected through the through hole to the contact pad, and leading from the contact pad to the edge of the electrode. The invention further provides a method for making a medical electrode which comprises: forming apertures in a strip of support material coated on its first and second faces with an adhesive; adhering a connector to the second face of the support, said connector extending from the through hole to the edge of the support; covering the second face and the connector with a protective plastics film coextensive with the support; adhering a contact pad of inert metal to the first face of the support so as to underlie the through-hole; adhering a conductive gel pad to the first face of the support so as to underlie and surround the contact pad; and impregnating the pad with -conductive gel. DESCRIPTION OF PREFERRED FEATURES Preferably a protective liquid-impermeable plastics film at least coextensive with the support and domed to receive the contact pad is attached to the first face of the support and a protective plastics film coextensive with the support and overlying the connector is adhered to the second face of the support. BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the invention will now be described with reference to the accompanying drawings, in which: Figure 1 is a section through a patient electrode according to the invention; Figure 2 is a section of a protective cover strip for releaseable attachment to the electrode of Figure 1; Figure 3 is a diagram showing successive stages in a process for manufacturing the electrode of Figure 1; and Figure 4 is a section of a complete electrode . DETAILED DESCRIPTION OF PREFERRED EMBODIMENT In the draw ings, a support 10 for the electrode is provided by a piece of double-sided adhesive plastics tape formed in its middle with a small through hole. Adhered beneath the hole is a contact pad 12 which may be a small square or disc of si lver. The contact pad 12 is adhered all around the hole and thereby prevents liquid pass ing therethrough. On the lower face of the support 10 and surrounding the contact pad 12 is adhered a disc 14 of pl astics sponge material impregnated with a conductive gel . On the outer face of the support 10 is adhered a connector in the form of a strip 16 of brass or other suitable material that extends from an edge of the support 10 to the through hole, where it is soldered or welded to the contact pad 12. It will be appreciated that the support 10 provides the two functions of acting as an insu lator and acting as a barrier to prevent contact between the brass or tin contact strip 16 and the gel in the pad 14. The si lver contact pad 12 may be used in assoc iation with a gel containing chloride ions, and the contact pad may have deposited thereon or formed in situ a fi lm of silver chloride. The couple Ag/AgCl gives a very low contact potential. The upper face of the support 10 may be covered with a plastics cover strip. The lower face of the electrode is covered with a release coated film 18 of PVC or other suitable plastics material coated with silicone as release agent. The film 18 may be formed by means of a heated tool to define a dome 20 into which the pad 14 on the lower face of the electrode fits. Figure 3 shows three separate forming stations in a process for forming a patient electrode of the kind described with reference to Figures 1 and 2. The support 10 is carried on a strip of protective release paper that is advanced in indexed steps by drive means ( not shown) and holes are formed therein by means of a hole puncher . The face of the support 10 that becomes the upper face of the electrode is initially exposed with the support inverted from the attitude on the patient, and the connector 16 is cut from brass strip and is adhered thereto from underneath. A slightly larger piece of brass strip is cut to define a blank for a contact bush 31 that is welded to the tip of the connector 16. A film of PVC 32 coextensive with the electrode support 10 is then rolled onto the exposed upper surface of the support 10, and the bush blank 31 is covered with adhesive tape. A forming machine then folds the bush blank 31 into a hollow bush 33, after which the release paper is removed from the top face of the support 10. The piece of silver 12 is then severed from strip and placed on the support from above, after which the connector 16 and the contact pad 12 are soldered or otherwise conductively joined together. The sponge pad 14 is then cut to size and placed on top of the silver contact pad 12 and adhesive, after which the conductive gel is squeezed into the sponge pad 14. The protective PVC film 18 which is coextensive with the electrode support 10 is then placed downwards onto the lower or working face of the support 10 with the pad 14 in the dome 20 and the two are pressed together, after which cuts in the support 10 are made between individual electrodes and the film 18 is cut to define strips of conveniently five or ten electrodes. It will be appreciated that various modifications may be made to the embodiment described above without departing from the invention, the scope of which is defined in the appended claims. For example, the electrodes could have a simple clamp connection instead of a bush connection, in which case the contact strip 16' (Fig. 3) is slightly larger and extends further beyond the edge of the electrode. Alternatively, they could have snap connectors.

Claims: CLAIMS: 1. A medical electrode comprising: (a) a support (10) coated on each face with an adhesive and formed with a through hole; (b) a conductive gel pad (14) adhered to a first face of the support (10) beneath the through hole; (c) a contact pad (12) of inert electrically conductive liquid impervious material adhered to the first face of the support (10) between the support (10) and the gel pad (14) beneath the through hole; and (d) a connector (16) adhered to the second face of the support, electrically connected through the through hole to the contact pad (12), and leading from the contact pad (12) to the edge of the electrode. 2. An electrode according to Claim 1, wherein the support (10) is a double-sided plastics adhesive tape. 3. An electrode according to Claim 1, wherein the contact pad (12) is of silver. 4. An electrode according to Claim 3, wherein the connector (16) is a brass strip. 5. An electrode according to Claim 4, wherein the free end of the connector (16) is provided with a contact bush (33). 6. An electrode according to Claim 1, wherein there is attached to the first face of the support (10) a protective liquid-impermeable plastics film (18) at least coextensive with the support (10) and domed (20) to receive the gel pad (14). 7. An electrode according to Claim 6, wherein there is adhered to the second face of the support (10) a protective plastics film (32) coextensive with the support (10) and overlying the connector (16). 8. A method for making a medical electrode which comprises: forming apertures in a strip (10) of support material coated on its first and second faces with an adhesive; adhering a connector (16) to the second face of the support, said connector extending from the through hole to the edge of the support; covering the second face and the connector (16) with a protective plastics film (32) coextensive with the support; adhering a contact pad (12) of inert metal to the first face of the support (10) so as to underlie the t rough-hole ; adhering a conductive gel pad (14) to the first face of the support (10) so as to underlie and surround the contact pad (12); and impregnating the pad (14) with conductive gel. 9. A method according to Claim 8, further comprising the steps of forming domes (20) in a strip of release coated protective plastics film material (18) at a spacing corresponding to the electrode spacing and adhering the protective film material (18) to the first face of the support (10) with the gel pads (14) received in the domes (20). 10. A method according to Claim 9, comprising severing the electrode (10) strip and protective film material (18, 32) to form strips of individual electrodes defined by lines of severance. 11. A method according to Claim 10, wherein the protective film (18) is wider than the support (10), the support (10) is severed between electrodes (12, 14), and the lines of severance in the strip are provided in the protective film (18). 12. A method according to Claim 8, wherein a bush blank (31) is fastened directly to the connector (16) and folded to form the bush (32).

Inventors: MUTTITT RASEEPO IRVING, MUTTITT, RASEEPO, IRVING
Applicants: SCIOTRONIC LTD, SCIOTRONIC LIMITED
Application year: 1985
Main classification: A61B5
IPC codes: A61B5