Flat, conformable, biomedical electrode allowing removal of electrical lead wire

Abstract: A biomedical electrode (10) adapted to be applied to a body, the biomedical electrode (10) having a surface area divided into a first zone (38), a second zone (40), and third zone (42). The biomedical electrode (10) has a first layer of adhesive (24) which is electrically conductive and which is adapted to be applied to the body, a conductive layer (22) positioned adjacent the first layer of adhesive (24), a second layer of adhesive (16), and a protective, electrically insulative web (12) positoned adjacent the second layer of adhesive (16). The second layer of adhesive (16) holds the protective, electrically insulative web (12) to the conductive layer (22) in the third zone (42) of the biomedical electrode (10). A removable release liner (18) is positioned in the first zone (38) between the second layer of adhesive (16) and the conductive layer (22) preventing the protective, electrically insulative web (12) from sticking to the conductive layer (22) in the first zone (38) of the biomedical electrode (10). An insertable electrical lead wire (14) is insertable in the first zone (38) between the second layer of adhesive (16) and the conductive layer (22) upon removal of the removable liner (18). The protective, electrically insulative web (12) has an edge (44) in the second zone (40) which is easily grasped so that the protective, electrically insulative web (12) may be pulled and removed from the biomedical electrode (10) allowing removal of the electrical lead wire (14).

Description: Technical Field The present invention relates generally to biomedical electrodes. Background Art Biomedical electrodes are useful for both stimulation and body monitoring functions. Stimulation uses of biomedical electrodes include transcutaneous electronic nerve stimulation (TENS) for the treatment of pain and neuromuscular stimulation (NMS) as, for example, treatment for scoliosis. Body monitoring uses for biomedical electrodes include electrocardiogram (ECG) for monitoring heart activity. Among biomedical electrodes in existence are those of Phipps et al., Cartmell and Larimore. Phipps et al in United States Patent No. 3,170,459 discloses a biomedical instrumentation electrode constructed from multiple plies of discs made from a relatively inflexible material, i.e., cork. The electrode utilizes a conductive gel to establish electrical contact with the body. Cartmell in United States Patent No. 4,543,958 discloses a medical electrode assembly. The electrode has a flexible, dimensionally stable substrate which is striped with an electrically conductive paint. The electrode is then clamped into a bulky cable connector. Larimore in United States Patent No. 4,458,696 (assigned to Minnesota Mining and Manufacturing Company) discloses a TENS electrode with a raised structure to permit entry of and attachment to a tubular electrical conductor. These electrodes suffer from several deficiencies including that all are "high profile" electrodes and that the electrodes do not "conform" well to the body. With a biomedical electrode such as is described in United States Patent No. 4,727,880 and EP-A-0,259,006, the electrode is applied to the body, the protective web is lifted at the spot of the removable release liner which is then removed, the electrical lead wire inserted and the protective web is placed over the electrical lead wire securing the lead wire in place. The biomedical electrode is now usable in its normal mode of operation. Electrical signals may be applied via the lead wire to the electrode which are then transmitted by the electrode to the body to which the electrode is applied or, alternatively, electrical signals from the body may be read by way of the electrode and the electrical lead wire. When use of the electrode in that situation is completed, it is desirable to remove the electrical lead wire from the electrode for reuse and to remove the remainder of the electrode from the body for disposal. Since the electrical lead wire is adhesively secured in the electrode with the protective web, it is difficult, if not impossible, to remove the electrical lead wire without first removing the covering of the protective web. Unfortunately in the electrodes described in the parent applications there is no readily available mechanism to allow the removal of the protective web. Disclosure of the Invention According to the present invention there is provided a biomedical electrode adapted to be applied to a body, said electrode having a surface area divided into a first zone, and a third zone comprising: a first layer of adhesive which is electrically conductive and which is adapted to be applied to said body; a conductive layer positioned adjacent said first layer of adhesive; a second layer of adhesive; a protective, electrically insulative web positioned adjacent said second layer of adhesive; said second layer of adhesive holding said protective, electrically insulative web to said conductive layer opposite of said first layer of adhesive in said third zone of said electrode; a removable release liner positioned in said first zone between said second layer of adhesive and said conductive layer preventing said protective, electrically insulative web from sticking to said conductive layer in said first zone of said electrode, whereby said release liner is removed for insertion of a distal uninsulated portion of an electrical lead wire also characterised in that:- said electrode surface area has a second zone whereby said third zone is intermediately located between said first zone and said second zone; and said protective, electrically insulative web has an edge in said second zone consisting of a section in which said conductive adhesive does not hold said web to said conductive layer which is therefore easily grasped so that said protective, electrically insulative web may be pulled and removed from said electrode allowing removal of said electrical lead wire. Thus, the biomedical electrode has features which readily allow the grasping of an edge of the protective web so that the protective web may be pulled to reveal the electrical lead wire and allow the removal and reuse of the electrical lead wire. It is preferred that the edge to be grasped be opposite from the side of the protective web from which the removable release liner is removed. In this invention the surface area of the biomedical electrode be divided into three zones as will hereafter be described in order to facilitate easy access to both the release liner and the edge to be grasped to remove the protective web. There is thus provided a biomedical electrode which is (1) flatter and more conformable, (2) has a very low profile, (3) may be trimmed to differing shapes, (4) has flexibility in lead wire insertion direction, and (5) allows ease of removal of the electrical lead wire following use of the biomedical electrode so that the electrical lead wire may be reused. The electrode of the present invention is flatter and more conformable to body contours and body movement than prior electrodes. The electrode relies on an adhesive contact with a flat electrical conductor as opposed to rubber connector strips or snaps. The electrode has a very low profile which makes it suitable to be worn under tight clothing and to be comfortable when slept upon or when leaned against, as, for example, when sitting in a chair. The electrode may be trimmed to virtually any size or shape to allow adaptability in placement and location. The electrode allows for flexibility in lead wire insertion and allows for the lead wire to be inserted from the end of the electrode or from either side. The reuseability of the lead wire leads to economy for use of the biomedical electrode. However, with some other biomedical electrodes it may be extremely difficult to actually remove the electrical lead wire from the biomedical electrode due to the adhesives involved and the degree to which the end of the electrical wire is secured. The present invention solves this problem by providing a zone in the biomedical electrode into which the electrical lead wire is inserted and a zone which facilitates the grasping and removal of the protective web allowing the easy removal of the electrical lead wire. The facility for grasping of the protective web in that zone may be provided by a portion which is uncoated by adhesive, by folding over the adhesive coated protective web, by coating the adhesive with a substance which renders the adhesive nonsticky, or other similar means. It is possible to further improve the ease with which that portion is grasped for removal by scalloping the edge. In one embodiment, the edge is formed by having a portion of the protective, electrically insulative web uncoated by the second layer of adhesive. In another embodiment, the edge is spaced from the outside perimeter of the electrode. In another embodiment, the edge is scalloped to permit easer grasping. In another embodiment, a portion of the protective, electrically insulating web forms the edge of being folded over in the second zone of the electrode. In another embodiment, the edge is formed by covering the second layer of adhesive over a portion of the second zone with a substance resulting in a nonsticky surface. In another embodiment, the nonsticky surface of the protective, electrically insulative web has a scalloped edge to permit easier grasping. In another embodiment, a third layer of adhesive which is electrically conductive is positioned between the electrically conductive layer and the release liner over another portion of the surface of the biomedical electrode where the distal end of the insertable electrical lead wire is adapted to be placed. In another embodiment, the protective, electrically insulative web is discontinuous in the second zone being composed of a first part covering the first and third zones and a portion of the second zone and of a second part covering a portion of the second zone, the first part of the protective, electrically insulative web having the edge. Brief Description of Drawings The foregoing advantages, construction and operation of the present invention will become more readily apparent from the following description and accompanying drawings in which: Figure 1 is a isometric view of a biomedical electrode; Figure 2 is a side view of the biomedical electrode of Figure 1; Figure 3 is a side view of an embodiment of the biomedical electrode of the present invention; Figure 4 is a side view of the biomedical electrode as in Figure 3 with the electrical lead wire installed; Figures 5, 6 and 7 illustrate side views of alternative embodiments of constructing the edge which can be grasped; and Figures 8 and 9 are top views of alternative embodiments of the biomedical electrode of the present invention which illustrate two variations of a scalloped edge. Detailed Description Figure 1 illustrates an isometric view of a biomedical electrode 10. The biomedical electrode 10 is also shown in expanded side view of Figure 2, The top of the biomedical electrode 10 is a protective, electrically insulative web 12. Web 12 protects the top of biomedical electrode 10 from physical damage and covers lead wire 14 when it is inserted in the biomedical electrode 10 to help secure lead wire 14 in place. Web 12 is electrically insulative to confine the electrical signals used in the biomedical electrode to the lead wire 14 or to the body (not shown). As shown in Figure 1, web 12 is preferably perforated making web 12 more conformable to the body contour and for esthetics. The perforations also assist in the tearability of web 12 once it is desired to remove lead wire 14 from the biomedical electrode 10. It is preferred that web 12 is approximately 4 mils (1.0 millimeters) thick and is constructed from a pigmented low molecular weight polyethylene film. Web 12 is attached to the remainder of biomedical electrode 10 with a pressure sensitive adhesive 16. It is preferred that the pressure sensitive adhesive 16 be an acrylate adhesive. A release liner 18, which is removable, is placed beneath pressure sensitive adhesive 16 covering a portion of the surface are a of biomedical electrode 10. Realease liner 18 facilitates the lifting of web 12 away from the remainder of the biomedical electrode 10 in order that lead 14 may be inserted and web 12 subsequently reapplied securing lead wire 14 in biomedical electrode 10. It is preferred that the release liner 18 be a Polyslick™ material as manufactured by James River Corporation, H.P. Smith Division, Bedford Park, Illinois. A conductive adhesive 20 is positioned in the biomedical electrode 10 below realease liner 18. Conductive adhesive 20 need only cover a portion of the surface area of biomedical electrode 10 to which lead wire 14 may be positioned. It is preferred that the conductive adhesive 20 cover approximately the same surface area of biomedical electrode 10 as does realease liner 18. This allows for relative general ease in the positioning of lead wire 14 once release liner 18 has been removed. It is also preferred that the conductive adhesive 20 be made conductive through the inclusion of silver particles. It is preferred that a resistivity measurement using a one inch square brass plate above and below the adhesive measures approximately 0.01 ohms. The exact conductivity of conductive adhesive 20, of course, depends upon the end use to which biomedical electrode 10 in intended. Generally, it is expected that resistivities of conductive adhesive may generally range up to one ohm. Alternatively, approximately ten ohms may be sufficient and higher resistivities may be allowable in other embodiments and for other uses for biomedical electrode 10. Conductive adhesive, especially conductive adhesives containing silver particles are widely available. An example of a suitable adhesive is a solvent based acrylate adhesive containing silver particles about 3 mils (0.76 mm) in diameter which is coated through a knife coater at about 12 mils (3.05 mm) thickness. The coated adhesive is heated to drive off the solvent resulting in an adhesive layer of about 1.0 mils (0.38 mm) in thickness. Note that the silver particles are larger than the thickness of the resulting adhesive giving the layer is needed electrical conductivity. An adhesive similar to this but which has been coated on aluminum is available as X1170 foil tape from Minnesota mining and Manufacturing Company, St. Paul, Minnesota. Below conductive adhesive 20 an electrically conductive film 22, preferably a metal vapor coated conductive film, covers a large portion of the surface area of biomedical electrode and, in a preferred embodiment, covers the entire surface of biomedical electrode 10. The purpose of electrically conductive film 22 is to disburse the current delivered by or received by biomedical electrode 10 over a larger portion of the surface area of biomedical electrode 10. Electrically conductive film 22 may also operate to provide an ion barrier between the insertable lead wire 14 and the body. In a preferred embodiment, the electrically conductive film is an ethylene vinyl acetate loaded with approximately 28% carbon or a, Velostat® film manufactured by Minnesota Mining and Manufacturing Company, Saint Paul, Minnesota in either case coated top side with 7 x 10⁻⁸ to 1.2 x 10⁻⁷ meters thick vapor coat of aluminum or silver. It is preferred that electrically conductive film 22 be approximately 3 mils (0.76 millimeters) thick. As indicated, conductive adhesive 24 operates to secure biomedical electrode 10 to the body to biomedical electrode 10 or visa versa. It is preferred that conductive adhesive 24 have better cohesion than adhesion in order to facilitate the ease in which the biomedical electrode 10 may be removed from the body. Conductive adhesive 24 may generally have a volume resistivity fo the range from 50 to 200 ohm-centimeters although lower and high volume resistivities may work for some uses of the biomedical electrode 10. It is preferred that conductive adhesive 24 be from 10 mils (2.5 millimeters) to 60 mils (15.2 millimeters) thick. In a reuseable electrode it is preferred that the conductive adhesive 24 be from 30 mils (7.6 mm) to 44 mils (11.2 mm) thick. In a disposable electrode it is preferred that the conductive adhesive be from 10 mils (2.5 mm) to 24 mils (6.3 mm) thick. An example of a conductive adhesive 24 desirable for a reuseable electrode is described in U.S. Patent No. 3,865,770, Blake, Water-Dispersable Pressure-Sensitive Adhesive Tape Made Therewith, and Novel Tackifiers Therefor, which is hereby incorporated by reference In one embodiment, the adhesive in Blake is modified and the following ingredients used: Ingredient Dry Weight Grams Dry Weight Percent Copolymer: Butyl Acrylate & Acrylic Acid in 3:1 ratio 83.177 40.945 Glycerin 20 9.8452 Butanediol 20 9.8452 Sorbitol 20 9.8452 Methyl diethanolamine (MDEA) 28 13.783 Potassium Chloride (KCl) 6.9678 3.4300 Foral AZ (hydrogenated wood rosin) 25 12.306 TOTAL 203.14 100.04 An example of a conductive adhesive 24 desirable for a disposable electrode is described in U.S. Patent 4,554,924, Engel, Conductive Adhesive and Biomedical Electrode, which is hereby incorporated by reference. In one embodiment, the adhesive in Engel is modified and the following ingredients be used: Ingredient Dry Weight Grams Dry Weight Percent 1,4 Butanediol 45 6.3993 Glycerin 75 10.665 Sorbitol 290 41.240 K739, Polyacrylic 17 2.4175 Potassium Hydroxide 3.25 0.46217 Total Water 155 22.042 Acrylic Acid 115 16.354 Irgacure 0.51635 0.07343 Tegbm 2.3186 0.32972 Methyl ethyl hydroquinone 0.12 0.01706 TOTAL 703.20 100.04 The preferred electrically conductive adhesive 24 is compriesed of the following ingredients: Ingredient Dry Weight Percent Copolymer: Acrylic Acid 10.00 N-vinyl pyrrolidone 10.00 Glycerin 50.88 Guar gum 0.12 Water 26.00 Sodium hydroxide 2.80 Irgacure 0.07 TEGBM 0.125 100.00 Optionally, a second release liner (not shown) may be provided below conductive adhesive 24 to facilitate transportation and storage of biomedical electrode 10 before use or between uses. Biomedical electrode 10 may be utilized by applying the biomedical electrode 10 to a body being secured by conductive adhesive 24. The protective, electrically insulative web 12 may be lifted since release liner 18 prevents the protective, electrically insulative web 12 from sticking to conductive adhesive 20. Once the protective insulative web 12 is lifted, release liner 18 may be removed and discarded. At this time, lead wire 14 may be inserted so that noninsulated portion 26 of lead wire 14 is positioned over conductive adhesive 20. Lead wire 14 also has an insulative portion 28 which extends from beneath the confines of protective, electrically insulative web 12 and may be connected to suitable electronic equipment intended to utilize biomedical electrode 10. Lead wire 14 may be a copper wire whose insulated portion 28 is insulated with any suitable insulation, as, for example, rubber or plastic. The end of noninsulated portion 26 of lead wire 14 is a flat crimped on conductor plate 30. Conductor plate 30 is flat which facilitates the biomedical electrode 10 being of low profile, flat and conformable to the body. Conductor plate 30 may, for example, be a zinc plated copper or, optionally, a silver plated copper with a chloride treatment, or, preferably nickel coated brass. In the embodiments of biomedical electrode illustrated in Figures 1, 2, a single sheet release liner 18 is illustrated. In these embodiments, release liner 18 is coated both sides with a release agent allowing the release liner 18 to release both from pressure sensitive adhesive 16 and conductive adhesive 20. Figures 3 and 4 illustrate a side view of a biomedical electrode 10G constructed in accordance with the present invention. As in the biomedical electrode 10 disclosed in Figures 1, 2 the biomedical electrode 10G and Figures 3 and 4 has a protective, electrically insulative web 12. An adhesive 16 secures the protective, electrically insulative web 12 to a conductive film 22. An electrically conductive adhesive 24 is applied to the opposite side of the conductive film 22 and itself is protected by an optional release liner 36. Release liner 36 protects the electrically conductive adhesive 24 until the electrode is to be applied to a body (not shown). A removable release liner 18 is positioned between adhesive 16 and electrically conductive film 22 to prevent the protective, electrically insulative web 12 from sticking to the electrically conductive film 22 in a first zone 38 of the biomedical electrode 10G. After the biomedical electrode 10G is applied to a body, removable release liner 18 may be removed and an electrical lead wire 14 may be inserted in the first zone 38 and secured by adhesive 16 as protective, electrically insulative web 12 is placed back over the electrical lead wire 14. In this configuration, the biomedical electrode, 10G is suitable for use in its normal mode of operation. The electrical signals may be applied via electrical lead wire 14 to the biomedical electrode 10G which are then transmitted by the biomedical electrode 10G through electrically conductive adhesive 24 to the body or, alternative electrical signals from the body may be read by way of the biomedical electrode 10G via a connection to electrical lead wire 14. In this configuration of the biomedical electrode after a protective, electrically insulative web 12 is secured over electrical lead wire 14, there is no longer a readily available mechanism for grasping the protective, electrically insulative web 12 in order to remove the protective, electrically insulative web 12 from the remainder of the biomedical electrode 10G. Upon completion of normal use of biomedical electrode 10G, it is highly desirable to reuse electrical lead wire 14 since the cost of the electrical lead wire 14 may be many times that of the remainder of the biomedical electrode 10G. Since the electrical lead wire 14 is secured within biomedical electrode 10G by adhesive 16, it is extremely difficult, if not impossible, to remove electrical lead wire 14 as long as it is so secured. It is necessary, in most incidences, to remove protective, electrically insulative web 12 in order to release adhesive 16 from the securing of electrical lead wire 14 in the biomedical electrode 10G. This is accomplished in the present invention by having a second zone 40 and a third zone 42, intermediate the first zone 38 and the second zone 40 of the biomedical electrode 10G. In the first zone 38 of the biomedical electrode 10G, protective, electrically insulative web 12 is prevented from being secured to electrically conductive film 22 by the removable release liner 18. In the third zone 42 of the biomedical electrode 10G, the protective, electrically insulative web 12 is secured by adhesive 16 to the electrically conductive film 22. In a second zone 40 of the biomedical electrode 10G, a provision is made in an edge of protective, electrically insulative web 12 to allow the protective, electrically insulative web to be easily grasped so that the protective, electrically insulative web 12 maybe pulled and removed from the remainder of the biomedical electrode 10G resulting in the easy removal of electrical lead wire 14 from the remainder of the biomedical electrode 10G. Electrical lead wire 14 may then be reused in another biomedical electrode 10G. The second zone 40, as illustrated in Figures 3 and 4, is located opposite the first zone 38 of the biomedical electrode 10G. So positioned the release liner 18 would be removed and the electrical lead wire 14 be inserted on one side of the biomedical electrode 10G and the electrical lead wire 14 would be removed by grasping the protective, electrically insulative web 12 starting from the opposite side of the biomedical electrode 10G. It is to be recognized and understood, however, that second zone 40 maybe positioned differently with respect to first the zone 38 and may even be positioned nearest the edge of the biomedical electrode 10G that the removable release liner 18 faces. It is necessary that an edge 44 be provided which can be easily grasped. In an embodiment edge 44 may spaced from the perimeter of biomedical electrode 10G or it may be otherwise desirable to have a separate portion of the protective, electrically insulative web 12A and its associated layer of adhesive 16A in the second zone 40 in order permit even easier grasping of edge 44, as illustrated in Figures 3 and 4. Figures 5, 6 and 7 show three different mechanisms in which the edge 44 which may be easily grasped may be constructed. In one embodiment of the present invention, edge 44 is formed by folding protective, electrically insulative web 12 over onto itself thus covering adhesive 16 with the protective, electrically insulative web 12. This will allow an edge 44 which is not adhesively stuck to electrically conductive film 22 and which may be easily grasped. This mechanism for forming edge of 44 is that mechanism illustrated in Figures 9 and 10. Figure 6 illustrates that edge 44 may be formed along a portion of protective, electrically insulative web 12 by covering electrically adhesive 16 with a separate piece 46 of nonadhesive material such as another short piece of the same material from which protective, electrically insulative web 12 is constructed. In another embodiment of the present invention, illustrated in Figure 7, edge 44 is formed by zone coating protective, electrically insulative web 12 with adhesive 16 allowing a section of protective, electrically insulative web 12 at edge 44 which is not covered by adhesive 16. Figures 8 and 9 illustrate slightly alternative embodiments of biomedical electrode 10G in which edge 44 is formed by making a scalloped edge of protective, electrically insulative web 12. Scalloped edge 44 would then slightly cover a separate piece of protective, electrically insulative web 12A allowing the entire top surface of biomedical electrode 10G to be covered with protective, electrically insulative web 12 or 12A but also allowing easily grasped edge 44. As shown in Figure 8, the scalloped edge 44 may be relatively small scallops and as shown in Figure 9 scalloped edge 44 may be formed with relatively large scallops.

Claims: A biomedical electrode adapted to be applied to a body, said electrode having a surface area divided into a first zone (38), and a third zone (42) comprising: a first layer of adhesive (24) which is electrically conductive and which is adapted to be applied to said body; a conductive layer (22) positioned adjacent said first layer of adhesive (24); a second layer of adhesive (16); a protective, electrically insulative web (12) positioned adjacent said second layer of adhesive (16); said second layer of adhesive (16) holding said protective, electrically insulative web (12) to said conductive layer (22) opposite of said first layer of adhesive in said third zone (42) of said electrode; a removable release liner (18) positioned in said first zone (38) between said second layer of adhesive and said conductive layer preventing said protective, electrically insulative web from sticking to said conductive layer in said first zone of said electrode, whereby said release liner (18) is removed for insertion of a distal uninsulated portion of an electrical lead wire (14), characterised in that:- said electrode surface area has a second zone (40) whereby said third zone is intermediately located between said first zone and said second zone; and said protective, electrically insulative web (12) has an edge (44) in said second zone (40) consisting of a section in which said conductive adhesive (16) does not hold said web (12) to said conductive layer (22) which is therefore easily grasped so that said protective, electrically insulative web (12) may be pulled and removed from said electrode allowing removal of said electrical lead wire. A biomedical electrode as in claim 1 wherein a third layer of adhesive (20) which is electrically conductive is positioned between said electrically conductive layer (22) and said release liner (18) over a portion of said first zone (38) of the surface of said biomedical electrode (10) where said distal end of said insertable electrical lead wire is to be placed. A biomedical electrode as in claim 1 wherein said protective, electrically insulative web (12) is discontinuous in said second zone (40) being composed of a first part covering said first (38) and third (42) zones and a portion of said second zone (40) and of a second part covering a portion of said second zone (40), said first part of said protective, electrically insulative web having said edge (44). A biomedical electrode as in claim 1 wherein said edge (44) is scalloped to facilitate easy grasping.

Inventors: BLY JEROME G C O MINNESOTA MIN, ROBERTS CHARLES W C O MINNESOT, BLY, JEROME G. C/O MINNESOTA MINING AND, ROBERTS, CHARLES W. C/O MINNESOTA MINING AND
Applicants: MINNESOTA MINING & MFG, MINNESOTA MINING AND MANUFACTURING COMPANY
Application year: 1989
Main classification: A61B5
IPC codes: A61N1, A61B5