Patent ID: 7169644

Claim:
A continuous method for making medical electrodes from a moving web comprising: providing a web of electrically conductive polymer film having first and second surfaces; applying a conductive metal-metal chloride coating to the first surface of the film in a predetermined pattern corresponding to the electrodes; curing the conductive coating; applying a hydrogel coating to the first surface of the film so as to overlie the conductive coating; curing the hydrogel coating; applying a release liner to the hydrogel; applying a conductive adhesive to the second surface of the film; curing the conductive adhesive; die-cutting the film to form individual electrode bodies; placing an end of a conductive lead having multi-wire strands on the conductive adhesive of each individual electrode body; fanning the ends of the conductive leads; applying a cover to the electrode bodies over the conductive leads; and die-cutting the cover to form the electrodes.