Abstract: An electrode includes a backing. The backing includes a first backing side and a second backing side. The backing has a planar surface and a portion of the backing forms a raised section on the first backing side and an indented section on the second backing side opposite the raised section. The indented section forms a cavity therein. Further, the backing is not electrically conductive. The electrode also includes an electrically conductive gel disposed at least partially within the cavity. The electrode further includes an eyelet penetrating the backing and electrically coupled with the electrically conductive gel. The electrode includes a stud adapted to detachably couple the electrode to a lead wire and configured to attach to the eyelet.

Abstract: A method of coating a substrate with a particulate coating composition is disclosed that creates a coated substrate having a controlled, nonuniform surface property profile that varies along at least one primary dimension. The substrate is positioned on a textured template. An effective amount of the particulate coating composition is buffed onto a surface of the substrate with the at least one orbital applicator moving in a plane parallel to surface in a plurality of directions relative to a point on the surface in an orbital manner while at least one process variable is changed during the coating of the substrate. Process variable that can be varied during coating include application time, application pressure, coating temperature, the contour of the textured template, orbital speed, web speed, and the particulate coating composition.

Abstract: An electrical film heater having a variable thermal output is described herein. The electrothermal film heater comprises a substrate having first and second major surfaces that is characterized by a length and a width. A nonuniform graphite coating layer is disposed on at least one major surface of the substrate creating a variable electrical resistance coating on the substrate along at least one of the length and/or the width of the substrate, and a pair of spaced apart bus bars disposed on top of the graphite coating layer.

Abstract: 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.

Abstract: A process for producing an eyelet for a biomedical electrode (e.g. an electrocardiogram (ECG) electrode) involves: hot pressing an electrically conductive thermoplastic or elastomeric resin to produce a film having a web of eyelets, each eyelet having a post protruding from a first face of the film and a flange at a second face of the film; applying a coating of a non-polarizable conductive material (e.g. a silver-containing material) on to a contact face of the flange; and, cutting the film to produce the eyelets separated from the web. Preferably, the process involves extrusion replication. A web of eyelets for biomedical electrodes has a film of an electrically conductive thermoplastic or elastomeric resin possessing a plurality of posts protruding from a first face of the film, and preferably a layer of a non-polarizable conductive material on a second face of the film. The process may be a one-step continuous process that is cheaper and simpler than current commercial processes.

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.

Abstract: A process for producing an eyelet for a biomedical electrode (e.g. an electrocardiogram (ECG) electrode) involves: hot pressing an electrically conductive thermoplastic or elastomeric resin to produce a film having a web of eyelets, each eyelet having a post protruding from a first face of the film and a flange at a second face of the film; applying a coating of a non-polarizable conductive material (e.g. a silver-containing material) on to a contact face of the flange; and, cutting the film to produce the eyelets separated from the web. Preferably, the process involves extrusion replication. A web of eyelets for biomedical electrodes has a film of an electrically conductive thermoplastic or elastomeric resin possessing a plurality of posts protruding from a first face of the film, and preferably a layer of a non-polarizable conductive material on a second face of the film. The process may be a one-step continuous process that is cheaper and simpler than current commercial processes.

Abstract: A process for producing an eyelet for a biomedical electrode (e.g. an electrocardiogram (ECG) electrode) involves: hot pressing an electrically conductive thermoplastic or elastomeric resin to produce a film having a web of eyelets, each eyelet having a post protruding from a first face of the film and a flange at a second face of the film; applying a coating of a non-polarizable conductive material (e.g. a silver-containing material) on to a contact face of the flange; and, cutting the film to produce the eyelets separated from the web. Preferably, the process involves extrusion replication. A web of eyelets for biomedical electrodes has a film of an electrically conductive thermoplastic or elastomeric resin possessing a plurality of posts protruding from a first face of the film, and preferably a layer of a non-polarizable conductive material on a second face of the film. The process may be a one-step continuous process that is cheaper and simpler than current commercial processes.

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.

Abstract: 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.

Abstract: A process for producing an eyelet for a biomedical electrode (e.g. an electrocardiogram (ECG) electrode) involves: hot pressing an electrically conductive thermoplastic or elastomeric resin to produce a film having a web of eyelets, each eyelet having a post protruding from a first face of the film and a flange at a second face of the film; applying a coating of a non-polarizable conductive material (e.g. a silver-containing material) on to a contact face of the flange; and, cutting the film to produce the eyelets separated from the web. Preferably, the process involves extrusion replication. A web of eyelets for biomedical electrodes has a film of an electrically conductive thermoplastic or elastomeric resin possessing a plurality of posts protruding from a first face of the film, and preferably a layer of a non-polarizable conductive material on a second face of the film. The process may be a one-step continuous process that is cheaper and simpler than current commercial processes.