Abstract: A method of making an electrosurgical patient electrode includes the steps of initially providing an electrode body having a recess defined therein with an electrically conductive bottom surface, and then casting a quantity of uncured hydrogel material into the recess. The gel material is sufficient in volume to fill the recess and is subsequently cured in situ.

Abstract: A medical electrode intended for short term use has a disposable electrode pad provided with a socket and a reusable electrode conductor which is attached to a lead wire and which has a ridged body adapted to enter and be retained by the socket. The pad includes a pair of spaced foam sheets with patient-contacting adhesive layers on their lower surfaces. An electrolyte gel matrix, preferably formed from conductive adhesive urethane hydrogel, is located between the foam sheets. The socket is formed in a relatively stiff socket plate that overlies the gel matrix and the foam sheets. The socket includes a bore located over the gel matrix shaped to receive the electrode conductor, which is slightly larger than the bore, and may optionally include outwardly extending slits projecting from the bore. A method of manufacturing a strip of the electrode pads on a release liner on a continuous basis is disclosed.

Abstract: A medical electrode intended for short term use has a disposable electrode pad provided with a socket and a reusable electrode conductor which is attached to a lead wire and which has a ridged body adapted to enter and be retained by the socket. The pad includes a pair of spaced foam sheets with patient-contacting adhesive layers on their lower surfaces. An electrolyte gel matrix, preferably formed from conductive adhesive urethane hydrogel, is located between the foam sheets. The socket is formed in a relatively stiff socket plate that overlies the gel matrix and the foam sheets. The socket includes a bore located over the gel matrix shaped to receive the electrode conductor, which is slightly larger than the bore, and may optionally include outwardly extending slits projecting from the bore. A method of manufacturing a strip of the electrode pads on a release liner on a continuous basis is disclosed.

Abstract: An electrolyte gel matrix, which may be a conductive adhesive such as a urethane hydrogel, is located in a cavity formed in a non-conductive tray. The matrix is adapted to engage the skin of a patient and transmit signals between the skin and an electrode conductor supported by the base of the tray for exchanging signals with peripheral equipment. A stiffening platform adhered to the tray extends across the cavity portion aligned with the conductor to minimize motion artifacts associated with the use of the electrode. The electrode is removably attachable to the skin by an adhesive layer on the lower surface of the tray and by a preferably more aggressive adhesive layer on the lower surface of the platform.