# US 11,304,640 B2 · Sensor for electrode and processes for production > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,304,640 B2 - Document ID: US11304640B2 - Status: Granted - Kind: B2 - Application number: 16/063,382 - Filed: 2016-12-05 - Published: 2019-01-03 - Granted: 2022-04-19 - Earliest claimed: 2015-12-22 - Assignees: 3M Innovative Properties Company - Applicants: 3M Innovative Properties Company - Inventors: Cameron E. Derry - Web page: https://patentgrep.com/patent/US11304640B2 ## CPC - A61B 5/265: containing silver or silver chloride - A61B 5/268: containing conductive polymers, e.g. PEDOT:PSS polymers - A61N 1/0456: {Specially adapted for transcutaneous electrical nerve stimulation [TENS]} - A61N 1/046: {Specially adapted for shock therapy, e.g. defibrillation} - A61N 1/0496: {characterised by using specific chemical compositions, e.g. hydrogel compositions, adhesives} - H01B 1/22: the conductive material comprising metals or alloys - A61B 2562/0209: Special features of electrodes classified in A61B5/24, A61B5/25, A61B5/283, A61B5/291, A61B5/296, A61B5/053 - A61B 2562/125: characterised by the manufacture of electrodes - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - A61N: ELECTROTHERAPY; MAGNETOTHERAPY; RADIATION THERAPY; ULTRASOUND THERAPY (measurement of bioelectric currents A61B; surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body A61B18/00; anaesthetic apparatus in general A61M; incandescent lamps H01K; infrared radiators for heating H05B) - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) ## 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. ## Claims ### Claim 1 An electrode sensor comprising: a solid conductive polymeric substrate comprising electrically conductive polymers and/or an electrically conductive filler and having a contact surface; and, a plurality of silver-coated particles thermally embedded into the contact surface of the solid conductive polymeric substrate, wherein a portion of each of the plurality of silver-coated particles are sufficiently anchored into the contact surface and surrounded by the solid conductive polymeric substrate while another portion of each of the plurality of silver-coated particles is exposed such that the plurality of silver-coated particles are not dispersed throughout the bulk of the solid conductive polymeric substrate. ### Claim 2 (depends on 1) The electrode sensor according to claim 1, wherein the plurality of silver-coated particles have an average size in a range of 1-300 um. ### Claim 3 (depends on 1) The electrode sensor according to claim 1, wherein an amount of silver of the plurality of silver-coated particles distributed on the contact surface is 10 mg Ag/sq. in. or less. ### Claim 4 (depends on 1) The electrode sensor according to claim 1, wherein an amount of silver of the plurality of silver-coated particles distributed on the surface is 8 mg Ag/sq. in. or less. ### Claim 5 (depends on 1) The electrode sensor according to claim 1, wherein an amount of silver of the plurality of silver-coated particles distributed on the surface is an amount in a range of 1-6 mg Ag/sq. in. ### Claim 6 (depends on 2) The electrode sensor according to claim 2, wherein an amount of silver of the plurality of silver-coated particles provides the electrode sensor with a pre-determined recovery time from charge accumulated by the electrode sensor in a defibrillation event during heart fail. ### Claim 7 (depends on 1) The electrode sensor according to claim 1, wherein surface roughness as measured by the arithmetic average of the absolute values (Ra) is in a range of 1-15 micron. ### Claim 8 (depends on 1) The electrode sensor according to claim 1, wherein the particles comprise glass. ### Claim 9 (depends on 1) The electrode sensor according to claim 1, wherein the particles are fibers. ### Claim 10 (depends on 1) The electrode sensor according to claim 1 wherein the plurality of silver-coated particles are distributed non-continuously on the contact surface providing a plurality of conductive channels rather than a single conductive channel as provided by the continuous layer of silver resulting from ink printing or electroplating processes. ### Claim 11 (depends on 1) An electrode assembly comprising: the electrode sensor as defined in claim 1; a conductive stud for attaching a backing to the electrode sensor; a conductive gel on a surface of the electrode sensor; and a removable cover attached to the conductive gel. ### Claim 12 (depends on 11) The electrode assembly according to claim 11 which is an electrocardiogram electrode. ### Claim 13 (depends on 11) The electrode assembly according to claim 11 which is a resting electrode. ### Claim 14 (depends on 11) The electrode assembly according to claim 11 which is a monitoring electrode. ### Claim 15 (depends on 1) A process for producing the electrode sensor of claim 1 comprising: distributing the plurality of silver-coated particles only on the contact surface of the solid conductive polymeric substrate comprising the electrically conductive polymers and/or the electrically conductive filler, and thermally embedding the plurality silver-coated particles into the contact surface. ### Claim 16 (depends on 15) The process according to claim 15, wherein the plurality of silver-coated particles comprise glass. ### Claim 17 (depends on 15) The process according to claim 15, wherein the plurality of silver-coated particles have an average size in a range of 1-300 μm. ### Claim 18 (depends on 15) The process according to claim 15, wherein the plurality of silver-coated particles are distributed on the contact surface to provide an amount of 10 mg Ag/sq. in. or less on the contact surface. ### Claim 19 (depends on 15) The process according to claim 15, wherein the plurality of silver-coated particles are distributed on the contact surface to provide an amount of 8 mg Ag/sq. in. or less on the contact surface. ### Claim 20 (depends on 15) The process according to claim 15, wherein the thermal embedding comprises calendering or compression pressing.