Methods of producing an electrode array

A method of making a transducer array for generating tumor treating fields (TTFields) having a frequency from 50 kHz to 1 MHz, comprising:

• providing an electrode layer having a plurality of electrode elements configured to generate tumor treating fields (TTFields) having the frequency from 50 kHz to 1 MHz in response to receiving an electrical signal from an electric field generator, the plurality of electrode elements being disposed in a first pattern;
• applying conductive gel elements in a flowable state to the plurality of electrode elements, the conductive gel elements including a first conductive gel layer and a second conductive gel layer by applying the first conductive gel layer to the plurality of electrode elements;
• applying a first side of a support layer onto the first conductive gel layer;
• and applying the second conductive gel layer, in the flowable state, onto a second side of the support layer in a second pattern corresponding to the first pattern such that the first and second conductive gel layers on each of the plurality of electrode elements overlap;
• and
• curing the conductive gel elements on the plurality of electrode elements;
• and
• wherein the support layer is a flexible material having a plurality of voids intersecting the first side and the second side, and the second conductive gel layer passes through the voids and bonds the support layer to the first conductive gel layer.

A transducer array, comprising:

• a plurality of electrode elements in a first pattern, the electrode elements configured to receive electrical signals from an electric field generator to produce a tumor treating field (TTField) having a frequency from 50 kHz to 1 MHz, the plurality of electrode elements forming a plurality of separate conductive regions;
• and
• a plurality of isolated conductive gel elements having a second pattern corresponding to the first pattern, a first isolated conductive gel element of the plurality of isolated conductive gel elements being in contact with a first electrode element of the plurality of electrode elements, a second isolated conductive gel element of the plurality of isolated conductive gel elements being in contact with a second electrode element of the plurality of electrode elements, the first isolated conductive gel element and the first electrode element being at least one of capacitively coupled and electrically coupled, the second isolated conductive gel element and the second electrode element being at least one of capacitively coupled and electrically coupled, the plurality of isolated conductive gel elements being in a flowable state, each conductive gel element of the plurality of isolated conductive gel elements includes a first conductive gel layer, a second conductive gel layer, and a support layer disposed between the first conductive gel layer and the second conductive gel layer, the first conductive gel layer and the second conductive gel layer overlapping, and the support layer being a flexible material having a first side, a second side, and a plurality of voids extending from the first side to the second side;
• and
• wherein the second conductive gel layer passes through the voids and bonds the support layer to the first conductive gel layer.