Design of a wearable pain management system with embroidered TENS electrodes

Abstract

Purpose The purpose of this paper is to develop a user friendly, wearable pain management system by optimizing CAD embroidery parameters for manufacturing high performance dry transcutaneous electrical neural stimulation (TENS) electrodes. Design/methodology/approach User-centered design methodology is employed to identify user needs related to TENS devices. Optimization of CAD embroidery parameters was done by measuring and calculating resistance and signal-to-noise values for electrodes manufactured with different conductive thread, stitch pattern, and stitch density types. Findings Characteristics of the conductive thread such as thickness and irregularity, embroidery stitch pattern, stitch density therefore the amount of conductive thread used all effect resistance values and signal-to-noise values of TENS electrodes. Low resistance of TENS electrode surface does not mean high signal-to-noise ratio and high TENS signal quality. Satin stitch type with low stitch density provides the best resistance and signal-to-noise ratio for a TENS electrode. Originality/value This study reported the design process of a wearable pain management system with a focus on optimization of embroidery manufacturing parameters for development of TENS electrodes. The design process not only required technical optimization but also understanding user problems related to use of conventional TENS devices. Proposed end product is a user friendly, electronic textile based, wireless wearable pain management system in different forms suitable for major pain areas such as knee, elbow and neck.

The Effect of Sleeve Pattern and Fit on E-Textile Electromyography (EMG) Electrode Performance in Smart Clothing Design

“…This particular thread was preferred since it is specifically developed for embroidery applications transforming Statex' silver plated Shieldex thread. A prior study also proved superior compatibility of Statex Shieldex thread in embroidery applications of e-textiles [17].…”

A review of textile-based electrodes developed for electrostimulation

“…63 developed control systems that could activate selected electrode fields to create ‘virtual electrodes’ of various shapes and sizes. 20 In recent years, the focus has shifted to the integration of electrodes into electrode garments for FES and TENS, as presented by Curteza et al., 35 Poboroniuc et al., 37 Dölker et al., 66 Goncu Berk 40 and Liu et al., 41 who manufactured various kinds of electrode sleeves and cuffs to stimulate limb muscles and nerves, whereas Moineau et al. 21 and Li et al.…”

“…45 Moreover, skin adherence often becomes ineffective after a few uses, thereby demanding the use of new electrodes for each session of a long-term therapy, which results in long preparation times and overall inconvenience for home-based therapies. 35,40,46…”

“…39 Further, an electrode with a uniform current distribution ensures a homogeneous distribution of electrical charges on the skin surface to avoid hot spots and stinging pain sensations caused by differing voltages. 35,40,41 Current density peaks arising from too small contact areas can be avoided by ensuring good electrode–skin contact to maximize the contact area. 20…”

Design and Analysis of Electrodes for Electrostimulation (TENS) Using the Technique of Film Printing and Embroidery in Textiles

“…Research by Goncu and Berk describes the design process of a pain management system using embroidered electrodes, which required not only technical optimization but also understanding the issues of users related to the use of conventional TENS devices. The proposed end product is a user-friendly, textile-based electronic pain management system suitable for major pain areas such as the knee, elbow, and neck [22].…”