A novel quasi-dry electrode prototype, based on a polymer wick structure filled with a specially designed hydrating solution is proposed for electroencephalography (EEG) applications. The new electrode does not require the use of a conventional electrolyte paste to achieve a wet, low-impedance scalp contact. When compared to standard commercial Ag/AgCl sensors, the proposed wick electrodes exhibit similar electrochemical noise and potential drift values. Lower impedances are observed when tested in human volunteers due to more effective electrode/skin contact. Furthermore, the electrodes exhibit an excellent autonomy, displaying an average interfacial impedance of 37±11 kΩ cm² for 7 h of skin contact. After performing bipolar EEG trials in human volunteers, no substantial differences are evident in terms of shape, amplitude and spectral characteristics between signals of wick and commercial wet electrodes. Thus, the wick electrodes can be considered suitable to be used for rapid EEG applications (electrodes can be prepared without the presence of the patient) without the traditional electrolyte paste. The main advantages of these novel electrodes over the Ag/AgCl system are their low and stable impedance (obtained without conventional paste), long autonomy, comfort, lack of dirtying or damaging of the hair and because only a minimal cleaning procedure is required after the exam.

Dry electrodes for electroencephalography (EEG) allow new fields of application, including telemedicine, mobile EEG, emergency EEG, and long-term repetitive measurements for research, neurofeedback, or brain–computer interfaces. Different dry electrode technologies have been proposed and validated in comparison to conventional gel-based electrodes. Most previous studies have been performed at a single center and by single operators. We conducted a multi-center and multi-operator study validating multipin dry electrodes to study the reproducibility and generalizability of their performance in different environments and for different operators. Moreover, we aimed to study the interrelation of operator experience, preparation time, and wearing comfort on the EEG signal quality. EEG acquisitions using dry and gel-based EEG caps were carried out in 6 different countries with 115 volunteers, recording electrode-skin impedances, resting state EEG and evoked activity. The dry cap showed average channel reliability of 81% but higher average impedances than the gel-based cap. However, the dry EEG caps required 62% less preparation time. No statistical differences were observed between the gel-based and dry EEG signal characteristics in all signal metrics. We conclude that the performance of the dry multipin electrodes is highly reproducible, whereas the primary influences on channel reliability and signal quality are operator skill and experience.

Electroencephalography (EEG) is increasingly used for repetitive and prolonged applications like neurofeedback, brain computer interfacing, and long-term intermittent monitoring. Dry-contact electrodes enable rapid self-application. A common drawback of existing dry electrodes is the limited wearing comfort during prolonged application. We propose a novel dry Arch electrode. Five semi-circular arches are arranged parallelly on a common baseplate. The electrode substrate material is a flexible thermoplastic polyurethane (TPU) produced by additive manufacturing. A chemical coating of Silver/Silver-Chloride (Ag/AgCl) is applied by electroless plating using a novel surface functionalization method. Arch electrodes were manufactured and validated in terms of mechanical durability, electrochemical stability, in vivo applicability, and signal characteristics. We compare the results of the dry arch electrodes with dry pin-shaped and conventional gel-based electrodes. 21-channel EEG recordings were acquired on 10 male and 5 female volunteers. The tests included resting state EEG, alpha activity, and a visual evoked potential. Wearing comfort was rated by the subjects directly after application, as well as at 30 min and 60 min of wearing. Our results show that the novel plating technique provides a well-adhering electrically conductive and electrochemically stable coating, withstanding repetitive strain and bending tests. The signal quality of the Arch electrodes is comparable to pin-shaped dry electrodes. The average channel reliability of the Arch electrode setup was 91.9 ± 9.5%. No considerable differences in signal characteristics have been observed for the gel-based, dry pin-shaped, and arch-shaped electrodes after the identification and exclusion of bad channels. The comfort was improved in comparison to pin-shaped electrodes and enabled applications of over 60 min duration. Arch electrodes required individual adaptation of the electrodes to the orientation and hairstyle of the volunteers. This initial preparation time of the 21-channel cap increased from an average of 5 min for pin-like electrodes to 15 min for Arch electrodes and 22 min for gel-based electrodes. However, when re-applying the arch electrode cap on the same volunteer, preparation times of pin-shaped and arch-shaped electrodes were comparable. In summary, our results indicate the applicability of the novel Arch electrode and coating for EEG acquisition. The novel electrode enables increased comfort for prolonged dry-contact measurement.

The use of rubber in dynamic contacts often results in severe degradation and wear of the rubber surface, which is why dynamic rubber seal contacts are usually oil lubricated to ensure their functionality. However, the increasing demand for more convenient and environmentally friendly sealing solutions has prompted the development of dry low-friction rubber coatings. In this work, and for the first time, Ni-P and polytetrafluoroethylene (PTFE) particles were co-deposited by electroless plating on Nitrile Butadiene Rubber (NBR), as a low-cost solution to improve the NBR tribological behavior. A cationic surfactant, cetyltrimethylammonium bromide (CTAB), was added to the plating bath to ensure a homogeneous and efficient incorporation of PTFE into the Ni-P. The optimized PTFE incorporation reached 6.8%, and the composite coating adhesion to NBR was 20% higher than that of nickel-phosphorous (Ni-P) films. The tribological properties of the coatings evaluated by pin-on-disk tests showed a marginal decrease in the coefficient of friction (CoF) (10%, 1 N load), compared to that of Ni-P. However, the tested PTFE-based coatings displayed significantly smoother surfaces with less debris and cracks, clearly demonstrating the benefits of the PTFE in terms of wear resistance for loads up to 5 N.