Researchers at Ulsan National Institute of Science and Technology (UNIST) have developed a reusable, self-adhesive ECG patch that eliminates the need for cold conductive gels and chemical adhesives. The innovation aims to improve patient comfort, reduce skin irritation and enhance signal reliability during continuous cardiac monitoring.
Conventional ECG patches rely on conductive gels and sticky adhesives to maintain contact with the skin. These materials can cause irritation, leave marks and lose effectiveness during movement, resulting in compromised signal quality. For patients requiring prolonged monitoring, particularly those with sensitive skin, these limitations can affect both comfort and diagnostic reliability.
Led by Professor Hoon Eui Jeong from the Department of Mechanical Engineering at UNIST, the research team introduced a structurally engineered alternative. The new patch integrates spiral-shaped liquid metal microchannels within a microstructured silicone elastomer. The liquid metal channel, approximately 20 micrometers wide, directly contacts the skin through an open-bottom design, enabling efficient transmission of cardiac signals to the electrodes. The findings were published in Advanced Science.
Structural design prevents leakage
One of the technical challenges in liquid metal bioelectronics is leakage under pressure. To address this, the team incorporated inwardly curled horizontal microstructures at the base of the channels. These features help contain the liquid metal and preserve device integrity during use.
The ultra-thin microchannels, less than 20 micrometers thick, also enhance user comfort by preventing the patch from feeling cold against the skin. Unlike traditional gel-based electrodes, the new system maintains consistent performance without drying out over time.
Durable adhesion
The entire surface of the patch is embedded with microscopic protrusions measuring 28 micrometers in diameter and 20 micrometers in height. These crown-like microstructures act as physical anchors, conforming closely to the skin’s natural microcurvatures. This structural adhesion mechanism enables strong attachment without chemical glues.
According to performance evaluations, the patch demonstrated electrode impedance more than five times lower than that of commercial products, allowing clearer detection of weak cardiac signals. It can withstand forces equivalent to supporting a 100-gram weight and remains securely attached during activities such as walking or running. Even after seven days of repeated use, the patch retained more than twice the adhesion strength of conventional disposable patches. The design reduces motion artifacts and maintains stable signal acquisition.
Next-generation wearable monitoring
Unlike single-use ECG patches, the new device can be reused more than 500 times while maintaining signal accuracy. The absence of gels and chemical adhesives not only improves comfort but may also lower long-term costs and environmental impact.
Professor Jeong stated: “We have successfully solved the challenges of liquid metal leakage and skin adhesion through precise structural design. This technology lays the foundation for next-generation wearable health monitoring systems, especially for patients with sensitive skin, and for high-precision human-machine interfaces.”
The research team is currently collaborating with Anvix Lab Co., Ltd. to commercialize the technology. If successfully translated into clinical practice, the patch could support more reliable long-term ECG monitoring in both hospital and home-care settings.
Wearable ECG-patch effectivity
Back in 2024 research proved that a than newly developed ECG-patch was as accurate, if not more accurate than traditional ECG-devices. The EKG Patch Solution, developed by MG Medical Products, is an all-in-one wearable ECG system with built-in lead wires and pre-positioned electrodes, designed to simplify placement and reduce electrode errors. Its user-friendly design requires minimal training and lowers the risk of artifacts caused by poorly attached leads by 50%.
In a prospective single-blind study involving 200 cardiac patients, the patch showed an error rate of 6.5%, compared to 15% with standard 12-lead ECGs, with most errors related to patient movement. Weighing five pounds and fully wireless, the device eliminates complex setup and may improve ECG accessibility, particularly in nursing homes, behavioral health and correctional facilities.
