Wireless TENS Unit Pads Manufacturer | Snap-On & Butterfly Electrodes (OEM)
Heavy-duty wireless electrode pads designed to support device weight. Custom snap spacing (standard 3.5mm or custom), butterfly shapes, and load-bearing hydrogel. ISO 13485 certified.
Product Overview
The rapid growth of wearable therapy has made Wireless Electrode Pads a critical consumable. Unlike traditional wired pads, wireless electrodes must serve a dual purpose: transmitting the electrical signal AND mechanically supporting the weight of the TENS/EMS host unit.
TOP-RANK Wireless Electrodes are specifically engineered for this "Load-Bearing" challenge. We utilize a reinforced non-woven backing and a proprietary High-Viscosity Hydrogel formulation that is engineered for superior vertical shear resistance. This ensures the device stays securely attached to the user's body-even during movement-preventing accidental detachment or signal interruption.
As a specialized OEM manufacturer, we can customize the snap distance (pitch) and electrode geometry to perfectly match your proprietary wireless device design.
Why Our Wireless Pads Perform Better
Standard electrodes often fail in wireless applications because they peel off under the device's weight. We solved this with a 3-point reinforcement system:
- Reinforced Snap Integration: Our automated assembly process ensures the stainless steel snap stud is anchored securely into the carbon film, preventing the "pull-out" failure common in lower-grade alternatives.
- Structural Backing Materials: We use high-tensile Sontara non-woven fabric or high-density foam that resists stretching, ensuring the pad maintains its shape even when holding a heavy control unit.
- Load-Bearing Hydrogel: Our lab-developed "High-Tack" gel formula is optimized for vertical hold, ensuring the pad sticks firmly to the lower back or shoulders without leaving residue upon removal.
Customization Capabilities (OEM Service)
We offer precise customization to ensure the pad fits your specific device interface:
1. Snap & Connection Options
- Standard Snap: 3.5mm (Most common), 2.2mm, 3.9mm stud diameters.
- Dual Snap Spacing: We can adjust the distance between snaps (e.g., 25mm, 30mm, 45mm pitch) to align exactly with your device's contact points.
- Magnetic Connectors: Custom magnetic ring integration for quick-attach devices.
2. Shape & Ergonomics
- Butterfly (Lumbar): The industry standard for lower back pain, offering a wide coverage area for stability.
- Long Strip (Joints): Curved designs for wrapping around shoulders, knees, or arms.
- Abs Wings: Large-format designs for abdominal EMS toning belts.
3. Private Labeling
- Branding: Print your logo on the release liner or directly on the cloth backing.
- Retail Kits: Custom foil pouches containing 1 pair or 2 pairs, ready for retail display.
Technical Specifications
| Feature | Specification Options |
| Connection Type | Snap Button (Stainless Steel) or Magnetic |
| Snap Diameter | 2.2mm / 3.5mm / 3.9mm / Custom |
| Snap Distance | Customizable (Standard: 25-45mm) |
| Backing Material | Non-woven Cloth (White/Tan) or PE Foam |
| Conductive Layer | Low-Impedance Carbon Film |
| Gel Type | TOP-RANK High-Tack Hydrogel (Weight-bearing) |
| Device Weight Support | Designed for typical wireless modules (Customizable for heavier units) |
| Biocompatibility | ISO 10993 Compliant (Latex-free) |
Applications
Wireless TENS Therapy
Pain relief for back, sciatica, and arthritis (Home use).
EMS Muscle Training
Wearable fitness gear for abs and limb toning.
Smart Wearables
Bio-sensing patches requiring snap-on data transmitters.
Inquiry
Developing a Wireless TENS Device?
Don't risk your user experience with weak pads. Send us your device for a Complimentary Fit & Adhesion Test.
Contact Engineering Team to discuss snap spacing and custom shapes.
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