Pre-wired Electrode Pads | Pigtail TENS Pads | TOP-RANK
Medical-grade pre-wired electrode pads with integrated 2.0mm female sockets. Features a high-pull-strength pigtail junction and cross-linked ionic hydrogel for clinical use.
Product Overview
These are self-adhesive electrodes featuring an integrated lead wire (pigtail) terminating in a 2.0mm female socket. Unlike snap or pin-insert pads, the wire is permanently bonded to the conductive substrate. We supply these to B2B clinical providers who require a "plug-and-play" interface that minimizes the mechanical stress on the stimulator's main lead wires.
Key Features
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Reinforced Pigtail Junction (Stress Distribution)
The primary failure mode for pre-wired pads is the wire pulling out of the pad substrate. We utilize a high-pressure ultrasonic bonding or specialized conductive adhesive bridge that anchors the wire over a 15mm section of the carbon film. This distributes tensile stress and prevents the wire from detaching during aggressive patient repositioning.
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Constant-Impedance Path
Electrical "dead zones" can occur if the wire-to-carbon contact is inconsistent. Our manufacturing process utilizes automated placement of the pigtail to ensure a calibrated contact area. This maintains a total path resistance of under 45 Ohms, preventing the stimulator from increasing voltage to compensate for junction loss.
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Zero-Leakage Over-molding
The 2.0mm female socket is over-molded with medical-grade PVC. This geometry provides a moisture-proof seal at the wire entry point, preventing clinical cleaning agents or perspiration from oxidizing the internal copper strands, which causes signal degradation over time.
Applications
In-Patient Clinical Rehab
High-volume use in hospitals where "pre-wired" setups reduce prep time.
Post-Surgical Recovery
Secure connections for long-term immobilization therapy.
Device Kitting
Standard accessory for TENS/EMS units requiring a pigtail interface.
OEM & Private Label
We operate production hubs in China and Vietnam to provide supply chain redundancy and logistics optimization.
- Wire Customization: Custom pigtail lengths, wire colors, and 1.5mm/2.0mm/2.5mm socket options.
- Branding: Private-label printing on the non-woven cloth or the PET release liners.
- Packaging: Bulk clinical packs or individual 2-pad/4-pad retail pouches.
Certifications
Compliance: FDA 510(k), CE (MDR), UKCA.
Quality Systems: ISO 13485 and MDSAP audited.
Batch QC: Every batch undergoes a 100% continuity test and a lot-based pull-strength verification to ensure junction integrity.
FAQ
Q: Why use pre-wired pads instead of pin-insertion pads?
A: Pre-wired pads eliminate the risk of the lead wire pin slipping out of the pad during treatment. The permanent bond provides a more reliable electrical path and reduces the "leverage" effect that can peel the pad off the skin when the lead wire moves.
Q: Does the integrated wire affect the recycling or disposal?
A: These are designed as single-patient, multi-use consumables. The integrated wire uses standard medical PVC and copper, which should be disposed of according to standard clinical waste protocols for electronic-related consumables.
CTA
B2B procurement teams can request technical drawings and junction pull-test data for verification.
👉 [Request Samples for Junction Integrity Testing]
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Specifications
| Component | Technical Specification | Engineering Detail |
| Connector | 2.0mm Female Socket | Universal clinical standard |
| Wire Length | 10cm - 15cm (Standard) | Customizable PVC/TPU jacket |
| Impedance | < 45 Ohms | Total path from socket to gel |
| Pull Strength | > 40N | Wire-to-pad junction durability |
| Backing | Spunlace Non-woven | High-porosity medical fabric |
