Electrical connector apparatus and methods

• US 20060110962A1
• Filed: 11/22/2004
• Published: 05/25/2006
• Est. Priority Date: 11/22/2004
• Status: Active Grant

• Current Assignee: FUJIFILM SonoSite, Inc. (Fujifilm Holdings Corporation)
• Original Assignee: Cardiodynamics International Corporation (Fujifilm Holdings Corporation)
• Inventors: Hepp, Dennis G., Powell, Francis, Jancsek, John
• Granted Patent: US 7,214,107 B2
• Time in Patent Office: Days
• US Class Current: 439/169
• CPC Class Codes: H01R 11/22 End pieces terminating in a spring clip
• CPC Class Codes: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/6275 Latching arms not integral with the housing H01R13/6276, H01R13/6277, H01R13/6278 take precedence
• CPC Class Codes: H01R 2201/12 for medicine and surgery

Abstract

Electrical connector apparatus optimized for biomedical applications. In one embodiment, the connector apparatus comprises a low-cost simplified device having a unitary conductor element adapted to interface with an electrode terminal such as used in impedance cardiography (ICG) or electrocardiograhy (ECG). The unitary conductor is shaped so as to provide a high degree of electrical performance and signal stability, and also be highly reliable. The simplified structure of the connector (including the use of the unitary conductor element) allows it to be manufactured for very low cost, so as to be disposable if desired. Methods of manufacturing and operating the connector are also disclosed.

Claims

1. A low-cost simplified electrical connector adapted for use with biomedical patch-type electrodes having at least one button-shaped terminal, comprising:

a unitary substantially metallic spring element having;

first and second substantially opposing bias portions;

first and second connecting portions coupled to respective ones of said first and second opposing portions;

a variable geometry portion coupled to both said connecting portions and comprising a variable size aperture and a fulcrum portion, said aperture being configured to receive one of said button-shaped terminals when properly expanded; and

a housing element having first and second movable actuation elements, said movable actuation communicating with respective ones of said opposing portions;

wherein upon biasing at least one of said first and second movable actuation elements, said aperture expands in size; and

wherein upon unbiasing said at least one movable actuation elements, said aperture contracts in size due at least in part to spring force generated by said fulcrum portion.

2. A method of manufacturing a connector, comprising:

providing a conductor element;

providing a housing;

providing at least one actuator adapted to move within said housing;

providing at least one electrical conductor;

deforming said conductor element into a shape having at least one bias portion and at least one connection portion having an aperture;

disposing said deformed conductor element and said at least one actuator at least partly within said housing; and

terminating said deformed conductor element to said at least one electrical conductor.

3. The method of claim 2, wherein said act of deforming comprises deforming said conductor element into a shape having first and second substantially opposed bias portions, said two substantially bias portions being disposed in a plane substantially parallel to but offset from said and at least one connection portion.

4. The method of claim 3, wherein said act of disposing said at least one actuator comprises disposing first and second actuators proximate to said conductor element so as to permit actuation of respective ones of said first and second bias portions.

5. The method of claim 2, further comprising testing said connector after assembly, said testing comprising biasing said first and second actuators inward in order to verify that said substantially opposed bias portions are engaged by said actuators.

6. The method of claim 5, wherein said testing further comprises mating said connector to a terminal and performing electrical continuity testing thereof.

7. A method of operating a biomedical connector, comprising:

disposing a biomedical electrode in a desired location on a subject;

coupling said connector to said electrode;

passing at least one electrical signal through said electrode and connector; and

removing said connector and said electrode as a unit from said location.

8. The method of claim 7, wherein said act of disposing comprises disposing a patch electrode having one or more terminals on exterior of said subject, and said act of coupling comprises mating said connector onto one of said terminals by applying a substantially normal force to said connector.

9. The method of claim 7, wherein said act of disposing comprises disposing a patch electrode having one or more terminals on exterior of said subject, and said act of coupling comprises actuating said connector so as to expand an aperture adapted to receive one of said terminals.

10. The method of claim 7, wherein said act of actuating comprises:

depressing at least one actuator element on said connector, said act of depressing causing an aperture of said connector to expand; and

releasing said at least one actuator, said releasing causing said aperture to contract around said electrode.

11. A method of operating a biomedical connector having at least two substantially opposing bias portions and at least one fulcrum portion, to a terminal, the method comprising:

biasing said at least two bias portions toward each other so as to expand an aperture proximate to said at least one fulcrum portion, said aperture being shaped to receive said terminal;

inserting said terminal at least partly into said aperture; and

unbiasing said bias portions, said unbiasing allowing said fulcrum portion to contract said aperture around said terminal.

12. The method of claim 11, wherein said terminal comprises a terminal adapted for cardiography measurements, said method further comprising passing a cardiographic signal through said terminal and connector after said act of unbiasing.

13. A method of operating a biomedical electrical connector having a bias element comprising first and second substantially opposing portions adapted to move relative to one another, first and second coupling portions coupled to respective ones of said first and second opposing portions, and a connection portion coupled to said coupling portions and comprising a variable size aperture, the method comprising:

disposing an electrode apparatus having one or more shaped terminals proximate to a living subject;

disposing said connector proximate to at least one of said terminals;

biasing said connector onto said at least one shaped terminal, said act of biasing comprising;

expanding said aperture at least temporarily to accommodate a first portion of said shaped terminal;

subsequently contracting said aperture to accommodate a second portion of said shaped terminal;

wherein after said acts of at least temporarily expanding and subsequently contracting have been completed, said connection portion and said at least one shaped terminal cooperate to maintain said connector in a substantially constant orientation with respect to one another.

14. The method of claim 13, wherein said maintaining in a substantially constant orientation comprises allowing said connector to rotate within a plane disposed normal to an axis of symmetry of said shaped terminal, yet not deflect substantially out of said plane.

15. An electrical connector, comprising:

a bias element having;

a movable portion and a stationary portion;

first and second connecting portions coupled to respective ones of said movable and stationary portions;

a variable geometry portion coupled to both said connecting portions and comprising a variable size aperture, said aperture being configured to receive a terminal; and

a housing element having a housing bias portion, said movable bias portion communicating with said movable portion of said spring element;

wherein upon biasing said housing bias portion, said aperture expands in size.

16. The connector of claim 15, wherein said movable and stationary portions are disposed substantially within a first plane, and said variable geometry portion is disposed substantially within a second plane, said first and second planes being substantially parallel.

17. The connector of claim 15, wherein said movable and stationary portions are disposed substantially within a first plane, and said variable geometry portion is disposed substantially within a second plane, said first plane being disposed above said second plane relative to the direction of insertion of said terminal into said aperture.

18. The connector of claim 15, wherein said bias element is formed from a single piece of electrically conductive metal.

19. The connector of claim 15, wherein said terminal comprises a terminal selected from the group consisting of:

(i) an ECG terminal and (ii) an ICG terminal.

20. An electrical connector, comprising:

a unitary spring element having;

first and second substantially opposing portions;

first and second connecting portions coupled to respective ones of said first and second opposing portions;

a variable geometry portion coupled to both said connecting portions and comprising a variable size aperture, said aperture being configured to receive a terminal when properly expanded; and

a housing element having first and second movable bias portions, said movable bias portions communicating with respective ones of said opposing portions;

wherein upon biasing at least one of said first and second bias portions, said aperture expands in size.

21. A variable geometry conductor element for forming an electrical connection with a terminal, comprising:

first and second substantially opposing portions;

first and second connecting portions coupled to respective ones of said first and second opposing portions; and

a variable geometry portion coupled to both said connecting portions and comprising a variable size aperture, said aperture being configured to receive a terminal when properly expanded;

wherein upon biasing at least one of said first and second substantially opposing portions, said aperture expands in size.

22. The contact element of claim 21, wherein said first and second opposing portions are disposed substantially within a first plane, and said variable geometry portion is disposed substantially within a second plane, said first and second planes being substantially parallel.

23. The contact element of claim 21, wherein said first and second opposing portions are disposed substantially within a first plane, and said variable geometry portion is disposed substantially within a second plane, said first plane being disposed above said second plane relative to the direction of insertion of said terminal into said aperture.

24. The contact element of claim 23, wherein said contact element is formed from a single piece of metal.

25. The contact element of claim 21, wherein said contact element is formed from a single piece of metal.

26. The contact element of claim 21, wherein said terminal comprises a terminal selected from the group consisting of:

(i) an ECG terminal and (ii) an ICG terminal.

27. The contact element of claim 26, wherein said terminal comprises a substantially button-shaped terminal

28. A low-force electrical connector, comprising:

a bias element having;

first and second substantially opposing portions adapted to move relative to one another;

first and second connecting portions coupled to respective ones of said first and second opposing portions;

an aperture portion coupled to both said connecting portions and comprising a variable size aperture, said aperture being configured to receive a terminal; and

a housing element substantially containing said bias element, said housing having an opening formed therein substantially coincident with said aperture;

wherein upon biasing said connector onto said terminal, said aperture at least temporarily expands in size to receive said terminal in a frictional engagement.

29. The connector of claim 28, wherein said terminal comprises a substantially rounded head region, and said aperture portion is configured to cooperate with said head region to cause said expansion of said aperture during said act of biasing.

30. The connector of 29, wherein said configuration of said aperture portion comprises providing said aperture portion of said bias element with a substantially rounded profile, said rounded profile cooperating with said substantially rounded head to minimize friction during said expansion.

31. The connector of 28, wherein said bias element is adapted such that said act of biasing said connector onto said terminal causes said first and second substantially opposing portions to become closer to one another.

32. The connector of 28, wherein said act of biasing said connector onto said terminal is accomplished without any inward external bias force being applied to either of said substantially opposing portions.