REPROCESSING OF A PHYSIOLOGICAL SENSOR

• US 20110214280A1
• Filed: 03/07/2011
• Published: 09/08/2011
• Est. Priority Date: 03/08/2010
• Status: Active Grant

• Current Assignee: Masimo Corporation
• Original Assignee: Masimo Corporation
• Inventors: Kiani, Massi Joe E.
• Granted Patent: US 8,584,345 B2
• Time in Patent Office: Days
• US Class Current: 29/592.1
• CPC Class Codes: A61B 2560/0276 Determining malfunction
• CPC Class Codes: A61B 5/0205 Simultaneously evaluating both cardiovascular conditions and different types of body conditions, e.g. heart and respiratory condition
• CPC Class Codes: A61B 5/14552 Details of sensors specially adapted therefor
• CPC Class Codes: A61B 5/1495 Calibrating or testing of in-vivo probes
• CPC Class Codes: B23P 6/00 Restoring or reconditioning objects straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49004 including measuring or testing of device or component part
• CPC Class Codes: Y10T 29/49007 Indicating transducer
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

Because reprocessing or refurbishing of physiological sensors reuses large portions of an existing sensor, the material costs for refurbishing sensors is significantly lower than the material costs for making an entirely new sensor. Typically, existing reprocessors replace only the adhesive portion of an adhesive physiological sensor and reuse the sensing components. However, re-using the sensing components can reduce the reliability of the refurbished sensor and/or reduce the number of sensors eligible for refurbishing due to out-of-specification sensor components. It is therefore desirable to provide a process for refurbishing physiological sensors that replaces the sensing components of the sensor. While sensing components are replaced, generally, sensor cable and/or patient monitor attachments are retained, resulting in cost savings over producing new sensors.

Claims

1. A method for reprocessing a previously used physiological sensor, the sensor comprising a plurality of sensor components, the method comprising:

determining one or more sensor components of a sensor to be replaced;

detaching the one or more sensor components to be replaced from the sensor including at least one sensing component;

attaching one or more new sensor components to the sensor to form an assembled sensor, the one or more new sensor components including a replacement for the at least one sensing component, the assembled sensor comprising the one or more new sensor components and at least one original sensor component;

determining whether sensing performance of the assembled sensor meets specified sensor performance criteria; and

sterilizing the sensor in preparation for use.

2. The method of claim 1, wherein determining one or more sensor components comprises:

testing performance of the one or more sensor components to determine if the performance is within specification for the sensor component.

3. The method of claim 1, wherein the at least one sensing component comprises at least one of an emitter and a detector.

4. The method of claim 1, wherein the sensor is a pulse oximetry sensor.

5. The method of claim 1, further comprising cleaning the sensor in order to remove visible contaminants.

6. The method of claim 1, wherein the at least one original sensor component comprises a cable.

7. A method for reprocessing a previously used physiological sensor assembly, the sensor assembly comprising a sensor portion, the method comprising:

detaching the sensor portion from the sensor assembly, the sensor portion comprising sensing components of the sensor assembly, wherein the sensor portion is operatively coupled to the sensor assembly via an attachment mechanism;

attaching a replacement sensor portion to the sensor assembly to form an assembled sensor assembly, the replacement sensor portion comprising new sensing components; and

testing sensing performance of the assembled sensor assembly.

8. The method of claim 7, wherein the new sensing components comprise one or more emitters and a detector.

9. The method of claim 8, wherein the sensor portion further comprises an electrical connector.

10. The method of claim 7, wherein the assembled sensor assembly comprises at least some portion of the used sensor assembly.

11. The method of claim 10, wherein attaching a replacement sensor portion comprises operatively connecting the replacement sensor portion to the sensor assembly to form a mechanical and electrical connection.

12. The method of claim 7, wherein the sensor assembly measures SpO2.

13. The method of claim 7, wherein the attachment mechanism is configured to allow detachment and reattachment of the sensor component.

14. The method of claim 7, further comprising sterilizing the sensor assembly in preparation for use.

15. A method for reprocessing a previously used physiological sensor, the sensor comprising a used sensor assembly and a cable assembly, the method comprising:

detaching the used sensor assembly including sensing components from the cable assembly, the cable assembly including a cable portion and a monitor connector;

cleaning at least the cable assembly in order to remove visible contaminants;

attaching a new sensor assembly comprising new sensing components to the cable assembly to form an assembled sensor; and

testing sensing performance of the assembled sensor.

16. The method of claim 15, wherein detaching the used sensor assembly comprises cutting the used sensor assembly from the cable assembly and attaching the new sensor assembly comprises splicing the new sensor assembly to the cable assembly.

17. The method of claim 15, wherein detaching the used sensor assembly comprises detaching the used sensor assembly from a connector of the cable assembly.

18. The method of claim 15, further comprising sterilizing the assembled sensor in preparation for use.