PULSE OXIMETRY DEVICES AND SYSTEMS AND METHODS OF MAKING THE SAME

• US 20160220158A1
• Filed: 04/07/2016
• Published: 08/04/2016
• Est. Priority Date: 11/14/2013
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Karp, Jason Harris, Kapusta, Christopher James, Gillespie, Paul Jeffrey, Keimel, Christopher Fred, Ashe, Jeffrey Michael, Sabatini, James Enrico
• Granted Patent: US 9,814,419 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61B 2562/0238 Optical sensor arrangements for performing transmission measurements on body tissue
• CPC Class Codes: A61B 2562/046 in a matrix array
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 2562/164 the sensor is mounted in or on a conformable substrate or carrier
• CPC Class Codes: A61B 2562/222 Electrical cables or leads therefor, e.g. coaxial cables or ribbon cables
• CPC Class Codes: A61B 2562/227 Sensors with electrical connectors
• CPC Class Codes: A61B 5/0002 Remote monitoring of patients using telemetry, e.g. transmission of vital signals via a communication network A61B5/07 takes precedence; transmission systems for measured values G08C; transmission H04B; transmission of digital information H04L; wireless communication networks H04W
• CPC Class Codes: A61B 5/029 Measuring or recording blood output from the heart, e.g. minute volume A61B8/065 takes precedence
• CPC Class Codes: A61B 5/0816 Measuring devices for examining respiratory frequency measuring frequency of electric signals G01R23/00
• CPC Class Codes: A61B 5/14552 Details of sensors specially adapted therefor
• CPC Class Codes: A61B 5/6826 Finger
• CPC Class Codes: A61B 5/742 using visual displays A61B5/339 takes precedence
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 2224/92247 the second connecting process involving a wire connector
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
• CPC Class Codes: H05K 1/189 : characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/10106 : Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10151 : Sensor
• CPC Class Codes: Y10T 29/49139 : by inserting component lead or terminal into base aperture

Abstract

An array of emitters includes a device substrate having first and second sides, a thermally and electrically conductive layer disposed on the first side of the device substrate, and an interconnect layer disposed on a first plurality of portions of the second side of the device substrate. The array of the emitters further includes a plurality of emitters disposed in a second plurality of portions of the device substrate, where the plurality of emitters is electrically coupled to the thermally and electrically conductive layer. Also, the array of the emitters includes a plurality of wirebond contacts configured to electrically couple a portion of the interconnect layer to a corresponding emitter of the plurality of emitters, and a plurality of encapsulations, where one or more encapsulations of the plurality of encapsulations are disposed on at least a portion of a corresponding wirebond contact of the plurality of wirebond contacts.

Claims

1. A pulse oximetry system, comprising:

a pulse oximetry device comprising;

a device substrate having a first side and a second side;

a thermally and electrically conductive layer disposed on the first side of the device substrate;

an interconnect layer disposed on the second side of the device substrate;

a plurality of arrays of emitters disposed on the second side of the device substrate, wherein the plurality of arrays of the emitters is electrically coupled to the thermally and electrically conductive layer;

a plurality of detectors disposed on the second side of the device substrate and configured to detect emission signals from one or more emitters of the plurality of arrays of the emitters;

a plurality of wirebond contacts configured to electrically couple a portion of the interconnect layer to a corresponding emitter of the plurality of arrays of the emitters; and

a processor configured to process the detected emission signals.

2. The pulse oximetry system of claim 1, wherein one or more emitters of the plurality of arrays of the emitters are disposed orthogonally opposite to one or more detectors of the plurality of detectors.

3. The pulse oximetry system of claim 1, wherein one or more emitters of the plurality of arrays of the emitters are disposed opposite to one or more detectors of the plurality of detectors, and wherein the one or more emitters of the plurality of arrays of the emitters are disposed in parallel to the one or more detectors of the plurality of detectors.

4. The pulse oximetry system of claim 1, wherein one or more emitters of the plurality of arrays of the emitters are disposed opposite to one or more detectors of the plurality of detectors, and wherein the one or more emitters of the plurality of arrays of the emitters are disposed in parallel and at an offset to the one or more detectors of the plurality of detectors.

5. The pulse oximetry system of claim 1, wherein the pulse oximetry device is configured to operate in a transmission mode, a reflection mode, or both.

6. The pulse oximetry system of claim 1, wherein the pulse oximetry device is configured to be disposed on one side of a body part.

7. The pulse oximetry system of claim 1, wherein the pulse oximetry device is configured to be disposed on two sides of a body part.

8. The pulse oximetry system of claim 1, wherein the pulse oximetry device is configured to conform to a shape of a body part.

9. The pulse oximetry system of claim 1, wherein the pulse oximetry device comprises an external connector.

10. The pulse oximetry system of claim 1, wherein the pulse oximetry device comprises a first plurality of electrical traces configured to provide an electrical connection to each emitter of the plurality of arrays of the emitters, and a second plurality of electrical traces configured to provide an electrical connection to each detector of the plurality of detectors.

11. The pulse oximetry system of claim 10, wherein the first plurality of electrical traces and the second plurality of electrical traces exit the device substrate from the same side of the device substrate.

12. The pulse oximetry system of claim 10, wherein the first plurality of electrical traces and the second plurality of electrical traces are coupled to an electrical connector.

13. The pulse oximetry system of claim 10, further comprising a cable assembly, wherein the cable assembly is configured to operatively couple the pulse oximetry device to an external device.

14. The pulse oximetry system of claim 13, wherein the cable assembly is operatively coupled to a display member configured to display the processed data from the processor.

15. The pulse oximetry system of claim 13, wherein the cable assembly comprises a receptor configured to operatively couple a first end of the cable assembly to an external connector.

16. The pulse oximetry system of claim 1, wherein the device substrate is configured to be disposed around at least a portion of a body part.

17. The pulse oximetry system of claim 1, wherein the pulse oximetry device and one or more of a display member and the processor are wirelessly coupled to one another.

18. The pulse oximetry system of claim 1, wherein the pulse oximetry device comprises a plurality of encapsulations, wherein one or more encapsulations of the plurality of encapsulations are configured to encapsulate one or more emitters of the plurality of arrays of the emitters.

19. The pulse oximetry system of claim 1, further comprising an encapsulation corresponding to each array of the plurality of arrays of the emitters.

20. A method of making a pulse oximetry device, comprising:

providing a device substrate having a first side and a second side, wherein a thermally and electrically conductive layer is disposed on at least a portion of the first side of the device substrate;

disposing an interconnect layer on a first plurality of portions on the second side of the device substrate;

forming a plurality of cavities in a second plurality of portions on the second side of the device substrate;

disposing one or more emitters in corresponding cavities of the plurality of cavities to form a plurality of arrays of emitters on the second side of the device substrate;

providing a plurality of wirebond contacts such that each wirebond contact electrically couples at least a portion of the interconnect layer to a corresponding emitter of the plurality of arrays of the emitters; and

disposing a plurality of detectors on the second side of the device substrate.

21. The method of claim 20, wherein the step of forming the plurality of cavities comprises forming through cavities in the device substrate.

22. The method of claim 20, wherein the step of disposing the plurality of arrays of the emitters in corresponding cavities of the plurality of cavities comprises:

disposing an electrically conductive coupler in one or more cavities of the plurality of cavities; and

disposing the one or more emitters of the plurality of arrays of the emitters in each of the plurality of cavities on the electrically conductive coupler.

23. The method of claim 22, further comprising applying a determined pressure, a determined temperature to the one or more emitters of the plurality of arrays of the emitters.

24. The method of claim 20, further comprising providing a plurality of protective covers on the interconnect layer.

25. The method of claim 20, further comprising providing a plurality of encapsulations, wherein each encapsulation of the plurality of encapsulations is configured to cover at least a portion of a wirebond contact of the plurality of wirebond contacts.

26. The method of claim 20, wherein the step of providing the plurality of encapsulations comprises:

disposing a determined amount of epoxy corresponding to each encapsulation of the plurality of encapsulations; and

curing the plurality of encapsulations.

27. The method of claim 20, further comprising providing external connectors for interfacing the pulse oximetry device with another device or circuitry.