REPROCESSING OF A PHYSIOLOGICAL SENSOR

• US 20170245790A1
• Filed: 05/11/2017
• Published: 08/31/2017
• Est. Priority Date: 03/08/2010
• Status: Active Grant

• Current Assignee: Masimo Corporation
• Original Assignee: Masimo Corporation
• Inventors: Al-Ali, Ammar, Abdul-Hafiz, Yassir, Kiani, Massi Joe E.
• Granted Patent: US 10,729,362 B2
• Time in Patent Office: Days
• 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. (canceled)

2. A reprocessed physiological sensor comprising:

a first electrical contact;

a first physiological sensor component coupled to the first electrical contact, wherein;

the first electrical contact is configured to communicate signals to and/or from the first physiological sensor component, and

the first physiological sensor component is not a replacement physiological sensor component;

a second electrical contact;

a second physiological sensor component coupled to the second electrical contact, wherein;

the second electrical contact is configured to communicate signals to and/or from the second physiological sensor component,

the second physiological sensor component is a replacement physiological sensor component for a previously used physiological sensor component, and

the second physiological sensor component is configured to operate within

a specification of the reprocessed physiological sensor; and

a used cable assembly that has been detached from a used physiological sensor and newly attached to the first and second electrical contacts.

3. The reprocessed physiological sensor of claim 2, wherein the second physiological sensor component was newly coupled to the second electrical contact when the second physiological sensor component replaced the previously used physiological sensor component that was uncoupled from the second electrical contact.

4. The reprocessed physiological sensor of claim 2, wherein the used cable assembly comprises a first end including a monitor connector and a second end from which the used physiological sensor was detached.

5. The reprocessed physiological sensor of claim 4, wherein attachment of the used cable assembly to the first and second electrical contacts comprises splicing.

6. The reprocessed physiological sensor of claim 5 further comprising:

a cable cover covering at least a portion of the used cable assembly where the used cable assembly is newly attached to the first and second electrical contacts, wherein the cable cover covers exposed wires and/or strengthens a mechanical connection between the used cable assembly and the first and second electrical contacts.

7. The reprocessed physiological sensor of claim 6, wherein a performance of the previously used physiological sensor component has been determined to not satisfy a threshold.

8. The reprocessed physiological sensor of claim 8, wherein a performance of the second physiological sensor component has been determined to satisfy the threshold.

9. The reprocessed physiological sensor of claim 8, wherein the second physiological sensor component includes at least one of an emitter or a detector.

10. The reprocessed physiological sensor of claim 9, wherein the reprocessed physiological sensor is a pulse oximetry sensor.

11. The reprocessed physiological sensor of claim 10, wherein the used cable assembly has been sterilized.

12. A reprocessed physiological sensor comprising:

a first physiological sensor component that is not a replacement physiological sensor component;

a second physiological sensor component that is a replacement physiological sensor component for a previously used physiological sensor component; and

a used cable assembly that has been detached from a used physiological sensor and newly attached to a portion of the reprocessed physiological sensor so as to communicate signals to and/or from the first and second physiological sensor components.

13. The reprocessed physiological sensor of claim 12, wherein:

a performance of the previously used physiological sensor component has been determined to not satisfy a threshold, and

a performance of the second physiological sensor component has been determined to satisfy the threshold.

14. The reprocessed physiological sensor of claim 13, wherein attachment of the used cable assembly to the first and second electrical contacts comprises splicing.

15. The reprocessed physiological sensor of claim 14, wherein:

the reprocessed physiological sensor is a pulse oximetry sensor, and

the second physiological sensor component includes at least one of an emitter or a detector.

16. The reprocessed physiological sensor of claim 15 further comprising:

a cable cover covering at least a portion of the used cable assembly where the used cable assembly is newly attached to the first and second electrical contacts, wherein the cable cover covers exposed wires and/or strengthens a mechanical connection between the used cable assembly and the first and second electrical contacts.

17. A method for reprocessing a previously used physiological sensor, the sensor including a plurality of physiological sensor components and a cable component, the method comprising:

determining a physiological sensor component of the plurality of physiological sensor components is to be replaced, wherein the physiological sensor component to be replaced does not comprise all of the plurality of physiological sensor components or the entire physiological sensor;

detaching the physiological sensor component to be replaced from the cable component;

obtaining a replacement physiological sensor component operates within a specification of the physiological sensor; and

attaching the replacement physiological sensor component to the cable component to form a reprocessed physiological sensor.

18. The method of claim 17, wherein attaching the replacement physiological sensor component to the cable component comprises splicing.

19. The method of claim 18 further comprising:

providing a cable cover covering at least a portion of the cable component where the cable component is attached to the replacement physiological sensor component, wherein the cable cover covers exposed wires and/or strengthens a mechanical connection between the cable component and the replacement physiological sensor component.

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

determining a physiological sensor component of the plurality of physiological sensor components is to be replaced, wherein the physiological sensor component to be replaced does not comprise all of the plurality of physiological sensor components or the entire physiological sensor;

detaching the physiological sensor component to be replaced from a first electrical contact of the physiological sensor;

obtaining a replacement physiological sensor component that operates within a specification of the physiological sensor, wherein a second electrical contact extends from the replacement physiological sensor component; and

attaching the second electrical contact extending from the replacement physiological sensor component to the first electrical contact to form a reprocessed physiological sensor.

21. The method of claim 20 further comprising:

attaching a used cable assembly that has been detached from a used physiological sensor to a portion of the previously used physiological sensor so as to communicate signals to and/or from the replacement physiological sensor component.

22. The method of claim 21, wherein attaching the used cable assembly to the portion of the previously used physiological sensor comprises splicing.

23. The method of claim 22 further comprising:

providing a cable cover covering at least a portion of the used cable assembly where the used cable assembly is attached to the re used physiological sensor, wherein the cable cover covers exposed wires and/or strengthens a mechanical connection between the used cable assembly and the used physiological sensor.