Oximeter sensor with rigid inner housing and pliable overmold
First Claim
1. An oximeter sensor comprising:
- a housing formed from a material with a first rigidity;
a plurality of oximeter components mounted in said housing, including at least a light source and a light detector;
an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector, said overmolding material having a second rigidity which is less than said first rigidity.
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Accused Products
Abstract
An oximeter sensor formed with a housing made of a relatively rigid material into which the oximeter electrical components can be mounted is provided. An overmolded material, of lesser rigidity, is injection-molded over the housing to complete the sensor. In one embodiment the housing is made of plastic, such as polypropylene, and the overmolded material is an injection-molded thermal plastic elastomer, such as Santoprene™ (polypropylene with 1 micron size particles of rubber). The housing preferably contains thin portions connecting thicker portions which support the electrical and optical components. These thin portions provide natural bending portions in the final oximeter sensor. By having the thin portions near or at the central, neutral axis of the sensor, flexibility is optimized in the longitudinal direction, while the housing provides stiffness laterally.
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Citations
41 Claims
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1. An oximeter sensor comprising:
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a housing formed from a material with a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector, said overmolding material having a second rigidity which is less than said first rigidity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. An oximeter sensor comprising:
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a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; and an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A fetal pulse oximeter reflectance sensor comprising:
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a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing; a plurality of alignment features for aligning said housing in a mold during an overmolding process; means for securing said oximeter components in proper alignment during an overmolding process; and wherein said housing is made of plastic and said overmolded material is an injection molded thermoplastic elastomer.
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41. An oximeter sensor comprising:
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a housing; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector; and said components being located adjacent a neutral axis of the combination of said housing and said overmolded material; wherein said housing is made of a material of a first rigidity and said overmolded material is made of a material of a second rigidity which is less than said first rigidity.
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Specification