Reflective non-invasive sensor

• US 8,712,494 B1
• Filed: 05/02/2011
• Issued: 04/29/2014
• Est. Priority Date: 05/03/2010
• Status: Active Grant

• Current Assignee: Masimo Corporation
• Sponsoring Entity: Masimo Corporation
• Inventors: MacNeish, William Jack III, Schmidt, John, Mason, Eugene E., Eichele, Chad Cory
• Primary Examiner(s): Winakur, Eric
• Assistant Examiner(s): Fardanesh, Marjan
• Time in USPTO: 1093 Days
• Field of Search: 600309-344
• US Class Current: 600/344
• CPC Class Codes: A61B 5/1455 : using optical sensors, e.g. spectral photometrical oximeters
• CPC Class Codes: A61B 5/14551 : for measuring blood gases
• CPC Class Codes: A61B 5/6826 : Finger

Abstract

Aspects of the present disclosure include a sensor emitter including a reflective cavity for re-directing light to a tissue site. By reflecting light towards the tissue site, the amount of light reaching the tissue site is increased. The increased light can improve parameter measurements taken by a non-invasive physiological sensor by producing a stronger and/or cleaner signal. In an embodiment, the reflective cavity is formed on one or more lead frames of the sensor emitter, wherein the lead frames are capable of transmitting electrical signals to emitting elements coupled to the lead frames. Aspects of the present disclosure also include a sensor component configured to protect connection points of wires to conductive leads on the sensor components by inhibiting flex or bending at the connection points. Connection points can protrude along edges of the sensor component. Aspects of the present disclosure also include techniques and processes for producing low-profile sensors.

Claims

1. A non-invasive physiological sensor configured to be used in a patient monitoring system, the physiological sensor configured to monitor a physiological parameter at a tissue site, the physiological sensor comprising:

at least one light emitting element configured to transmit light at a plurality of wavelengths, wherein a portion of the light is transmitted towards the tissue site and a portion of the light is transmitted in a different direction from the tissue site;

at least one reflective frame positioned at least partially on one side of the light emitting element and electrically connected to the light emitting element, the at least one reflective frame being electrically conductive and comprising a cavity, the cavity configured to redirect at least a portion of the light transmitted in a different direction from the tissue site to the tissue site; and

an encapsulate surrounding at least a portion of the reflective frame and the at least one light emitting element, the encapsulate configured to allow at least some of the light transmitted by the at least one light emitting element to pass through, the encapsulate comprising a top, a bottom and at least one edge.

2. The non-invasive physiological sensor of claim 1, wherein the at least one reflective frame comprises a first frame and a second frame, the first frame separate from the second frame.

3. The non-invasive physiological sensor of claim 2, wherein the first and the second frame are electrically connected through one or more wires, the first frame and second frame configured into an inverse parallel circuit.

4. The non-invasive physiological sensor of claim 2, wherein the first and the second frame are configured into an inverse parallel circuit.

5. The non-invasive physiological sensor of claim 2, wherein the first frame comprises a first conductive lead and the second frame comprises a second conductive lead.

6. The non-invasive physiological sensor of claim 2, wherein the cavity is formed on portions of the first frame and second frame.

7. The non-invasive physiological sensor of claim 1, wherein the encapsulate comprises an at least semi-transparent material.

8. The non-invasive physiological sensor of claim 1, wherein the at least one light emitting element comprises a first light emitting element configured to transmit red wavelength light and a second light emitting element configured to transmit infrared wavelength light.

9. The non-invasive physiological sensor of claim 1, wherein the at least one reflective frame comprises a conductive lead protruding from the edge of the encapsulate, the conductive lead configured to accept an electrical connection with a conductive material.

10. The non-invasive physiological sensor of claim 1, wherein the at least one reflective frame provide operating current to the light emitting element.

11. A non-invasive physiological sensor configured to be used in a patient monitoring system, the physiological sensor comprising:

an at least semi-rigid encapsulate surrounding at least a portion of a sensor component, the encapsulate having a top, a bottom, and at least one edge;

an at least semi-flexible substrate layer, the encapsulate coupled to the substrate layer, wherein the encapsulate inhibits flexing of at least a portion of the substrate layer around the encapsulate; and

a conductive lead, the conductive lead protruding from the at least one edge of the encapsulate, the conductive lead located along the flex-inhibited portion of the substrate layer, the conductive lead electrically connected to the sensor component within the encapsulate and including a reflective cavity configured to redirect at least a portion of light transmitted by the sensor component toward a tissue site,

wherein the encapsulate is configured to inhibit flexing of a wire coupled to the conductive lead.

12. The non-invasive physiological sensor of claim 11, wherein the conductive lead extends along the at least one edge of the encapsulate, the conductive lead configured to inhibit flexing of the substrate layer.

13. The non-invasive physiological sensor of claim 11, wherein the encapsulate comprises a disk shape.

14. The non-invasive physiological sensor of claim 11, wherein the encapsulate comprises a cuboid shape.

15. The non-invasive physiological sensor of claim 11, wherein the substrate layer comprises one or more tape layers.

16. The non-invasive physiological sensor of claim 11, wherein the sensor component comprises at least one emitter.

17. The non-invasive physiological sensor of claim 11, wherein the sensor component comprises an emitter.

18. The non-invasive physiological sensor of claim 11, wherein the semi-flexible substrate comprises at least one wire for coupling with the conductive lead.

19. The non-invasive physiological sensor of claim 11, wherein the conductive lead provides operating current to the sensor component.