Body worn physiological sensor device having a disposable electrode module

• US 8,965,492 B2
• Filed: 05/02/2014
• Issued: 02/24/2015
• Est. Priority Date: 11/01/2006
• Status: Active Grant

• Current Assignee: Welch Allyn Incorporated
• Original Assignee: Welch Allyn Incorporated
• Inventors: Baker, Steven D., McAdams, Eric T., Welch, James P.
• Primary Examiner(s): Lavert, Nicole F
• Application Number:
  US14/268,666
• Publication Number:
  US 20140243694A1
• Time in Patent Office: 298 Days
• Field of Search: 600/372, 600508-509
• US Class Current: 600/509
• CPC Class Codes: A61B 2560/0209 adapted for power saving
• CPC Class Codes: A61B 2560/0214 of power generation or supply
• CPC Class Codes: A61B 2560/0412 Low-profile patch shaped housings
• CPC Class Codes: A61B 2562/0214 Capacitive electrodes
• CPC Class Codes: A61B 2562/182 Electrical shielding, e.g. using a Faraday cage
• CPC Class Codes: A61B 5/0006 ECG or EEG signals
• CPC Class Codes: A61B 5/024 Detecting, measuring or recording pulse rate or heart rate A61B5/0205, A61B5/021 take precedence
• CPC Class Codes: A61B 5/02438 with portable devices, e.g. worn by the patient
• CPC Class Codes: A61B 5/0816 Measuring devices for examining respiratory frequency measuring frequency of electric signals G01R23/00
• CPC Class Codes: A61B 5/14542 for measuring blood gases A61B5/14551 takes precedence
• CPC Class Codes: A61B 5/14552 Details of sensors specially adapted therefor
• CPC Class Codes: A61B 5/259 using conductive adhesive means, e.g. gels
• CPC Class Codes: A61B 5/274 using snap or button fasteners
• CPC Class Codes: A61B 5/282 Holders for multiple electrodes for introduction into the body A61B5/287
• CPC Class Codes: A61B 5/301 providing electrical separation, e.g. by using isolating transformers or optocouplers
• CPC Class Codes: A61B 5/303 Patient cord assembly, e.g. cable harness
• CPC Class Codes: A61B 5/316 Modalities, i.e. specific diagnostic methods
• CPC Class Codes: A61B 5/68335 including release sheets or liners
• CPC Class Codes: A61B 5/7232 involving compression of the physiological signal, e.g. to extend the signal recording period
• CPC Class Codes: A61B 5/742 using visual displays A61B5/339 takes precedence
• CPC Class Codes: A61B 5/746 : Alarms related to a physiological condition, e.g. details of setting alarm thresholds or avoiding false alarms alarms per se G08B

Abstract

A body-worn patient monitoring device includes providing a substrate that supports one or more electrical connections to a patient'"'"'s body. The method further includes determining a print pattern and thickness of a first material having a first resistivity to be printed on the substrate, determining a print pattern and thickness of a second material having a second resistivity to be printed on the substrate, printing the first material onto the substrate, and printing the second material onto the substrate wherein at least part of the second the material overlays the first material.

Claims

1. A body-worn patient monitoring device comprising:

a flexible printed circuit layer made from an insulating material and defining a substrate;

at least one electrode disposed onto a surface of the substrate;

at least one connection pad;

at least one electrical trace extending between the at least one connection pad and a conductive surface of the least one electrode, the at least one electrical trace being made at least in part from a resistive material; and

an insulating layer covering the flexible printed circuit layer.

2. The body-worn patient monitoring device of claim 1, wherein the at least one electrical trace includes a filleted portion formed at the electrode.

3. The body-worn patient monitoring device of claim 2, including at least one battery mounted on the flexible circuit layer.

4. The body-worn patient monitoring device of claim 3, including a retention member to provide mechanical support for the at least one battery and to enable an electrical connection with the conductive surface of the at least one electrode.

5. The body worn patient monitoring device of claim 1, further comprising an ECG monitor having a programmed microprocessor and a plurality of electrical connections to measure patient heartbeat signals.

6. The body-worn patient monitoring device of claim 1, wherein the at least one electrode includes an electrode gel and a conductive surface, thereby creating a half cell.

7. A body-worn patient monitoring device comprising:

a disposable electrode portion; and

a reusable communication module, the disposable electrode portion comprising a flexible printed circuit layer made from an insulating material and defining a substrate, at least two electrodes being disposed onto a surface of the substrate and electrical traces defined between the at least two electrodes and a connection pad,

wherein the reusable communication and computation module comprises a housing containing a processor and a wireless communication unit, and in which the reusable communication module is releasably attached to the disposable electrode portion by at least one latching clip.

8. The body-worn patient monitoring device of claim 7, wherein the electrodes are integrated into the flexible printed circuit layer of the disposable portion of the device.

9. The body-worn patient monitoring device of claim 7, wherein the electrodes are snap fitted to the flexible printed circuit layer.

10. The body-worn patient monitoring device of claim 9, wherein the snap is disposed at the end of an extension.

11. The body-worn patient monitoring device of claim 7, wherein the electrical traces are screened onto the flexible printed circuit layer.

12. The body-worn patient monitoring device of claim 11, including an insulating layer applied onto the electrical traces.

13. The body-worn patient monitoring device of claim 12, wherein the insulating layer is screen printed onto the electrical traces of the flexible printed circuit layer.

14. The body-worn patient monitoring device of claim 7, wherein each electrode includes an electrode gel and a conductive surface defining a half cell.