Bi-stable medical sensor and technique for using the same

• US 9,216,528 B2
• Filed: 08/15/2013
• Issued: 12/22/2015
• Est. Priority Date: 08/08/2005
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Raridan, William, Matlock, George L., Coakley, Joseph, Eghbal, Darius
• Primary Examiner(s): Hong, John C
• Application Number:
  US13/968,196
• Publication Number:
  US 20130330465A1
• Time in Patent Office: 859 Days
• Field of Search: 294/60, 295/271, 295/272, 297/09, 427/2.12, 427/2.1, 427/2.11, 264/272.11, 264/328.1, 600/344, 600/310, 600/323
• US Class Current: 1/1
• CPC Class Codes: A61B 2562/02 Details of sensors specially adapted for in-vivo measurements
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 2562/187 Strain relief means
• CPC Class Codes: A61B 5/14532 for measuring glucose, e.g. by tissue impedance measurement
• CPC Class Codes: A61B 5/14552 Details of sensors specially adapted therefor
• CPC Class Codes: A61B 5/4869 Determining body composition
• CPC Class Codes: A61B 5/6826 Finger
• CPC Class Codes: A61B 5/6838 Clamps or clips
• CPC Class Codes: A61B 5/6843 Monitoring or controlling sensor contact pressure
• CPC Class Codes: B29C 45/14819 the inserts being completely encapsulated
• CPC Class Codes: Y10T 29/49888 Subsequently coating
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49982 Coating
• CPC Class Codes: Y10T 29/53039 with control means energized in response to activator stimulated by condition sensor

Abstract

A bi-stable sensor is provided that includes a frame upon which electrical and optical components may be disposed and a coating, such as an overmold coating, provided about the frame. A resistance-providing component is provided integral with or external to the coated bi-stable sensor such that the bi-stable sensor has two mechanically stable configurations that may be transitioned between by overcoming the resistance provided by the resistance-providing component and/or the by the coating. In one embodiment, the resistance-providing component comprises an elastic band provided about a hinge of the frame, either within or external to the coating. In one embodiment, the sensor may be placed on a patient'"'"'s finger, toe, ear, and so forth to obtain pulse oximetry or other physiological measurements.

Claims

1. A method of manufacturing a bi-stable sensor body, comprising:

positioning a skeletal frame within a mold; and

coating the skeletal frame with a coating material to form a sensor body having at least two stable configurations.

2. The method of claim 1, wherein the skeletal frame is substantially open when coated.

3. The method of claim 1, wherein the skeletal frame is substantially closed when coated.

4. The method of claim 1, comprising attaching a resistance-providing component about a hinge on the skeletal frame prior to coating the skeletal frame.

5. The method of claim 1, comprising attaching a resistance-providing component about a coated hinge of the sensor body.

6. The method of claim 1, comprising bending the skeletal frame from a relatively open configuration to a relatively closed configuration prior to coating.

7. The method of claim 1, comprising bending the skeletal frame from a relatively open configuration to a relatively closed configuration subsequent to coating.

8. The method of claim 1, wherein coating the skeletal frame comprises injecting an unset coating material into the mold.

9. A method of manufacturing a sensor body, comprising:

disposing a frame within a mold, wherein the frame has at least two mechanically stable configurations such that a resistance must be overcome to transition between the mechanically stable configurations; and

injecting or blowing a molding material into the mold such that the molding material coats the frame to form an overmolded sensor body.

10. The method of claim 9, comprising attaching a resistance component to the frame prior to coating.

11. The method of claim 10, wherein the resistance component comprises a hinge.

12. The method of claim 10, wherein the resistance component has a thicker coating than a coating on the frame.

13. The method of claim 9, wherein the molding material provides additional resistance after being applied to the frame.

14. The method of claim 9, comprising chemically bonding the molding material to the frame.

15. The method of claim 9, comprising positioning an emitter and a detector on the frame prior to coating.

16. The method of claim 9, comprising molding the frame in an substantially open configuration.

17. The method of claim 9, comprising bending the frame to form a substantially closed configuration after molding.

18. The method of claim 9, wherein the frame is constructed of a single piece.

19. The method of claim 9, wherein the frame is assembled from two or more separable pieces.