Water resistant connector for noninvasive patient monitor

• US 10,637,181 B2
• Filed: 08/13/2018
• Issued: 04/28/2020
• Est. Priority Date: 08/15/2017
• Status: Active Grant

• Current Assignee: Masimo Corporation
• Original Assignee: Masimo Corporation
• Inventors: Al-Ali, Ammar, Forrest, Kevin, Abdul-Hafiz, Yassir Kamel
• Primary Examiner(s): Abrams, Neil
• Application Number:
  US16/102,456
• Publication Number:
  US 20190058280A1
• Time in Patent Office: 624 Days
• Field of Search: 439 761, 439604, 439281, 439282
• CPC Class Codes: A61B 2562/227 Sensors with electrical connectors
• CPC Class Codes: A61B 2562/247 Hygienic covers, i.e. for covering the sensor or apparatus during use
• CPC Class Codes: A61B 5/303 Patient cord assembly, e.g. cable harness
• CPC Class Codes: H01R 13/5202 Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 13/5219 Sealing means between coupling parts, e.g. interfacial seal
• CPC Class Codes: H01R 13/5224 for medical use
• CPC Class Codes: H01R 2201/12 for medicine and surgery

Abstract

Systems and methods are provided for water resistant connectors. A male connector includes a rib or a draft angle that creates a seal when engaged with a female connector. A male connector includes an overmold that includes or is made of a thermoplastic elastomer. Male or female connectors include molds that include or are made of a thermoplastic polymer, such as polypropylene. A female connector includes spring contacts that fit within individual pockets of the female connector.

Claims

1. A water-resistant medical device cable assembly configured to interface one or more noninvasive physiological sensors with a patient monitor, the cable assembly comprising:

a cable configured to connect to a physiological sensor, the cable comprising a plurality of conductors configured to obtain physiological signals from a patient; and

a male connector attached to the cable and configured to couple the cable with a patient monitor so as to convey the physiological signals from the physiological sensor to the patient monitor, the male connector comprising;

a rigid frame;

a circuit board disposed within the rigid frame and connected with the conductors in the cable;

a plurality of electrical contacts disposed on the circuit board, the plurality of electrical contacts operative to contact second electrical contacts in a corresponding female connector of the patient monitor when the male connector is inserted into the female connector;

a pliable overmold configured to cover a portion of the rigid frame and a portion of the circuit board but not the plurality of electrical contacts, wherein the plurality of electrical contacts are open to air when the male connector is disconnected from the female connector of the patient monitor; and

a raised rib disposed on the pliable overmold, the raised rib circumferentially surrounding the pliable overmold and configured to create a seal with the female connector when the male connector is inserted into the female connector, such that when the male connector is inserted into the female connector, the plurality electrical contacts of the male connector are no longer exposed to air, such that a water-resistant seal is created between the male connector and the female connector.

2. The water-resistant medical device cable assembly of claim 1, wherein the raised rib is part of the pliable overmold.

3. The water-resistant medical device cable assembly of claim 1, wherein the raised rib comprises a thermoplastic elastomer.

4. The water-resistant medical device cable assembly of claim 1, wherein the pliable overmold comprises a thermoplastic elastomer.

5. The water-resistant medical device cable assembly of claim 1, wherein a width of the raised rib is between approximately 0.762 millimeters and approximately 0.8128 millimeters.

6. The water-resistant medical device cable assembly of claim 1, wherein a height of the raised rib is between approximately 0.254 millimeters and approximately 0.508 millimeters.

7. The water-resistant medical device cable assembly of claim 1, wherein the pliable overmold further comprises a first portion and a second portion, the first portion located between the plurality of electrical contacts and the second portion, the second portion adjacent to the cable, wherein a first width of a proximal end of the first portion is narrower than a second width of a distal end of the first portion.

8. The water-resistant medical device cable assembly of claim 7, wherein the first width is between approximately 2.03 centimeters and approximately 2.06 centimeters, and the second width is between approximately 2.06 centimeters and approximately 2.08 centimeters.

9. The water-resistant medical device cable assembly of claim 1, further comprising:

an inner covering configured to cover a portion of the cable, the inner covering is adjacent to the rigid frame and is located between the rigid frame and a distal end of the cable, wherein the inner covering is further configured to seal a distal end of the rigid frame and a proximal end of the cable, and wherein the pliable overmold is further configured to cover the inner covering.

10. The water-resistant medical device cable assembly of claim 9, wherein the inner covering further comprises a thermoplastic polymer.

11. The water-resistant medical device cable assembly of claim 10, wherein the thermoplastic polymer comprises polypropylene.

12. A water-resistant medical device cable assembly configured to interface one or more noninvasive physiological sensors with a patient monitor, the cable assembly comprising:

a cable configured to connect to a physiological sensor, the cable comprising a plurality of conductors configured to obtain physiological signals from a patient; and

a male connector attached to the cable and configured to couple the cable with a patient monitor so as to convey the physiological signals from the physiological sensor to the patient monitor, the male connector comprising;

a rigid frame;

a circuit board disposed within the rigid frame and connected with the conductors in the cable;

a plurality of electrical contacts disposed on the circuit board, the plurality of electrical contacts operative to contact second electrical contacts in a corresponding female connector of the patient monitor when the male connector is inserted into the female connector;

a pliable overmold configured to cover a portion of the rigid frame and a portion of the circuit board but not the plurality of electrical contacts; and

a raised rib disposed on the pliable overmold, the raised rib circumferentially surrounding the pliable overmold,

wherein the plurality of electrical contacts are open to air when the male connector is disconnected from the female connector of the patient monitor, and

wherein the pliable overmold is further configured to create a seal with the female connector when the male connector is inserted into the female connector, such that when the male connector is inserted into the female connector, the plurality electrical contacts of the male connector are no longer exposed to air, such that a water-resistant seal is created between the male connector and the female connector.

13. The water-resistant medical device cable assembly of claim 12, wherein a width of the raised rib is between approximately 0.762 millimeters and approximately 0.8128 millimeters.

14. The water-resistant medical device cable assembly of claim 12, wherein a height of the raised rib is between approximately 0.254 millimeters and approximately 0.508 millimeters.

15. The water-resistant medical device cable assembly of claim 12, wherein the pliable overmold comprises a thermoplastic elastomer.

16. The water-resistant medical device cable assembly of claim 12, wherein the pliable overmold further comprises a first portion and a second portion, the first portion located between the plurality of electrical contacts and the second portion, the second portion adjacent to the cable, wherein a first width of a proximal end of the first portion is narrower than a second width of a distal end of the first portion.

17. The water-resistant medical device cable assembly of claim 16, wherein the first width is between approximately 2.03 centimeters and approximately 2.06 centimeters, and the second width is between approximately 2.06 centimeters and approximately 2.08 centimeters.

18. The water-resistant medical device cable assembly of claim 12, further comprising:

an inner covering configured to cover a portion of the cable, the inner covering is adjacent to the rigid frame and is located between the rigid frame and a distal end of the cable, wherein the inner covering is further configured to seal a distal end of the rigid frame and a proximal end of the cable, and wherein the pliable overmold is further configured to cover the inner covering.

19. The water-resistant medical device cable assembly of claim 18, wherein the inner covering further comprises a thermoplastic polymer.