Molded pulse oximeter sensor

Claim 2

A molded pulse oximeter sensor apparatus, comprising: a preform first section; oximeter sensing components, comprising a light source, a detector, and connecting wires; and an overmolded second section bonded to said preform first section when said overmolded second section is formed by overmolding such that said sensing components are enclosed between said first and second sections, and wherein the bond between said first and second sections at their peripheries comprises a molded mechanical bond of overlapping elements.

Claim 3

The apparatus of claim 1 wherein said bond between said first and second sections is resistant to penetration by liquid.

Claim 4

The apparatus of claim 1 wherein said bond between said first and second sections is formed during overmolding of said second section.

Claim 5

A molded pulse oximeter sensor apparatus, comprising: a preform first section having an interior surface and an exterior surface; oximeter sensing components, comprising a light source, a detector, and connecting wires; and an overmolded second section bonded to said preform first section such that said sensing components are enclosed between said first and second sections, and wherein the bond between said first and second sections at their peripheries comprises a molded mechanical bond of overlapping elements; and wherein said preform first section has raised protuberances extending from its interior surface along its periphery, said protuberances having a shape such that said protuberances are wider at a point more distant from the interior surface of said preform first section than at a point closer to the interior surface of said preform first section, and wherein said protuberances are surrounded by and molded into said overmolded second section to form said molded mechanical bond of overlapping elements.

Claim 6

A molded pulse oximeter sensor apparatus, comprising: a preform first section having an interior surface and an exterior surface; oximeter sensing components, comprising a light source, a detector, and connecting wires; and an overmolded second section bonded to said preform first section such that said sensing components are enclosed between said first and second sections, and wherein the bond between said first and second sections at their peripheries comprises a molded mechanical bond of overlapping elements; and wherein said preform first section has raised protuberances extending from its interior surface along its periphery, said protuberances having a shape such that said protuberances are wider at a point more distant from the interior surface of said preform first section than at a point closer to the interior surface of said preform first section, and wherein said protuberances are surrounded by and molded into said overmolded second section to form said molded mechanical bond of overlapping elements.

Claim 7

The apparatus of claim 4 wherein said protuberances have a dovetail shape having a wide portion and a narrower portion such that the narrowest portion of the dovetail shape is closer than its widest portion to the interior surface of said preform first section from which said protuberances extend.

Claim 8

A molded pulse oximeter sensor apparatus, comprising: a premolded preform first section having an exterior and an interior surface, and having raised protuberances extending from the interior surface of said preform first section along its periphery, said protuberances having a shape such that said protuberances are wider at a point more distant from the interior surface of said preform first section than at a point closer to the surface of said preform first section; window compartments sealably secured into said preform first section such that said window compartments extend through said preform first section to its exterior surface; oximeter sensing components, comprising a light source, a detector, and connecting wires, said components secured along the interior surface of said preform first section in a fixed configuration, with said light source and said detector each secured into said window compartments; and an overmolded second section bonded to said preform first section such that said sensing components are enclosed between said first and second sections and wherein said protuberances extending from the interior surface of said preform first section are surrounded by and molded into said overmolded second section.

Claim 9

A molded pulse oximeter sensor apparatus, comprising: a premolded preform first section having an exterior and an interior surface, and having raised protuberances extending from the interior surface of said preform first section along its periphery, said protuberances having a shape such that said protuberances are wider at a point more distant from the interior surface of said preform first section than at a point closer to the surface of said preform first section; window compartments sealably secured into said preform first section such that said window compartments extend through said preform first section to its exterior surface; oximeter sensing components, comprising a light source, a detector, and connecting wires, said components secured along the interior surface of said preform first section in a fixed configuration, with said light source and said detector each secured into said window compartments; and an overmolded second section bonded to said preform first section such that said sensing components are enclosed between said first and second sections and wherein said protuberances extending from the interior surface of said preform first section are surrounded by and molded into said overmolded second section.

Claim 10

The apparatus of claim 6 wherein said protuberances extend from the interior surface of said preformed first section.

Claim 11

The apparatus of claim 6 wherein said protuberances have a dovetail shape such that the narrowest portion of the dovetail shape is closer than its widest portion to the surface of said preform first section from which said protuberances extend.

Claim 12

The apparatus of claim 6 wherein said protuberances extend perpendicularly from the surface of said preform first section.

Claim 13

The apparatus of claim 6 wherein said preform first section contains guides along its interior surface for positioning and securing said connecting wires.

Claim 14

The apparatus of claim 6 wherein the bond between said overmolded second section and said preform first section is formed as the overmolded second section is formed during overmolding.

Claim 15

The apparatus of claim 11 wherein said bond formed between said overmolded second section and said preform first section is resistant to penetration by liquid.

Claim 16

The apparatus of claim 6 wherein said window compartments interlock into said preform first section and form a liquid resistant seal with said preform first section.

Claim 17

The apparatus of claim 6 wherein said oximeter sensing components are contained in a one-piece flex circuit.