US5839439A — Oximeter sensor with rigid inner housing and plia…

Claim 1

Independent Claim 74 words

An oximeter sensor comprising: a housing formed from a material with a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector, said overmolding material having a second rigidity which is less than said first rigidity.

Claim 2

Dependent Claim 74 words

An oximeter sensor comprising: a housing formed from a material with a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector, said overmolding material having a second rigidity which is less than said first rigidity.

Claim 3

Dependent Claim 22 words

The sensor of claim 1 wherein said housing is made of plastic and said overmolded material is an injection molded thermoplastic elastomer.

Claim 4

Dependent Claim 12 words

The sensor of claim 2 wherein said housing is made of polypropylene.

Claim 5

Dependent Claim 49 words

The sensor of claim 1 wherein said housing has at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend in the Z direction.

Claim 6

Dependent Claim 12 words

The sensor of claim 1 wherein said sensor is a fetal sensor.

Claim 7

Dependent Claim 14 words

The sensor of claim 1 wherein said oximeter sensor is a pulse oximeter sensor.

Claim 8

Dependent Claim 20 words

The sensor of claim 1 wherein said light source and light detector are mounted at positions effective for reflectance oximetry.

Claim 9

Dependent Claim 43 words

The sensor of claim 1 further comprising: a plurality of contact electrodes; a plurality of lines connecting said contact electrodes to said oximeter components; and an opening in said housing having a size to provide a press-fit for one of said contact electrodes.

Claim 10

Dependent Claim 28 words

The sensor of claim 8 wherein said opening is flared at an exposed surface, exposing a portion of a side of each of said plurality of contact electrodes.

Claim 11

Dependent Claim 39 words

The sensor of claim 1 further comprising: a plurality of wires extending along said housing and connected to said oximeter components; and a plurality of castellations extending from said housing and bent over said wires to secure said wires.

Claim 12

Dependent Claim 34 words

The sensor of claim 1 further comprising: a feature in said housing for mating with a feature in a mold to hold said housing in place against a longitudinal stream of injected overmolding material.

Claim 13

Dependent Claim 18 words

The sensor of claim 11 wherein said feature in said housing comprises a curved groove in said housing.

Claim 14

Dependent Claim 35 words

The sensor of claim 1 further comprising at least one feature of said housing for registering said housing in a mold to insure proper lateral alignment of said housing during an injection of overmolding material.

Claim 15

Dependent Claim 22 words

The sensor of claim 13 wherein said feature of said housing is a pair of wings extending from sides of said housing.

Claim 16

Dependent Claim 35 words

The sensor of claim 1 further comprising at least one stand-off feature of said housing on the same side as said openings to insure coverage of said side of said housing by said overmolding material.

Claim 17

Dependent Claim 49 words

The sensor of claim 1 further comprising: a cable attached to a first end of said housing; and a rigid cap mounted to said housing adjacent said first end of said housing, said cap having a recess shaped to receive the end of a stylet inserted through said cable.

Claim 18

Dependent Claim 28 words

The sensor of claim 1 further comprising: a rectangular block having a void for receiving said detector; and an enclosure in said housing for receiving said detector block.

Claim 19

Dependent Claim 32 words

The sensor of claim 17 further comprising a Faraday shield shaped to fold around said rectangular block, and held in place by a press fit between said rectangular block and said enclosure.

Claim 20

Dependent Claim 43 words

The sensor of claim 1 further comprising: a pair of enclosures in said housing for receiving said light source and said light detector, respectively; and a pair of lids for covering said enclosures to seal said emitter and detector from said overmolding material.

Claim 21

Dependent Claim 43 words

The sensor of claim 1 further comprising: a plurality of wires connected to said oximeter components; at least one braided wire shield covering at least one of said wires; and a thin heat shrink tubing around an end of said braided wire shield.

Claim 22

Dependent Claim 26 words

The oximeter sensor of claim 1 further comprising an injection molded clear plastic covering said openings, and wherein said housing and said overmold material are opaque.

Claim 23

Dependent Claim 98 words

An oximeter sensor comprising: a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; and an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing.

Claim 24

Dependent Claim 98 words

An oximeter sensor comprising: a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; and an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing.

Claim 25

Dependent Claim 24 words

The oximeter sensor of claim 22 further comprising a plurality of alignment features for aligning said housing in a mold during an overmolding process.

Claim 26

Dependent Claim 41 words

The sensor of claim 23 wherein one of said alignment features comprises: a curved groove in said housing for mating with a corresponding groove in a mold to hold said housing in place against a longitudinal stream of injected overmolding material.

Claim 27

Dependent Claim 35 words

The sensor of claim 23 wherein one of said alignment features comprises a pair of wings extending from sides of said housing for registering said housing in a mold during an injection of overmolding material.

Claim 28

Dependent Claim 41 words

The sensor of claim 23 wherein one of said alignment features comprises at least one stand-off protrusion extending from said housing on the same side as said openings to insure coverage of said side of said housing by said overmolding material.

Claim 29

Dependent Claim 25 words

The sensor of claim 22, wherein said sensor is a fetal pulse oximeter sensor with said light source and light detector positioned for reflectance oximetry.

Claim 30

Dependent Claim 20 words

The sensor of claim 22 further comprising means for securing said oximeter components in proper alignment during an overmolding process.

Claim 31

Dependent Claim 44 words

The sensor of claim 28 further comprising: a plurality of wires extending along said housing and connected to said oximeter components; and said means for securing including a plurality of castellations extending from said housing and bent over said wires to secure said wires.

Claim 32

Dependent Claim 32 words

The sensor of claim 28 wherein said means for securing comprises: a rectangular block having a void for receiving said detector; and an enclosure in said housing for receiving said detector block.

Claim 33

Dependent Claim 32 words

The sensor of claim 30 further comprising a Faraday shield shaped to fold around said rectangular block, and held in place by a press fit between said rectangular block and said enclosure.

Claim 34

Dependent Claim 48 words

The sensor of claim 28 wherein said means for securing comprises: a pair of enclosures in said first housing for receiving said light source and said light detector, respectively; and a pair of lids for covering said enclosures to seal said emitter and detector from said overmolding material.

Claim 35

Dependent Claim 22 words

The sensor of claim 22 wherein said housing is made of plastic and said overmolded material is an injection molded thermoplastic elastomer.

Claim 36

Dependent Claim 12 words

The sensor of claim 33 wherein said housing is made of polypropylene.

Claim 37

Dependent Claim 43 words

The sensor of claim 22 further comprising: a plurality of contact electrodes; a plurality of lines connecting said contact electrodes to said oximeter components, and an opening in said housing having a size to provide a press-fit for one of said contact electrodes.

Claim 38

Dependent Claim 28 words

The sensor of claim 35 wherein said opening is flared at an exposed surface, exposing a portion of a side of each of said plurality of contact electrodes.

Claim 39

Dependent Claim 49 words

The sensor of claim 22 further comprising: a cable attached to a first end of said housing; and a rigid cap mounted to said housing adjacent said first end of said housing, said cap having a recess shaped to receive the end of a stylet inserted through said cable.

Claim 40

Dependent Claim 43 words

The sensor of claim 22 further comprising: a plurality of wires connected to said oximeter components; at least one braided wire shield covering at least one of said wires; and a thin heat shrink tubing around an end of said braided wire shield.

Claim 41

Dependent Claim 26 words

The oximeter sensor of claim 22 further comprising an injection molded clear plastic covering said openings, and wherein said housing and said overmold material are opaque.

Claim 42

Dependent Claim 147 words

A fetal pulse oximeter reflectance sensor comprising: a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing; a plurality of alignment features for aligning said housing in a mold during an overmolding process; means for securing said oximeter components in proper alignment during an overmolding process; and wherein said housing is made of plastic and said overmolded material is an injection molded thermoplastic elastomer.

Claim 43

Dependent Claim 147 words

A fetal pulse oximeter reflectance sensor comprising: a housing having at least portions which are thinner in a Z direction than a dimension of said housing in an X direction, such that the combination of said first housing and said overmolded material is flexible to bend away from a Y axis, said housing being made of a material of a first rigidity; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering portions of said housing, said overmolded material being of a lesser rigidity than said housing; a plurality of alignment features for aligning said housing in a mold during an overmolding process; means for securing said oximeter components in proper alignment during an overmolding process; and wherein said housing is made of plastic and said overmolded material is an injection molded thermoplastic elastomer.

Claim 44

Dependent Claim 103 words

An oximeter sensor comprising: a housing; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector; and said components being located adjacent a neutral axis of the combination of said housing and said overmolded material; wherein said housing is made of a material of a first rigidity and said overmolded material is made of a material of a second rigidity which is less than said first rigidity.

Claim 45

Dependent Claim 103 words

An oximeter sensor comprising: a housing; a plurality of oximeter components mounted in said housing, including at least a light source and a light detector; an overmolded material covering most of said housing on multiple sides of said housing, leaving openings to expose at least said light source and said light detector; and said components being located adjacent a neutral axis of the combination of said housing and said overmolded material; wherein said housing is made of a material of a first rigidity and said overmolded material is made of a material of a second rigidity which is less than said first rigidity.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-11-23	2002-05-25	2002-11-24	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-11-23	2006-05-25	2006-11-24	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-11-23	2010-05-25	2010-11-24	$7700.00	Window Closed / Lapsed

Oximeter sensor with rigid inner housing and pliable overmold

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