Injection molded, heat-sealed housing and half-etched lead frame for oximeter sensor

Claim 2

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a leadframe for operatively connecting at least one of (a) an emitter means for irradiating the patient's bloodstream and (b) a detector means for providing a signal in response to a radiation portion passing through the bloodstream to an oximeter processing and display unit, the leadframe having a first portion having a first thickness and a second portion having a second thickness with the first thickness being greater than the second thickness.

Claim 3

The sensing device of claim 1, wherein the first portion of the leadframe contacts at least one of the detector means and the emitter means.

Claim 4

The sensing device of claim 1, wherein the first thickness ranges from about 10 to about 20 mils.

Claim 5

The sensing device of claim 1, wherein the detector means and emitter means are at opposite ends of the leadframe and the second portion of the leadframe is located between the detector means and emitter means.

Claim 6

The sensing device of claim 1, wherein the second thickness ranges from about 5 to about 10 mils.

Claim 7

The sensing device of claim 1, wherein the leadframe comprises a first set of traces between the emitter means and detector means and a second set of traces extending from the emitter means to wire means for connecting the sensing device to an oximeter processing and display unit, the first portion including the second set of traces and the second portion including the first set of traces.

Claim 8

The sensing device of claim 1, further comprising a housing for containing the at least one of the emitter means and detector means, the housing including a substantially transparent lens adjacent to the at least one of the emitter means and detector means and a housing body enclosing the at least one of the emitter means and detector means, wherein the housing body and lens are composed of the same base thermoplastic material and have substantially the same degree of elasticity; wherein the lead frame includes a plurality of spaced-apart traces and the housing body includes a plurality of rib members, with one or more rib members being received between adjacent traces; and wherein the housing has upper and lower portions and the upper and lower portion each has a lip portion projecting outwardly from the corresponding one of the upper and lower portions, the lip portion of the upper portion being sealed to a lip portion on the lower portion to protect at least one of the emitter means and detector means from fluids in the terrestrial environment.

Claim 9

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing for containing at least one of (a) an emitter means to irradiating the patient's bloodstream and (b) a detector means for providing a signal in response to a radiation portion passing through the bloodstream, the housing including a substantially transparent lens adjacent to the at least one of the emitter means and detector means and a housing body enclosing the at least one of the emitter means and detector means, wherein the housing body and the lens are composed of the same base thermoplastic material that at least one of the melting point, yield tensile strength, ultimate tensile strength, modulus of elasticity, coefficient of thermal expansion, and durometer of the lens is within about 10% of a corresponding at least one of the melting point, yield tensile strength, ultimate tensile strength, modulus of elasticity, coefficient of thermal expansion, and durometer of the housing body, and wherein the lens is molded to the housing to provide a sealed and smooth transition therebetween.

Claim 10

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing for containing at least one of (a) an emitter means to irradiating the patient's bloodstream and (b) a detector means for providing a signal in response to a radiation portion passing through the bloodstream, the housing including a substantially transparent lens adjacent to the at least one of the emitter means and detector means and a housing body enclosing the at least one of the emitter means and detector means, wherein the housing body and the lens are composed of the same base thermoplastic material that at least one of the melting point, yield tensile strength, ultimate tensile strength, modulus of elasticity, coefficient of thermal expansion, and durometer of the lens is within about 10% of a corresponding at least one of the melting point, yield tensile strength, ultimate tensile strength, modulus of elasticity, coefficient of thermal expansion, and durometer of the housing body, and wherein the lens is molded to the housing to provide a sealed and smooth transition therebetween.

Claim 11

The sensing device of claim 8, wherein the lens is substantially free of color bodies.

Claim 12

The sensing device of claim 8, wherein the housing body contains color bodies.

Claim 13

The sensing device of claim 8, wherein the housing body contains from about 2 to about 30% by weight color bodies.

Claim 14

The sensing device of claim 8, wherein thermoplastic resin forming the lens has substantially the same melting point as the thermoplastic resin forming the housing body.

Claim 15

The sensing device of claim 8, wherein the difference between the melting point of the thermoplastic resin forming the lens and melting point as the thermoplastic resin forming the housing body is no more than about 25° F.

Claim 16

The sensing device of claim 8, wherein the melting point of the thermoplastic resin forming the lens is at least about 75% and no more than about 125% of the melting point of the thermoplastic resin forming the housing body.

Claim 17

The sensing device of claim 8, wherein the housing body and lens have substantially the same degree of elasticity and has upper and lower portions with the upper and lower portion each having a lip portion projecting outwardly from the corresponding one of the upper and lower portions, the lip portion of the upper portion being sealed to a lip portion on the lower portion to protect at least one of the emitter means and detector means from fluids in the terrestrial environment, and further comprising a lead frame for operably connecting at least one of the emitter means and detector means to an oximeter processing and display unit, the lead frame having a first portion having a first thickness and a second portion having a second thickness with the first thickness being greater than the second thickness and wherein the lead frame includes a plurality of spaced-apart traces and the housing body includes a plurality of rib members, with one or more rib members being received between adjacent traces.

Claim 18

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing for containing at least one of (a) an emitter mean for irradiating the patient's bloodstream and (b) a detector means for providing a signal in response to a radiation portion passing through the bloodstream, the housing including a substantially transparent lens adjacent to the at least one of the emitter means and detector means and a housing body enclosing the at least one of the emitter means and detector means, and wherein the lens is molded to the housing to provide a sealed and smooth transition therebetween.

Claim 19

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing for containing at least one of (a) an emitter mean for irradiating the patient's bloodstream and (b) a detector means for providing a signal in response to a radiation portion passing through the bloodstream, the housing including a substantially transparent lens adjacent to the at least one of the emitter means and detector means and a housing body enclosing the at least one of the emitter means and detector means, and wherein the lens is molded to the housing to provide a sealed and smooth transition therebetween.

Claim 20

The sensing device of claim 16, wherein the lens is substantially free of color bodies.

Claim 21

The sensing device of claim 16, wherein lens and housing body are composed of the same base thermoplastic material.

Claim 22

The sensing device of claim 16, wherein the housing body contains from about 2 to about 30% by weight color bodies.

Claim 23

The sensing device of claim 16, wherein thermoplastic resin forming the lens has substantially the same melting point as the thermoplastic resin forming the housing body.

Claim 24

The sensing device of claim 16, wherein the difference between the melting point of the thermoplastic resin forming the lens and melting point as the thermoplastic resin forming the housing body is no more than about 25% .

Claim 25

The sensing device of claim 16, wherein the melting point of the thermoplastic resin forming the lens is at least about 75% and no more than about 125% of the melting point of the thermoplastic resin forming the housing body.

Claim 26

The sensing device of claim 16, wherein the housing body and lens are composed of the same base thermoplastic material and has upper and lower portions with the upper and lower portion each having a lip portion projecting outwardly from the corresponding one of the upper and lower portions, the lip portion of the upper portion being sealed to a lip portion on the lower portion to protect at least one of the emitter means and detector means from fluids in the terrestrial environment, and further comprising a lead frame for operatively connecting at least one of the emitter means and detector means to an oximeter processing and display unit, the lead frame having a first portion having a first thickness and a second portion having a second thickness with the first thickness being greater than the second thickness and wherein the lead frame includes a plurality of spaced-apart traces and the housing body includes a plurality of rib members, with one or more rib members being received between adjacent traces.

Claim 27

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing enclosing (a) at least one of an emitter means for irradiating the patient's bloodstream and a detector means for providing a signal in response to a radiation portion passing through the bloodstream and (b) a leadframe for operatively connecting the at least one of the emitter means and detector means with an oximeter processing and display unit, wherein the leadframe includes a plurality of bare, spaced-apart, conductive traces and the housing body includes a plurality of rib members, with one or more rib members being positioned between adjacent traces to align and electrically isolate the bare traces.

Claim 28

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing enclosing (a) at least one of an emitter means for irradiating the patient's bloodstream and a detector means for providing a signal in response to a radiation portion passing through the bloodstream and (b) a leadframe for operatively connecting the at least one of the emitter means and detector means with an oximeter processing and display unit, wherein the leadframe includes a plurality of bare, spaced-apart, conductive traces and the housing body includes a plurality of rib members, with one or more rib members being positioned between adjacent traces to align and electrically isolate the bare traces.

Claim 29

The sensing device of claim 24, wherein the thickness of the rib members is at least 25% of the distance between adjacent traces.

Claim 30

The sensing device of claim 24, wherein a first set of traces is located between the detector means and the emitter means and a second set of traces is located between the at least one of the detector means and emitter means and wire means for connecting the sensing device to the oximeter processing and display unit and a first set of rib members engages the first set of traces and a second set of rib members engages the second set of traces.

Claim 31

The sensing device of claim 24, wherein a first portion of a first rib member received between adjacent traces has a greater width than an adjacent portion of the first rib member, thereby defining a nub.

Claim 32

The sensing device of claim 27, wherein a second rib member is adjacent to the first rib member, the second rib member comprising a second portion having a width greater than an adjacent portion thereof and wherein the distance between the first portion of the first rib member and the second portion of the second rib member is less than the width of a trace received therebetween.

Claim 33

The sensing device of claim 24, wherein the lead frame has a first portion having a first thickness and a second portion having a second thickness with the first thickness being greater than the second thickness and the housing includes a housing body and lens, with the housing body and lens being composed of the same base thermoplastic material and having the same degree of elasticity and has upper and lower portions with the upper and lower portion each having a lip portion projecting outwardly from the corresponding one of the upper and lower portions, the lip portion of the upper portion being sealed to a lip portion on the lower portion to protect at least one of the emitter means and detector means from fluids in the terrestrial environment.

Claim 34

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing enclosing at least one of an emitter means for irradiating the patient's bloodstream and a detector means for providing a signal in response to a radiation portion passing through the bloodstream, wherein the housing has adjoined upper and lower portions, and wherein the upper portion and lower portion are heat-sealed together about their respective peripherals to form a lip portion projecting outwardly from the upper and lower portions, the lip portion protecting emitter means and detector means from fluids in the terrestrial environment.

Claim 35

In a sensing device for measuring the oxygen content of a patient's bloodstream, the sensing device comprising: a housing enclosing at least one of an emitter means for irradiating the patient's bloodstream and a detector means for providing a signal in response to a radiation portion passing through the bloodstream, wherein the housing has adjoined upper and lower portions, and wherein the upper portion and lower portion are heat-sealed together about their respective peripherals to form a lip portion projecting outwardly from the upper and lower portions, the lip portion protecting emitter means and detector means from fluids in the terrestrial environment.

Claim 36

The sensing device of claim 30, wherein at least one of the lip portions has a tongue or a groove to engage a groove or a tongue, respectively, on the other lip portion.

Claim 37

The sensing device of claim 30, wherein the upper and lower portions of the housing form a housing body and include a lens adjacent to at least one of the emitter means and detector means and wherein the housing body and lens are composed of the same base thermoplastic material and have the same degree of elasticity and further comprising a lead frame for operatively connecting at least one of the emitter means and detector means to an oximeter processing and display unit, the lead frame having a first portion having a first thickness and a second portion having a second thickness with the first being greater than the second thickness and the lead frame including a plurality of spaced-apart traces and the housing body including a plurality of rib members, with one or more rib members being received between adjacent traces.

Claim 40

The method of claim 33, wherein the applying step comprises: applying a masking material to a second portion of the leadframe body other than the selected portion; and applying the etchant to the selected portion and the second portion.

Claim 41

The method of claim 33, wherein the applying step comprises: applying the etchant only to the selected portion of the leadframe body.

Claim 42

The method of claim 33, wherein the applying step comprises: etching the selected portion of the leadframe body for a first time period; and etching another portion of the leadframe for a second time period, wherein the first time period exceeds the second time period.

Claim 43

The method of claim 33, wherein the cutting step comprises cutting the leadframe from a conductive sheet using a cutting die having substantially the same size and shape as a cavity in an oximeter sensor housing for receiving a leadframe and further comprising: forming a thermoplastic resin; molding a first portion of the thermoplastic resin to form a light transparent lens for at least one of a detector and emitter; mixing a second portion of the thermoplastic resin with a color body to form a substantially light opaque, thermoplastic resin; molding the substantially light opaque, thermoplastic resin to form a housing body having upper and lower portions for enclosing a lead frame, the upper portion of the housing having a first lip projecting outwardly from the upper portion for engaging a second lip on the lower portion with the second lip projecting outwardly from the lower portion; engaging the first lip with the second lip; and heating the upper and lower portions to above the melting point of the first and second lips to seal the upper portion and the lower portion.

Claim 46

The method of claim 38, wherein the distance between the edge of the cavity and the outer edge of the leadframe is no more than about 25 mils.

Claim 47

The method of claim 38, further comprising: applying an etchant to a selected portion of the lead frame body to form a lead frame having different thicknesses; forming a thermoplastic resin; molding a first portion of the thermoplastic resin to form a light transparent lens for at least one of a detector and emitter; mixing a second portion of the thermoplastic resin with a color body to form a substantially light opaque thermoplastic resin; forming upper and lower portions of the housing for enclosing the lead frame, the upper portion of the housing having a first lip projecting outwardly from the upper portion for engaging a second lip on the lower portion with the second lip projecting outwardly from the lower portion; engaging the first lip with the second lip; and heating only the first lip and second lip to above the melting point of the first and second lips to seal the upper portion to the lower portion.

Claim 50

The method of claim 41, wherein the molding step comprises: forming upper and lower portions of the housing for enclosing the lead frame, the upper portion of the housing having a first lip projecting outwardly from the upper portion for engaging a second lip on the lower portion with the second lip projecting outwardly from the lower portion; engaging the first lip with the second lip; and heating the upper and lower portions to above the melting point of the first and second lips to seal the upper portion to the lower portion; and further comprising: cutting the lead frame from a conductive sheet using a cutting die having substantially the same size and shape as a cavity in the housing for receiving the lead frame; and applying an etchant to a selected portion of the lead frame body to form a lead frame having different thicknesses.

Claim 53

The method of claim 43 wherein the forming step comprises: forming a thermoplastic resin; molding a first portion of the thermoplastic resin to form a light transparent lens for at least one of a detector and emitter; mixing a second portion of the thermoplastic resin with a color body to form a substantially light opaque thermoplastic resin; and molding the substantially light opaque thermoplastic resin to form a housing body for the oximeter sensing device; and further comprising: cutting the lead frame from a conductive sheet using a cutting die having substantially the same size and shape as a cavity in an oximeter sensor housing for receiving the lead frame; and applying an etchant to a selected portion of the lead frame body to form a lead frame having different thicknesses.