Sensor with integrated living hinge and spring

Abstract

Embodiments of the present disclosure relate generally to a sensor assembly. In various embodiments the sensor assembly includes a body having a first segment, a second segment, and a living hinge. The living hinge has a pivot axis and mechanically couples the first segment and the second segment. Further, the living hinge facilitates the first segment and the second segment to pivoting relative to one another about the pivot axis. Embodiments may also relate to a method of manufacturing a sensor frame. The method may include forming an integral sensor body having a first frame segment, a second frame segment, and a living hinge. The first frame segment and the second frame segment are configured to pivot relative to one another about a pivot axis of the living hinge. The method may also include coupling one or more biasing mechanisms to the first frame segment and the second frame segment. The biasing mechanism is configured to generate a moment about the pivot axis of the living hinge. The moment biases the first segment and second segment into a closed position.

Description

BACKGROUND

The present disclosure relates generally to medical devices and, more particularly, to sensors used for sensing physiological parameters of a patient.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

In the field of medicine, doctors often desire to monitor certain physiological characteristics of their patients. Accordingly, a wide variety of devices have been developed for monitoring physiological characteristics. Such devices provide doctors and other healthcare personnel with the information they need to provide the best possible healthcare for their patients. As a result, such monitoring devices have become an indispensable part of modern medicine.

One such monitoring technique is commonly referred to as pulse oximetry. Pulse oximetry may be used to measure various blood flow characteristics, such as the blood-oxygen saturation of hemoglobin in arterial blood and/or the rate of blood pulsations corresponding to each heartbeat of a patient.

The devices based upon pulse oximetry techniques are commonly referred to as pulse oximeters. Pulse oximeters typically utilize a non-invasive sensor that is placed on or against a patient's tissue that is well perfused with blood, such as a patient's finger, toe, forehead or earlobe. The pulse oximeter sensor emits light and photoelectrically senses the absorption and/or scattering of the light after passage through the perfused tissue. The data collected by the sensor may then be used to calculate one or more of the above physiological characteristics based upon the absorption or scattering of the light. More specifically, the emitted light is typically selected to be of one or more wavelengths that are absorbed or scattered in an amount related to the presence of oxygenated versus deoxygenated hemoglobin in the blood. The amount of light absorbed and/or scattered may then be used to estimate the amount of the oxygen in the tissue using various algorithms.

During use, the performance of a pulse oximetry sensor may rely on there being substantial contact between the surface of the patient's tissue (i.e., skin or nail bed) and the light emitting and detecting sensors. Good contact between the sensor and the tissue helps prevent light from scattering before being detected by the detecting sensor and helps to prevent additional light, i.e., ambient light or other light not emitted by the sensor, from reaching the detector. For example, a sensor may be clipped about a patients finger tip with the emitter placed on the finger nail, and the detector placed on the under side of the finger tip. In this configuration, the sensor should clip about the finger with enough force to eliminate or reduce the gap between the emitter and the finger nail, as well as eliminate the gap between the detector and the underside of the finger tip. By providing a sufficiently tight fit, the emitted light may travel directly through the tissue of the finger and be detected without additional light being introduced or the emitted light being scattered. Further, the sufficiently tight fit may reduce the likelihood of the pulse oximetry sensor moving relative to the patient's tissue and/or falling off of the patient. However, in practice, anatomic variation between individuals may make achieving such a tight fit with good contact difficult using standardized sensor sizes.

SUMMARY

Certain aspects commensurate in scope with the disclosure are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the disclosure might take and that these aspects are not intended to limit the scope of the disclosure. Indeed, the disclosure may encompass a variety of aspects that may not be set forth below.

In accordance with an embodiment, there is provided a sensor assembly. The sensor assembly includes a body having a first segment, a second segment, and a living hinge. The living hinge has a pivot axis and mechanically couples the first segment and the second segment. Further, the living hinge facilitates the first segment and the second segment to pivoting relative to one another about the pivot axis.

In accordance with an embodiment, there is provided a sensor system. The sensor system includes a sensor assembly having a sensor, a sensor frame, and a living hinge. The sensor has a first sensor portion and a second sensor portion. The sensor frame is configured to support the sensor and includes a first body portion and a second body portion. The living hinge mechanically couples the first body portion and the second body portion, such that the first body portion and the second body portion are configured to pivot relative to one another about a pivot axis of the living hinge. The sensor system also includes at least one member configured to generate a moment about the pivot axis of the living hinge and bias a first end of the first body portion and a first end of the second body portion toward one another.

In accordance with an embodiment, there is provided a method of manufacturing a sensor frame. The method includes forming an integral sensor body having a first frame segment, a second frame segment, and a living hinge. The first frame segment and the second frame segment are configured to pivot relative to one another about a pivot axis of the living hinge. The method also includes coupling one or more biasing mechanisms to the first frame segment and the second frame segment. The biasing mechanism is configured to generate a moment about the pivot axis of the living hinge. The moment biases the first segment and second segment into a closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the disclosure may become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 illustrates a patient monitoring system coupled to a multi-parameter patient monitor and a sensor, in accordance with an embodiment;

FIG. 2 is a side view of a first embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 3 is a perspective view of the first embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 4 is a perspective view of a second embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 5 is a perspective view of a third embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 6 is a perspective view of a fourth embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 7 is a perspective view of a fifth embodiment of the sensor having a living hinge, in accordance with an embodiment;

FIG. 8 is a flowchart that depicts a method for manufacturing a sensor having a living hinge, in accordance with an embodiment; and

FIG. 9 is a flowchart that depicts a method for operating a sensor having a living hinge, in accordance with an embodiment.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

One or more embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

As described herein, various embodiments of sensors are provided which are believed to provide good contact and fit for a range of patient anatomies. In general, examples of these sensors, as described herein, include a living hinge. Prior to discussing such sensors in detail, it should be appreciated that such sensors are typically designed for use with a patient monitoring system.

Referring now to FIG. 1, a sensor 10 according to an embodiment may be used in conjunction with a patient monitor 12. In the depicted embodiment, a cable 14 connects the sensor 10 to the patient monitor 12. As will be appreciated, the sensor 10 and/or the cable 14 may include or incorporate one or more integrated circuit devices or electrical devices, such as a memory, processor chip, or resistor, that may facilitate or enhance communication between the sensor 10 and the patient monitor 12. Likewise the cable 14 may be an adaptor cable, with or without an integrated circuit or electrical device, for facilitating communication between the sensor 10 and various types of monitors, including older or newer versions of the patient monitor 12 or other physiological monitors.

In other embodiments, the sensor 10 and the patient monitor 12 may communicate via wireless means, such as using radio, infrared, or optical signals. In such embodiments, a transmission device (not shown) may be connected to the sensor 10 to facilitate wireless transmission between the sensor 10 and the patient monitor 12. As will be appreciated by those of ordinary skill in the art, the cable 14 (or a corresponding wireless transmission) may be used to transmit control or timing signals from the monitor 12 to the sensor 10 and/or to transmit acquired data from the sensor 10 to the monitor 12. In some embodiments, the cable 14 may be an optical fiber that enables optical signals to be conducted between the patient monitor 12 and the sensor 10.

In an embodiment, the patient monitor 12 may be a suitable pulse oximeter, such as those available from Nellcor Puritan Bennett LLC. In other embodiments, the patient monitor 12 may be a monitor suitable for measuring tissue water fractions, or other body fluid related metrics, using spectrophotometric or other techniques. Furthermore, the patient monitor 12 may be a multi-purpose monitor suitable for performing pulse oximetry and measurement of tissue water fraction, or other combinations of physiological and/or biochemical monitoring processes, using data acquired via the sensor 10. Furthermore, to upgrade conventional monitoring functions provided by the monitor 12 and to provide additional functions, the patient monitor 12 may be coupled to a multi-parameter patient monitor 16 via a cable 18 connected to a sensor input port and/or a cable 20 connected to a digital communication port.

In an embodiment, the sensor 10, as depicted in FIG. 1, is a clip-style sensor that is overmolded to provide a unitary or enclosed assembly. The sensor 10 may include an emitter 22 and a detector 24 which may be of any suitable type. For example the emitter 22 may be one or more light emitting diodes adapted to transmit one or more wavelengths of light, such as in the red to infrared range, and the detector 24 may be a photodetector, such as a silicon photodiode package, selected to receive light in the range emitted from the emitter 22. In the depicted embodiment, the sensor 10 is coupled to a cable 14 that is responsible for transmitting electrical and/or optical signals to and from the emitter 22 and the detector 24 of the sensor 10. The cable 14 may be permanently coupled to the sensor 10, or it may be removably coupled to the sensor 10—the latter alternative being more useful and cost efficient in situations where the sensor 10 is disposable.

In an embodiment, the sensor 10 discussed herein may be configured for either transmission or reflectance type sensing, for example. Furthermore, the sensor 10 may include various structural and functional features designed to facilitate its use. An example of such a sensor and its use and construction may be found in U.S. application Ser. No. 11/199,524 titled “Medical Sensor and Technique for Using the Same” and filed on Aug. 8, 2005, which is hereby incorporated by reference in its entirety for all purposes. As will be appreciated by those of ordinary skill in the art, however, such discussion is merely an example and is not intended to limit the scope of the present technique.

As discussed in greater detail below with regards to FIGS. 2-9, to provide a sufficiently tight fit of the emitter 22 and the detector 24 against the tissue of the patient, certain embodiments of the sensor 10 may include a biasing mechanism, such as a spring, that provides a biasing force to close the distance between the emitter 22 and the detector 24. The spring may also maintain or increase the biasing force as the emitter 22 and detector 24 are spread farther apart from one another. For example, the sensor 10 may include a frame with a top portion that contains the emitter 22 and bottom portion that includes a detector 24, and the frame may take the form of a clip that allows a practitioner to squeeze tabs to separate the emitter 22 and detector 24. The sensor 10 can be opened by a sufficient amount such that the sensor 10 can be clipped to a patient's finger, or to another location on the patient's body. Once attached to the patient, the biasing force may provide resistance to secure and maintain the sensor 10 in contact with the patient's tissue.

Turning now to FIG. 2, an embodiment of the sensor 10 is illustrated. In the embodiment, the sensor 10 includes a body (e.g., frame) 25 including a first segment 26, a second segment 28, a living hinge 30, and a biasing mechanism 32. The first segment 26 may be coupled to the second segment 28 via the living hinge 30 such that the first segment 26 and the second segment 28 can rotate relative to one another and about a pivot axis 34 of the living hinge 30. In the illustrated embodiment, the sensor 10 may also include a cable connection 36 that couples the cable 14 to the first segment 26 of the sensor 10. The cable connection 36 may include a strain relief, a permanent cabled connection, a quick disconnect mechanism, an overmolded portion of the cable, or the like. Further, the sensor 10 may include overmolding 37. In the illustrated embodiment, the overmolding 37 may encapsulate entirety of the sensor 10. In other embodiments, the overmolding 37 may be affixed to only a portion of the sensor 10.

In an embodiment, the first segment 26 includes a first end 38 and a second end 40. The first end 38 of the first segment 26 may include a first sensing device that is disposed internal to the first segment 26. For example, the emitter 22 of the sensor 10 may be disposed internal to the first end 38 of the first segment 26. The emitter 22 may be mechanically affixed in position via an interference fit, an adhesive, plastic welding, overmolding, or other technique that couples, adheres or holds the emitter 22 to the first segment 26.

In an embodiment, the second segment 28 may include a first end 44 and a second end 46. The first end 44 of the second segment 28 may include a second sensing device that is disposed internal to the second segment 28. For example, the detector 24 of the sensor 10 may be disposed internal to the first end 44 of the second segment 28 and in optical alignment with an emitter 22 disposed in the first segment 26. The detector 24 may be mechanically affixed in position via an interference fit, an adhesive, plastic welding, overmolding, or other technique that couples, attaches or holds the detector 24 to the second segment 28.

The second ends 40 and 46 of the first segment 26 and the second segment 28 may include extensions or tabs that facilitate handling of the sensor 10. For example, in the illustrated embodiment, the second ends 40 and 46 of the sensor 10 include respective protrusions 47 and 48 that extend outward from a location where the living hinge 30 is coupled to the second segment 28. Accordingly, applying squeezing force to the protrusions 47 and 48 to move them toward one another may create a moment about the pivot axis 34 of the living hinge 30. In other words, the protrusions 47 and 48 may act as levers to enable rotation of the first segment 26 and the second segment 28 about the pivot axis 34 of the living hinge 30.

In an embodiment, the first segment 26 and the second segment 28 may be coupled to one another via the living hinge 30. To promote flexure and rotation of the first segment 26 and second segment 28 relative to one another and about the pivot axis 34, the living hinge 30 may, in some embodiments, have a greater tendency to flex than other portions (e.g., the first segment 26 and the second segment 28) of the sensor 10. In certain embodiments, the living hinge 30 includes a necked portion 50 that has a cross-sectional width 52 that is less than the cross-sectional widths 54 and 55 of the components immediately coupled to and adjacent the living hinge 30. In certain embodiments, the first segment 26 and the second segment 28 may include regions proximate the living hinge 30 that have cross sectional widths 54 and 55 that are greater than the cross-sectional width 52 of the living hinge 30. Accordingly, where the living hinge 30, the first segment 26, and the second segment 28 are of similar properties (e.g., mechanical properties), a force applied to the second end 40 of the first segment 26 and/or the second end 46 of the second segment 28 may promote pivoting of the first segment 26 and the second segment 28 about the pivot axis 34. In other words, the living hinge 30 may bend or flex at or near the pivot axis 34 due to the living hinge 30 being a suitable cross sectional width 52 relative to adjacent or nearly adjacent regions.

In an embodiment, applying a force in the direction of arrows 56 to squeeze the second ends 40 and 46 of the first and second segments 26 and 28 together may bend or flex the living hinge 30, enabling the first and second segments 26 and 28 to rotate about the pivot axis 34. In turn, the rotation causes the first ends 38 and 44 to open in the direction of arrows 58, enlarging the gap 60 between the first ends 38 and 44. For example, a medical practitioner may squeeze the second ends 40 and 46 of the sensor 10 to enlarge the gap 60 so that the sensor 10 is in an open position where the first ends 38 and 44 of the sensor 10 can be clipped about a patient's finger, or other location.

In the illustrated embodiment, the pivot axis 34 of the living hinge 30 is offset from a centerline 62 of the sensor 10 by an offset distance 63. The centerline 62 may include a line, axis, or plane that is approximately the same distance from the first segment 26 and the second segment 28 at a referenced location or orientation of the sensor 10. For example, in the illustrated embodiment, the centerline 62 includes a plane that passes through a midpoint 64 of a segment 65 that extends between the first body portion 26 and the second body portion 28. In another embodiment, the centerline 62 may be defined by other features and orientations. For example, in one embodiment, the centerline 62 may be defined by a plane that bisects an angle 66 formed between interior faces 67 of the first end 38 of the first segment 26 and the first end 38 of the second segment 28 when the sensor 10 is closed. In another embodiment, the centerline 62 may include a plane that is approximately equal distance between the interior faces 67 when the sensor 10 is opened such that the faces 67 are parallel to one another.

In an embodiment, offsetting the pivot axis 34 of the living hinge 30 may facilitate manipulating the size and location of the gap 60. For example, increasing the offset distance 63 of the pivot axis 34 may increase the opening angle between the first and second segments 26 and 28 and increase the size of the gap 60 relative to the distance the second ends 40 and 46 are moved (i.e., squeezed) toward one another.

In an embodiment, the recovery of the living hinge 30 may cause the living hinge 30 to have a tendency to return to its unflexed state and, therefore, may provide a restoring (e.g., biasing force) that urges the first segment 26 and the second segment 28 to an unbiased position, such as the opened or closed position. The recovery of the living hinge 30 may be characterized by several mechanical properties, including, but not limited to, the elasticity, stiffness, and/or strength of the material used to form the living hinge 30. In the illustrated embodiment, when the second ends 40 and 46 of the first and second segments 26 and 28 are squeezed to open the sensor 10 (i.e., increase the size of the gap 60), the living hinge 30 may generate a restoring force that resist the bending or flexing of the living hinge 30. Accordingly, when the force applied to open the first and second segments 26 and 28 is reduced, the living hinge 30 may urge the first and second segments 26 and 28 into the closed position (i.e., a position where the size of the gap 60 is reduced). Such a restoring force may enable the sensor 10 to clip and grip to the finger of a patient.

Although the restoring force provided by the living hinge 30 may be sufficient to provide a tight fit with good contact against the patient's tissue, other embodiments may include the addition of a biasing mechanism to provide or increase the restoring force. For example, in the illustrated embodiment, the sensor 10 includes a biasing mechanism 32 disposed between the first segment 26 and the second segment 28. The biasing mechanism 32 may provide a biasing force to cause the first segment 26 and the second segment 28 to rotate relative to one another and reduce the size of the gap 60.

For example, in the illustrated embodiment, the biasing mechanism 32 includes a torsion spring 68 that provides a biasing force in a direction opposite from the direction of the force employed to squeeze the second ends 40 and 46 of the first and second segments 26 and 28 (e.g., a force in the direction of arrows 69). Thus, the biasing mechanism 32 may provide a biasing moment acting on the first and second segments 26 and 28 that urges the sensor 10 to the closed position. As is discussed in further detail below, the biasing mechanism 32 can take a variety of forms, including but not limited to the torsion spring 68, a double torsion spring, a flat spring, a compression spring, a conical compression spring, or combinations thereof. Other embodiments may include one or more of the biasing mechanism 32 coupled to the sensor 10. For example, two biasing mechanisms 32 may be disposed coaxially (i.e., coincident) and abutting one another.

Further, the axis of the biasing mechanism 32 may be coaxial with the pivot axis 34 of the living hinge 30. For example, in the illustrated embodiment, the longitudinal axis of the torsion spring and the pivot axis 34 are coaxial. Locating the axis of the biasing mechanism 32 and the pivot axis 34 coaxial to one another may promote bending and flexing of the living hinge 30 about the pivot axis 34. The axis of the biasing mechanism 32 and the pivot axis 34 may both be offset from the centerline 62 of the sensor 10. For example, as illustrated and discussed above, the axis of the biasing mechanism 32 and the pivot axis 34 may be offset by the offset distance 63 from the centerline 62.

Turning now to FIG. 3, a perspective of an embodiment of the sensor 10 including the biasing mechanism 32 is illustrated. The biasing mechanism 32 may include the torsion spring 68 disposed in a slot 70. The slot 70 may include a region void of material, such as a cutout, in a central portion in of the living hinge 30. In such an embodiment, the living hinge 30 is formed from first living hinge portion 72 on one side of the slot 70 and a second living hinge portion 73 on the other side of the slot 70. Further, in the depicted embodiment, the sensor 10 includes indentations that are conducive to the placement and retention of the biasing mechanism 32. For example, a first indentation 74 and a first retaining hole 76 may be formed into the second segment 28. A first leg 78 of the torsion spring 68 may be disposed in the indentation 74 and the retaining hole 76. Similarly, a second indentation 80 may be formed into the first segment 26. A second leg 82 of the torsion spring 68 may be disposed in the second indentation 80. Disposing the first leg 78 into the first indentation 74 and the retaining hole 76 and/or disposing the second leg 82 into the second indentation 80 may facilitate alignment and retention of the torsion spring 68 relative to the living hinge 30.

Turning now to FIG. 4, a perspective view of an embodiment of the sensor 10 including the biasing mechanism 32 is illustrated. In this embodiment, the biasing mechanism 32 includes the torsion spring 68 disposed in the slot 70 and about a mandrel 84. In the illustrated embodiment, the mandrel 84 includes a portion of material of the sensor 10 extending from the periphery of the slot 70 through the center of the torsion spring 68. The mandrel 84 may extend coaxial with the pivot axis 34 and the axis of the torsion spring 68. The mandrel 84 may facilitate alignment and retention of the biasing mechanism 32 relative to the living hinge 30 during assembly and operation.

In an embodiment, the mandrel 84 may also include features that facilitate assembly of the biasing mechanism 32 to the sensor 10. For example, the mandrel 84 may extend only a portion of the distance across the slot 70 such that the biasing mechanism 32 may be threaded onto the mandrel 84. Further, in the illustrated embodiment, the mandrel 84 includes a first mandrel portion 86 and a second mandrel portion 88 that each extend from opposite sides of the slot 70. In such an embodiment, the sensor 10 may comprise a first sensor portion 90 and a second sensor portion 92 that are assembled to one another to form the sensor 10. The first sensor portion 90 and the second sensor portion 92 can be assembled around the biasing mechanism 32, such that the first mandrel portion 86 and the second mandrel portion 88 extend through the center of the biasing mechanism 32. In the illustrated embodiment, the mandrel 84 includes at least a portion of the living hinge 30. In other embodiments, the mandrel 84 may include a portion of the first segment 26, the second segment 28, or a combination of the first segment 26, the second segment 28 and/or the living hinge 30.

Turning now to FIG. 5, a perspective view of an embodiment of the sensor 10 including the biasing mechanism 32 is illustrated. In the depicted embodiment, the biasing mechanism 32 includes a flat spring 93 coupled to the sensor 10. For example, in the illustrated embodiment, the biasing mechanism 32, including the flat spring 93, is disposed in a first indentation 94 in the first segment 26 and a second indentation 96 in the second segment 28. The indentations 94 and 96 may facilitate alignment and retention of the biasing mechanism 32 relative to the living hinge 30.

Further, in certain embodiments, the biasing mechanism 32, including the flat spring 93, may include features conducive to flexing of the flat spring at or near the pivot axis 34. For example, in the illustrated embodiment, the flat spring 93 includes a cutout 98 proximate the pivot axis 34. The cutout 98 may encourage flexing and bending of the flat spring 93 at or near the pivot axis 34 and, thus, encourage the first segment 26 and the second segment 28 to pivot about the pivot axis 34 relative to one another. Further, the geometry and material of the flat spring 93 may be varied to accommodate various designs. For example, the flat spring 93 may include a metal (e.g., steel or aluminum), polymeric composition (e.g., polypropylene), or a similar material. Further, the size, shape, and number of cutouts 98 may be varied to influence the stiffness of the flat spring 93 and the resulting biasing force. For example, the size, number, and location of cutouts 98 may be increased or decreased to vary the force applied to open the sensor 10.

Turning now to FIG. 6, a perspective view of an embodiment of the sensor 10 including the biasing mechanism 32 is illustrated. In the depicted embodiment, the biasing mechanism 32 includes a compression spring 99 coupled to the sensor 10. For example, in the illustrated embodiment, the biasing mechanism 32 includes the compression spring 99 disposed about a first protrusion 100 on a face of the first segment 26 and about a second protrusion 102 on a face of the second segment 28. Accordingly, when an opening force is applied in the direction of the arrows 56 to squeeze the sensor 10 to the open position, the biasing mechanism 32 including a compression spring may generate a biasing force in the opposite direction (e.g., in the direction of arrows 101). The biasing force biases the sensor 10 to the closed position as discussed previously.

In an embodiment, the protrusions 100 and 102 are disposed along a protrusion axis 104. In one embodiment, the protrusion axis 104 is not parallel to the pivot axis 34. For example, in the illustrated embodiment, the protrusion axis 104 is generally perpendicular to and offset from the pivot axis 34. Each of the protrusions 100 and 102 may have axes that are coaxial or not coaxial. Further, the protrusions 100 and 102 may have a height 106 of approximately 0.1 inches, 0.2 inches, 0.4 inches, 0.5 inches or more. In operation and assembly, the protrusions 100 and 102 can facilitate alignment and retention of the biasing mechanism 32 relative to the living hinge 30.

In various embodiments, the protrusions 100 and 102 may be replaced or used in combination with indentations in the first segment 26 and/or the second segment 28. For example, the first and second segments 26 and 28 may include recesses 105 proximate the intersection of the protrusions 100 and 102 and the segments 26 and 28. In other words, the segments 26 and 28 may include a channel that surrounds the base of the protrusions 100 and 102, and that accepts at least a portion of the biasing mechanism 32. Further, an embodiment may include recesses 105 without employing a protrusion 100 or 102, i.e., the recesses 105 alone hold the biasing mechanism 32 in place. The recesses 105 may further promote alignment and retention of the biasing mechanism 32.

Turning now to FIG. 7, an embodiment of the sensor 10 including a plurality of biasing mechanisms 32 is illustrated. In the depicted embodiment, the sensor 10 includes two biasing mechanisms 32. A first biasing mechanism 32 may be disposed about a first axis 108, and a second biasing mechanism 32 may be disposed about a second axis 112. In the depicted embodiment, each of the first and second biasing mechanisms 32 and 110 include a double torsion spring 113. The first axis 108 and the second axis 110 may be parallel and offset from the pivot axis 34 of the living hinge 30. Each of the double torsion springs 113 may include a first end 114 having a coil disposed in a first indentation 116 and a second end 118 having a coil disposed in a second indentation 120. The first end 114 and the second end 116 may be coupled to one another via a leg 122 disposed in a channel 124 of the living hinge 30. The channels 124 may run parallel to the first axis 108 and the second axis 112. A second leg 126 may be disposed in an indentation 128 in the first and second segments 26 and 28. During assembly of the sensor 10, the biasing mechanisms 106 and 110 may be snapped into the indentations 116 and 120, the channels 124 and the indentation 128. Accordingly, in the depicted embodiment, the indentations 116, 120 and 128 and channels 124 may facilitate alignment and retention of the double torsion springs 113 relative to the living hinge 30.

In accordance with the previously discussed embodiments, the sensor 10 may be formed from various materials and by various processes. For example, the sensor 10 may be formed from a single type material or a combination of material types. In one embodiment, the first segment 26, the second segment 28 and the living hinge 30 may be formed from the same or similar material, such as polypropylene or other elastomers. In such an embodiment, these three components can be formed in a single-shot molding process that integrates each of the components into a single body that includes the first segment 26, the second segment 28 and the living hinge 30, and includes other features discussed previously. Alternately, the components can be formed separately, such as by independent molding processes, and subsequently coupled to one another, such as by an adhesive, a plastic weld, or other form of assembly.

In an embodiment, the first segment 26, the second segment 28 and the living hinge 30 may not be formed from the same material. For example, in one embodiment, the first segment 26 and the second segment 28 may be formed from a first material, such as polypropylene, and the living hinge 30 may be formed from a second material, such as a rubber thermoplastic elastomer (TPE). In such an embodiment, these three components can be formed in a two-shot molding process (i.e., a process that includes molding the components formed from the first material, followed by molding the components formed from the second material) that integrates each of the components in to a single body (e.g., body 25) that including the first segment 26, the second segment 28 and the living hinge 30, and any of the features discussed previously.

Further, forming the sensor 10 may include overmolding the sensor 10 with an additional material, such as a conformable or soft material (e.g., a material having a durometer below 40 Shore A). Overmolding may include disposing a material about the sensor that encapsulates or coats at least a portion of the segments 26 and 28, the living hinge 30, and/or other components of the sensor 10, such as the biasing mechanism 32, the emitter 22, the detector 24, and the cable 14. Overmolding may increase the durability of the sensor 10 by providing a flexible covering, and may enhance the overall appearance and ergonomics of the sensor 10.

Turning now to FIG. 8, an embodiment of a method 130 for manufacturing the sensor 10 is depicted. The depicted method 130 may include forming the sensor body, as illustrated at block 132. Forming the sensor body (block 132) may include molding the first segment 26, the second segment 28, the living hinge 30, and other features as discussed above. In certain embodiments, forming the sensor body (block 132) may include a one-shot molding, a two-shot molding, overmolding and/or similar processes. However, in some embodiments, overmolding may be performed at a later stage in the manufacturing process.

The method 130 may also include assembling the biasing mechanism, as illustrated at block 134. Assembling the biasing mechanism (block 134) may generally include snapping, or otherwise positioning, the biasing mechanism 32 into place relative to the first segment 26, the second segment 28 and the living hinge 30. For example, a spring may be snapped into the slot 70, in the indentations 74, 80, 94, 96, 116, 118 and 128, around protrusions 100 and 102, in the hole 76, around the mandrel 84, in the channels 124, and the like, as discussed in the preceding embodiments.

The method 130 may also include assembling the emitter and the detector to the sensor 10, as illustrated at block 136. As discussed above, embodiments may include employing an adhesive, an interference fit, or other attachment technique to couple the emitter 22 and the detector 24 to the first segment 26 and the second segment 28, respectively. Further, the emitter 22 and detector 24 may be assembled prior to or after the sensor 10 is overmolded.

The method 130 may also include assembling the cable to the sensor, as illustrated at block 138. Assembling the cable 14 to the sensor 10 (block 138) may include making electrical connections between the cable and the sensing devices (e.g., the emitter 22 and the detector 24). For example, ends of the cable 14 may be soldered to complementary electrical leads, a strain relief snapped into place, or the like. It should be noted that in some embodiments, the cable 14 may be formed integrally with the sensor 10, and assembling the cable to 14 to the sensor 10 (block 138) may be performed prior to or integral with forming the sensor body (block 132). For example, the cable 14 may be coupled to the sensor 10 and/or the emitter 22, and molded as an integral component of the first segment 26, or integral to the overmolding of the sensor 10. As will be appreciated, the method 130 may include additional steps, and/or accomplish the method steps in various orders to achieve the desired result.

Turning now to FIG. 9, an embodiment of a method 140 of operating the sensor 10 is illustrated. The method may include applying an opening force to the sensor, as illustrated at block 142. Applying an opening force (block 142) may include applying force in the direction of arrows 56 to increase the size of the gap 60 to bias the sensor 10 to the open position. The method 140 also includes affixing the sensor to the patient, as illustrated at block 144. For example, the first ends 38 and 44 of the sensor 10 may be disposed about the finger tip or other tissue of a patient, and the opening force removed, as illustrated at block 146. Removing the opening force may enable the sensor 10 to return to the closed position and be secured to the patient. As discussed previously, when the opening force is removed, the living hinge 30 and/or the biasing mechanism 32 may provide a sufficient biasing force to return the sensor 10 to the closed position and ensure the sensor 10 remains in contact with and attached to the patient. Accordingly, with the sensor 10 secured to the patient, the sensor 10 may be employed to acquire patient information, as illustrated at block 148. In other words, signals may be transmitted between the monitor 12 and the sensor 10 to acquire information relating to the patient. As will be appreciated, the method 140 may include additional steps, and/or accomplish the method steps in various orders to achieve the desired result.

While the medical sensors 10 discussed herein are some examples of integrally molded medical devices, other such devices are also contemplated and fall within the scope of the present disclosure. For example, other medical sensors and/or contacts applied externally to a patient may be advantageously applied using a sensor 10 having an integral living hinge 30. For example, devices for measuring tissue water fraction or other body fluid related metrics may utilize a sensor as described herein. Likewise, other spectrophotometric applications where a probe is attached to a patient may utilize a sensor as described herein.

While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

Claims

1. A medical sensor assembly, comprising: a sensor body comprising: a first segment having a first protrusion;a second segment having a second protrusion;at least one sensing element disposed internally within the first segment or the second segment;a living hinge comprising a pivot axis, wherein the living hinge mechanically couples the first segment and the second segment, and is configured to enable the first segment and the second segment to pivot relative to one another generally about the pivot axis when a compression force is applied to the first protrusion and the second protrusion to move the first and second protrusions generally toward one another, and wherein the living hinge is configured to apply a first biasing force in the absence of the compression force to move ends of the first and second segments distal from the first and second protrusions generally toward one another; anda biasing member configured to generate a moment about the pivot axis of the living hinge, wherein the biasing member generates a second biasing force that moves the ends of the first and second segments generally toward one another.

2. The medical sensor assembly of claim 1, wherein the pivot axis is offset from a centerline of the sensor body.

3. The medical sensor assembly of claim 1, wherein the living hinge comprises a cross-sectional width that is generally less than the cross-sectional width of portions of the first segment and the second segment that are proximate the living hinge.

4. The medical sensor assembly of claim 1, wherein the biasing member comprises a torsion spring, a double torsion spring, a flat spring, a compression spring, a conical compression spring, or combinations thereof.

5. The medical sensor assembly of claim 1, wherein an axis of the biasing member is generally coaxial with the pivot axis of the living hinge.

6. The medical sensor assembly of claim 1, wherein an axis of the biasing member is generally not parallel to the pivot axis of the living hinge.

7. The medical sensor assembly of claim 1, comprising a mandrel configured to be disposed generally internal to a biasing member.

8. The medical sensor assembly of claim 1, wherein the body comprises a cutout that is configured to accept a biasing member.

9. The medical sensor assembly of claim 1, wherein the sensor body is formed from polypropylene.

10. The medical sensor assembly of claim 1, wherein the sensor body is formed from a first material and the living hinge is formed from a second material, and wherein the first material is different from the second material.

11. The medical sensor assembly of claim 10, wherein the first material comprises polypropylene and the second material comprises a thermoplastic elastomer.

12. The medical sensor assembly of claim 1, wherein the medical sensor assembly is configured for use in a pulse oximetry sensor.

13. The medical sensor assembly of claim 1, comprising an output cable coupled to a first end of the first segment, wherein the first end is configured to contact a patient.

14. The medical sensor assembly of claim 1, wherein the sensing element is an optical emitter configured to emit light in a red to infrared range or an optical detector configured to receive light in the red to infrared range.

15. The medical sensor assembly of claim 1, wherein the first and second protrusions extend outward from a location where the living hinge mechanically couples the first segment and the second segment.

16. The medical sensor assembly of claim 1, wherein the pivot axis of the living hinge is generally perpendicular to a longitudinal axis of the sensor body.

17. The medical sensor assembly of claim 1, wherein the at least one sensing element is disposed internally within an end of the first segment or the second segment, and the living hinge couples the first segment and the second segment at a location distal from the end.

18. A sensor system, comprising: a sensor assembly comprising: a sensor comprising a first sensing element and a second sensing element;a sensor frame configured to support the sensor, comprising:a first body portion configured to support the first sensing element internally within the first body portion, wherein the first body portion comprises a first protrusion;a second body portion configured to support the second sensing element internally within the second body portion, wherein the second body portion comprises a second protrusion; anda living hinge mechanically coupling the first body portion and the second body portion, wherein the first body portion and the second body portion are configured to pivot relative to one another generally about a pivot axis of the living hinge when a compression force is applied to the first protrusion and the second protrusion to move the first and second protrusions generally toward one another, wherein the pivot axis of the living hinge is generally perpendicular to a longitudinal axis of the sensor frame, and wherein the living hinge is configured to apply a first biasing force in the absence of the compression force to move the first body portion and the second body portion toward one another; andat least one member configured to generate a moment about the pivot axis of the living hinge and generally bias a first end of the first body portion and a second end of the second body portion toward one another.

19. The sensor system of claim 18, wherein the member comprises a torsion spring, a double torsion spring, a flat spring, a compression spring, or a conical compression spring.

20. The sensor system of claim 18, wherein an axis of the member is generally coincident with the pivot axis of the living hinge.

21. The sensor system of claim 18, wherein the sensor frame is overmolded to enclose the first body portion, the second body portion, and the living hinge.

22. The sensor system of claim 18, comprising a monitor coupled to the sensor assembly.

23. The sensor system of claim 18, wherein the first and second sensing elements are optical emitters configured to emit light in a red to infrared range or optical detectors configured to receive light in the red to infrared range.

24. The sensor system of claim 18, wherein the first and second body portions are configured to support the first and second sensing elements internally within an end of the sensor frame, and wherein the living hinge mechanically couples the first and second body portions at a location of the sensor frame distal from the end of the sensor frame.

25. The sensor system of claim 18, wherein the living hinge comprises a first living hinge portion disposed on a first side of the at least one member, and a second living hinge portion disposed on a second side of the at least one member.

26. A method of manufacturing a sensor frame, comprising: forming an integral sensor body having a first frame segment having a first protrusion, a second frame segment having a second protrusion, at least one sensing element disposed internally within the first frame segment or second frame segment, and a living hinge, wherein the first frame segment and the second frame segment are configured to pivot relative to one another generally about a pivot axis of the living hinge; andcoupling at least one biasing mechanism to the first frame segment and the second frame segment, wherein the at least one biasing mechanism is configured to generate a moment about the pivot axis of the living hinge, and wherein the moment generally biases the first frame segment and second frame segment into a closed position, and wherein applying a compression force to the first protrusion and the second protrusion enables the first and second frame segments to pivot relative to each other into an open position, and wherein in the absence of the compression force the living hinge is configured to generate a biasing force configured to bias the first frame segment and the second frame segment into the closed position.

27. The method of claim 26, wherein the pivot axis of the living hinge is generally perpendicular to a longitudinal axis of the integral sensor body.

28. The method of claim 26, wherein the at least one sensing element is disposed within an end of the first frame segment or the second frame segment, and the living hinge couples the first frame segment and the second frame segment at a location of the integral sensor body distal from the end.

29. The method of claim 26, wherein the integral sensor body is overmolded to enclose the first frame segment, the second frame segment, and the living hinge.