Disposable Barrier Layer for Reusable Optical Physiological Sensor

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Solution Overview

Problem

Existing non-invasive physiological sensing devices, such as oximeters using near-infrared spectroscopy, face issues with skin irritation and bacteria growth due to moisture buildup under occlusive sensor pads, leading to costly single-use devices and compromised data quality when repeatedly removed and reattached.

Innovation Solution

A reusable sensor assembly with a thin, disposable, non-occlusive near-infrared transparent barrier layer that allows moisture evaporation and can be easily reattached, featuring semi-permanent adhesives and being sterilizable to prevent infection, while maintaining protection for the sensor electronics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hydrophobic occlusive material is used in the sensor pad to protect electronics from moisture, then the sensor electronics are protected from moisture damage, but moisture vapor cannot escape from the patient's skin leading to skin irritation and bacteria growth

Engineering Contradiction:

Improveprotection of sensor electronics from moistureVSAvoidskin irritation and bacteria growth from moisture buildup

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sensor pad is divided into multiple functional layers: an occlusive layer for protecting electronics and a non-occlusive barrier layer for allowing moisture vapor to escape from the skin surface while still providing a protective barrier. This segmentation resolves the contradiction by assigning different moisture management functions to different layers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A non-occlusive barrier layer is introduced as an intermediary between the patient's skin and the occlusive sensor pad. This intermediate layer allows moisture vapor to pass through while still providing protection, thereby resolving the contradiction between moisture protection and moisture vapor escape.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the sensor is designed as a one-time use device to maintain adhesive integrity, then data quality is maintained, but the cost increases significantly due to repeated disposal and replacement

Engineering Contradiction:

Improvedata qualityVSAvoidcost of disposable sensors

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The sensor system is segmented into a reusable sensor component and a disposable barrier layer. The sensor itself can be repeatedly removed and reattached without compromising adhesive integrity, while only the inexpensive barrier layer is discarded after single use, thereby reducing overall cost while maintaining data quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the entire expensive sensor disposable, only the inexpensive barrier layer is designed as a single-use component. This allows the costly sensor to be reused multiple times while still providing a fresh protective layer for each application, resolving the cost-quality contradiction.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If the sensor pad is made occlusive to prevent moisture passage, then electronics are protected, but the normal transport of moisture from the skin surface is prevented

Engineering Contradiction:

Improveprotection of sensor electronicsVSAvoidmoisture transport from skin surface

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The barrier system is segmented into an occlusive layer for electronics protection and a non-occlusive layer for maintaining skin moisture transport. This allows both functions to operate simultaneously without interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the barrier system have different moisture permeability properties: the area in contact with electronics is occlusive for protection, while the area in contact with skin is non-occlusive to allow moisture vapor escape, thereby resolving the contradiction between protection and moisture transport.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables cost-effective, repeated use of sensors with improved moisture management, reducing skin irritation and bacteria growth, and maintaining data quality by allowing moisture evaporation and easy reapplication without compromising sensor functionality.

Implementation Method 1

facilitates the evaporation of moisture from the surface of the patient's skin

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

non-occlusive near-infrared transparent barrier layer

Methodology Applied

Scientific EffectNear-infrared transmission: Infrared Radiation

Data Source

PatentUS9179874B2Optical-based physiological sensor assembly with disposable barrier layer

Publication Date: 2015.11.10 COVIDIEN LP

AI summary

A physiological sensor assembly includes a physiological sensor having at least one light source and at least one optical receiver. A substantially transparent barrier layer is disposed between the physiological sensor and the patient's skin such that the barrier layer is removably adhered to the physiological sensor and removably adhered to the patient's skin.