Pulse Oximeter Sensor Coating for Accuracy and Comfort
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Solution Overview
Problem
Pulse oximeter sensors face issues with measurement accuracy due to delamination of protective layers, leading to shunting and discomfort for patients, particularly when external light and electromagnetic fields interfere with the sensor's operation.
Innovation Solution
The sensors are coated with a polymeric material to block external light and a conductive polymeric layer to shield against electromagnetic forces, improving fit and accuracy while being designed for various patient applications and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If protective layers are applied to prevent external light interference, then measurement accuracy is improved, but the layers may delaminate causing shunting and discomfort
Solution Approach 1:
The patent combines the protective layer and adhesive layer into a single integrated component where the protective layer is formed as one piece with the adhesive layer, eliminating the interface between them and preventing delamination while maintaining both protective function and patient comfort
Solution Approach 2:
The patent uses a composite structure where the protective layer is made of opaque material and the adhesive layer provides bonding functionality, creating a multi-functional integrated layer that simultaneously protects from external light and adheres to the sensor
2Object-affected harmful factors
If wire mesh is used to shield the photodetector from external electromagnetic fields, then shielding effectiveness is improved, but it exacerbates delamination of the light blocking layer
Solution Approach 1:
The patent removes the wire mesh component entirely and replaces it with an alternative shielding approach using the integrated protective and adhesive layers, eliminating the source of delamination while maintaining shielding functionality through the opaque protective layer structure
Solution Approach 2:
The patent introduces an intermediate shielding layer or alternative shielding mechanism that does not interfere with the protective layer integrity, using a different approach to achieve electromagnetic shielding without the mechanical stress that causes delamination
3Reliability
If multiple layers are added to the sensor, then protection and shielding are improved, but the sensor becomes uncomfortable for patients
Solution Approach 1:
The patent merges multiple protective functions into a single integrated layer structure where the protective layer and adhesive layer are formed as one piece, reducing the total number of separate layers and interfaces while maintaining comprehensive protection and improving patient comfort
4Measurement precision
If protective layers are added to prevent external light, then measurement accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple layers into a single integrated protective and adhesive layer structure, reducing the number of separate manufacturing steps and assembly operations while maintaining the protective function, thereby simplifying the manufacturing process
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
The coatings enhance measurement accuracy by preventing shunting and external interference, providing a comfortable fit for patients and simplifying the manufacturing process.
Implementation Method 1
The sensors are coated with a polymeric material to block external light
Implementation Method 2
a conductive polymeric layer to shield against electromagnetic forces
Implementation Method 3
The pulse oximeter sensor emits light and photoelectrically senses the absorption and/or scattering of the light after passage through the perfused tissue
Implementation Method 4
photoelectrically senses the absorption and/or scattering of the light
Data Source
AI summary
Embodiments described herein may include devices and methods of manufacturing sensors for monitoring physiological parameters of a patient. Specifically, embodiments disclose the use of conductive and nonconductive coating materials to increase comfort of sensor and increase accuracy of the parameters measured. The sensor may include a flexible circuit and an optical device with an active face. A generally opaque, nonconductive coating may be disposed over the optical device, except for the active face, which allows for passage of light to the active face. The nonconductive coating may comprise a medical grade silicone of a specified thickness. A second conductive layer may be disposed on a portion of the conductive layer, to provide a Faraday shield for the optical device.