DISPOSABLE SENSING ELEMENTS COMPRISING A PIEZOELECTRIC UNIT

Abstract

A device for detecting stenosis comprising disposable components to ensure function and sanitary conditions, said device having a disposable sensing pad, a disposable piezo assembly, and a disposable sensing pod, wherein the entire device can be disposed of after a predetermined number of uses to ensure accuracy of results and of sanitary conditions.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 16/309,773 filed Dec. 13, 2018, which is a 371 National Phase Entry of International Patent Application No. PCT/US2017/037726, filed Jun. 15, 2017, which claims the benefit of U.S. Provisional Patent Application No. 62/350,617, filed Jun. 15, 2016, the disclosure content of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present application is generally related to disposable components for detecting blockage in a fluid flow vessel. In particular, the application is directed towards a disposable sensor pod that configures to a sensing device, wherein said disposable sensor comprises a piezoelectric component that is utilized on a sensing device to be positioned on the skin of a patient for detecting acoustic sound from the flow of bodily fluids. Additional disposable components include a disposable sensor pod and a disposable array.

BACKGROUND OF THE INVENTION

Piezoelectric units function based on the occurrence of electric dipole moments in solids. The solid may be either induced for ions on crystal lattice sites with asymmetric charge surroundings or may directly be carried by molecular groups. The dipole density or polarization may be calculated by summing up the dipole moment per volume of the crystallographic unit cell.

There is a need to sterilize equipment in all medical settings. Medical devices should be sterile to prevent transmission of bacteria and disease. As such, medical devices are typically cleaned or, where not possible, replaced entirely. Cleaning solvents are frequently harsh chemicals to ensure high kill rates of bacterial and viral loads that may be transmitted by touch. Accordingly, devices that are reused need to be able to support the rigors of these chemicals.

Like all components, piezo elements wear over time from ordinary use. Furthermore, accidental damage can and will occur, and thus replacement components are necessary to ensure that devices are not out of order for longer than necessary. Furthermore, because of the sensitive nature of the piezo, it is necessary to ensure that they are properly functioning before each use. Accordingly, the piezos must be designed to allow for easy replacement of the piezo, while ensuring that a device maintains operation and reliability during ordinary use.

SUMMARY OF THE INVENTION

The summary is provided as nonlimiting examples of the embodiments of the invention. Each of the embodiments can be combined with the other additional embodiments without deviating from the scope of the invention as envisioned by the inventors. Additionally components of one embodiment can be combined with components of another embodiment as described herein and as understood by a person of ordinary skill in the art. Accordingly, a first embodiment is directed to a disposable sensor, comprising a piezoelectric element (“piezo”), a cap, and a contact board. The sensor is mounted to the cap on one end, and the contact board mounted on the opposing end of the cap, wherein the cap comprises attachment means to secure to a base component, together defining a sensor pod.

A further embodiment is directed towards a disposable sensor assembly comprising a piezoelectric sensor, a contact board, and a circular shaped housing cap, having a top side and a bottom side, an inner surface and an outer surface, and a central opening extending through the top and bottom sides, on the top side a flange is positioned inside the central opening and disposed of to receive said piezoelectric sensor around the circumference of said piezoelectric sensor; the bottom side engaging said contact board which is secured beneath the flange; and one half of a locking means on said inner surface. In preferred embodiments, the one half of a locking means connects to a paired locking means, forcing contact with the contact board and powering the piezo. However, upon need for replacement, said disposable sensor assembly is quickly and easily withdrawn and replaced.

A further embodiment is directed towards a disposable sensor pod, comprising a piezo, a cap, a contact board, a PCB processor board, and a PCB housing, wherein the PCB housing comprises attachment means to secure to an array, suitable for placing said sensor pod on a patient.

A further embodiment is directed towards a disposable sensor pod comprising a disposable sensor assembly and a disposable sensor base assembly, said disposable sensor base assembly comprising a PCB processor board, a PCB housing, a diaphragm bellows membrane, locking means to secure said diaphragm bellows membrane, and a locking cap, wherein attachment means are provided to allow said disposable sensor base assembly to engage to and disengage from an array device.

A further embodiment is directed towards a disposable sensor pod comprising a piezo, a cap, a contact board, a PCB processor board, a PCB housing, a diaphragm bellows membrane (DBM) and a locking cap, wherein said piezo, cap and contact board are secured to the PCB housing, which forces contact between the contact board and the PCB processor board, and on an opposing end of the PCB housing, the DBM is defined through an aperture in an array device, and secured to said array with a locking cap that secures said DBM to said array device, with the DBM being positioned through said aperture allowing movement of the disposable sensor pod.

A further embodiment is directed towards a disposable sensor pod comprising a diaphragm bellow membrane (DBM), said DBM comprising a top, a bottom, and outer edge comprising a flange, and an opening, between said top and bottom, with an inner flange around said opening; said DMB being secured at the outer flange between an inner and outer array; and said inner flange being secured between a locking cap and a PCB housing; wherein a disposable sensor assembly engages to and selectively engages the PCB housing. In certain embodiments, the disposable sensor assembly comprises a piezoelectric sensor, a contact board, and a circular shaped housing cap, having a top side and a bottom side, an inner surface and an outer surface, and a central opening extending through the top and bottom sides, on the top side a flange is positioned inside the central opening and disposed of to receive said piezoelectric sensor around the circumference of said piezoelectric sensor; the bottom side engaging said contact board which is secured beneath the flange; and one half of a locking means on said inner surface. In preferred embodiments, the one half of a locking means connects to a paired locking means, forcing contact with the contact board and powering the piezo. However, upon need for replacement, said disposable sensor assembly is quickly and easily withdrawn and replaced.

A further embodiment is directed towards a disposable sensor array comprising a track structure for securing at least two sensor pods; a disposable sensor pod comprising a sensor base having an track engaging means for selectively engaging to a slidably attaching to said track structure; said disposable sensor pod comprising a disposable piezo sensor and a PCB board. In certain embodiments said disposable sensor pod comprises a diaphragm bellow membrane (DBM), said DBM comprising a top a bottom and outer edge comprising a flange, and an opening, between said top and bottom, with an inner flange around said opening; said DMB being secured at the outer flange between an inner and outer array; and said inner flange being secured between a locking cap and a PCB housing; wherein a disposable sensor assembly engages to and selectively engages the PCB housing. In certain embodiments, the disposable sensor assembly comprises a piezoelectric sensor, a contact board, and a circular shaped housing cap, having a top side and a bottom side, an inner surface and an outer surface, and a central opening extending through the top and bottom sides, on the top side a flange is positioned inside the central opening and disposed of to receive said piezoelectric sensor around the circumference of said piezoelectric sensor; the bottom side engaging said contact board which is secured beneath the flange; and one half of a locking means on said inner surface. In preferred embodiments, the one half of a locking means connects to a paired locking means, forcing contact with the contact board and powering the piezo. However, upon need for replacement, said disposable sensor assembly is quickly and easily withdrawn and replaced.

A further embodiment is directed towards a disposable sensor array comprising a track structure for securing at least two sensor pods; a disposable sensor pod comprising a sensor base having a track engaging means for selectively engaging to a slidably attaching to said track structure. A further embodiment is directed to disposable curved sensor pads that are configured to selectively secure to a sensor pod, and which are replaceable units for use with an individual patient. The sensor pads are made from a silicon like gel material and are molded into a predetermined shape, wherein the predetermined shape aids in transmitting sound waves from the body to the piezo elements and also in blocking out extraneous noise to prevent debris and noise within the signal and data to be analyzed.

A further embodiment is directed towards a disposable array for determining carotid artery stenosis in a human patient comprising: a stem; a neck coupled to the stem and defining an angle of between 125° and 175°; a neck vertex coupled to the neck opposite the stem; and a pair of arms extending from the neck vertex, the pair of arms defining an angle of between 90° and 145°, and wherein each of the legs and arms are made of a flexible material that is configured to be flexed away from its resting state; and wherein the flexible plastic material imparts a force to return back to its resting state. A further embodiment is directed towards the array wherein the stem and arms define a track section. A further embodiment is directed towards the array wherein each of the arms and the stem are configured to receive a sensor pod.

A further embodiment is directed towards the array for determining carotid artery stenosis in the human patient wherein each of the sensor pods comprises: a housing configured to be coupled to the arms and the stem; a disposable cap configured to removably attach to the housing; a diaphragm that extends out of the disposable cap; a printed circuit board having integrated circuits, a rechargeable battery, spring loaded contact, an input, and LED status lights arranged thereon; a piezo element configured to receive vibrations from the diaphragm and output a signal to the input of the printed circuit board; and, optionally, a wireless charging coil configured to inductively charge the rechargeable battery.

A further embodiment is directed towards a disposable array for use in a carotid artery sensor configured as a Y-shaped structure comprising: a neck; a stem; a stem vertex arranged between the neck and the stem; a neck vertex coupled to the neck opposite the stem vertex; a left and a right arm coupled to the neck vertex, wherein the neck and stem are connected via the stem vertex such that the neck is biased at an angle of about 165°; wherein the left and right arms extend substantially perpendicularly from the neck from the neck vertex, and wherein the left and right arms create a bell-like shape. A further embodiment is directed towards the array wherein each of the arms and the stem define a track like structure are configured to receive a sensor pod. A further embodiment is directed towards the array wherein the sensor pod comprises: a housing configured to be coupled to the arms and the stem; a friction plunger defined to secure the sensor pod to the track like structure on the array; a disposable cap configured to removably attach to the housing; a diaphragm that extends out of the disposable cap; a printed circuit board having integrated circuits, a rechargeable battery, spring loaded contact, an input, and LED status lights arranged thereon; a piezo element configured to receive vibrations from the diaphragm and output a signal to the input of the printed circuit board; and, optionally, a wireless charging coil configured to inductively charge the rechargeable battery.

A further embodiment is directed towards a disposable piezo assembly comprising: a circular piezo cap comprising a top and a bottom an inner face and an outer face, with an opening between the top and bottom with the opening larger at the top than the opening at the bottom; a flange positioned on the inner face of the opening; a piezo having a top, a bottom, and a perimeter support; said piezo disposed of within said opening, with the bottom of the perimeter support engaged to an adhered to said flange; a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and on said inner face one half of an attachment means for securing said disposably piezo assembly to an assembly base.

A further embodiment is directed towards a sensor base for connecting to an array comprising a diaphragm bellows membrane a printed circuit board housing, a printed circuit board, and a cap; said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring, and an inner flange on an inner circumference of said ring; said outer flange engaging to said array and said inner flange engaging between said cap and said printed circuit board housing; said printed circuit board housing comprising a bell shape, having a narrow bottom and a wide top, with an opening between the top and bottom, a locking groove on said narrow bottom to engage said inner flange; and an attachment means a the top of the top; said printed circuit board fitting within said opening. In certain embodiments, the attachment means being a magnet, one half of a quarter turn locking mechanism; a groove, a pin, or threading.

A further embodiment is directed towards a disposable sensor pod comprising disposable piezo assembly and a sensor base, said disposable piezo assembly comprising: a circular piezo cap comprising a top and a bottom, an inner face and an outer face, with an opening between the top and bottom with the opening larger at the top than the opening at the bottom; a flange positioned on the inner face of the opening; a piezo having a top, a bottom, and a perimeter support; said piezo disposed of within said opening, with the bottom of the perimeter support engaged to an adhered to said flange; a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and on said inner face one half of an attachment means for securing said disposably piezo assembly to said sensor base; and said sensor base comprising a diaphragm bellows membrane, a printed circuit board housing, a printed circuit board, and a cap; said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring, and an inner flange on an inner circumference of said ring; said outer flange engaging to said array and said inner flange engaging between said cap and said printed circuit board housing; said printed circuit board housing comprising a bell shape, having a narrow bottom and a wide top, with an opening between the top and bottom, a locking groove on said narrow bottom to engage said inner flange; and an attachment means at the top of the top; said printed circuit board fitting within said opening.

A further embodiment is directed towards a disposable array comprising an array body, and three sensor pods; said array body comprising an inner array half and an outer array half, each inner and outer half comprising two arms and a neck; and three openings defined at each end of the arms and neck; said openings defined to accept a diaphragm bellows membrane, wherein said diaphragm bellows membrane comprises an outer flange to be accepted between said inner array half and outer array half; and a disposable sensor pod comprising a disposable piezo assembly and a sensor base, said disposable piezo assembly comprising: a circular piezo cap comprising a top and a bottom, an inner face and an outer face, with an opening between the top and bottom with the opening larger at the top than the opening at the bottom; a flange positioned on the inner face of the opening; a piezo having a top, a bottom, and a perimeter support; said piezo disposed of within said opening, with the bottom of the perimeter support engaged to an adhered to said flange; a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and on said inner face one half of an attachment means for securing said disposably piezo assembly to said sensor base; and said sensor base comprising a diaphragm bellows membrane, a printed circuit board housing, a printed circuit board, and a cap; said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring, and an inner flange on an inner circumference of said ring; said outer flange engaging between said inner array half and said outer array half in each of said three openings, and said inner flange engaging between said cap and said printed circuit board housing; said printed circuit board housing comprising a bell shape, having a narrow bottom and a wide top, with an opening between the top and bottom, a locking groove on said narrow bottom to engage said inner flange; and an attachment means at the top of the top; said printed circuit board fitting within said opening.

A further embodiment is directed towards a disposable array comprising a track body for accepting at least two sensor pods; said disposable array defined in a C-like shape, wherein the track body receives a sensor having a track accepting opening, and wherein said sensor is capable of being positioned on said array by sliding said sensor along said track.

A further embodiment is directed towards a slideable disposable sensor pod comprising a disposable piezo assembly and a track accepting base end, comprising an opening defined to position on a track structure of an array; said disposable piezo assembly comprising: a circular piezo cap comprising a top and a bottom, an inner face and an outer face, with an opening between the top and bottom with the opening larger at the top than the opening at the bottom; a flange positioned on the inner face of the opening; a piezo having a top, a bottom, and a perimeter support; said piezo disposed of within said opening, with the bottom of the perimeter support engaged to an adhered to said flange; a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and on said inner face one half of an attachment means for securing said disposably piezo assembly to said sensor base; and said sensor base comprising a diaphragm bellows membrane, a printed circuit board housing, a printed circuit board, and a cap; said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring, and an inner flange on an inner circumference of said ring; said outer flange engaging to a locking groove in said track accepting base end; and said inner flange engaging between said cap and said printed circuit board housing; said printed circuit board housing comprising a bell shape, having a narrow bottom and a wide top, with an opening between the top and bottom, a locking groove on said narrow bottom to engage said inner flange; and an attachment means at the top of the top; said printed circuit board fitting within said opening.

A further embodiment is directed towards a slideable sensor pod comprising a piezo cap defining an opening between a top and bottom, a flange in said top, disposed to accept a piezo through said bottom and secure adjacent to said flange; a printed circuit contact board engaging electrical contacts between said piezo and a printed circuit board positioned below said piezo; a knuckle having an opening between a top and bottom, with said top opening receiving said printed circuit board and the bottom opening receiving a sled ball; said sled ball comprising a top having a globular shape to match the shape of the opening in the bottom of said knuckle, and a bottom defined to slide along a track of an array; a compression spring and compression washer engaging the knuckle and said sled ball to allow for movement of the sled ball to orient the sensor pod at angles from the sled ball.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts a partial exploded view of a sensor array and piezo pods.

FIG. 2 depicts an exploded view of a sensor array and piezo pods.

FIGS. 3A and 3B depict an exploded view of a piezo pod with bellows membrane.

FIG. 4 depicts various views of a sensory array with piezo pods attached.

FIG. 5 depicts the movement of a bellows membrane on a piezo pod.

FIG. 6 depicts a sensor array on a person.

FIG. 7 depicts a side and sectional view of a bellows piezo pod.

FIG. 8 depicts a rear neck sensor array and two attached slideable sensor pods.

FIG. 9 depicts a front view of a rear neck sensor array and two attached slideable sensor pods.

FIG. 10 depicts an alternative view of FIGS. 8 and 9.

FIG. 11 depict an alternative sensor array and sensor pods secured on the array, with a partial exploded view of certain disposable components.

FIG. 12 depicts an exploded view of a sensor pod having sliding means on an array.

FIG. 13 depicts a cross-sectional view of a slideable sensor pod.

FIG. 14 depicts a disposable sensor pod with pin mount.

FIG. 15 is a view of two piezos without an array.

FIG. 16 is a side view of a piezo without an array.

FIG. 17 depicts a sensor paid with a curved, concave piezo.

FIG. 18 depicts a concave piezo.

FIG. 19 depicts nonsymmetrical sensor pads.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “a” “an” and “the” are intended to be singular or plural.

As used herein, the term “piezoelectric sensor” is used interchangeably with “piezo” or “piezo sensor.”

As used herein the term diaphragm bellows membrane is also referred to as DBM or a diaphragm.

Piezoelectric sensors have a variety of potential uses, but as described herein, they are being utilized as a contact microphone. The principle of operation of a piezoelectric sensor is that a physical dimension, transformed into a force, acts on two opposing faces of the sensing element. Detection of pressure variations in the form of sound is the most common sensor application, e.g., acting as a microphone, wherein the sound waves bend the piezoelectric material creating changing voltage. Accordingly, the piezo sensor can be placed on or near a sound to receive the sounds.

Piezo sensors are especially used with high frequency sound in ultrasonic transducers for medical imaging and industrial nondestructive testing. However, piezo sensors are also frequently used for the detection and activation of a device, based on the ability to receive a signal and to then send an electronic signal, thereby acting as the actuator. In the embodiments herein, piezoelectric sensors (“piezo”) are utilized for their ability to detect certain frequency sounds or vibrations caused by the distortion of a fluid flow vessel, specifically of the arterial circulatory system.

Because of the sensitivity of these sensors, piezoelectric sensors can be somewhat fragile and can be broken from both normal use and misuse. Furthermore, as utilized in a medical device, there is the inherent need to ensure accuracy of each of the three piezoelectric sensors. Accordingly, any slight modification of the sensor may result in a modification of the input received and thus would result in erroneous data.

Replacement components may be one of three different components as described herein. A first component may be a disposable piezo assembly, a second component may be a sensor pod, which comprises the disposable piezo assembly and a sensor base, and a third component may be a disposable array, comprising one or more sensor pods. In this manner, each component may be disposable to allow for easy replacement after use.

Piezo sensors can include any number of materials. Typically, however, the sensor contains a portion of ceramic material and a metallic component. Piezo sensors may also use a polymer film configuration which exhibits a low acoustic impedance similar to that of human tissue, or made of metallic materials. These sensors, as used in the invention herein, are typically a circular shape with a diameter of about 3 inches. Typical piezos have a diameter from about 0.01 inch to about 6 inches for use in medical settings, with most typical sizes between about 0.5 inch to about 4 inches in diameter. For most applications, including industrial settings, a range of 0.01 inch to about 12.0 inches is preferred, wherein the size of the piezo is generally related to the diameter of the fluid flow vessel to be measured. In preferred embodiments, the fluid flow vessels are veins and arteries in the body, for which a 4.0 inch or smaller diameter piezo is preferable.

There is no inherent frequency limit for a piezoelectric sensor. However, the limits of applications are usually determined by resonances associated with the shape and/or the size of the transducer design. The piezo sensors utilized herein have a thickness of about 0.01 mm to 2.0 mm and are capable of detecting sounds between 10 Hz and 32 kHz and an amplitude of 0.0002 N/m² to greater than 10 N/m². In preferred embodiments, the piezos attached to a sensor pod detect sounds between about 20 Hz and 3,000 Hz, which are relevant towards measurements of fluid flow in the body. Typically, these sounds have an amplitude of between 0.002 N/m² and 20 N/m². While additional sounds are recorded, many of these sounds, i.e., the heart beat and extraneous noise, are removed from the data set through several filters.

FIGS. 17 and 18 specifically depict a new piezo and mount. The piezo (602) is a concave piezo, made of metallic or polymeric materials. Curved cap (601) contains an outer rim, and an inner flange adjacent to a central opening having a similar size and shape to the piezo. The flange supports the piezo (602) which can be engaged with an adhesive (603).

In the broadest sense, the piezo sensors are disposed of within a pod. On one side of the piezo is placed a sensor pad, for example those of (1), (2), (17), and (19). The sensor pad is then pressed against the skin or clothing of a patient to listen to the underlying circulatory system. The sensor pad allows for transmission of energy waves, sound and vibrations, which are received by the piezo element. Gel or other impedance matching substance may be applied to the skin facing surface of the pad.

In view of FIG. 1, a sensor array is defined comprising a disposable sensor assembly (85), and a disposable sensor pad (18). These two features are replaced frequently, to prevent contamination and error. For example, the sensor can be placed on a patient as depicted in FIG. 6. The yoke (140, 130, and 3) is handheld by the patient during the test. Piezos wear over time and that damage can unfortunately occur from use. Because of the sensitive nature of the piezo, it is necessary to ensure that they are properly functioning before each use. Proper testing protocols utilize a program implemented through a computer, which generates a known set of sounds related to the sounds to be detected on the fluid flow vessel and matches the known played sound to the sounds detected and recorded in real time by the sensor pods. Where the known sounds and detected sounds match, the sensor pod is confirmed to be working to specification. Wherein the sensor pod is not functioning properly, the system will sound an alarm, which will indicate to the operator the need to replace the disposable component. Accordingly, the piezos must be designed to allow for easy replacement of the piezo, while ensuring that the device maintains operation and reliability during ordinary use.

There are several ways in which the piezoelectric elements can wear or be damaged including ordinary and standard use of the device. Ordinary wear may occur as the piezoelectric element wears from ordinary and standard use, and after about 10 to about 400 uses, the piezoelectric element breaks down so that the function and the electrical currents generated are different when comparing the first use to the second, fifth, tenth, 25th, 50th, 75th, 100th, 200th, 300th, or 400th use and all numbers in between. Accordingly, to ensure that accurate results are received by each of the units, it is imperative to replace the unit that has worn to maintain consistent results.

Additional wear or breakage can occur to the piezoelectric sensors by error or accident. For example, human error may lead to the array being dropped, or placed onto the base in a manner that breaks, bends, or otherwise damages the piezoelectric unit. Further damage may occur as clean sensor pads are attached and placed against the piezoelectric sensor for use on a patient.

To ensure sanitary use of the device, the sensor pads are replaced between each use of the device. However, because the sensor pads are placed directly onto the piezoelectric unit, there is risk that human error may damage the piezoelectric sensor, either by too much force, or simply through improper pressure applied to the piezo when installing or removing a sensor pad.

Ordinary wear or accidental damage is tested through routine quality control procedures performed in a self-diagnosis module. The sensor pods can be placed in a base or holding device that comprises a speaker embedded within the base which provides a predetermined sound that can be measured by each piezoelectric sensor. When the sensor device is activated for use, the sound, which can include both audible and inaudible sound waves, is played for between about 1 second and about 20 seconds. During the time that the sound is playing, each of the piezoelectric sensors records the sound and a program then confirms that each of the three sensors is recording the appropriate sounds being played. If each of the three sensors detects the appropriate sounds, then the sensor device is ready for use. However, if one or more of the sensors detects sounds that do not match with the predicted sounds, the device will provide an alert, which may include lights, sounds, or other display elements, to alert the user of the device that one or more of the piezos needs to be replaced.

An optional display screen attached to the base can further display the device and identify the sensor pod containing the piezo that failed the QC test. Another manner for identifying the failed sensor is to have lights that correspond to working or failed tests either on the base or on the sensor array itself. Once the failed piezo is identified, the user can then replace one or more of the components, as described herein, and then perform the QC test again to ensure that the device is now ready for use.

Accordingly, in a preferred method, a piezo is replaced every 10 uses to ensure that there is no noticeable wear and tear on the piezo, and to prevent the possibility of erroneous data. Accordingly, the sensor device comprises a counter wherein the number of times that a test is run with each of the piezo is counted, so that the sensor device notifies a user that the piezo needs to be replaced, even if each of the piezos are working properly.

In other embodiments, the piezos can be replaced every 1, 2, 5, 10, 25, 50, 75, 100, 125, 150 uses, about every 200 uses, or about every 400 uses or a number in between. The particular number of uses for each piezo will be determined through additional use of the devices in normal practices. However, to ensure sanitary and consistent results, it is preferred that the piezos are changed after no more than 100 uses.

To facilitate easy changing of the disposable piezo assembly (85), the disposable piezo assembly (85) is able to easily attach to an underlying disposable sensor base (86), and to be replaced. For example, a simple threaded attachment mechanism allows the sensor pod to be removed from the sliding sensor pod base, which is attached to the sensor array. Alternatively quarter, or half turn attachment means, magnetic attachment, and others as known to one of ordinary skill in the art are known.

FIG. 1 depicts a sensor array comprised of an inner array half (130) and an outer array half (140). The halves are secured together with threaded fasteners (134 and 133), though adhesives, snap fits, or plastic welding can be utilized for securing means. At the bottom of the array is a first sensor pod, depicting a locking cap (125) and a DBM (120) with a sensor pad (18) positioned on the obverse side, with a threaded fastener (133) securing said membrane in place. The DBM (120) is an elastomeric member, with or without articulating bellows geometry, containing an inner opening and an inner and outer flange, suitable to secure the DBM to an array, and to allow for the sensor pod to move freely on said array. The DBM (120) may also be attached to feature (130) or (140) via insert molding.

Near the vertex of the Y is a charging port (820) and a PCB charging contact (131) disposed therein. This allows the array to be placed into a charging port and charge a central battery.

Attached to the array is a sensor pod, made up of the components of a locking cap (125), a DBM (120), a PCB processor board (110), a PCB housing (115), a piezo cap (100), a piezo (90), and a disposable piezo assembly (85). These features are further detailed below. A disposable sensor pad (18) can be affixed to the piezo (90) via adhesives or by the natural adhesion of the pad material. For example, the piezo cap (100) can be attached to the PCB housing (115) in several ways, including as in FIG. 1 with a quarter turn feature, comprising a recess (101) and a locking feature (116) having corresponding openings to the pins on the piezo cap (100). By securing these together, the spring pin (111) is engaged and provides electrical contact between the components to power the piezo (90) from an internal power source. Features (101) and (116) can be swapped, provided they are maintained as a matching pair, to allow for selective attachment and detachment of the disposable piezo assembly (85). A recess is provided in the top of the piezo cap (100) for mounting the piezo (90) via pressure sensitive adhesive (92). The recess contains a flange which supports the circumference of the piezo (90) within the piezo cap (100). This recess also allows the piezo to sit about flush with the top of the piezo cap (10), for placement of the sensor pad (18).

FIG. 2 provides a further exploded view of FIG. 1. A disposable sensor pad (18) is provided to be attached to the disposable piezo assembly (85). The assembly (85) comprises a piezo wiring (91) which connects the piezo (90) to the PCB contact board (105). Two pressure sensitive adhesives (92) are provided, one connecting the piezo (90) to the piezo cap (100) and another adhesive (92) connecting the piezo cap (100) to the PCB contact board (105). These components make up the disposable assembly (85).

In one embodiment, this disposable assembly (85) is the smallest disposable component, which allows for quick and easy replacement of the piezo without replacement of any further components (except for the disposable sensor pad [18], which is replaced for every use). The disposable assembly (85) comprises a quarter turn locking feature (101) that corresponds to a paired feature (116) on the PCB housing (115). This allows for a small turn of the disposable assembly (85) to remove the component and replace. Additional attachment mechanisms can be easily exchanged, for example magnetic, threaded engagement, or simply a threaded fastener or two that can be engaged for replacement. Finger capable fasteners can use a full, half, or quarter twist to secure a fastener between two components. A person of skill in the art will recognize that numerous options exist for attaching and detaching such components and that attaching means incorporates these listed and additional options not described in detail herein.

The PCB housing contains a locking groove (117) that engages with and locks the elastomer DBM (120) to the PCB housing (115). In particular, locking groove (117) engages locking key (121) between the locking cap (125) and the PCB housing (115). A locking cap (125) engages to a fastener (113) to secure the key (121). A second key (122) is also provided to lock the DBM (120) between the outer array housing (140) and the inner array housing (130). A further detail of these locking features are provided in FIG. 7.

While the disposable assembly (85) can be easily removed and replaced, it is also contemplated that the entire sensor pod can be removed and replaced easily. For example, removal of threaded fasteners (133) will allow for quick and easy replacement of the entirety of the pod, inclusive of the DBM (120). Furthermore, the DBM (120) can be held in place, and the locking cap (125) can reveal a threaded fastener (113) to replace the remaining components. In the figure, the fastener (113) can be oriented in either direction to allow for quick replacement.

FIG. 2 further details components of the array including a PCB charging contact (131) connecting a wiring harness (132) to each of the piezo sensors (90). A battery, not depicted, can be positioned within the array handle to power the devices, or can be attached directly to an AC or DC power source with a wire.

FIGS. 3A and 3B depict further exploded views of a sensor pod. FIG. 3A specifically defines a dual piezo mechanism, wherein a second piezo (150) is attached to the rear of the PCB processor board (110) to allow for noise cancelling. Briefly, though described above, FIG. 3A depicts a piezo (90) a pressure sensitive adhesive (92) and a piezo cap (100). The adhesive (92) engages the flange of the cap (100), and said flange supports the piezo (90) at its circumference. A second pressure sensitive adhesive (92) is positioned inside of the piezo cap (100) and engages to the PCB contact board (105), which contacts a PCB processor board (110). A second piezo (150) is engaged on the rear of the PCB processor board and a wiring (91) attaches the piezos to the PCB processor board (110). A threaded fastener (113) secures the PCB housing. The details of the locking features (121) and (122) are best seen in a later figure. Sound locking holes (118) are depicted as well as the entrance hole (119) for the wiring harness (132).

FIG. 3B depicts a single piezo (90), a piezo wire (91), and the adhesive (92). These combine into the piezo cap (100), which contains a locking feature (101). The second adhesive strip (92) attaches to the PCB contact board. The spring pin (111) is seen positioned to contact the PCB contact (106). A battery (112) is attached to the PCB board (110). A screw (113) attaches the PCB housing to the locking cap (125), which secures the DBM (120). The disposable piezo assembly (85) is combined with the sensor base (86) to form a sensor pod. Each of the disposable piezo assembly (85) and the sensor base (86) are replaceable or disposable, as needed.

FIG. 4 depicts several views of an array, with an angled sensor pad (18) positioned on each of the different sensor pods.

FIG. 5 depicts the possible movement of the DBM (120). The arrows (200) refer to spherical movement of the entire assembly, including the sensor pad (18), and the disposable piezo (85). The centerline (205) is provided, with all features moving in the direction of (210), both forward and backward, as necessary. In this manner, the DBM (120) allows for the entire feature of the sensor pad (18) and piezo (90) to press against a surface and extend away from the surface, but to return back to a central position after use. Furthermore, the spherical movement (200) allows for angular rotation to rotate and angle the sensor pad (18) to best fit against the skin surface of a patient, for example as depicted in FIG. 6. Here, a different sensor pad (36) is used against the skin surface on the neck, as compared to the sensor pad (18) at the torso. Appropriate pads having different shapes can be used based on the needs of the particular patient.

FIG. 7 depicts a side profile and cross-sectional view through line A-A of a sensor pod with DBM (120). The side profile shows a sensor pad (18) positioned above the piezo cap (100), PCB housing (115), the wiring harness (132), and the inner array (130) and outer array (140) connected with threaded fasteners (133). The cross-sectional view depicts a PCB housing (115) engaged to the piezo cap (100), with the adhesive (92) securing the piezo (90) at the righthand side. The lefthand side depicts the inner array 130 secured to the outer array (140) with a fastener (133). By compressing these together, the elastomer DBM (120) is compressed together. For example, the locking feature (122) is depicted securing the edge of the membrane (120) between the inner array (130) and the outer array 140. The inner locking feature (121) is secured between the PCB housing (115) and the locking cap (125). A fastener (113) is provided therein. Each side is similar through the cross-sectional view.

The DBM (120) is a circular feature having an inner opening. At the outer edge of the DBM (120) is an outer flange (122). At the circumference of the inner opening, there is an inner flange (121). These flanges (122 and 121) are used to lock the DBM (120) into place between the array features (130 and 140), as well as between the locking cap (125) and the housing (115).

Therefore, the DBM (120) is an elastomeric material, capable of allowing the attached piezo to flex in any direction, as well as move away from the surface to be compressed. This allows for a consistent pressure to be applied to the skin surface by the sensor pad (18), based on the rigidity of the membrane (120).

FIG. 8 depicts a rear image of a neck array (30). Threaded on the neck array (30) is a piezo base (38) comprising openings to allow for movement along the neck array (30). Attached to the piezo base (30) is a DBM (120) as depicted in part of FIG. 7, with the difference being features (130) and (140) are exchanged for the components of the piezo base (38). The neck array (30) is a track-like structure, about which the sensor pods can slide on openings in the piezo base (38). The neck array (30) is generally C-shaped, and when the sensor pods are at the end of the track, are oriented for placement on the carotid artery. However, the sensor pods can be centrally aligned, thus being side-by-side and placed together on an area of interest.

FIG. 9 depicts a front view of the neck array (30), which more particularly depicts the piezo cap (100), the sensor pad (36), the PCB housing (115), the DBM (120), the locking cap (125). FIG. 10 provides an alternative view of FIGS. 8 and 9.

FIG. 11 depicts a variation of an array (5) having a stem (10), a left arm (6), and a right arm (7). Like the neck array (30), this embodiment of an array comprises a pod sled (11), which allows the sensor pods (1) to move along the arms (6 and 7) or the neck (10), to allow for fit of these sensor pods (1) on a patient. A rear pod mount (12) comprises attachment means (16) which secures to the piezo cap (14). For example, the attachment means (16) may be a quarter thread, pin and recess. Alternative is a paired threaded fastener, a set of magnets, threaded fasteners having an opening in one end and threads in the other. A piezo (13) is depicted at one end, and the sensor pad (18) can be placed on said piezo. Rotation of the rear pod mount (12) will remove the piezo cap (14) and included piezo (13). Alternatively, the pod sled (11) can be rotated in a quarter, half, or full turn to separate from the sled ball (17) and remove the entire part of the sensor pod (1) or be attached with mechanical fasteners (415). Accordingly, easy removal is possible for either just the disposable piezo component (13) or for the entirety of the sensor pod (1) by removal of the pod sled (11).

In an ideal world, every patient would be the same shape and size, and modification of the structure would not be required. However, in practice, men, women, and children have significantly different shapes and sizes due to the amount of body mass, muscle, breast tissue, fat deposits, etc. Specifically, changes in body mass and shape between the neck and the torso create issues where the array must be modified to position one or more sensors in appropriate positions for acoustic sensing.

Therefore, as used on human patients, a difficulty in such devices is that people come in all shapes and sizes and that the array must be easily modified to fit these different shapes and sizes. One option would be to utilize different sized, fixed position sensing elements, due to the fragile nature of the sensing elements. However, constant movement and replacement of the sensing elements from one device to another would likely result in more damage to the sensing elements and increase the risk for the need for frequent replacement of these elements. Therefore, an array with rails, both the neck and Y versions, provides the necessary stability and flexibility provides a great advantage in the array for use on patients.

A particular feature of the sensor pods when affixed to an array is that they are adjustable and can be configured to account for the anatomical differences between individuals while remaining sufficiently rigid to support the sensing elements. Such flexibility can be seen in the depiction of FIG. 5 or in the angled pod, in FIG. 12.

The exploded view of FIG. 12 details a variation of a sensor pod (1), showing the components that make up the sensor pod (1) able to slide along the array. The sensor pad (18) attaches to the piezo (90) via adhesives or the natural adhesion of the material. Within the piezo cap (100), receiving charging coil (400) attaches to inside of (100) with a pressure sensitive adhesive (92). Piezo (90) attaches with pressure sensitive (92) to receiving charging coil (400). PCB contact board (105) attaches via pressure sensitive adhesive (92) to piezo (90). The receiving charging coil (400) makes electrical contact with the PCB contact board (105) with a soldered or crimped connection along wires (430). A PCB processor board (110) is then compressed adjacent into (12) and makes electrical connection via spring pins (111) to PCB contact board (105). The sensor pad (18) fits within the piezo cap (100), which is attached to a pin board (400) with a pressure adhesive (92). Another adhesive connects the board to the piezo (90) and another adhesive connects this to the PCB contact board (105). A fastener (403) with a washer (405) compress with a friction washer (407) into the knuckle (12). A sled ball (17) allows rotation of the piezo when mounted, held, in part, by the friction of the knuckle (12) and the friction washer (407). A spring (409) compresses against spring cap (410) and sled ball (17) when pod sled (11) is assembled to sled ball (17) via washers (412) and threaded fasteners (415), creating frictional pressure against the inside surface of array arm (2). This allows for very easy positioning of the pod assembly (1) anywhere along array arms without actuating any mechanical buttons. Fasteners (415) can be excluded for attachment means, such as quarter turn, half turn, full turn threaded attachment, magnetic, or other similar attachment means, to allow for easy removal of the sensor pod. Alternatively, the sensor pods can simply slide off of the end of the senor and a new one replaced by sliding it into place. The spring (409) holds the sensor pod into place during use.

FIG. 13 depicts a cross-sectional view of FIG. 12.

FIG. 14 depicts a sensor pod having a pin mount (38). This pin mount can engage to a ball mounting system, to allow for rotation of the sensor pod. A corresponding ball recess can be provided to allow for such attachment means and rotation. The fastener acts as a ball and socket, allowing rotational movement.

FIGS. 15 and 16 depict a piezo pair that does not utilize an array. Accordingly, the piezo (150) relies upon an adhesive surface on a sensor pad (18) to allow the piezo to stick to the skin surface. In certain embodiments, it is advantageous to perform a test with one piezo at a time, with the patient laying in a position to allow for the piezo to rest with gravity. Thus, the adhesive does not need to be so strong but rather merely sufficient to hold the piezo in a relatively stable position. This may be useful for situations where an array is impracticable, whether due to the dimensions of the patient, surgical procedures, or the like, that would restrict access of an array. Furthermore, by eliminating the array, a further source of noise may be eliminated from the data sample.

FIGS. 17 and 18 depict a gel pad with cylindrical surface (600) that contacts with the piezo film (602). The upper frame (601) supports the piezo film (602) and engages with an adhesive (603) to the lower frame (604). A wiring harness (605) and solder or welds (606) connect the wiring harness to the piezo film (602). The lower frame (604) has a concave surface, and the piezo film (602) engages with this curvature resulting in a piezo having a concave surface. The concave surface allows for increased reception of both high and low frequencies, thereby increasing sensitivity in certain instances, wherein peaks may be identified at these margins.

FIG. 17 particularly depicts the cross-sectional view and side view of the film piezo (602), while FIG. 18 depicts the exploded view.

A curved film piezo can be exchanged for any of the piezos in embodiments described herein. For example, the lower frame (604) may comprise a relevant attachment means, and further comprise a PCB contact point to allow for direct exchange with prior examples and figures.

FIG. 19 depicts two different sensor pads (18) for use in an array with a piezo sensor. The sensor pads are angled at the skin facing surface, such that on the lefthand side, the curvature on the bottom right engages to an angled structure to ensure a good acoustic fit. By contrast, the sensor pad on the righthand side of the page comprises a dual concave structure, to fit around a structure that is rounded. In each case, there is a proper fit, and so the sensor pod must be able to rotate to allow the sensor to be properly fit against the skin to achieve a proper acoustic contact for data collection. Cross-sectional views of the left and right sensor pads are depicted for clarity.

The sensor pods, including both (85) and (86) components, are replaced as necessary to allow for proper functioning of the piezo sensor. These replacements are performed as necessary, but at least every 10, 25, 50, 75, 100, 150, or 200 tests. When the sensor base (86) is replaced, the disposable piezo assembly (85) is also replaced. By contrast, in each test, sensor pads (18) are replaced.

In certain preferred embodiments, the sensor pads (18) can be secured onto the piezoelectric unit via an adhesive, such as one of several common low tack adhesives for providing for a temporary securing of the sensor pad to the piezo element. Other embodiments may utilize a gel or other water or solvent based material that may secure the sensor pads without the need for an additional adhesive material. In further embodiments, the sensor pad fits into the sensor pod and secures onto the piezo without the need for any adhesive.

A particular feature of the sensor pads described in the embodiments herein is the fact that the top face shape (that contacts the patient), and the bottom face shape (that contacts the piezo) are made so that when the top face contacts the patient and thus applies pressure to the sensor pad and through to the bottom face, the piezo does not flex when pressure is applied to the sensor pad. This is important to ensure consistency and accuracy of the piezo device. Therefore, the sensor pad, in certain embodiments, is designed such that the piezo does not flex when pressure is applied to the sensor pad. In a further preferred embodiment, the piezo flexes less than about 0.1%, 0.5%, 1.0%, 5.0%, 20%, and 25% and all percentages in between.

Accordingly, in certain embodiments, the amount of flex is greater than zero (i.e., rigid and does not flex), but the amount of flex is minimized to maintain accuracy of the piezoelectric unit.

It is also preferred that the sensor pads create a proper impedance matching with a patient. Accordingly, the sensor pad is designed to have a slight tackiness which ensures a proper impedance matching with the patient, which then successfully transfers sounds through to the piezo element so that the piezo can properly detect vibrations and noise signals from the patient.

Therefore, in order to maintain both sterility of the medical device and proper function of the medical device, it is necessary to provide replaceable components. The entire device is a complex system comprising a display, a base unit, an array, a sensor base, a disposable piezo assembly, and a sensor pad. Each of the last four are disposable. The array itself can be disposed of after a number of uses, likely between 100 and 1,000 uses. The array may lose elasticity to ensure proper fit on a patient, gain cracks, or simply lose stability. Each of these may increase variability and thus replacement is warranted.

The sensor base comprises attachment means for the sensor pod to the array, and comprises electronics for connecting the sensor itself, typically a piezo, to the device. The base, using certain elastomeric materials to allow for movement of the sensor pod, will wear with time, necessitating replacement for minimizing variability.

The disposable piezo assembly is intended for more frequent replacement than the base or the array, as the piezo is susceptible to wear or damage. Accordingly, frequent changes, such as between every use and every 10, 25, 50, or 100 uses is necessary for accurate results.

The device is a complex system comprising multiple components, each working together to ensure that accurate results are obtained. Disposable components ensure that the system works properly, every time, and that it generates accurate and reliable data.

A kit is envisioned with the system, wherein a plurality of sensor pads are provided, a plurality of disposable piezo assemblies are provided, at least two sensor base assemblies, and at least two arrays. Said kit can be used with a system comprising the base and a display, as well as necessary software and hardware for energizing and running the device through its necessary protocols.

Claims

1. A disposable piezo assembly comprising:

a circular piezo cap comprising a top, a bottom, an inner face, and an outer face, with an opening between the top and the bottom with a larger diameter at the top than at the bottom;

a flange positioned on the inner face of the opening;

a piezo having a top, a bottom, and a perimeter support;

said piezo disposed within said opening with the bottom of the perimeter support engaged to and adhered to said flange;

a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and

one half of an attachment means on said inner face for securing said disposable piezo assembly to an assembly base.

2. The disposable piezo assembly of claim 1 comprising an adhesive between said piezo and said flange and between said printed circuit board and said flange.

3. The disposable piezo assembly of claim 1 wherein said disposable piezo assembly is attached to an array body via a sensor base.

4. The disposable piezo assembly of claim 3 wherein the array body comprises:

a stem;

a neck coupled to the stem and defining an angle of between 125° and 175°;

a neck vertex coupled to the neck opposite the stem; and

a pair of arms extending from the neck vertex, each concluding at an end, the pair of arms defining an angle of between 90° and 145°, and wherein each of the arms are made of a flexible plastic material that is configured to be flexed away from its resting state;

the sensor base being positioned at the end of each arm; and

wherein the flexible plastic material imparts a force to return back to its resting state.

5. The disposable piezo assembly of claim 4 wherein the stem and arms of the array body define a track section.

6. The disposable piezo assembly of claim 5 wherein the sensor base is slidably attached to the track section of the stem and the arms.

7. The disposable piezo assembly of claim 1 further comprising a disposable sensor pad wherein the disposable sensor pad is one of a silicone gel pack, an epoxy/fiberglass diaphragm, or a polyurethane-coated silicone.

8. A sensor base for connecting to an array comprising:

a diaphragm bellows membrane, a printed circuit board housing, a printed circuit board, and a cap;

said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring shape and an inner flange on an inner circumference of said ring shape;

said outer flange engaging to said array and said inner flange engaging between said cap and said printed circuit board housing;

said printed circuit board housing comprising a bell shape having a narrow bottom and a wide top, with an opening between the wide top and the narrow bottom and a locking groove on said narrow bottom to engage said inner flange;

an attachment means at one end of the wide top; and

said printed circuit board fitting within said opening.

9. The sensor base of claim 8 further comprising an adhesive to secure said printed circuit board to said printed circuit board housing.

10. The sensor base of claim 8 wherein said attachment means on said wide top is engaged at an outer edge of said wide top.

11. The sensor base of claim 10 wherein the attachment means is a magnet, one half of a quarter turn locking mechanism, a groove, a pin, or threading.

12. A disposable sensor pod comprising:

a disposable piezo assembly and a sensor base, said disposable piezo assembly comprising a circular piezo cap comprising a top, a bottom, an inner face, and an outer face, with an opening between the top and the bottom with the opening larger at the top than the opening at the bottom;

a flange positioned on the inner face of the opening;

a piezo having a top, a bottom, and a perimeter support;

said piezo disposed of within said opening with the bottom of the perimeter support engaged to and adhered to said flange;

a printed circuit board having a ring shape and an outer diameter to fit within the opening and engaged to the bottom of said flange; and

one half of an attachment means on said inner face for securing said disposably piezo assembly to said sensor base;

said sensor base comprising a diaphragm bellows membrane, a printed circuit board housing, a printed circuit board, and a cap;

said diaphragm bellows membrane being a ring shape having an outer flange on an outer circumference of said ring shape and an inner flange on an inner circumference of said ring shape;

said outer flange engaging to an array and said inner flange engaging between said cap and said printed circuit board housing;

said printed circuit board housing comprising a bell shape having a narrow bottom and a wide top with an opening between the wide top and the narrow bottom, and a locking groove on said narrow bottom to engage said inner flange;

an attachment means at one end of the wide top; and

said printed circuit board fitting within said opening.