Body worn physiological sensor device having a disposable electrode module

1. A body worn patient monitoring device comprising:

a disposable electrode module comprising a flexible circuit layer and an insulating member having an opening on opposing sides of the module, each opening sized to receive an electrode gel, the insulating member forming a bottom layer of the disposable electrode module that is adapted to be directly and non-permanently affixed to a skin surface of a patient and configured for single patient use, the disposable electrode module being crescent-shaped to enable the monitoring device to be placed on a portion of the chest or the side of a patient;

a reusable communication-computation module removably attached to an upper surface of the disposable electrode module, the computation-computation module being configured to receive physiological signals from the flexible printed circuit layer and having a microprocessor that is configured to process and analyze the physiological signals, the communication-computation module being powered upon attachment to the disposable electrode module by batteries disposed on opposing sides of the disposable electrode module, each battery disposed above an electrode; and

a series of resistive traces screened onto the flexible printed circuit layer, at least one of the resistive traces being configured as at least one series current-limiting resistor to protect the communication-computation module.

2. The device of claim 1 , including a power source to power the patient monitoring device.

3. The device of claim 2 , wherein the communication-computation module is reusable.

4. The device of claim 3 , wherein the flexible substrate and the communication-computation module each include a connector, the connectors enabling the communication-computation module to be releasably connected to the flexible substrate and to receive the physiological signals.

5. The device of claim 2 , wherein at least two of the plurality of electrical connections are ECG electrodes.

6. The device of claim 5 , wherein the series of resistive traces protects the communication-computation module during a patient defibrillation event.

7. The device of claim 6 , wherein a mechanical interface from the series of resistive traces includes a filleted edge.

8. The device of claim 1 , wherein the plurality of electrical connections comprise at least one of direct electrical connections to the skin surface of the patient and indirect electrical connections to the skin surface of the patient.

9. The device of claim 8 , wherein the indirect electrical connections comprise capacitive connections to the skin surface.

10. The device of claim 5 , wherein the communication-computation module includes a pacer detection circuit.

11. The device of claim 10 , wherein the pacer detection circuit generates a microprocessor interrupt to inform the microprocessor that a pacer event occurred.

12. The device of claim 11 , wherein the microprocessor interrupt is used to mark a corresponding physiological signal in time as related to a pacer event.

13. The device of claim 11 , wherein the device automatically determines if a patient has a pacemaker and only enables the pacer detect circuit when a pacemaker is present.

14. The device of claim 1 , wherein the series of resistive traces are at least partially covered by a non-removable insulating coating.

15. The device of claim 2 , further comprising a hard-wired communication cable between the reusable communication-computation module and a remote device.

16. The device of claim 2 , further comprising a radio circuit that communicates a result of an analysis of the physiological signals by the microprocessor.

17. The device of claim 16 , wherein the radio circuit is configured to communicate the result only upon occurrence of a predetermined physiological event as determined by the microprocessor.

18. The device of claim 1 , wherein the flexible circuit layer is made from an insulating material.