Body worn physiological sensor device having a disposable electrode module

1. A body-worn physiological sensor comprising:

a computation-communication module including a housing retaining a processor;

a flexible circuit layer configured to be coupled to a skin surface of a subject to measure physiological signals, said computation-communication module being attached to the flexible circuit layer;

an adhesive covering at least a portion of the flexible circuit layer; and

a protective covering that protects the adhesive.

2. The sensor of claim 1 , in which the flexible circuit layer has traces of determinable electrical resistance.

3. The sensor of claim 2 , in which the traces on the flexible circuit layer are configured to electrically couple the computation-communication module to the flexible circuit layer, thereby forming a disposable module connector.

4. The sensor of claim 1 , in which the traces on the flexible circuit layer are at least partially covered by a non-removable insulating covering.

5. The sensor of claim 1 , wherein the flexible circuit layer further comprises a plurality of openings sized to receive electrode gels.

6. The sensor of claim 1 , further comprising a hard-wired communication cable.

7. A body-worn patient monitoring device comprising:

a disposable electrode portion comprising:

a flexible printed circuit layer made from an insulating material and defining a substrate,

at least two electrodes being disposed onto a surface of the substrate,

electrical traces defined between the at least two electrodes, and

a connection pad;

a reusable communication module comprising:

a housing containing a processor, and

a wireless communication unit, and in which the reusable communication module is releasably attached to the disposable electrode portion by at least one latching clip; and

a hard-wired communication cable.

8. The body-worn patient monitoring device of claim 7 , wherein the electrodes are integrated into the flexible circuit layer of the disposable electrode portion.

9. The body-worn patient monitoring device of claim 7 , wherein the electrodes are snap fitted to the flexible printed circuit layer.

10. The body-worn patient monitoring device of claim 9 , wherein the snap is disposed at the end of an extension.

11. The body-worn patient monitoring device of claim 7 , wherein the electrical traces are screened onto the flexible printed circuit layer.

12. The body-worn patient monitoring device of claim 11 , including an insulating layer applied onto the electrical traces.

13. The body-worn patient monitoring device of claim 12 , wherein the insulating layer is a fabric applied over the electrical traces of the flexible printed circuit layer.

14. The body-worn patient monitoring device of claim 13 , wherein each electrode includes an electrode gel and a conductive surface defining a half cell.

15. A body-worn physiological sensor comprising:

a computation-communication module including a housing retaining a processor;

a flexible printed circuit layer configured to be coupled to a skin surface of a subject to measure physiological signals, the computation-communication module being attached to the flexible printed circuit layer;

an adhesive covering at least a portion of the flexible printed circuit layer;

and a protective covering for the flexible printed circuit layer.

16. The body-worn physiological sensor of claim 15 , in which the protective covering includes at least one opening for electrode gels.

17. The body-worn physiological sensor of claim 15 , wherein the flexible printed circuit layer includes openings sized to receive electrode gels.

18. The body-worn physiological sensor of claim 15 , wherein the protective covering is non removable and made from an insulating material.

19. The body-worn physiological sensor of claim 15 , wherein the computation communication module is releasably attached to the flexible printed circuit layer.

20. The body-worn physiological sensor of claim 15 , wherein the protective covering covers the adhesive.