FEATURE INTERCONNECTION MAKING THE RIGHT CONNECTION
Anthony Kalaijakis, Strategic Industry Marketing Manager at Molex explores how optimal patient comfort and mobility depends on packaging more features into thinner, smaller devices
A hybrid connector option can balance C
onnectors are ubiquitous in devices across medical modalities, including
imaging, therapeutic, minimally invasive surgical devices, implanted electronics, patient monitors, and sensors. Today’s connector options often combine copper power and signal, fibre optics, fluid or gas connections, even an RF antenna interface, all packaged in a single integrated interface. The right connectors can yield overall lower cost for the manufacturer, a more compact package, and improve healthcare provision. So it is important to successfully navigate the connector technology maze. Mating cycles for medtech device connections may range from a single-use connector in a disposable sensor to tens of thousands of mating cycles in an MRI coil or portable glucose monitor worn by a mobile patient 24/7 (Figure 1). Medical device sterilisation, specifically
exposure to sterilised wipes, gamma radiation, ethylene gas, autoclave, and Sterrad process, also factor into material selection and design. Each sterilisation method presents different exposure levels, chemicals, reactivity, and risks to connector integrity. Medtech applications typically require connectors resistant to fluid ingress, with most requiring an IP6 or IP7 rating level (Figure 2). Pin and socket selection, and the
physical design of plug and receptacle, allow control over insertion and retention force. Retention force defines how firmly a connector is held by a receptacle. If a connector is expected to have a high number of mate and un-mate cycles, it is generally desirable to achieve retention force from the metallic pins and sockets. In some instances, such as a portable
24 JULY/AUGUST 2015 | ELECTRONICS Figure 1:
Circular connectors with medical-grade plastic housings have proven an economical option in a wide range of portable diagnostic and patient monitoring equipment
defibrillator requiring a securely latched connector, it may be advisable to overmould a connector with a flexible hood to protect the latch mechanism. If the retention force achieved by pin-to- socket and friction of the connector housing is insufficient, retention force can be enhanced via design, so axial force applied to the cable is not directly applied to the removal axis of the connector. Conversely, a non-locking connector can be designed such that it can be disconnected by axial force applied to the cable. Use of right angle connectors is another approach to enhance retention and prevent accidental unmating.
Figure 2:
High-performance and affordable custom-off- the-shelf circular connectors feature lightweight medical grade plastic housings to withstand autoclave and other sterilisation processes
THREE TIER CONNECTOR DESIGNS Off-the-shelf connector solutions can provide medtech manufacturers a means to leverage economical technologies proven in other industries. High- performance medical circular connectors, for example, provide an economical choice with a proven contact design, durable mating force, and plastic or metal body styles to withstand sterilisation. Circular connectors with a lightweight medical- grade plastic housing offer high quality electrical performance at a competitive price for many applications, such as catheters and other portable devices. In some applications a standard off-the- shelf connector will not suffice. A custom or hybrid connector may be more appropriate for design requirements. Tooling a new connector provides the most design flexibility and comprehensive options, but comes at a higher price. Custom connectors typically demand higher upfront engineering and fabrication costs, but may be worth the investment.
price and features. Hybrids take a proven technology, utilising base components from a standard connector, and optimise features, without the extra cost of tooling a new connector. Hybrid connectors may incorporate robust overmoulded shells for improved grip and pre-moulded boots or collars for strain relief or a higher IP rating. Hybrid connectors are less costly, yet the finished product can look, feel, and feature most of the desired performance advantages of a custom connector. Additionally, designing a hybrid connector generally shortens the development schedule. Medtech manufacturers need best-in- class technologies to fill the healthcare pipeline with quality, compliant products to meet complex patient medical needs. MID (moulded interconnect device)/LDS (laser direct structuring) offers 3D selective trace functionality, coupled with the flexibility of using injection moulded plastics that can be soldered, plastic welded, insert moulded, over-moulded, and wire bonded. Addressing functionality, space, weight, and cost concerns, MID/LDS 3D custom assembly solutions streamline the manufacture of miniaturised connectors, antenna, and sensors. The assemblies combine MID technology
with LDS antenna expertise to deliver fine- pitch 3D circuitry in single compact moulded devices for high density implantable and wearable patient monitors. LDS uses fewer components and improves functionality over bulkier, less ideal processors or assemblies in applications like catheters. The technology is well suited to wireless remote and sensor- based patient monitoring (i.e., a glucose meter transmitting readings to a physician’s office via a remote base station connected device). Making well-informed connector choices to streamline the design and manufacturing processes, an experienced medical component supplier can guide designers, ensuring due diligence in specifications, risk assessment, cost estimates, and test verification of fully compliant electrical, signal, and mechanical interconnects for portable and wearable medical devices.
Molex
www.molex.com 01252 720 720
/ ELECTRONICS
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