Company insight
Thermal solutions in medical device design
Thermal management within medical devices, clinical diagnostics instruments and analytical instruments involves the sophisticated control of temperatures to prevent overheating and ensure devices operate within their optimal performance range. Leading design and manufaturing experts Watlow discuss why proper thermal regulation is vital because even the slightest of deviations can lead to device failure, diminished treatment effectiveness, or serious risks to user safety.
ffective thermal management is crucial for devices that generate significant heat during operation or that use heat as part of therapeutic treatments. Examples include maintaining body-temperature fluids in dialysis machines and regulating the temperature of surgical tools to avoid tissue damage.
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Addressing the challenges The introduction of sophisticated heating technologies into medical devices brings complex challenges that must be carefully managed. Advanced heating solutions must not only provide effective temperature control, but also ensure safety, requiring rigorous testing and adherence to international safety standards such as IEC 60601-1-11. This regulatory standard outlines specific safety requirements for medical electrical equipment. Achieving high thermal efficiency is essential to prevent overheating, enhance energy efficiency and minimise operational costs. This involves optimising heat transfer
capabilities, improving insulation and selecting materials that exhibit excellent thermal properties. Each of these factors plays a critical role in the development of safe and effective medical devices. Furthermore, the development of cutting- edge thermal solutions can be both complex and costly. Manufacturers must balance these factors with the need to produce affordable medical devices. Balancing cost and complexity requires innovative design strategies, efficient manufacturing processes and careful material selection to ensure the final product is both effective and economically viable for the market.
Layered heater technology The move to advanced heater solutions is motivated by demand for medical devices that are not only compact and energy- efficient, but also reliable and consistent in operation. Traditional solutions have relied on nichrome element wires embedded within magnesium oxide insulation. These products have been foundational, yet come
with limitations. They often struggle with heat distribution and temperature stability, leading to energy inefficiency and environmental risks due to high operating temperatures and potential insulation breakdown. They also operate at lower watt densities leading to larger physical sizes. Layered heater technology marks a significant leap forward, employing meticulously deposited thin layers of heating elements. These are engineered to achieve optimal thermal performance. By stacking layers with precise control, these heaters provide unmatched temperature uniformity and quicker thermal response times, allowing for precise thermal expansion matching, which is crucial for maintaining structural integrity and functional reliability under varying thermal conditions.
Materials used in layered heaters, such as aluminium nitride, play a crucial role in their performance. These materials are selected for their high electrical insulation and superior thermal conductivity, crucial for safe and efficient operations. Layered heater technology not only represents a significant technological advancement but also a paradigm shift in thermal management set to redefine standards and expectations within the medtech industry. The push for greater efficiency, miniaturisation and safety points to broader adoption of these heaters. As medical technology continues to advance, the role of sophisticated thermal management systems will remain crucial. Ongoing innovations in heater technologies promise to enhance device performance, improve patient safety, meet the complex demands of next-generation medical devices and facilitate the development of new and effective medical treatments. ●
Watlow’s layered heaters provide the precision and flexibility needed to ensure the highest level of thermal performance and meet the complex demands of next-generation medical devices.
Medical Device Developments /
www.nsmedicaldevices.com
www.watlow.com 81
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