Modern medicine requires specifi c connectors
Feature: Connectors
specifi cations. T e existing solution used hyperboloid-shaped contacts, and with electrical requirements (high cycle life and low contact resistance) and the durability and reliability to survive the harsh chemicals and temperatures associated with the required sterilisation processes. T e system-side panel-mount receptacle contained the
hyperboloid contacts whilst the cost-eff ective plug used male pins to ensure longer device life and an aff ordable cable solution. T e existing high-strength polymer, used for both plug and receptacle, and widely accepted within the medical industry, was evaluated against alternative materials for ease of use, availability, chemical resistance and mechanical robustness, as well as the ability to maintain the same features and aesthetics of the original materials.
A perfect fi t Ultimately, polyetherimide was chosen as the replacement material for all plastic components. Connectors using the new material were then built and subjected to autoclave, electrical and mechanical testing to ensure survivability and consistent electrical properties before and aſt er testing. T e tests included 20 pre-vacuum autoclave cycles at 135°C for four minutes each; then, the connectors were mated and unmated 200 times to ensure no substantial changes in performance. Finally, the dielectric withstanding voltage was measured, confi rming that the insulators continued to meet the design specifi cation. At the end of testing, the new connectors functioned without any detectable impact on their mechanical or electrical performance. By performing a material analysis and selecting the correct
polymer, existing D series connector features were maintained, including high mating-cycle life on the system side increasing the MTBF (mean time between failures), a user-friendly pushbutton latching system that ensures the connectors stay dependably mated during the procedure, and low mating and de-mating forces. In addition, new benefi ts emerged, including high-temperature resistance, improved mechanical properties,
The tests included 20 autoclave cycles at 135°C for four minutes each, then mating and unmating 200 times
lower water absorption and improved chemical resistance to harsh environments and sterilisation protocols (including steam autoclaving), all addressing emerging trends in today’s medical market and meeting customer needs. This solution was also economical, since new materials
could be applied across the D Series platform’s standard sizes, without impacting contact density, the ability to mate with existing D Series designs, or the integration of existing contact technologies, including crimp and poke contacts for automated assembly. This allowed for a mix of disposable and reusable solutions in the same family, providing the flexibility to integrate reusable receptacles with both disposable and reusable plugs for the same system, or any other combination, depending on the need.
Proven heritage D Series connectors have a proven heritage in medical devices and applications used globally; from disposable catheters to their mating cables, to bedside patient monitors, patient-worn therapeutic devices and rugged automatic external defi brillators, which are critical to fi rst responders. T e D Series has now been updated to meet market requirements for reusability and sterilisation in both manufacturing and hospital settings by implementing a new material without aff ecting existing features or reducing cost-eff ectiveness.
www.electronicsworld.co.uk September/October 2020 57
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