Medical Cable Assembly Waterproofing via Integrated Resilient Contacts
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Solution Overview
Problem
Conventional cable assemblies for medical devices have inferior waterproofing and higher costs due to the use of printed circuit boards with resistors and FPCs in SPO2 applications.
Innovation Solution
A cable assembly with an electrical connector featuring integrally formed resilient contacts within an insulator and a sensor sub-assembly without FPCs, where the resistor is directly soldered to the contacts, eliminating the need for a printed circuit board and enhancing waterproofing through insert-molding and a robust design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coupling cable connector is used, then the assembly can be manufactured with traditional components, but the waterproofing function is inferior
Solution Approach 1:
The patent merges the connector housing and contacts into a single integrated component. The housing forms a recess that receives and secures the contacts, eliminating the need for separate connector parts. This integration maintains waterproofing reliability while simplifying the overall device structure.
2Ease of manufacture
If printed circuit board with resistor and FPC is used, then the sensor can be connected to contacts, but the cost increases
Solution Approach 1:
The patent extracts and eliminates the printed circuit board and FPC from the assembly. Instead of using these intermediate components, the sensor is directly connected to the contacts through wires, removing unnecessary parts and reducing manufacturing cost while maintaining the same functional connectivity.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, creates a waterproof enclosure, forms a recess to secure contacts, and acts as a mounting structure for the sensor. This multi-functionality reduces the need for additional specialized components, lowering overall device complexity and cost.
3Reliability
If resilient contacts are exposed upon exterior, then the contacts can be connected to wires, but water penetration risk increases
Solution Approach 1:
The contacts are nested within a recess formed in the housing. This nested structure allows the contacts to be accessible for wire connection while being protected by the housing enclosure, preventing water penetration. The resilient portion extends outward from the recess to maintain electrical contact functionality.
Data Source
AI summary
A cable includes an electrical connector at one end and a sensor at the other end. The connector includes a terminal module having a plurality of contacts embedded within an insulator wherein each contact has a resilient contacting section exposed upon to an exterior in a first vertical direction, and a soldering section exposed in a second vertical direction to be connected to the corresponding wires of the cable and selectively further to a resistor. The sensor includes a case enclosing an LED (Light Emitting Diode) and a PD (Photo Diode both of which are respectively connected to the corresponding contacts respectively soldered to the corresponding wires.