Clamshell Medical Cable Enclosure for PCB Pressure Protection
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Solution Overview
Problem
Current cable designs for medical devices like pulse oximeters are susceptible to damage during assembly and use due to the vulnerability of internal components, particularly ball grid arrays and crystal oscillators, despite the use of soft materials for encapsulation and high-pressure molding.
Innovation Solution
A clamshell mid-layer and overmold configuration is introduced, with separately molded clamshell pieces and minimal overlap with the printed circuit board to provide enhanced protection against pressure, using higher modulus materials like polycarbonate with glass fiber for increased strength and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soft material is used for encapsulation of the printed circuit board, then the cable provides flexibility and comfort, but the internal components remain susceptible to pressure damage during assembly and use
Solution Approach 1:
The cable enclosure is divided into multiple layers: an inner soft encapsulating layer for flexibility, a mid-layer clamshell structure for mechanical protection, and an outer overmold layer for additional protection. This segmentation allows each layer to perform its specialized function without compromising the others.
Solution Approach 2:
The patent uses composite material structures combining soft encapsulating material with harder clamshell and overmold materials. The overmold is configured to minimize overlap with the printed circuit board, providing pressure resistance while maintaining flexibility in non-overlapping regions.
2Strength
If high-pressure molding is used to construct the mid-layer for mechanical strength, then the cable gains structural integrity, but the soft inner layer becomes too soft to resist added pressure
Solution Approach 1:
The enclosure is segmented into functional layers where the mid-layer clamshell provides the primary structural framework through high-pressure molding, while the inner and outer layers provide complementary protection. This segmentation allows optimization of each layer's material properties for its specific function.
Solution Approach 2:
Different regions of the enclosure have different material properties: the inner layer is soft for flexibility, the mid-layer is hard for structural integrity, and the outer overmold is positioned to provide localized protection where needed while minimizing overlap with sensitive components.
3Reliability
If the overmold overlaps significantly with the printed circuit board, then the cable gains additional protection, but the risk of damage to the printed circuit board during molding increases
Solution Approach 1:
The overmold is strategically positioned to overlap with the cable housing and provide protection in those regions while deliberately minimizing overlap with the printed circuit board area. This localized quality approach provides protection where needed without exposing sensitive components to molding hazards.
Solution Approach 2:
The printed circuit board is effectively extracted from the high-risk molding zone by positioning it within the clamshell structure where the overmold does not overlap, separating it from the harmful high-pressure molding process while maintaining overall cable protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design reduces damage to internal components during manufacturing and use, enhancing product yield and durability while maintaining complex structural integrity.
Implementation Method 1
the clamshell includes an opening for injection molding of a soft inner encapsulating material for the printed circuit board
Implementation Method 2
an overmold is provided around at least an end portion of the clamshell structure
Data Source
AI summary
A pressure resistant medical cable enclosure is provided, including a clamshell, a printed circuit board, and at least one overmold, wherein the clamshell is configured for assembly over the printed circuit board for a medical cable, one overmold provided at least partially around the clamshell layer with minimal overlap between the overmold and the printed circuit board in the vertical direction.