Multi-Channel Connector Segmentation for Medical Lead Sets
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Solution Overview
Problem
Traditional lead-set connectors in patient-worn devices are difficult to clean and disinfect, prone to corrosion from disinfectant residues, and costly to manufacture, with design constraints due to safety requirements and trapped air under cantilevered electrical connector elements.
Innovation Solution
A multi-channel electrical connector design featuring a first connector element with pins engaging flexible conductive pads on a compressible substrate, integrated into a housing with a rigid face and side members, providing an interference fit and easy disinfection, while reducing manufacturing costs and improving safety compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cantilevered electrical connector elements are used, then firm electrical contact is achieved, but the connector becomes difficult to clean and disinfect
Solution Approach 1:
The connector is divided into two separate elements: a first connector element with pins and a second connector element with flexible conductive pads. This segmentation eliminates the cantilevered spring structure while maintaining electrical contact through a simpler pin-to-pad engagement system that allows complete surface access for cleaning.
Solution Approach 2:
Instead of using spring-biased cantilevered elements that create hidden spaces, the invention inverts the approach by using rigid pins that engage with flexible pads mounted on a compressible substrate. This inversion creates an open, accessible structure where all surfaces are easily reachable for disinfection without trapped air pockets.
2Reliability
If cantilevered connector elements are used, then electrical connection is maintained, but liquid disinfectants become trapped causing corrosion
Solution Approach 1:
By separating the connector into discrete pin and pad elements with an interference fit housing, the design eliminates crevices where liquid could be trapped. The flat, open surfaces of the pins and pads allow complete drainage and evaporation of disinfectant solutions.
Solution Approach 2:
The spring mechanism and cantilevered structure are extracted from the design, removing the source of trapped spaces. The electrical connection is achieved through direct pin-to-pad contact within an interference fit housing, eliminating the complex geometry that causes liquid entrapment.
3Reliability
If traditional lead-set connectors are used, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The connector is segmented into simple, manufacturable components: a housing with interference fit, rigid pins, flexible circuits with conductive pads, and a compressible substrate. Each component can be manufactured using standard, cost-effective processes rather than requiring expensive precision machining of integrated spring mechanisms.
Solution Approach 2:
The design changes the mechanical parameter from spring-biased cantilevered elements to rigid pins with flexible pads on a compressible substrate. This parameter change enables the use of simpler, less expensive manufacturing processes while maintaining reliable electrical connection through the interference fit and flexible pad compliance.
4Volume of moving object
If compact connector design is used, then space efficiency is improved, but access for cleaning is reduced
Solution Approach 1:
The connector elements are designed as separate, modular components that can be easily assembled and disassembled. The pins and pads are positioned on flat surfaces that are fully accessible for cleaning, while the overall compactness is achieved through the interference fit housing that contains the elements in a space-efficient arrangement.
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 solution enhances disinfection ease, reduces manufacturing costs, and improves connector reliability and lifespan by preventing fluid ingress and accidental short circuits, while meeting safety standards.
Implementation Method 1
flexible conductive pads on a compressible substrate
Implementation Method 2
compressible substrate of a second connector element
Implementation Method 3
housing with a rigid face and two side members, providing an interference fit
Data Source
AI summary
A patient worn medical monitoring device (10) includes a multi-channel electrical connector (18) for connecting a lead set (22) to a monitoring unit (16) is able to wirelessly transmit a patient's physiological data over a telemetric link to a receiver unit for remote monitoring purposes. The multi-channel electrical connector includes first and second connector elements (40,42) disposed on either one of the monitoring unit or lead set. The first connector element includes a plurality of rigid pins (44) disposed between a plurality of ribs (50). The second connector element includes a compressible substrate carrying flexible electrically conductive pads (46) that flex independently of one another. The connector elements to are configured to such that the pins of the first connector element electrically engage the flexible electrically conductive pads of the second connector element.