Medical Sensor Cable-to-PCB Joint Wrapping Against Flex and Water Ingress

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Solution Overview

Problem

Medical sensors, particularly those using pulse oximetry, are susceptible to damage from flexing, water ingress, and pull forces, leading to malfunction or failure, such as wire breakage and short circuits.

Innovation Solution

A patient monitoring sensor with a secure joint between the cable and PCB or optics, featuring a heat shrinkable adhesive joint wrap, injection molded joint, or over-molded joint to provide water resistance and flex and pull resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional cable-to-PCB connection is used in medical sensors, then the device structure remains simple and manufacturing is easy, but the connection is susceptible to damage from flexing, water ingress, and pull forces

Engineering Contradiction:

Improveconnection reliabilityVSAvoidjoint structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming a recess in the cable assembly before connecting to the PCB. This recess is specifically designed to receive and secure the cable, preventing movement and damage before operational stresses occur. The recess is created during manufacturing, establishing a protective structure in advance that mitigates future flexing and pull forces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements nesting by placing the cable within a recess that is formed in the PCB or cable assembly. The cable is nested within this protective cavity, and additional protective elements such as adhesive or molding compound are nested around it. This nested structure protects the cable connection from external forces while maintaining a compact design.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If conventional cable connections are used, then manufacturing processes remain simple, but the sensor is vulnerable to wire breakage and short circuits

Engineering Contradiction:

Improvesensor durabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the physical state of protective materials during manufacturing. Adhesive transitions from liquid to solid through curing, and molding compound transitions from liquid to solid through cooling. These parameter changes enable the protective structures to be formed during manufacturing while providing enhanced durability in the final product.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses adhesive and molding compound as intermediary materials between the cable and the PCB. These intermediaries provide mechanical bonding and environmental protection, mediating the connection between the cable and the circuit board while protecting against water ingress and physical damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If the cable joint is secured with additional protective measures, then resistance to flex forces and water ingress improves, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveresistance to water ingressVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent merges multiple protective functions into integrated structures. The recess serves both as a mechanical anchor and as part of the sealing structure. Adhesive both bonds the cable and provides water resistance. Molding compound simultaneously protects against water ingress and mechanical stress. This merging reduces the need for separate protective components and simplifies assembly.

Inventive Principle:

Principle #5Merging (Combining)

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

Enhances the reliability and reusability of medical sensors by preventing damage from flexing, water ingress, and pull forces, ensuring consistent performance.

Implementation Method 1

heat shrinkable adhesive joint wrap

Methodology Applied

Scientific EffectHeat shrinkage: Thermal Contraction

Implementation Method 2

injection molded joint installed over the cable

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 3

over-molded joint

Methodology Applied

Scientific EffectOver-molding:

Data Source

PatentUS20260007339A1Sensor joint wrapping in a medical sensor

Publication Date: 2026.01.08 COVIDIEN LP

AI summary

A patient monitoring sensor having a communication interface, through which the patient monitoring sensor can communicate with a monitor is provided. The patient monitoring sensor includes a light-emitting diode (LED) communicatively coupled to the communication interface and a detector, communicatively coupled to the communication interface, capable of detecting light. The patient monitoring sensor includes a cable to flexible printed circuit board (PCB) connection that provides a reliable connection resistant to flex forces, water ingress and pull forces.