Sterilizable Medical Connector Overmolding for Open-Mate Sealing

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Solution Overview

Problem

Conventional electrical connectors for medical devices are not adequately cleanable and sterilizable, posing challenges for medical imaging systems that require regular cleaning and sterilization between uses, especially when used on different patients.

Innovation Solution

The development of a cleanable and sterilizable electrical connector for medical devices, which includes a connector assembly with a self-locking lid and overmolded clamshells and nose housing, optimized for sealing and compatibility with cleaning and sterilization processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electrical connectors are used for medical devices, then the connector structure is simple, but the connector cannot withstand cleaning and sterilization processes

Engineering Contradiction:

Improveconnector durability during cleaning and sterilizationVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector employs composite construction combining metal components (clamps, contacts) with polymer materials (overmolding, nose housing, clamshells). This composite approach provides both mechanical strength from metal and chemical resistance/sealing capabilities from polymers, enabling the connector to withstand cleaning and sterilization processes while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The connector is divided into distinct functional segments: metal clamps for electrical contact, polymer overmolding for sealing, nose housing for structural support, and clamshells for assembly. This segmentation allows each component to be optimized for its specific function while collectively providing sterilization resistance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the connector is designed to be cleanable and sterilizable, then the connector can withstand cleaning processes, but the connector requires complex sealing mechanisms

Engineering Contradiction:

Improvesterilization compatibilityVSAvoidsealing mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The polymer overmolding acts as a flexible sealing shell that conformally coats the metal components. This flexible polymer layer provides effective sealing without requiring rigid, complex sealing mechanisms, while still withstanding the mechanical stresses of cleaning and sterilization processes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The combination of metal and polymer materials creates inherent sealing interfaces where the polymer overmolding bonds to metal clamps and housing components. This material composite approach provides sealing functionality through material properties rather than complex mechanical sealing structures.

Inventive Principle:

Principle #40Composite materials

3Reliability

If the connector uses traditional locking mechanisms, then the connector can be secured, but the connector requires regular checks and maintenance

Engineering Contradiction:

Improveconnector securityVSAvoidmaintenance requirements

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector employs self-latching clamshells that automatically secure to the housing through their own elastic deformation and mechanical interlocking features. This self-service mechanism eliminates the need for external locking components or regular maintenance checks, as the connector maintains its own security through inherent mechanical properties.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The design replaces traditional mechanical locking systems (screws, bolts, external latches) with integrated elastic clamping forces from the clamshells and bonding forces from the overmolding. This substitution of mechanical locking with material-based securing reduces maintenance requirements while maintaining connector security.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12295785B2Cleanable and sterilizable electrical connector for medical devices

Publication Date: 2025.05.13 GE PRECISION HEALTHCARE LLC

AI summary

Systems and methods are provided for cleanable and sterilizable electrical connector for medical devices. A sterilizable connector may include a first shell and a second shell configured to engage one another, a nose housing that includes a mating area of the connector for engaging a corresponding mating area in a component of a medical device, and an overmolding that overmolds a combination of the first shell, the second shell, and the nose housing. Each of the first shell, the second shell, and the nose housing includes a first material that is compatible with cleaning and sterilization (C&S) treatment. The overmolding includes a second material that provides sealing of the combination of the first shell, the second shell, and the nose housing during the cleaning and sterilization (C&S) treatment. The connector is configured to enable applying at least sterilization without requiring closing or covering of the mating area of the connector.