There are many factors to consider when choosing a custom or off-the-shelf medical connector, and the advantages and disadvantages of both may surprise you. When designing a new medical device, one of the decisions facing manufacturers is to choose a connector and matching socket. For some applications, standard (or off-the-shelf) connectors are a viable option; for other applications, custom or hybrid connectors may be more appropriate. Reasons to consider choosing a custom medical connector include: â—Ž A unique design is required to ensure that only certain cables or connectors can be plugged into the device â—Ž The shape of the connector must match the shape of the medical device â—Ž Multiple signal types (high voltage, low voltage, high bandwidth, data, thermocouple) must be carried in a single connector â—Ž Better meet cost targets â—Ž Need to customize logo or mark â—Ž Through the unique pin-to-socket pattern or connector shape to prevent the insertion of incompatible connectors to improve safety Custom 11 contact connector Custom connectors to match the outline of the device housing Custom connectors usually include engineering technology and mold manufacturing costs, and these upfront costs may be an obstacle to choosing a custom connector solution. However, when the cost of connector design and molds is determined, the cost of custom connectors is usually much lower than off-the-shelf connectors. Custom connector solutions can meet the physical characteristics required for each item. Custom connectors are designed so that the plug and unplug forces can be matched to specific customer requirements. This plug and unplug force is determined by each pin It is formed by friction with the socket and the mechanical interface between the connector and the socket. Moisture resistance is usually a consideration in medical interconnection systems. Off-the-shelf connectors usually integrate a housing and a pre-molded protective cover. When these components are assembled on a finished connector, they usually do not provide the required ingress protection IP) level. But customized overmolded connectors can be designed to have any required intrusion prevention (IP) rating. Standard shields usually do not have a high level of intrusion protection The customized edge card connector is specially designed to directly plug into the PCB In addition, the connector supply of major manufacturers may also be a problem. The delivery time is generally 8 to 16 weeks. When the mold preparation is completed, the delivery time of the customized connector may be much shorter than the ready-made connector. Establishing detailed design requirements is to determine whether custom or standard connectors are one of the first steps of the best choice. Factors to consider include: â—Ž Number and type of contacts (pin or socket and specification of each) â—Ž Cable configuration (ECG, defib, power supply, analog, digital, bandwidth, pneumatic, optical fiber or a combination of two or more) â—Ž Cable diameter, material and shape â—Ž Regulations and environmental protection level (RoHS, REACH, ISO 10993, UL) â—Ž Strain relief requirements â—Ž Shielding requirements of connectors and cables â—Ž Voltage and current requirements â—Ž Size limitation and / or required physical size â—Ž Intrusion prevention (IP) requirements or levels â—Ž Number of connecting or disconnecting cycles required â—Ž Locking mechanism (if any) â—Ž Keying requirements â—Ž Required plugging and unplugging force â—Ž Cleaning, disinfection and sterilization requirements â—Ž Logo, mark and serial layout Keyway (Keyway) prevents non-keyed (non-keyed) connector mating Custom connectors usually include an injection molded rigid plastic insulator and are inserted into pins or / and sockets. The most common is to use soldering or crimping to terminate the conductor to a pin or socket. This component is then molded using a rigid material, such as polypropylene, to hold the structure together and provide physical strength. Secondary over-molding using materials such as thermoplastic resins or silicone resins can provide connectors with the desired color, coating, appearance, and feel. For some applications, a hybrid connector may be the best choice. Hybrid connectors are off-the-shelf connectors with customized features such as over-molded handles or strain relief. The design and mold cost of the hybrid connector may be lower than that of the custom connector, but the finished product has the look and feel of the custom connector and some additional performance advantages. In addition to lower engineering and technical costs, the design and development process for hybrid connectors is shorter than for fully customized connector designs. Ready-made connector products with customized over-molded bending release become hybrid connectors Hybrid 3M MDR connector with custom angle over-molded strain relief Custom or hybrid connectors can provide unique characteristics and advantages for medical devices. Compared with the use of off-the-shelf connectors, each design element can be achieved with less compromise, which can improve safety and reliability, while custom connectors It may be a more cost-effective solution. However, compared to off-the-shelf connectors, custom and hybrid connectors generally require greater engineering and mold investment.
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