Common Connector Types Used in the Medical Field are also Utilized in Data Centers, Communication Equipment, Industrial Systems, Military, Aerospace Designs, and Other High-Reliability, High-Performance Markets.
In medical device design, the selection of each component is crucial. However, specifying electronic connectors for medical technology is not always exclusively tailored to this market. In fact, as medicine increasingly relies on audiovisual capabilities, high-speed data transmission, artificial intelligence, real-time services such as remote-guided surgeries and home care, the common connector types used in medical devices may be the same as those applied in other high-reliability markets. The growth of wearable products has led to an increase in applications such as sensor data collection, biocompatibility and sterilizable materials, wireless data/power transmission, and smaller medical products. Artificial intelligence is now used for diagnostics. Remote surgeries are conducted using robotic arms. Advanced imaging systems can provide detailed information to healthcare teams immediately. These trends require edge devices to handle power density and performance while downsizing. For connector types, this means higher pin counts and rated power. Connector types such as board-to-board, wire-to-board, and wire-to-wire are widely used in medical devices, while common connectors like USB, HDMI, and D-sub are suitable for such applications. High-quality universal connectors can also meet the standards and regulatory compliance of the medical industry. Here are six common connector types used for medical devices.
1、Card-edge Connector
Card-edge connectors can be directly inserted into PCBs to connect systems. Common card-edge connectors are often used in computers for expansion cards, memory modules, or Data Acquisition (DAQ) cards, connecting high-speed interfaces such as PCIe. In medical applications, common connector systems support complex computation and data analysis. For example, in blood analyzers, DAQ cards in the A/D sample system collect and process input sensor data. In advanced patient monitoring systems, card-edge connectors are used for expanding storage or testing capabilities. Card-edge connectors used in medical devices must meet high-performance requirements. Thicker gold plating is used on the contacts to ensure that the pins are not oxidized, which could negatively impact conductivity. In high-vibration environments, connectors are prone to fretting corrosion, where the mating metal contacts rub against the plating and underlying material, deteriorating over time. This type of wear also occurs in frequent plug-in applications. Potential exposure to reagents is also a concern in medical environments. Choosing card-edge connector types with thicker plating can reduce these risks.
EDAC’s card-edge connector types provide excellent contact elasticity, capable of resisting vibration. When mated, they form a high-integrity connection with copper alloy contacts that have low resistance (up to 10 mΩ). To enhance additional vibration resistance, EDAC’s metal card-edge connector types feature a highly reliable interlocking mate, utilizing an innovative male-female contact design that employs a fork-shaped configuration, sliding together to form a hermetic fit. Another factor to consider is vibration, which could potentially degrade or interrupt a connection. When the card moves due to vibration or transient impact, card-edge connector types provide some elastic support.
EDAC’s E-Met card-edge connector features a unibody contact design and cross-sectional diagram, demonstrating a hermetic connection capable of withstanding vibration and impact.
2、Header Connectors in Multi-Board Solutions
Header connectors are utilized in various medical applications such as X-ray, CT scanners, ultrasound devices, cardiac diagnostic equipment, MRI machines, cardiopulmonary support systems, patient monitoring systems, control boards for blood analyzers, and more. These connectors are used in all multi-board solutions to facilitate inter-board connections. Typically, flexible cables such as ribbon cables are employed for connecting header connectors. They serve as a reliable and cost-effective choice for wire-to-board and board-to-board connections. High-conductivity copper alloy used for pin connections offers low resistance and better contact spring force. An additional 50µ of gold plating helps resist corrosion and damage to pins caused by vibration. The UL 94V-0 thermoplastic polyester base material operates within a temperature range of -40°C to 105°C, and other high-temperature materials are also available to expand the temperature range. These durable connections can withstand at least 200 mating cycles.
EDAC offers standard box headers as well as more specialized E-Socket and E-Pin, high-power headers, and DIN connectors. Here, the E-Socket and E-Pin form a vibration-resistant board-to-board connection. The fork-shaped design of the E-Socket provides a secure grip on the E-Pin male connector, with a maximum contact resistance of 10 mΩ. For power connections between circuit boards, high-power headers offer a rated current of up to 20 amps.
The power pins themselves have a considerable 4 mm spacing, reducing the risk of arcing between contacts and increasing connection safety.
3、Inline Connectors
For certain medical devices, a wire-to-wire and wire-to-board solution, such as inline connectors, may be required. Inline connector types have relatively fewer pins. In some medical environments, such as laboratories, inline connector types may face the risk factors of liquid exposure, leading to water ingress and corrosion, which may result in intermittent or failed connections.
EDAC’s E-Seal inline connectors utilize a proprietary epoxy sealing process that seals the entire backside of the connector, rather than individual pins, achieving an IP67 sealing rating. They are fully dustproof and can withstand temporary immersion in water.
4、D-Sub Connectors
D-sub connectors are used in a wide range of applications, from personal computers and industrial automation controllers to aircraft connections. They are also widely used in the medical field, such as connecting sensors and actuators in monitors.
The D-sub connector connects to the pulse oximeter probe in the defibrillator to measure blood oxygen saturation. Source: Philips
Over time, continuous vibration can degrade connection quality. Sufficient gold plating and proper installation can help mitigate these effects. D-sub connectors in medical applications should have an IP sealing rating to prevent dust and moisture ingress. Another consideration for D-sub connectors in medical applications is radiation and electromagnetic interference (RFI and EMI) or noise. For example, this noise can come from high-speed switching device power supplies inside the machine. The cable can also conduct noise from other sources and bring it to sensitive internal circuits, leading to equipment failures. D-sub connectors with metal housings, when connected to chassis ground and cable shielding, can effectively mitigate electromagnetic interference.
IP67 sealed grade D-sub cable assembly with waterproof cover and rubber seal.
5、HDMI Connectors
HDMI connectors are the standard interface for all displays. D-sub connectors and HDMI connectors are used to send video signals from computers or monitors to view images. For example, ultrasound machines will use several video output options, including VGA, DVI, and HDMI, as well as traditional video outputs such as S-video or C-video. However, traditional HDMI connector designs may need to withstand vibrations, mechanical shocks, or moisture ingress in medical environments. EDAC’s waterproof HDMI connectors use electronic sealing technology to resist splashes and potential corrosive substances.
EDAC’s ip67 sealed grade HDMI connector
6、Spring-Loaded (or Pogo-Pin) Connectors
For wearable health monitors and other portable medical devices, user-friendliness is crucial when specifying universal connectors. Connector solutions for wearable devices, monitors, and home health devices need a simple blind-mate connector with high durability to charge or dock their devices for users of all skill levels. Pogo-pin connectors are easy to operate and can be used to charge small medical applications such as hearing aids. EDAC’s spring-loaded universal connectors feature precision-machined surface treatments and magnetism, providing polarization and increasing the reliability of universal connectors. This makes them more convenient to use than standard pogo pins and allows them to maintain a connection in vibration environments. One factor in maintaining high vibration resistance is the travel distance of spring-loaded universal connectors, i.e., the distance from the pogo pin’s resting position to its maximum compressed position. The travel distance of EDAC’s pogo pins ensures reliable contact in vibration and slight misalignment, which can often interrupt connections with standard contacts.
EDAC’s spring-loaded connectors
EDAC’s spring-loaded universal connectors are suitable for testing/charging applications in wearable devices and medical device production. With durability of up to 30,000 mating cycles, they can withstand frequent mating and unmating cycles. They are over-molded in high-temperature thermoplastic plastic, providing a wide operating temperature range. While there are connectors for specific applications in medical technology, such as connectors for probes connecting to ultrasound devices, the medical industry has adopted many common connector types. As long as they are sufficiently robust and have an IP sealing rating, these reliable connectors can be well applied to medical devices.