Requirements for medical cables and interconnect systems are becoming more complex.  This often leads to the requirement that electronics to be incorporated into a connector or cable system.  A cable assembly in which active electronics have been incorporated is often referred to as a “smart cable.”

Encapsulating electronic components as part of a cable assembly is most commonly done using hard plastic shells that are screwed or ultrasonically welded together.  If tactile feel and appearance of the enclosure is important, one option is to overmold the enclosure with a softer rubber-like material.

Hybrid enclosures are a combination of hard plastic cases overmolded with a softer thermoplastic material.  Typically for this type of construction, the clamshell case is filled with a light weight potting material before being overmolded.  If this is not done, mold pressures could collapse the case.

There are several advantages to this type of enclosure including:Hybrid enclosures are a combination of hard plastic cases overmolded with a softer thermoplastic material.  Typically for this type of construction, the clamshell case is filled with a light weight potting material before being overmolded.  If this is not done, mold pressures could collapse the case.

• Protecting the electronic components from the temperature and pressure of direct overmolding
• Achieving a lighter weight assembly by using a fill material that is lighter in weight than mold material
• Producing larger overmolded electronic enclosures than could be achieved by direct overmolding.

With a hybrid design, the outer mold can be designed to follow the contours of the inner case allowing a uniform wall thickness.  A uniform wall thickness will typically produce a more consistent outer surface even when large assemblies are encapsulated by overmolding.

Summary

Incorporating electronic circuits into external enclosures can offer medical device manufacturers additional alternatives.  The Affinity engineering team has experience designing and manufacturing a wide variety of enclosures and incorporating circuits, connectors and cable assemblies.

For additional information, contact your local Molex Sales Engineer, Account Manager or call Affinity at +1 949.477.9495 or email us at custcare2@molex.com.