Problem:  A leading medical component manufacturer required an 11-conductor hybrid cable that offered considerable pull strength with a small overall diameter of .22". Because of its use in a medical application, the cable needed to meet autoclave sterilization requirements.

Solution:  To minimize the overall diameter, Bay Associates' engineers selected a Teflon® insulation to achieve a wall thickness of 5 Mils. Kevlar® strands were pulled in during the cabling process to increase the pull strength. An overall braided shield and drain wire were added to ensure electrical integrity and performance. For sterilization procedures and requirements, a thermoplastic rubber jacket was used. Just one week before releasing its end product, the medical manufacturer reported some conductor failure after a number of cycles. Bay's engineers quickly identified the problem and suggested that additional requirements for high flex be added to the medical manufacturer's initial design specification. Within two weeks, Bay Associates was able to redesign, manufacture and begin production runs for a high flex version.

Problem: Experiencing breaking, stiffness and size problems with the cable they had been using in their oximeter application, a leading medical manufacturer turned to Bay Associates for help. The application design called for an autoclavable four-conductor cable that was limp, flexible, small-sized, and perfectly round.

Solution:  To decrease the overall diameter of the cable, Bay Associates' selected a Teflon® insulation for the four conductors to minimize wall thickness. Upon research into the application, Bay's engineers discovered that the cleaning solution used by the medical manufacturer during the termination process had a stiffening effect on most PVC compounds. Testing various compounds for their reaction to the cleaning solution, Bay Associates discovered a polyvinyl chloride (PVC) compound that was not affected by the chemical. Additional flexibility and limpness were achieved through the use of a high-strand count of ultra-fine high strength special alloy conductors, a served shield and the special PVC compound. Fillers and binders helped achieve the roundness required, and the completed cable was color-matched to the molded oximeter body.

For more information about our products or to find out how we can help you with your specific application, please contact us.

Tel: 650-847-3900
Fax: 650-327-4171

Click on any of the pictures above to find out more about our products and services