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Case Study: Robust Hospital Grade Plug Leads to Lower Overall Costs

A major medical device manu­facturer producing warming beds faced with major preventable repair costs  and UL listing difficulties turned to MEGA to provide a solution.

In the harsh environment of hospitals, hospital grade plugs are often yanked from walls, hit and smashed with no apparent damage. However, small repetitive breaks at the pin and conduc­tor junctions eventually can cause the plugs to overheat and fail. The failure of a competitor’s plug caused costly repair calls and the need to improve the plug performance.

MEGA created a new plug tool with a larger body capable of withstanding greater stresses. Each nickel-plated solid pin is soldered to the conductor lowering the risk of individual strands breaking. In addition, a metal retaining ring is applied to the cordage prior to over molding, greatly increasing the retention strength. The combi­nation of these developments resulted in a zero failure rate in the field.

Because of the proximity of the cord to the heating element inside of the bed, UL request­ed a heat shield be installed to shield the 60°C rated PVC cable. MEGA suggested the use of a 105°C rated SJT cable and upon testing the cord, was accepted and removed an additional component and manu­facturing step.

MEGA ELECTRONICS | (732) 249-2656