Breakaway Electrical Connector Magnetic Release Mechanism
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Solution Overview
Problem
Existing breakaway electrical connectors for vehicles are prone to damage during accidental movement due to insufficient disconnection mechanisms, leading to costly repairs and safety hazards from improper mating.
Innovation Solution
A breakaway electrical connector design featuring magnetically secured line and load sides with multiple contacts, where the magnetic connection force is lower than the pull-apart strength, ensuring secure connection during normal operation but allowing safe disconnection without damage, and alignment features to ensure proper mating and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connector uses a strong mechanical connection to ensure secure attachment, then the connection strength is improved, but the connector becomes damaged during accidental drive-off events
Solution Approach 1:
The patent changes the fundamental parameter of connection mechanism from mechanical to magnetic. The magnetic connection force is carefully selected to be stronger than normal operating forces (vibration, thermal expansion, minor movements) but weaker than accidental drive-off forces, thereby maintaining secure connection during normal operation while allowing safe disconnection during accidents without damaging the rigid infrastructure.
Solution Approach 2:
The magnetic connection provides dynamic adaptability - it automatically adjusts its holding strength based on the applied force. During normal operation, the magnetic force maintains secure attachment; during accidental drive-off, when force exceeds the magnetic threshold, the connection dynamically releases without causing damage to the rigid outlet or plug components.
2Object-affected harmful factors
If the connector uses a magnetic connection force lower than pull-apart strength, then safe disconnection during accidents is achieved, but the connection may be weaker than traditional mechanical connectors
Solution Approach 1:
The patent selects specific magnetic connection force parameters that create an optimal window: strong enough to resist normal operational forces including vibration, thermal expansion and contraction, and minor movements, but weak enough to release during accidental drive-off events before damaging forces are applied to the rigid infrastructure.
Solution Approach 2:
The magnetic connection acts as a pre-designed safety mechanism that cushions against accidental damage. By setting the magnetic force threshold below the damage threshold of the rigid infrastructure, the system provides beforehand protection - the connector will release during accidents before forces can damage the outlet or plug, preventing costly repairs and safety hazards.
3Device complexity
If the connector lacks alignment features, then the structure is simpler, but improper mating can occur leading to safety hazards
Solution Approach 1:
The patent incorporates asymmetric alignment features including guide pins on one connector and corresponding guide holes on the other, along with asymmetric contact pad arrangements. These features ensure that only properly aligned connectors can mate, preventing improper connections while maintaining relatively simple overall structure. The asymmetric geometry provides mechanical guidance that complements the magnetic attraction.
Solution Approach 2:
The guide pins and guide holes act as intermediary alignment mechanisms that facilitate proper mating before the magnetic connection takes full effect. These intermediary features guide the connectors into correct alignment, ensuring that contact pads properly engage and that the magnetic poles align correctly, thereby preventing improper mating while adding minimal structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The connector effectively prevents damage during accidental disconnections and ensures secure, safe, and easy mating, reducing repair costs and enhancing safety by maintaining electrical integrity and alignment.
Implementation Method 1
The first and second magnets provide a magnetic connection force to maintain the line and load sides connected to one another with the first and second plurality of contacts electrically coupled to one another
Data Source
AI summary
A breakaway electrical connector is provided that includes a line side and a load side. The line side that is connectable to a line conductor, while the load side is connectable to a load conductor. The line side has a first magnet and a first plurality of contacts. The load side has a second magnet and a second plurality of contacts. The first and second magnets provide a magnetic connection force to maintain the line and load sides connected to one another with the first and second plurality of contacts electrically coupled to one another.