Electromagnetic Connector With E-Core And I-Core Magnetic Coupling
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Solution Overview
Problem
Conventional electrical connectors in harsh environments, such as industrial process control applications, are prone to corrosion and connection failures due to physical constraints and environmental factors, which can render them nonfunctional over time, especially in backplane applications where multiple modules are connected with limited space.
Innovation Solution
The use of E-cores and I-cores with ferrite magnetic materials for separate power and signal transfer, respectively, along with spring-loaded assemblies and potting compounds to maintain a consistent magnetic gap and prevent mechanical stress, while also employing C-cores as alternatives for power transfer, and conductive enclosures for shielding to prevent crosstalk and electromagnetic radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connectors are used in harsh environments, then initial connection is achieved, but corrosion and connection failures occur over time
Solution Approach 1:
The patent replaces the mechanical direct metal-to-metal contact system with an electromagnetic field-based power and data transfer system. Power is transferred through magnetic coupling between transmitter and receiver coils, eliminating the need for physical electrical contacts that are susceptible to corrosion and wear in harsh environments.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary medium to transfer power and data between the backplane and modules. Instead of direct electrical contact, electromagnetic coupling through magnetic fields serves as the mediator, preventing direct exposure of electrical contacts to corrosive environmental factors.
2Ease of operation
If direct metal to metal contact connectors are used, then electrical connections are established, but pin bending and connection failures occur on initial installation
Solution Approach 1:
The patent eliminates mechanical pin insertion and metal-to-metal contact by using electromagnetic coupling. Power and data are transferred through magnetic fields between transmitter and receiver coils, removing vulnerable mechanical contact points that can bend or fail during installation.
3Reliability
If O-ring sealed connectors are used for high reliability applications, then environmental sealing is achieved, but physical constraints in backplane applications prevent their use
Solution Approach 1:
The patent replaces the mechanical O-ring sealing system with an electromagnetic field-based transfer system. By eliminating the need for physical electrical contacts and their associated sealing requirements, the system achieves environmental compatibility without the complexity of O-ring seals and rotary collars.
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
This solution enhances the reliability and durability of electrical connections by ensuring efficient power transfer, maintaining signal integrity, and reducing the risk of corrosion and mechanical stress, thereby extending the operational lifespan of connectors in harsh environments.
Implementation Method 1
The use of E-cores and I-cores with ferrite magnetic materials for separate power and signal transfer
Implementation Method 2
spring-loaded assemblies and potting compounds to maintain a consistent magnetic gap and prevent mechanical stress
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
An electromagnetic connector well suited for use in harsh environments. The connector used an E-core or C-core magnetic members for coupling power such as from a backplane to a module mounted on the backplane and using I-cores for coupling signals to and from the module. Separation of the power and signaling allows optimization of each coupling without compromise in performance of each function. Use of I-cores for signal coupling provides efficient use of space, with the use of E-cores or C-cores providing maximum power coupling to the module in a minimum space. Various aspects of exemplary embodiments are disclosed.