Electromagnetic Connector Locking for High-Density Pin Alignment

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Solution Overview

Problem

Advanced physiological monitoring systems require high pin density connectors, which pose challenges in ease of connection/disconnection, connection integrity, cost, and durability due to high demands on connector mechanisms.

Innovation Solution

Magnetic connectors utilizing electromagnets, permanent magnets, magnetically permeable materials, and air gaps to auto-align, attach, hold, and release connectors, enabling easy connection and disconnection while maintaining electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional mechanical connectors are used for high pin density applications, then connection integrity can be maintained, but ease of operation deteriorates due to difficulty in connection and disconnection

Engineering Contradiction:

Improveease of connection and disconnectionVSAvoidconnection integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces traditional mechanical connector mechanisms with a magnetic field-based system. Electromagnets generate magnetic fields that attract magnetic anchors in the plug, providing both connection force and alignment without mechanical interlocking components. This substitution enables easy one-handed connection while maintaining secure, reliable connections through controlled magnetic attraction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic connector system performs auto-alignment and self-latching functions. The magnetic field automatically guides the plug into proper alignment with the receptacle during insertion, and the magnetic attraction automatically secures the connection without requiring manual latching or twisting actions. The system serves itself by using magnetic forces for both positioning and securing.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If high pin density connectors are used to support advanced physiological monitoring systems, then functionality is improved, but device complexity increases making connectors more difficult to operate

Engineering Contradiction:

Improvefunctionality for physiological monitoringVSAvoidconnector mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Complex mechanical interlocking mechanisms required for high pin density connectors are replaced with a simplified electromagnetic system. The electromagnet and magnetic anchor provide both alignment and securing functions that would otherwise require multiple mechanical components, reducing overall connector complexity while supporting high pin density configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic field system performs multiple functions simultaneously: it provides alignment guidance, connection force, and secure latching. This multi-functionality is achieved through a single electromagnetic mechanism rather than separate mechanical components for each function, simplifying the overall connector design while supporting advanced physiological monitoring requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional connectors are used for frequent connection and disconnection, then connection integrity can be maintained, but durability deteriorates due to wear and tear

Engineering Contradiction:

Improveconnection integrityVSAvoidconnector durability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent eliminates mechanical contact and friction between connector components by using magnetic fields for connection and securement. Without mechanical interlocking, twisting, or sliding actions, there is no wear and tear on connector parts. The electromagnetic interaction allows for unlimited connection and disconnection cycles without degrading connection integrity or reducing durability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 magnetic connectors provide a reliable, durable, and cost-effective solution for high pin density connections, enhancing ease of use and reducing wear and tear, particularly suitable for handheld monitoring applications.

Implementation Method 1

The coil, the core and the air gap form a magnetic circuit so that energizing the coil creates a magnetic field in the air gap

Methodology Applied

Scientific EffectElectromagnetism: Electromagnet

Implementation Method 2

A magnetic connector advantageously utilizes one or more of electromagnets, permanent magnets, magnetically permeable materials and air gaps

Methodology Applied

Scientific EffectMagnetic permeability: Magnetic Field

Data Source

PatentUS20240006807A1Magnetic connector

Publication Date: 2024.01.04 MASIMO CORP

AI summary

A magnetic connector has a plug core disposed around a plug contact set and a receptacle core disposed around a receptacle contact set. The plug core defines a generally elongated circular plug core edge. The receptacle core defines a generally elongated concentric-circular receptacle core edge. The receptacle core edge defines an air gap, and the plug core defines an anchor configured to insert into the air gap. A coil is disposed around the receptacle core, and the coil, the plug core and the air gap define a magnetic circuit. The coil is electrically energized so as to form a magnetic field within an air gap, lock the anchor within the air gap and lock the plug contact set to the receptacle contact set accordingly.