Floating Pogo Connector Assembly for Vibration-Stable Aircraft Docking

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Solution Overview

Problem

Aircraft environments cause unreliable connectivity between electronic devices and docking interfaces due to high levels of vibration, leading to intermittent disconnections of pogo pins and loss of communication connectivity and data.

Innovation Solution

A connector system utilizing spring-biased pogo pins and magnetic couplers, combined with a resilient structure, to maintain contact with target contact pads even in high vibration environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If attach-type electrical connector with pogo pins and magnets is used, then electrical connection is established, but intermittent disconnections occur due to vibration

Engineering Contradiction:

Improveconnection reliabilityVSAvoidvibration impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The pogo pins are made floating and spring-biased, allowing them to dynamically adjust their position and maintain contact with contact pads during vibration. The springs provide continuous adaptive pressure compensation, enabling the connector to respond to vibrational movements rather than being rigidly fixed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A resilient structure (elastomeric material) is introduced as an intermediary between the magnetic couplers and the pogo pins. This resilient structure absorbs and dampens vibration energy, preventing it from directly affecting the electrical contact while still allowing the magnetic force to compress it and bias the pogo pins against the contact pads.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If insertion based connector is used, then charging and data transmission are enabled, but fatigue failure occurs from cyclic stresses

Engineering Contradiction:

Improvedocking functionalityVSAvoidconnector durability

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The traditional mechanical insertion and locking mechanism is replaced with a magnetic coupling system. The magnetic force provides the necessary holding force without requiring physical interlocking features that are susceptible to fatigue from cyclic insertion and removal operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connector transitions from a static inserted state to a dynamic magnetic attachment state. The spring-biased pogo pins continuously adapt to maintain electrical contact without requiring rigid mechanical constraints, reducing stress concentration and fatigue accumulation.

Inventive Principle:

Principle #15Dynamics

3Reliability

If magnetic couplers are added to maintain connection, then connection stability improves, but device complexity increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functions are merged into a single integrated connector assembly: magnetic coupling for attachment, spring mechanisms for contact pressure, resilient structures for vibration damping, and electrical contacts for data/power transmission. This consolidation reduces the number of separate components and simplifies the overall system architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector design serves multiple functions simultaneously: mechanical attachment via magnetic couplers, electrical contact via spring-biased pogo pins, vibration damping via resilient structures, and alignment guidance. This multi-functionality eliminates the need for separate systems for each function, reducing overall complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system ensures reliable electrical connection and data transmission by aligning and biasing pogo pins against contact pads, preventing intermittent disconnections and maintaining communication connectivity.

Implementation Method 1

spring-biased pogo pins...bias the set of spring-biased pogo pins against a corresponding set of target contact pads

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a first pair of magnetic couplers...configured to mate with a corresponding second pair of magnetic couplers...compress the resilient structure

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentUS12470016B2Floating pogo connectors for tablet computers of aircraft inflight entertainment systems and crew terminals

Publication Date: 2025.11.11 THALES AVIONICS INC

AI summary

A first connector, for coupling to a second connector, including a support structure, a set of spring-biased pogo pins arranged in a linear configuration and configured to carry at least one of electrical signals and power, a resilient structure extending across a face of the support structure, and a first pair of magnetic couplers attached to the resilient structure on opposite sides of the set of spring-biased pogo pins is disclosed. The spring- biased pogo pins are each located in a corresponding passage in the support structure. The first pair of magnetic couplers are configured to mate with a corresponding second pair of magnetic couplers of the second connector and compress the resilient structure to bias the set of spring-biased pogo pins against a corresponding set of target contact pads of the second connector.