Magnetic Connector Assembly for Space-Limited Panel Connections
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Solution Overview
Problem
The existing methods for connecting electrical cables to electrical panels, such as circuit breaker screws, are impractical and unreliable due to the limited space between the screws and the front cover, requiring unscrewing and rescrewing, which is cumbersome and inefficient.
Innovation Solution
A magnetic connector that combines a magnet, a conductive metal part, and a plastic capsule, allowing for magnetic attraction and mechanical retention, along with electrical connection, facilitating easy and reliable attachment to the electrical panel without the need for screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional screw connection methods are used to connect electrical cables to electrical panels, then reliable electrical connection is achieved, but the operation becomes impractical and cumbersome due to limited space and the need to unscrew and rescrew
Solution Approach 1:
The patent replaces the traditional mechanical screw connection system with a magnetic connection system. The magnetic connector uses magnetic attraction force to hold the electrical connection in place, eliminating the need for screws while maintaining reliable electrical contact. This substitution of mechanical fastening with magnetic field-based fastening resolves the contradiction by providing both ease of operation (no tools needed) and reliability (strong magnetic holding force).
Solution Approach 2:
The patent introduces a magnetic field as an intermediary force between the connector and the electrical panel. The magnetic connector contains magnetic elements that generate a magnetic field to attract and hold the connector against the panel's electrical terminals. This intermediary magnetic force enables reliable connection without mechanical fasteners, solving the contradiction between ease of operation and connection reliability.
2Strength
If screw connection methods are used, then secure mechanical retention is achieved, but the space requirements between screws and front cover become problematic
Solution Approach 1:
The patent replaces mechanical screw fastening with a magnetic retention system. The magnetic connector uses strong magnetic attraction to secure itself to the electrical panel terminals, eliminating the need for screw threads and associated space requirements. This allows the connector to function effectively in the limited space between the front cover and the terminals, while still achieving secure mechanical retention through magnetic force.
Solution Approach 2:
The patent changes the fundamental parameter of mechanical retention from friction-based screw threading to field-based magnetic attraction. By transitioning from contact mechanics (screws engaging threads) to field mechanics (magnetic attraction across a small gap), the system achieves strong mechanical retention with significantly reduced space requirements, fitting within the constrained volume of the electrical panel.
3Ease of manufacture
If magnetic connector design is simplified, then ease of manufacture is improved, but manufacturing precision may be compromised
Solution Approach 1:
The patent employs composite construction by encapsulating magnetic elements within a plastic housing. This composite approach allows the magnetic components to be manufactured separately with standard tolerances, then encapsulated in the plastic housing which provides the final precise geometry and electrical insulation. This division of manufacturing complexity resolves the contradiction by allowing easy manufacture of individual components while achieving precise final assembly through the encapsulation process.
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 connector provides a secure mechanical and electrical connection with minimal space requirements, ensuring easy installation and reliable operation, with a holding force equivalent to 500g to 1 kg and low contact resistance, suitable for various applications like energy measurement and dielectric testing.
Implementation Method 1
A magnetic connector that combines a magnet, a conductive metal part, and a plastic capsule, allowing for magnetic attraction and mechanical retention
Data Source
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AI summary
This magnetic connector (5) for connecting an electrical device to an electrical panel includes at least one magnet (50), a conductive metal part (52) attached to this magnet (50), a connecting cable (54) attached to the conductive metal part (52), and a plastic capsule (56) overmolded on the connecting cable (54), the conductive metal part (52) and the magnet (50), except for a contact surface (500) of the magnet (50) intended to be made in contact with a metal part of the electrical panel.