Magnetic Connector Retention for Tool-Free Mating
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Solution Overview
Problem
Existing connector systems require significant time and effort to mate and un-mate, often necessitating tool use and two hands, which complicates operations in low-visibility conditions such as emergencies or combat situations.
Innovation Solution
The connector system incorporates a housing with pin-type contacts and permanent magnets oriented at specific angles to facilitate easy mating and un-mating, eliminating the need for tools and allowing single-handed operation by utilizing magnetic attraction to secure the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners or interlocking features are used to retain connectors in a mated condition, then the connection reliability is improved, but the time and effort required for mating and un-mating increases significantly
Solution Approach 1:
The patent replaces traditional mechanical fasteners, latches, or interlocking features with a magnetic retention system. Magnets mounted on the connector housing provide retaining force through magnetic attraction, eliminating the need for manual tightening, twisting, or manipulation of mechanical components. This substitution dramatically reduces mating and un-mating time while maintaining connection reliability through the magnetic holding force.
Solution Approach 2:
The magnetic retention system provides self-aligning and self-retaining functionality. The magnetic field automatically guides the connectors into proper alignment during mating and maintains the connection without requiring active engagement by the user. Un-mating simply requires overcoming the magnetic force, eliminating the need for complex release mechanisms or manual manipulation of fasteners.
2Strength
If mechanical fasteners or interlocking features are used to retain connectors, then the connection strength is improved, but the complexity of the connector system increases
Solution Approach 1:
The patent replaces complex mechanical retention systems with a simple magnetic field-based system. Instead of incorporating multiple moving parts, springs, latches, or interlocking geometries, the design uses magnets mounted on the housing to provide retaining force. This dramatically simplifies the connector structure while maintaining adequate connection strength through magnetic attraction.
Solution Approach 2:
The patent extracts the retention function from complex mechanical subsystems and implements it through a separate magnetic field mechanism. The magnets are mounted on the housing but function independently to provide retaining force, separating the retention function from the electrical contact function and simplifying the overall system architecture.
3Reliability
If traditional connector retention mechanisms are used, then the connection reliability is improved, but the ease of operation deteriorates, especially in low-visibility conditions
Solution Approach 1:
The magnetic retention system eliminates the need for visual alignment and manual manipulation of fasteners or interlocking features. The magnetic field provides automatic guidance and retention, allowing users to mate and un-mate connectors by simple pulling motions without needing to see or manipulate complex mechanical components. This dramatically improves ease of operation in low-visibility conditions while maintaining connection reliability.
4Ease of operation
If magnets are mounted on the connector housing, then the ease of operation for mating and un-mating is improved, but the manufacturing complexity increases
Solution Approach 1:
The magnetic retention system is implemented as a separate module that can be independently manufactured and then integrated into the connector housing. The magnets are mounted on the housing as a distinct component, allowing for specialized manufacturing of the magnetic assembly and simplifying the overall manufacturing process. This segmentation enables flexible manufacturing approaches while maintaining ease of operation.
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 design reduces the force required for un-mating and allows for quick, tool-free connection and disconnection, enhancing usability in challenging conditions like emergencies or combat operations.
Implementation Method 1
The magnet has a pole face. The first housing and the magnet are configured so that a normal to the pole face extends in a second direction.
Data Source
AI summary
Connector systems (10, 100) for electrically connecting two or more electrical components include a connector (14, 114) having one or more magnets (36a, 136a). Each magnet (36a, 136a) is attracted to another magnet (36b, 136b), or to a magnetically-attractable element on the other connector (14, 114) of the system (10, 100) when the connectors (14, 12, 112, 114) are mated. The magnetic attraction helps to maintain the connectors (14, 12, 112, 114) in a mated condition. The magnets (36a, 36b, 136a, 136b) can be oriented so that surface normals of pole faces (37a, 37b, 137a, 137b) of the magnets (36a, 36b, 136a, 136b) are angled in relation to a mating direction of the connectors (14, 12, 112, 114).