Magnetic Interposer Connectors for Blind Mating Alignment
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Solution Overview
Problem
Conventional electrical connectors face challenges in maintaining electrical continuity and mechanical attachment, especially in applications where connectors are hidden or require precise alignment, and they can be fragile or unreliable over time.
Innovation Solution
The use of magnetic interposer electrical connector systems with permanent magnets and flexible magnetic interconnects that provide self-mating forces, protection from dust and moisture, and mechanical flexibility, allowing for alignment and attachment without the need for precise orientation or mechanical force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical connectors are used, then electrical continuity is maintained, but precise alignment and mechanical force are required making connection difficult when connectors are hidden
Solution Approach 1:
The patent replaces conventional mechanical connection systems with a magnetic connection system. Magnets embedded in the connector housing generate magnetic attraction forces that automatically pull the connector into proper alignment and maintain contact pressure, eliminating the need for manual alignment and mechanical insertion force. This allows connectors to be easily connected even when hidden in cavities without visual feedback.
Solution Approach 2:
The magnetic connector system is self-aligning and self-mating. The magnetic field automatically guides the connector into the correct position and maintains electrical contact without requiring external alignment tools or manual adjustment, enabling blind mating operations where connectors are not visible during connection.
2Reliability
If conventional connectors with pins and springs are used, then electrical connections are established, but the pins are fragile and springs relax overtime reducing reliability
Solution Approach 1:
The patent removes the fragile pin and spring components from the connector design. Instead, it uses a magnetic field to provide both the electrical connection and the mechanical retention force. This extraction of problematic mechanical elements eliminates the issues of pin breakage and spring relaxation over time.
Solution Approach 2:
The patent substitutes mechanical spring-loaded contacts with a magnetic attraction system. The magnetic force provides continuous contact pressure without requiring physical springs, and the magnetic connection is more resistant to wear and relaxation over time compared to conventional mechanical spring contacts.
3Ease of operation
If guiding ramps and floating mechanical assemblies are used to ease connection, then alignment is improved, but the size and cost of the assembly increases
Solution Approach 1:
The patent replaces complex mechanical guiding ramps and floating assemblies with a magnetic field-based alignment system. The magnetic attraction force automatically guides the connector into proper alignment during the mating process, eliminating the need for additional mechanical guiding structures and reducing overall assembly complexity.
Solution Approach 2:
The magnetic field serves multiple functions simultaneously: it provides alignment guidance, maintains contact pressure, and ensures electrical continuity. This multi-functionality eliminates the need for separate mechanical components for each function, simplifying the overall connector design.
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
These systems ensure robust electrical and mechanical attachment, are insensitive to dimensional tolerances, and provide a flexible and durable connection that can conform to curved surfaces, reducing the risk of damage and improving reliability.
Implementation Method 1
electrical continuity is maintained through magnetic attraction
Data Source
AI summary
Disclosed are interposer electrical connector embodiments including magnetic components used to facilitate interconnection of peripheral devices to standard input/output, or “I/O”, connectors (such as USB connectors) of devices such as mobile communications products (e.g. smart phones, tablets, and personal computers). The interposer connector embodiments disclosed include those in which a plurality of discrete permanent magnets are arranged with magnetic poles aligned in the same orientation perpendicular to and on one side of the electrical interface. Other embodiments include a plurality of bar permanent magnets located on opposite sides of the interface with all poles of the same type directed at the interface, but each one opposing a ferromagnetic element. These arrangements provide self-aligning capabilities useful for electrical connections that have restrictions on visibility or connection approach geometries. Other embodiments have a single magnet per mated connector pair and magnetic pole pieces and/or actuators to concentrate magnetic flux providing the magnetic attractive force for a plurality of electrical connections.