Magnetic Repulsion Electrical Connector for Self-Aligning Assembly
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Solution Overview
Problem
Existing electrical connectors for artificial holiday trees face assembly and safety issues due to mechanical connections that require manual effort and can become misaligned or stuck, especially in limited access conditions.
Innovation Solution
The use of magnetic repulsion for proper orientation and magnetic attraction to hold connectors together in the correct polarity, with identical connectors featuring a housing with parallel passages, torus-shaped magnets and ferromagnets, and compression springs to simplify assembly and ensure reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical connection methods are used for electrical connectors, then the connectors can be joined manually, but the assembly process becomes complex and safety issues arise due to misalignment and connectors coming apart
Solution Approach 1:
The patent replaces the traditional mechanical friction-fit connection system with a magnetic field-based connection system. Magnets embedded in the connector housings create magnetic attraction forces that automatically align and secure the connectors together, eliminating the need for manual alignment and mechanical interlocking mechanisms.
Solution Approach 2:
The magnetic connection system enables self-alignment and self-securing of connectors. When two connectors are brought near each other, the magnetic fields automatically orient them in the correct polarity and hold them together without requiring manual intervention for alignment or securing.
2Ease of operation
If magnetic connection is used to simplify assembly, then manual effort is reduced, but manufacturing complexity increases due to magnet integration
Solution Approach 1:
The patent merges the magnetic field generation function directly into the connector housing structure. By embedding magnets within the housing during manufacturing, the connector integrates both structural support and magnetic connection functions into a single unified component, reducing overall system complexity.
Solution Approach 2:
The magnetic connector design creates a universal connection system where the same connector type can be used for both male and female connections. The magnets are positioned and oriented to work bidirectionally, allowing any connector of this type to connect to another of the same type, simplifying inventory and assembly.
3Manufacturing precision
If traditional interlock systems are used for orientation, then connectors can be oriented correctly, but the system becomes outdated and safety issues arise from connectors coming apart
Solution Approach 1:
The patent replaces mechanical interlock orientation systems with magnetic field-based orientation. The magnetic poles are arranged to create attractive and repulsive forces that naturally guide the connectors into the correct oriented position, providing more reliable and precise alignment than mechanical keyways.
Solution Approach 2:
The patent changes the fundamental parameter of connection from mechanical interlocking to magnetic field interaction. By utilizing magnetic field strength, pole orientation, and magnetic attraction/repulsion parameters, the system achieves superior orientation precision and connection stability compared to mechanical systems.
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 solution simplifies the assembly process, enhances safety by eliminating manual effort, and ensures reliable polarity alignment, making the connectors more durable and cost-effective for manufacturing.
Implementation Method 1
use magnetic attraction for holding two connectors together in the right polarity
Implementation Method 2
use magnetic repulsion for orienting one connector properly with respect to another
Implementation Method 3
a ferromagnet in the first passage proximate to the first contact of the fixed terminal. A ferromagnet is a device made of ferromagnetic material, that is, material attracted to a magnet but which material is not magnetic
Data Source
AI summary
Electrical connectors use magnetic repulsion for orienting themselves in the right polarity and magnetic attraction for holding together. When inserted into the ends of a conduit, a pair of these electrical connectors can transfer electricity through the conduit. Each electrical connector includes a housing with top and bottom surfaces and a fixed and a movable terminal both of which are recessed below the top surface of their respective, parallel passages. A spring controls terminal movement. Each terminal carries an electrical contact. A torus-shaped magnet surrounds the contact of the contact in the movable terminal so that its magnetic field energizes that contact. The magnets in movable terminals of each electrical connector are oriented in the same way so movable terminals of electrical connectors repel each other but fixed terminals attract movable terminals from their passages and into the passages of the fixed terminals so that two electrical connectors lock together.