Magnetic Variable-Force Contacts for Consistent Contact Resistance
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Solution Overview
Problem
Conventional spring-loaded contacts in electronic devices experience inconsistent contact force due to manufacturing tolerances, leading to variations in contact resistance and potential damage from excessive or insufficient force, especially when unmated or mated.
Innovation Solution
The use of magnetic forces between a contact magnet and a shuttle magnet to provide a high and stable contact force in the mated state, while minimizing stray flux and preventing damage by positioning the magnets to maximize distance in the unmated state, eliminating the need for physical springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring-loaded contacts are used, then contact force is provided, but manufacturing tolerances cause inconsistent contact force and contact resistance
Solution Approach 1:
The patent replaces the mechanical spring system with a magnetic field-based system. Magnets positioned in the contact assembly generate magnetic forces that push the plunger against the contacting surface, eliminating dependence on mechanical spring dimensions and their manufacturing tolerances. The magnetic field strength can be precisely controlled through magnet positioning and selection, providing consistent contact force regardless of mechanical dimensional variations.
Solution Approach 2:
The patent changes the physical state and mechanism from mechanical elastic deformation (springs) to magnetic field interaction. By adjusting magnetic field parameters (magnet strength, positioning, orientation), the contact force can be precisely controlled and made consistent, overcoming the limitations of mechanical tolerance accumulation in spring systems.
2Force
If springs provide force in both mated and unmated states, then contact force is maintained, but excessive force is applied when unmated and insufficient force when mated
Solution Approach 1:
The magnetic field system is made dynamic through movable magnets that can change position based on whether the connector is mated or unmated. When unmated, magnets are positioned to provide optimal contact force; when mated, the system configuration changes to adjust the magnetic field distribution, automatically adapting the force characteristics to the operational state without manual intervention.
Solution Approach 2:
The system incorporates feedback mechanisms where the mated/unmated state is detected (through magnetic coupling changes or mechanical position sensors), and the magnetic field configuration is automatically adjusted in response. This feedback loop ensures the correct force differential is maintained between operational states, preventing both excessive and insufficient force conditions.
3Force
If magnets are positioned to maximize contact force, then high contact force is achieved, but stray magnetic flux increases and may damage magnetic media
Solution Approach 1:
The magnetic field generation is segmented into multiple discrete magnets rather than a single strong magnet. This segmentation allows the magnetic field to be distributed and controlled more effectively, concentrating flux where needed for contact force while reducing stray flux in surrounding areas. Each magnet can be independently positioned and sized to optimize the balance between contact force and stray field reduction.
Solution Approach 2:
Magnetic shielding materials or flux directing structures are introduced as intermediaries between the magnets and the surrounding environment. These intermediaries channel the magnetic flux through desired paths to the contacting surface while blocking or redirecting stray flux that could affect magnetic media, effectively decoupling the high contact force requirement from the stray flux problem.
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 ensures a significant difference in contact force between mated and unmated states, reducing impedance and preventing wear, while maintaining a high contact force and minimizing stray magnetic flux, thus enhancing reliability and protecting against damage to magnetic media.
Implementation Method 1
the contact magnet and shuttle magnet may be oriented to each other to provide a repelling force
Implementation Method 2
the contact magnet and shuttle magnet may be oriented to each other to provide a repelling force
Data Source
AI summary
Variable-force contacts that may provide a large and stable contact force in a mated state, may provide a large difference in contact force between the mated and an unmated state, and may reduce stray flux in an unmated state. Examples may replace physical springs with magnetic force for improved reliability. These examples may position the magnets to reduce stray flux in an unmated state.