PCB-Mounted Magnetic Connector Assembly Without Pole Pre-Sorting
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Solution Overview
Problem
Conventional magnetic connectors have complex manufacturing processes due to the need to differentiate magnetic poles and use adhesives for assembly, which increases production steps and costs.
Innovation Solution
A magnetic connector design where magnetic bodies are mounted to a printed circuit board without pre-defined magnetic poles, magnetized after soldering, and assembled into an insulating housing with fewer steps, eliminating the need for magnetic pole differentiation and adhesive assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic bodies are assembled in predetermination positions according to magnetic pole differentiation, then the magnetic connector achieves proper magnetic connection, but the manufacturing process becomes complicated with multiple steps
Solution Approach 1:
The magnetic bodies are mounted on the printed circuit board in predetermined positions before magnetization. This preliminary positioning allows the magnetic pole differentiation to be performed after assembly, eliminating the need for pre-differentiation and complex assembly processes while ensuring proper magnetic connection.
Solution Approach 2:
Instead of the conventional approach of differentiating magnetic poles before assembly, this invention inverts the sequence by assembling the magnetic bodies first in unmagnetized state, then differentiating the magnetic poles after assembly. This reversal simplifies the manufacturing process while achieving the same functional result.
2Stability of the object's composition
If magnetic bodies are fixed in insulating housing by adhesives, then the magnetic bodies are securely held, but the manufacturing process requires additional assembly steps
Solution Approach 1:
The magnetic bodies are integrated directly with the printed circuit board through mounting and soldering, combining the fixation function with the electrical connection structure. This eliminates the need for separate adhesive fixation steps and insulating housing assembly, reducing manufacturing complexity while maintaining stability.
3Manufacturing precision
If printed circuit board is assembled in insulating housing before magnetic bodies, then proper positioning is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The magnetic bodies are mounted on the printed circuit board in predetermined positions during the PCB assembly process itself, before final housing assembly. This preliminary positioning integrates the magnetic body placement with the existing PCB manufacturing workflow, achieving precise positioning without adding complex assembly steps.
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
Simplifies the manufacturing process, reduces production costs, and improves efficiency by eliminating the need for magnetic pole differentiation and adhesive assembly.
Implementation Method 1
Each of the magnetic bodies has a predetermination magnetic pole by magnetizing the magnetic bodies after the magnetic bodies are mounted to the printed circuit board
Data Source
AI summary
A magnetic connector includes a first insulating housing, a printed circuit board, a plurality of magnetic bodies, a plurality of terminals and a second insulating housing. The first insulating housing has a bottom wall, a side wall, a recess being defined between the bottom wall and the side wall. The printed circuit board is received in the recess. The magnetic bodies are mounted to the printed circuit board. The terminals are mounted to the printed circuit board. The second insulating housing is mounted to the top of the first insulating housing and is covered the recess. The magnetic bodies and the terminals are exposed from a top surface of the second insulating housing. As described above, the magnetic bodies are mounted to the printed circuit board, and then the magnetic bodies are magnetized. Hence, manufacture cost of the magnetic connector is saved.