Retractable Probe Connector Alignment via Magnetic Force

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Solution Overview

Problem

Existing electrical connector assemblies rely on housing structures for alignment, which can lead to uneven and rough configurations, and fail to utilize the intimacy of mated contacts for alignment during mating.

Innovation Solution

The electrical connector assembly features a receptacle and plug connector with magnetic sections and hidden wireless modules, where retractable probe contacts and stationary pad contacts are exposed, allowing magnetic forces to align the mating surfaces and ensure alignment between wireless modules for efficient wireless transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional housing-based alignment structures (protruding structures and recessed structures) are used, then alignment between connectors can be achieved, but the appearance becomes uneven and rough

Engineering Contradiction:

Improvealignment precisionVSAvoidappearance smoothness

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The alignment function is extracted from the housing structure and transferred to the contact structure itself. The probe contact is designed with a protruding tip that extends beyond the mating surface, while the pad contact has a corresponding recessed receiving area. This extraction allows the housing to maintain a smooth, even appearance without protruding structures, while the contacts provide the necessary alignment function through their intimate mating relationship.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The probe contact and pad contact serve as intermediary elements that mediate the alignment between the two connectors. Instead of relying on the housing surfaces to align directly, the protruding probe contact tip and recessed pad contact structure act as intermediaries that guide and secure the alignment during the mating process, ensuring precise positioning while keeping the external housing surfaces smooth.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If housing structures are used for alignment, then connector alignment can be achieved, but the contact alignment reliability is compromised

Engineering Contradiction:

Improvealignment reliabilityVSAvoidhousing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The alignment function is merged with the contact structure itself rather than being a separate housing feature. The probe contact is integrated with the retractable contact mechanism, and the pad contact is integrated with the stationary contact structure. This merging ensures that alignment and electrical contact occur simultaneously through the same intimate mating interface, improving reliability by eliminating the disconnect between alignment structures and contact structures.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If probe contact extends beyond mating surface and pad contact is coplanar, then alignment can be achieved, but the configuration becomes uneven

Engineering Contradiction:

Improvecontact alignment precisionVSAvoidmating surface configuration

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The traditional configuration is inverted: instead of having the pad contact protrude and the probe contact be recessed (or both coplanar), the invention makes the probe contact protrude beyond the mating surface while the pad contact has a recessed receiving area. This inversion allows the probe contact tip to actively engage with the pad contact recess, achieving precise alignment through this intimate mating relationship while the housing surfaces remain smooth and even.

Inventive Principle:

Principle #13The other way round (Inversion)

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 achieves precise alignment and efficient wireless transmission by using magnetic forces to position the contacts, enhancing the alignment and appearance of the connector assembly beyond traditional housing-based methods.

Implementation Method 1

the first mating surface and the second mating surface intimately confront each other in the mating direction by the corresponding magnetic forces

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS10541484B2Connector assembly with retractable probe contact recessed behind mating surface and stationary pad contact extending beyond mating surface

Publication Date: 2020.01.21 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An electrical connector assembly comprising a first connector and a second connector mated with each other. The first connector includes a first shell forming a first mating surface thereon. A retractable first contact has a first contacting section moveable between an outer position coplanar with the first mating surface and an inner position recessed from the first mating surface. The second connector includes a second shell forming a second mating surface thereon. A stationary second contact has a second contacting section protruding beyond the second mating surface. During mating, the second contacting section abuts against the first contacting section in the mating direction and protrudes beyond the first mating surface to be snugly received within the first connector.