Integrated magnetic connectors

Magnetic connectors with spring contacts meet the high requirements of medical technology in terms of safety, reliability, hygiene and cleanability. They are increasingly used in the development of small medical devices such as hearing aids and wearables as they enable fast, secure and user-friendly connection of devices and components. Older users in particular, who have difficulties operating small and filigree connection systems due to limited fine motor skills or poor eyesight, can benefit from the practical solution of the magnetic connectors.

They are also an advantageous option for handheld devices, prostheses and electronics housings, as the magnetic sockets can be integrated directly into the housing. This results in compact and robust connection solutions that save space and simplify construction. Integrated magnetic connectors also contribute to economical production by reducing assembly times and costs.

Extremely flat design

In contrast to conventional plug-in systems, which require a certain insertion depth to ensure secure locking, magnetic plug-in systems can be built very flat. This means that the sockets can be integrated almost flush into plastic housings, as a shallow installation depth of just a few millimeters is sufficient for a reliable connection.

Magnetic connectors are particularly interesting in medical applications, where conventional connector systems pose a high risk of contamination due to raised areas, gaps and cracks. They can be cleaned and disinfected very easily by sealing them with elastomer materials or directly overmolding the magnetic connector with plastic. They are also able to achieve protection classes of up to IP68 for immersion disinfection.

Magnetic connector - Easy to use

The connection between the magnetic plug and socket is simple and intuitive. The polarity of the magnets means that incorrect connection is impossible. This makes handling easier and reduces the risk of connection errors, which at the same time increases contact and functional reliability.

In addition, magnetic connectors are particularly durable due to their low load and low wear on the socket. The risk of cable breakage and other cable damage is also significantly reduced. The magnetic force can be adapted to the specific requirements of the respective devices, which is particularly important for sensitive devices in medical technology.

Large variety of magnet shapes

Magnets come in a variety of shapes that allow for great flexibility in integration. Some of these shapes also offer special advantages, such as round connectors with an outer magnetic ring that allow 360° rotation while maintaining consistent contact and preventing twisting and cable breakage. This is particularly advantageous in applications where the cable is often moved, such as in a hand switch.

Another practical advantage is the magnetic release mechanism. If the cable is accidentally pulled, the device and the plug are not damaged. This not only extends the life of the product, but also reduces the risk of injury to the user.

Safe and reliable

Magnetic connectors are combined with spring contacts to transmit signals and currents. This provides an additional level of safety and reliability for medical devices. Spring contacts have a high current carrying capacity of up to 15A per pin and can also support high frequencies and data transfer rates.

The spring contacts are also impressive due to their small pitch and high tolerance compensation. They enable a high integration density and have a long service life. Vibrations and shocks are therefore no problem for magnetic connectors with spring contacts.

New coatings

The spring contacts are usually coated with gold, which is used due to its excellent electrical conductivity and high protection against corrosion and oxidation. However, there are already further developments such as the Super AP coating, which are extremely resistant to electrolytic or galvanic corrosion and maintain a very low resistance.

Compared to gold plating, Super AP plating is twice as resistant to salt water, five times more resistant to perspiration and 30 times more resistant to electrolysis. This effectively minimizes corrosion of the electrical contacts caused by sweat or moisture.

Areas of application for magnetic connectors

Magnetic plugs are used in imaging, diagnostics, therapy, patient monitoring and much more. Examples of applications include mobile ultrasound devices, endoscopes, pulse oximeters and prostheses. Not only are they functional and safe, but they also offer numerous options for designers to meet individual design requirements. The integration of the connectors into the design of the product can be seamless and increase the aesthetic value of the final product. The choice of shapes and colors is practically unlimited and allows for unique designs to be created.

Similar to conventional plugs, additional Components such as status lights be integrated into magnetic connectors. Sensitive electronic components, circuit boards or sensors are sealed using the hot melt process to ensure flexibility, impact resistance, shock absorption, UV protection and chemical resistance. The electronic components are protected against corrosion and environmental influences, which also makes them suitable for demanding applications with high humidity or strong temperature fluctuations. The user can choose from a wide range of cables, as magnetic connectors can be assembled with almost any cable.

Conclusion

In summary, it can be said that magnetic plug-in systems open up creative solutions and new design approaches for developers in various industries - not only in medical technology. However, whether a tailor-made solution makes sense, taking economic aspects into account, always depends on the individual case. As an innovative and convenient connection solution, magnetic connectors undoubtedly offer added value in terms of design and handling, setting them apart from competitive products.

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