Magnetic plugs and connectors for industrial applications

Everyone knows situations in which connecting the plug and socket is uncomfortable and difficult. Diffuse light situations and installation situations that are difficult to access have presented many a user with a real challenge. Especially small, filigree connector systems are often difficult to handle. In addition to the frustration of the user, such circumstances often lead to damage to the plug, socket or cable. Individual magnetic plugs can offer a solution for a comfortable and at the same time safe application.

Trend: miniaturization

The trend towards more mobile, lighter and more powerful devices presents designers with enormous challenges when developing innovative solutions. The devices not only have to cover a wide range of functions and be attractive in design for the end customer, but also, as in medical technology, for example, also meet the high requirements in terms of safety, reliability and hygiene. The development of small medical devices such as hearing aids, wearables or tracking systems, where powerful electronics have to be implemented in the smallest of spaces, is particularly challenging. Printed circuit boards are being fitted more and more densely with high-performance components or multi-layer, flexible printed circuit boards.

Things get more complicated when it comes to connection technology, because the integration of plug-in sockets is often difficult, especially in small devices, due to the required installation depth. Connectors and Cables The device connection must be designed to suit the target group in order to function intuitively and safely. Older users in particular often find it difficult to operate small and delicate connection systems.

Magnetic connectors: Flat design and space-saving

Plugs with a magnetic connection system based on spring contacts can offer a solution for a comfortable and at the same time safe application.

In contrast to conventional plug-in systems, which require a certain insertion depth for optimal locking, magnetic plug-in systems can be implemented with a very flat and level design. This means that the socket can be inserted almost flat into a Plastic housing An installation depth of just a few millimeters is sufficient for secure contact. This makes the technology particularly interesting for applications in industrial and medical environments. This is because the bumps, gaps and crevices that come with conventional plug-in systems pose a high risk of contamination and soiling.

Self-guiding connection through magnetic force

The implementation of magnets also ensures a self-guiding, shock- and vibration-resistant connection between the connector and the device. This makes it very easy and convenient to use, especially in awkward and tricky installation situations, such as overhead applications.

polarity & magnetic force

Due to the polarity of the magnets, incorrect connection can be ruled out, which ensures high contact and functional reliability. In contrast to conventional plugs, the stress during contact and the associated wear on the socket with magnetic plugs is minimal. The risk of moisture and dirt penetrating the interior of the device is also virtually eliminated. In addition, the magnetic force can be adjusted to the respective requirement by means of different compositions.

In one example, a high magnetic force was required for a diagnostic cable in order to quickly contact the socket under the table through strong self-guiding. For power and data transmission, spring contacts which impress with a small pitch and high tolerance compensation. They also allow a high integration density and have a long service life.

Spring contacts up to 15A nominal current

The default current rating is 1A per pin. Depending on the material and internal structure of the spring contact probe, currents of up to 15A per pin are also possible. This is a decisive advantage, especially for the charging time of batteries, for example in the e-bike segment. There are spring contacts in very small designs, with working heights from 1,2mm. The arrangement in the so-called right-angle design also saves space and allows contacting in a very small space.

Super AP coating for wearables

The spring contacts are coated with gold as standard, which has excellent electrical conductivity and offers a high level of protection against corrosion and oxidation. Customer-specific special coatings are also possible. The Super-AP coating is particularly interesting for medical wearables, as it is extremely resistant to electrolytic or galvanic corrosion while maintaining a very low resistance.

Compared to a gold coating, the Super AP coating is twice as resistant to salt water, five times more resistant to perspiration and 30 times more resistant to electrolysis. Corrosion of the electrical contacts caused by sweat or moisture is effectively minimized.

For devices that are permanently exposed to environmental influences, the magnetic connector and the socket can be sealed with elastomer materials or by direct overmoulding with plastic up to IP68. Another advantage of direct implementation or overmoulded system solutions is that assembly times and assembly costs are significantly reduced.

Free shaping

There are almost no limits to the shape and color of a magnetic connection system. Individual color accents and design requirements can be easily implemented using appropriate tools. Some shapes also have advantageous features. For example, round plugs with an outer magnetic ring enable 360° rotation with constant contact.

When used in a handset, the cable cannot become twisted and cable breaks can be avoided. The user has a wide range of cables to choose from. The magnetic plugs can be fitted with almost any cable.

hot melt process

As with conventional connectors, other components such as status lights can also be integrated. Sensitive electronic components, circuit boards or sensors are sealed using the hotmelt process. Specifications related to flexibility, impact resistance and shock absorption, as well as UV protection and chemical resistance can be accommodated by different materials. The electronic components are protected against corrosion and environmental influences and are therefore also suitable for difficult applications with high humidity or strong temperature fluctuations.

A safe connection

In practice, the great advantages of a magnetic release mechanism are evident. In this way, the device and the plug are not damaged if the cable is pulled unintentionally, and ultimately the risk of injury to the user is avoided. In a current project, the integration of magnetic plugs into a battery e-bike system prevented the plug from being torn out and the associated damage to the socket in the battery. This could happen if the user moves the bike without checking that the battery is charging.

Areas of application in the medical field are, for example, nurse emergency call systems. The use of magnetic connectors can prevent the integrated wall socket from being torn out and the associated damage to the handset. Magnetic plugs are also used as charging cables for prostheses and wheelchairs.

Re-design for proven products

The wheel does not always have to be reinvented to equip a product with magnetic plugs. With the help of customer-specifically developed magnetic adapters, existing operating systems can also be easily converted to this convenient connection system. Proven input devices are given a design-oriented relaunch. In addition, some standard solutions enable a quick conversion of USB connections. In summary, it can be said that magnetic connectors offer developers creative solutions and open up new design approaches.