Integrated Magnetic Connectors - Flat, safe and fast connections
Also published in the Meditronic Journal 03/2023.
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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 connector systems, which require a certain insertion depth to ensure secure locking, magnetic connector systems can be built very flat. The sockets can therefore be integrated almost flush into the plastic housing, since a low installation depth of just a few millimeters is sufficient for a reliable connection. Magnetic connectors are therefore extremely interesting, especially in medical applications, where conventional connector systems harbor a high risk of contamination due to elevations, gaps and cracks. They can be very easily cleaned and disinfected by sealing them with elastomer materials or by directly overmoulding the magnetic connector with plastic. They are also able to achieve protection classes up to IP68 for immersion disinfection.
Magnetic connector - Easy to use
The connection between magnetic plug and socket is simple and intuitive. Incorrect connection can be ruled out by the polarity of the magnets. 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 stress and low wear on the socket. The risk of cable breaks and other cable damage will also be significantly reduced. The magnetic force can be adjusted 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 plugs with an outer magnetic ring that allow 360° rotation with consistent contact and prevent twisting and cable breaks. This is particularly beneficial in applications where the cable is moved frequently, such as in a manual switch. Another practical advantage is the magnetic release mechanism. If you pull the cable unintentionally, the device and the plug will not be 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 for the transmission of signals and currents. This provides an additional level of security 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. In addition, the spring contacts convince 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 not a problem for magnetic plugs with spring contacts.
New coatings
The spring contacts are usually coated with gold, which is used because of its excellent electrical conductivity and its high level of protection against corrosion and oxidation. However, there are advancements such as the Super AP coating that are extremely resistant to electrolytic or galvanic corrosion while maintaining very low resistance. Compared to gold plating, Super AP plating is 30x more resistant to salt water, XNUMXx more resistant to perspiration, and XNUMXx more resistant to electrolysis. This effectively minimizes corrosion of the electrical contacts from sweat or moisture.
Areas of application for magnetic connectors
Magnetic connectors are used in imaging, diagnostics, therapy, patient monitoring and much more. Examples of applications are mobile ultrasound devices, endoscopes, pulse oximeters and prostheses. They are not only functional and safe, but also offer numerous options for designers to meet individual design requirements. The integration of the plugs into the design of the product can be seamless and increase the aesthetic value of the end product. The choice of shapes and colors is practically unlimited and makes it possible to create unique designs.
Similar to traditional connectors, additional components such as status lights can be integrated into magnetic connectors. Sensitive electronic components, circuit boards or sensors are sealed using the hotmelt process to ensure flexibility, impact strength, 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 variety of cables, since 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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