Magnetic connectors - design-oriented solution & efficient connection
customer-specific magnet solution for a round installation situation
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.
It gets more complicated with the connection technology, because the integration of plug-in sockets is often difficult, especially with small devices, due to the required installation depth. In addition, connectors and cables for connecting devices must be designed for the target group in order to function intuitively and safely. Older users in particular often find it difficult to operate small and filigree 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 planar design. In this way, the socket can be integrated almost flat into a plastic housing. An installation depth of just a few millimeters is sufficient for reliable contacting. This makes the technology particularly interesting for applications in industrial and medical environments. Because it is precisely the elevations, gaps and crevices that conventional connector systems entail that harbor a high risk of contamination and dirt.
Magnetic connectors can be implemented in a flat design
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.
Customized magnetic connector for housing installation
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 desired for a diagnostic cable in order to quickly contact the socket located under the table through strong self-guidance. Spring contacts are used for power and data transmission, which impress with their 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 as standard with gold, which has excellent electrical conductivity and offers a high level of protection against corrosion and oxidation. Customized special coatings are also possible. The Super-AP coating, which is extremely resistant to electrolytic and galvanic corrosion while maintaining a very low resistance, is particularly interesting for medical wearables. 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.
Spring contacts with custom coatings
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 the appropriate tools. Some forms also require advantageous features. For example, round plugs with an outer magnetic ring allow 360° rotations with constant contact. When used in a handset, the cable cannot be twisted and cable breaks avoided. When selecting the cables, the user can draw from plenty. The magnetic connectors can be assembled with almost any cable.
Round magnetic connectors allow 360° rotation
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.
Hotmelt process for magnetic connectors
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.
Magnetic adapter for re-design - custom development
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.
Contact
The extent to which a customer-specific solution is worthwhile always depends on the individual case. Perceived as a convenient and innovative connection solution, a magnetic connection in the devices definitely offers added value in terms of design and handling, along with a differentiation from competitor products.
Our engineers will advise you in detail on the selection of a suitable connection solution for your application. We are also happy to take on the design and development.
We look forward to your inquiry, gladly by email: info@nh-technology.de or by telephone: 02154 81250.
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From our N&H NEWS 01 / 2022
