Magnetic connector apparatus and related systems and methods

A magnetic connector apparatus may comprise one or more magnet housings, each of which may comprise one or more magnets positioned therein to rotate within the magnet housing(s). The apparatus may be configured using one or more safety features in order to prevent access and/or removal of the magnet(s). In some embodiments, the apparatus may further comprise an inner retainer piece coupled with the one or more magnet housings, a first outer housing piece coupled with the inner retainer piece, and a second outer housing piece coupled with the inner retainer piece. The first outer housing piece may be positioned on an opposite side of the connector apparatus from the second outer housing piece such that the inner retainer piece is positioned in between the first outer housing piece and the second outer housing piece. Novel methods for manufacturing a magnetic connector apparatus are also disclosed.

TECHNICAL FIELD

This disclosure relates to magnetic connectors. More particularly, this disclosure relates to magnetic connectors configured to rotate in order to magnetically link two objects, and related systems and methods, including housings and magnetic assemblies for such magnetic connectors.

In the following description, numerous specific details are provided for a thorough understanding of the various embodiments disclosed herein. The systems and methods disclosed herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In addition, in some cases, well-known structures, materials, or operations may not be shown or described in detail in order to avoid obscuring aspects of the disclosure. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more alternative embodiments.

DETAILED DESCRIPTION

Described herein are embodiments of magnetic connector apparatus that may comprise magnetic connectors configured to rotate in order to magnetically link two objects. Such magnetic connectors as described herein may comprise one or more magnet housings. One or more magnets may be positioned within one or more of the magnet housings such that the magnet(s) can rotate within the magnet housing(s). In preferred embodiments, the magnet(s) may comprise a neodymium magnet(s) or another high-strength/flux magnet.

In some embodiments, the magnet housing(s) may be configured to inhibit removal of the magnets for safety purposes. Because of the high strength of neodymium magnets and other similar magnets, it may be desirable to restrict access to such magnets to users of a magnetic connector apparatus, particularly children. The dangers associated with ingesting such magnets have been well documented. Ingesting high-strength magnets can, in some cases, even lead to death. It may therefore be desirable to construct the magnet housing(s) in such a manner that access to the magnets contained within such housings is restricted. This may be done in a variety of ways, as described in greater detail.

For example, the material(s) used to form the magnet housing(s) may be very rigid, durable, strong, and/or tough to prevent a user (such as a child) from breaking the housing to allow the magnet(s) contained therein to be removed or accessed. As another example, sonic welding may be used such that various components of the apparatus are sealed together in such a manner that these components are difficult, if not impossible, to separate by breaking the sonic weld. As still another example, one or more components may be provided in order to at least substantially plug one or more openings in the magnet housings to further restrict access to the magnet within. As yet another example, part of the magnetic connector apparatus may comprise one or more recessed regions that may be configured to receive one or more portions of the magnet housing to make it more difficult to remove the magnet housing from the magnetic connector apparatus.

As still another example of a safety feature for restricting access to the magnet(s), the magnetic connector apparatus may include one or more fasteners for coupling the magnet housing to another portion of the apparatus. In some preferred embodiments, the fasteners may comprise rivets or other such fasteners that cannot easily be removed by a user in order to further enhance the safety features of the apparatus.

The magnet housing may also comprise one or more reinforced regions wherein the material is thicker at locations that might otherwise be vulnerable to wear, tampering, and the like. Similarly, areas of the magnet housing adjacent to any opening for receiving a fastener may be reinforced, appropriately bent, shaped, or otherwise configured to further ensure that the magnet contained therein cannot be removed and/or that the magnet housing cannot be removed from the magnetic connector apparatus. In preferred embodiments, multiple, redundant safety features/components are incorporated into the apparatus to provide further protection against unwanted access to the magnet(s). By providing redundant safety features/components, such as a high-strength steel magnet housing and sonic welding, the chances that a magnet may be removed from the apparatus may be dramatically decreased, if not eliminated altogether.

The magnet housing(s) may each be positioned along a connection edge of the magnetic connector apparatus, such that the connection edge is configured to be magnetically connected with a connection edge of another magnetic connector apparatus. In this manner, magnetic connector apparatus of various different shapes and sizes may be coupled together to build larger structures, toys, play games, etc.

As described in greater detail below, in some embodiments, each magnet may comprise a multi-pole magnet assembly. Such an assembly may comprise a first half and a second half extending substantially along a longitudinal axis. The first half may comprise at least two magnetic sections of alternating polarity and the second half may comprise a corresponding number of magnetic sections. Each magnetic section in the second half may have a polarity opposite that of an adjacent magnetic section in the first half such that the polarity of the magnet alternates along its length. As described below, these assemblies may provide several advantages that may be useful for certain implementations of the inventions described herein.

However, various components and elements disclosed herein, including but not limited to the magnet housing and, retainer pieces, and housing pieces disclosed herein, may be used with other types of magnets. For example, in some embodiments, the magnets need not be configured such that they alternate in polarity along their respective lengths. Instead, magnets with just two poles may be used, such as those disclosed in U.S. Pat. No. 7,154,363 titled “Magnetic Connector Apparatus,” for example.

In some embodiments, the magnetic connector apparatus may comprise a housing comprising an inner retainer piece coupled with the magnet housing, a first outer housing piece coupled with the inner retainer piece, and a second outer housing piece coupled with the inner retainer piece. The first outer housing piece may be positioned on an opposite side of the connector apparatus from the second outer housing piece such that the inner retainer piece is positioned in between the first outer housing piece and the second outer housing piece.

In some embodiments, the magnetic connector apparatus may further comprise a magnet housing receiver configured to engage the magnet housing to couple the magnet housing to the inner retainer piece. The magnet housing receiver may comprise one or more magnet housing engaging members. In embodiments comprising two magnet housing engaging members, a first magnet housing engaging member may be configured to engage a first end of the magnet housing, and a second magnet housing engaging member may be configured to engage a second end of the magnet housing opposite from the first end.

In some embodiments, the first magnet housing engaging member may comprise one or more magnet housing plugs. In embodiments comprising two magnet housing plugs, a first magnet housing plug may be configured to at least substantially seal an opening in the magnet housing at the first end, and a second magnet housing plug may be configured to at least substantially seal an opening in the magnet housing at the second end.

The magnet housing may, in some embodiments, comprise a body member comprising a cylindrical cavity. The magnet may be positioned within the cylindrical cavity. The magnet may be rotatable within the cavity or, alternatively, and as explained in greater detail below, the magnet may be rotatable within another enclosure positioned within the cavity. As still another alternative, the magnet may be positioned within another enclosure and the enclosure/magnet combination may be rotatable with respect to the magnet housing.

One or more plate members may extend from the body member of the magnet housing. The plate member(s) may be coupled to an outer surface of the inner retainer piece. The magnetic connector apparatus may further comprise one or more fasteners for coupling the plate member(s) to the inner retainer piece. The fastener(s) may be positioned through fastener openings within the plate member(s) and/or inner retainer piece. The fastener(s) may comprise a rivet, screw, bolt, pin, or the like.

In embodiments comprising magnet housings having two plate members, a first plate member may extend from the body member and be coupled to a first surface of the inner retainer piece. A second plate member may extend from the body member and be coupled to a second surface of the inner retainer piece opposite from the first surface.

The inner retainer piece may comprise one or more recessed regions on the inner retainer piece for seating/receiving the one or more plate members. For example, a first recessed region may be formed within or otherwise positioned on the first surface for receiving the first plate member, and a second recessed region may be formed within or otherwise positioned on the second surface for receiving the second plate member.

The magnetic connector may further comprise an enclosure to encase the magnet. The enclosure may be positioned within the magnet housing. The enclosure may be configured such that it is rotatable with respect to the magnet housing. Alternatively, the enclosure may be fixed with respect to the magnet housing such that the magnet is rotatable with respect to the enclosure (and the housing).

The magnetic connector apparatus may comprise a plurality of magnets/magnet housings, each of which may be positioned along a connection edge of the apparatus such that multiple edges of the apparatus may be used to magnetically couple the apparatus with another magnetic connector apparatus. Each magnet positioned within each of the magnet housings may be configured such that the magnet can rotate within its respective magnet housing such that opposing polarities of the magnets can be aligned and lock two or more magnet connector apparatus together.

In some embodiments, two or more multi-pole magnetic assemblies may be configured to rotate with respect to one another in order to align opposite polarities and magnetically link two or more components. According to various embodiments, a multi-pole magnetic assembly may be cylindrical, rectangular, prismic, and/or oblong. Alternative shapes are contemplated as well. A multi-pole magnetic assembly may include any number of magnetic sections, each adjacent magnetic section having an alternating polarity. Magnetic assemblies may be encased within an enclosure, such as a cylindrical or triangular prismic enclosure. Alternatively, magnetic assemblies may be otherwise affixed to a connection member or another component of the connector apparatus. For example, a rod may be positioned to extend through a central axis of one or more magnetic assemblies to facilitate the rotation.

In some embodiments, the multi-pole magnetic assembly may be configured to rotate within and with respect to the enclosure. In alternative embodiments, the enclosure encasing the multi-pole magnetic assembly is configured to rotate. Enclosures and/or magnetic assemblies forming part of a universal connector apparatus may be configured to rotate with respect to one another in order to align opposite polarities. In some embodiments, the magnetic assemblies rotate with respect to the enclosures. In other embodiments, the magnetic assemblies are fixed within their respective enclosures and the enclosures rotate with respect to one another in order to align the polarities of the encased magnetic assemblies.

In some embodiments, connection members may be secured end to end in order to form a triangle, square, rectangle, another polygon, or another shape. Alternatively, connection members may be joined together at the ends in order to form a polygonal framework having any number of sides, or connection edges. A rotatable multi-pole magnetic assembly may be positioned and rotatably secured adjacent one or more edges of the polygon. For example, a cylindrical magnet may be positioned adjacent each side of a polygon. With regard to still other embodiments, solid objects, such as triangles and squares, may include rotatable multi-pole magnetic assemblies positioned adjacent one or more edges of the polygonal solid object.

An enclosure may be fixedly secured adjacent one or more side edges of a polygonal shape. Accordingly, in order to align polarities, a magnetic assembly within each secured enclosure may be configured to freely rotate in order to align polarities.

In other embodiments, two-dimensional objects, such as squares, rectangles, and triangles, may be magnetically linked in order to create three-dimensional objects, such as pyramids and tetrahedrons.

In some embodiments of methods for forming the multi-pole magnets, a magnetizing apparatus may be adapted to form a multi-pole magnetic assembly, including multiple magnetic sections. A bottom plate may be secured to a top press section via one or more hinges. A cylindrical rod placed within the magnetizing apparatus may then be used to create a multi-pole magnet.

Novel manufacturing methods and precursor components used in such methods are also disclosed herein. In one example of such a method for manufacturing a magnetic connector apparatus, an outer housing piece may be provided that comprises one or more weld joint protrusions.

In some embodiments, these weld joint protrusions may comprise a V-shaped ridge formed adjacent to at least a portion of a perimeter of the outer housing piece. Alternatively, the weld joint protrusion may comprise another suitable shape, such as, for example, a weld joint protrusion with a relatively flat top and/or relatively parallel sides, rather than the relatively pointed tip and slanted sides of a V-shaped ridge. A second outer housing piece may also be provided. The second outer housing piece may also comprise a weld joint protrusion.

One or both of the outer housing pieces may also be formed with one or more melt chambers. The melt chamber(s) may be positioned adjacent to the weld joint protrusion(s) such that material from the weld joint protrusion(s) will melt into the melt chamber(s) during a welding process, as described in greater detail below. As described below, in preferred embodiments, the welding process may comprise a sonic welding process.

In embodiments in which melt chambers are provided in both of the outer housing pieces, the respective melt chambers may be configured and positioned such that a the first outer housing piece melt chamber is at least substantially aligned with a second outer housing piece melt chamber during the welding process. In such embodiments, material from the weld joint protrusion(s) may fill in the partial melt chambers from both outer housing pieces (together forming a joint melt chamber) such that, when the melted material solidifies, it bonds to both of the outer housing pieces and, in some implementations, an inner retainer piece as well. In some embodiments, the joint melt chamber may be formed by a melt chamber from an upper housing piece, a melt chamber from a lower housing piece, and at least a portion of a surface of the inner retainer piece. One or more of the outer housing pieces and/or inner retainer piece may comprise a suitable material for sonic welding, such as a thermoplastic material, a carbon fiber material, a metallic material, or a composite material, for example.

As described elsewhere herein, one or more magnet housings may also be provided, each of which may contain a magnet therein such that the magnet is rotatable within the magnet housing. The magnet housing(s) may be coupled to at least one of the first outer housing piece, the second outer housing piece, and the inner retainer piece. The first outer housing piece may then be sonically welded to the second outer housing piece and/or the inner retainer piece.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. In particular, an “embodiment” may be a system, an article of manufacture, a method, or a product of a process.

The components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Some of the infrastructure and manufacturing processes that can be used with embodiments disclosed herein are already available. Accordingly, well-known structures and manufacturing processes associated with magnets, connectors, plastics, forms, metals, composites, and the like, have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the present exemplary embodiments. In addition, the steps of the described methods do not necessarily need to be executed in any specific order, or even sequentially, nor need the steps be executed only once, unless otherwise specified.

The embodiments of the disclosure are best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. In the following description, numerous details are provided to give a thorough understanding of various embodiments. However, the embodiments disclosed herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of this disclosure.

FIG. 1Aillustrates a multi-pole magnetic assembly100configured with four magnetic sections101,103,105, and107of alternating polarities. As illustrated, multi-pole magnetic assembly100may include a first half111and a second half112extending along a longitudinal axis110. First half111may comprise a first magnetic section101having a first magnetic polarity (north) and a second magnetic section105having an opposite magnetic polarity (south). Second half112may include a corresponding number of magnetic sections103and107having a magnetic polarity opposite that of an adjacent magnetic section101and105, respectively, in first half111.

FIG. 1Billustrates another embodiment of a multi-pole magnetic assembly120similar to that ofFIG. 1A. As illustrated, multi-pole magnetic assembly120may include eight magnetic sections121-128, each magnetic section having a magnetic polarity opposite that of each adjacent magnetic section. Again, multi-pole magnetic assembly120may include a first half and a second half extending along a longitudinal axis. Each half may include a corresponding number of magnetic sections. As illustrated, a left half may include four magnetic sections121,123,125, and127having magnetic polarities north, south, north, south, respectively. A right half may include four corresponding magnetic sections122,124,126, and128, each having a magnetic polarity opposite that of the adjacent magnetic section in the left half. Accordingly, magnetic sections122,124,126, and128may have magnetic polarities south, north, south, north, respectively.

FIG. 1Cillustrates a multi-pole magnetic assembly130configured with any number of magnetic sections131-N2, with each magnetic section having a magnetic polarity opposite that of each adjacent magnetic section. As conveyed byFIG. 1C, a multi-pole magnetic assembly130may include any number of magnetic sections as desired. According to various embodiments, a magnetic assembly may include an equal number of magnetic sections with a north polarization as a south polarization. Additionally, the magnetic strength of the magnetic sections having a south polarization may be equal to the magnetic strength of the magnetic sections having a north polarization. According to some embodiments, the volume and/or mass of the magnetic sections having a south polarization may be less than or greater than the volume and/or mass of the magnetic sections having a north polarization.

According to some embodiments, the adjacent oppositely polarized magnetic sections may strengthen or otherwise modify the magnetic fields of other magnetic sections. In some embodiments, the assemblies may be configured such that the magnetic field of one or more outer magnetic sections magnify the magnetic field of one or more of the center magnetic sections. For example, magnetic section134may have an increased magnetic flux adjacent thereto due to the interaction of magnetic flux from adjacent magnetic sections132and136. This may lead to the inner magnetic sections having greater lifting strength than the outer magnetic sections.

FIG. 2illustrates a multi-pole magnetic assembly200configured with six magnetic sections210-235, each magnetic section having a magnetic polarity opposite that of each adjacent magnetic section. As illustrated, magnetic sections220and225may be configured with opposite polarities (south and north, respectively) and may be physically larger magnetic sections than magnetic sections210,215,230, and235. According to some embodiments, magnetic sections220and225may have a stronger magnetic strength than magnetic sections210,215,230, and235. Alternatively, any magnetic section or pair of magnetic sections having opposite polarities may have a stronger magnetic strength than another magnetic section or pair of magnetic sections, independent of physical shape, volume, weight, or dimensions.

FIGS. 1A-2illustrate various embodiments of multi-pole magnetic assemblies100,120,130, and200having cylindrical configurations. As illustrated inFIGS. 3A and 3B, a multi-pole magnetic assembly may be any shape or size.FIG. 3Aillustrates a multi-pole magnetic assembly300configured with eight magnetic sections305-340each having a magnetic polarity opposite that of each adjacent magnetic section. As illustrated, multi-pole magnetic assembly300may be in an oblong, or egg-shaped configuration. The length, width, height, and/or contour of the perimeter of multi-pole magnetic assembly300may be adapted or modified as is deemed suitable for a particular application.

Providing another alternative configuration,FIG. 3Billustrates a multi-pole magnetic assembly350configured with six magnetic sections360-385, each having a magnetic polarity opposite that of each adjacent magnetic section. Multi-pole magnetic assembly350is a rectangular prism configuration. According to various embodiments, the length, width, and height of magnetic assembly350may be adapted for a particular application.

The various embodiments of multi-pole magnetic assemblies described in conjunction withFIGS. 1A-3Bare merely illustrative and are not the only contemplated shapes, sizes, or configurations. Additional shapes and sizes of multi-pole magnetic assemblies are contemplated having any of a wide variety of shapes and sizes, including any polygonal regular or irregular prismic, circular cylindrical, and/or elliptical cylindrical shape. Prismic multi-pole magnetic assemblies may include bases at right angles, obtuse angles, and/or acute angles. Moreover, the perimeter may be irregular and/or include a non-flat base, such as the oblong multi-pole magnetic assembly illustrated inFIG. 3A.

A multi-pole magnetic assembly may be formed using any of a wide variety of magnetizable materials. A multi-pole magnetic assembly may be a single continuous magnetic material including a plurality of adjacent magnetic sections each polarized with a magnetic polarity opposite that of each adjacent magnetic section. Alternatively, a multi-pole magnetic assembly may be a single physical material including a plurality of adjacent magnetic sections each polarized with a magnetic polarity opposite that of each adjacent magnetic section, where each pair of oppositely polarized magnetic sections is separated from another pair of oppositely polarized magnetic sections by a non-magnetically polarized section of material. According to yet another embodiment, a multi-pole magnetic assembly may be formed by joining multiple pairs of oppositely polarized magnetic sections. In such an embodiment, a multi-pole magnetic assembly may include a plurality of magnets polarized along their longitudinal axes magnetically linked end to end, such that each magnetic section is magnetically polarized opposite that of each adjacent magnetic section.

FIG. 4illustrates a cylindrical multi-pole magnetic assembly450encased within a connection member comprising a cylindrical enclosure475. As illustrated, multi-pole magnetic assembly450may include six magnetic sections410-435, each magnetic section410-435having a magnetic polarity opposite that of each adjacent magnetic section. According to various embodiments, cylindrical enclosure475may be a circular cylinder, as illustrated, or may be an elliptical cylinder. Multi-pole magnetic assembly450may be free to translate within cylindrical enclosure475along a longitudinal axis, or may be longitudinally fixed. Additionally, multi-pole magnetic assembly450may be free to rotate about its longitudinal axis within cylindrical enclosure475, or may be fixedly secured within cylindrical enclosure475.

Other embodiments are contemplated in which an enclosure is not necessary. For example, a rod may be positioned to extend through a central axis of one or more magnetic assemblies to facilitate the rotation. Such a rod may be positioned within a cavity or opening positioned within the magnetic connector apparatus if desired.

FIG. 5illustrates a rectangular prismic multi-pole magnetic assembly550encased within a connection member comprising a cylindrical enclosure575. Rectangular prismic multi-pole magnetic assembly550may include six magnetic sections510-535, each magnetic section510-535having a magnetic polarity opposite that of each adjacent magnetic section. According to various embodiments, cylindrical enclosure575may be a circular cylinder, as illustrated, or may be an elliptical cylinder. Multi-pole magnetic assembly550may be free to translate within cylindrical enclosure575along a longitudinal axis, or may be longitudinally fixed. Multi-pole magnetic assembly550may be free to rotate about its longitudinal axis within cylindrical enclosure575, or may be fixedly secured within cylindrical enclosure575.

FIG. 6illustrates a cylindrical multi-pole magnetic assembly650encased within a connection member comprising a triangular prismic enclosure675. Multi-pole magnetic assembly650may include six magnetic sections610-635, each magnetic section610-635having a magnetic polarity opposite that of each adjacent magnetic section. According to various embodiments, triangular prismic enclosure675may be modified to be any polygonal prismic enclosure having any number of sides, dimensions, heights, and/or base angles. Multi-pole magnetic assembly650may be free to translate within prismic enclosure675along a longitudinal axis, or may be longitudinally fixed. Multi-pole magnetic assembly650may be free to rotate about its longitudinal axis within prismic enclosure675, or may be fixedly secured within prismic enclosure675.

FIG. 7Aillustrates a connector apparatus700comprising two cylindrical multi-pole magnetic assemblies710and730configured to rotatably align polarities in order to magnetically link two connection members comprising sections750and760of a fabric. As illustrated, each multi-pole magnetic assembly710and730may be encased within an enclosure720and740, respectively. As illustrated, the polarities of the magnetic sections of multi-pole magnetic assembly710are not aligned with the magnetic sections of multi-pole magnetic assembly730. Accordingly, in the orientation illustrated inFIG. 7A, multi-pole magnetic assemblies710and730would repel one another.

According to various embodiments, the repulsion of the magnetic sections of multi-pole magnetic assemblies710and730may cause one or both of multi-pole magnetic assemblies710and730to rotate about a longitudinal axis in order to align the polarities of the magnetic sections of each of multi-pole magnetic assemblies710and730. This rotation may comprise a rotation of the magnetic assemblies within a fixed enclosure or, alternatively, may comprise a rotation of the enclosures themselves, as described in greater detail below. The transition fromFIG. 7AtoFIG. 7Billustrates multi-pole magnetic assembly710rotating about its longitudinal axis in order to magnetically link with multi-pole magnetic assembly730.

According to some embodiments, multi-pole magnetic assembly710may rotate about a longitudinal axis within and with respect to enclosure720. In such an embodiment, multi-pole magnetic assembly and enclosure combinations710,720and730,740may be fixedly attached to fabric sections750and760. Alternatively, multi-pole magnetic assembly710may be fixed within enclosure720, and enclosure720may be configured to rotate about its longitudinal axis in order to align the magnetic sections of each of multi-pole magnetic assemblies710and730. In such an embodiment, Multi-pole magnetic assembly and enclosure combinations710,720and730,740may be rotatably secured within a hem or other cavity of fabric sections750and760.

FIG. 7Billustrates a connector apparatus700comprising the two cylindrical multi-pole magnetic assembly and enclosure combinations710,720and730,740. As illustrated, with the magnetic sections of each of multi-pole magnetic assemblies710and730aligned, multi-pole magnetic assembly and enclosure combinations710,720and730,740may magnetically link with one another, and thereby link fabric sections750and760. In addition to linking fabric, such as fabric sections750and760, one or more multi-pole magnetic assembly and enclosure combinations, such as multi-pole magnetic assembly and enclosure combinations710,720and730,740, may be used to magnetically link any of a wide variety of materials, components, or products.

FIG. 8Aillustrates a first multi-pole magnetic assembly825and a second multi-pole magnetic assembly850. In this embodiment, each of the first and second multi-pole magnetic assemblies825and850include eight magnetic sections. Each magnetic section may have a magnetic polarity opposite that of each adjacent magnetic section. As second multi-pole magnetic assembly850approaches first multi-pole magnetic assembly825, first multi-pole magnetic assembly825may rotate to align the polarities of the respective magnetic sections of first and second multi-pole magnetic assemblies825and850so that they may magnetically link.

As illustrated inFIG. 8B, the rotation of first multi-pole magnetic assembly825about its longitudinal axis may align the polarities of its magnetic sections with those of the second multi-pole magnetic assembly. Once the polarities are properly aligned, first and second multi-pole magnetic assemblies825and850may magnetically link along aligned outside perimeters. In an alternative embodiment, second multi-pole magnetic assembly850may rotate in addition to, or instead of, first multi-pole magnetic assembly825.

FIGS. 8C-8Dillustrate first multi-pole magnetic assembly825rotating about its longitudinal axis in order to magnetically link with second multi-pole magnetic assembly850along askew outer perimeters. As illustrated inFIG. 8C, first multi-pole magnetic assembly825may rotate about its longitudinal axis in order to properly align the respective magnetic sections of first and second multi-pole magnetic assemblies825and850.

One result of using multi-pole magnetic assemblies, as opposed to bi-pole magnets, is that two or more multi-pole magnetic assemblies may be magnetically linked along outer perimeters that are longitudinally askew with respect to one another. As illustrated inFIG. 8D, first multi-pole magnetic assembly825may be magnetically linked to second multi-pole magnetic assembly850longitudinally askew by two magnetic sections. In other embodiments, first multi-pole magnetic assembly825may include any number of magnetic sections, and second multi-pole magnetic assembly850may be magnetically linked along longitudinally askew outer perimeters by one or more magnetic sections.

FIGS. 9A-9Gillustrate a first multi-pole magnetic assembly925and a second multi-pole magnetic assembly950rotatably interacting and maintaining a magnetic link while second multi-pole magnetic assembly950is translated along a longitudinal axis with respect to first multi-pole magnetic assembly925. Beginning withFIG. 9A, first multi-pole magnetic assembly925may be magnetically linked with second multi-pole magnetic assembly950along aligned outer perimeters. Though illustrated as cylindrical herein, first and second multi-pole magnetic assemblies925and950may be cylindrical, spherical, oblong, rectangular, parallelepiped, trapezoidal, and/or any other suitable shape. Moreover, first and second multi-pole magnetic assemblies925and950may each include a first half and a second half extending along a longitudinal axis, each half including any number of magnetic sections having magnetic polarities opposite that of each adjacent magnetic section. As illustrated inFIGS. 9A-9G, each multi-pole magnetic assembly925and950includes eight magnetic sections of alternating polarities.

InFIG. 9B, second multi-pole magnetic assembly950is longitudinally translated along an outer perimeter of first multi-pole magnetic assembly925. As the polarities of the respective magnetic sections become misaligned, first multi-pole magnetic assembly925may rotate in order to maintain the proper polarity alignment. Once first multi-pole magnetic assembly925has rotated, second multi-pole magnetic assembly950may be magnetically linked longitudinally askew by one magnetic section, as illustrated inFIG. 9C. Alternatively, second multi-pole magnetic assembly950may rotate to maintain the proper polarity alignment.

Continuing withFIG. 9D, second multi-pole magnetic assembly950may be further longitudinally translated with respect to first multi-pole magnetic assembly925. Again, as the polarities of the respective magnetic sections become misaligned, first multi-pole magnetic assembly925may rotate in order to maintain the proper polarity alignment for first and second multi-pole magnetic assemblies925and950to remain magnetically linked. As illustrated inFIG. 9E, first and second multi-pole magnetic assemblies925and950remain magnetically linked longitudinally askew by two magnetic sections.

FIG. 9Fillustrates second multi-pole magnetic assembly950as it is further translated with respect to first multi-pole magnetic assembly925. First multi-pole magnetic assembly925may rotate again in order to maintain an attractive polarity alignment between the respective magnetic sections of first and second multi-pole magnetic assemblies925and950. As illustrated inFIG. 9G, first and second multi-pole magnetic assemblies925and950may remain magnetically linked along askew outer perimeters, such that a single magnetic section from each multi-pole magnetic assembly925and950maintains the magnetic link.

It should be understood from the discussion accompanyingFIGS. 8A-8Dand9A-9F that various embodiments of the multi-pole magnetic assemblies disclosed herein may have a plurality of individual connection points with respect to an adjacent multi-pole magnetic assembly. Typically, each such assembly will have as many connection points as there are pairs of magnetic sections.

FIG. 10Aillustrates a connection apparatus comprising a connection member1000. Connection member1000comprises three connection edges1003,1005, and1007. Connection edge1003comprises an open region comprising a connection rod1004. Connection rod1004extends through a central axis of multi-pole magnetic assembly1017and allows multi-pole magnetic assembly1017to rotate around the connection rod1004. In some embodiments, rod1004may comprise an upper rod section and a lower rod section, and may be connected to a central axis of multi-pole magnetic assembly1017, but not extend all of the way therethrough. Additionally, instead of an open region, connection rod1004may be positioned within a cavity formed within a connection member.

Connection member1000also comprises two other connection edges1005and1007, each of which encloses a multi-pole magnetic assembly1018and1019in an enclosure1013and1015, respectively. Each of the connection edges together make up a triangular configuration. As illustrated inFIG. 10A, each multi-pole magnetic assembly1017,1018, and1019may be configured to rotate about its longitudinal axis. Thus, each connection edge1003,1005and1007of triangle1000may include a multi-pole magnetic assembly1017,1018, and1019adapted to rotate about its longitudinal axis. The multi-pole magnetic assembly1017,1018, and1019may rotate adjacent the connection edge1003,1005and1007of triangle1000and align the polarities of each of its magnetic sections with those of another multi-pole magnetic assembly. Accordingly, triangle1000may be magnetically linked at any angle with another triangle with a similar configuration as triangle1000, or another magnetic connector apparatus of another configuration, along any of sides1003,1005and1007.

FIG. 10Billustrates a connection member1020comprising three connection edges or sides1023,1025and1027in a triangular configuration, including a magnetic assembly and enclosure combination1037,1031and1038,1033and1039,1035adjacent each connection edge. According to various embodiments, multi-pole magnetic assemblies1037,1038, and1039may be cylindrical, prismic, and/or another shape. Enclosures1031,1033, and1035may be cylindrical, prismic and/or another shape. For example, magnetic assemblies1037,1038, and1039may be configured as spherical magnetic assemblies having two or more magnetic sections. In such an embodiment, enclosures1031,1033, and1035may be configured as corresponding spheres or cylinders adapted to encase the spherical magnetic assemblies.

Magnetic assemblies1037,1038, and1039may be configured to rotate within and with respect to enclosures1031,1033, and1035. Alternatively, magnetic assemblies1037,1038, and1039may be fixed within enclosures1031,1033, and1035. In such an embodiment, magnetic assemblies1037,1038, and1039may be configured to rotate about their longitudinal axes. In either embodiment, enclosures1031,1033, and1035may rotate about their longitudinal axes to align the polarities of each magnetic section of each magnetic assembly1037,1038, and1039with another magnetic assembly in order to magnetically link a side1023,1025and1027with another object containing a similar magnetic assembly, such as another triangle similar to triangular connection member1020.

FIG. 10Cillustrates a connection member1040comprising three connection edges in a triangular configuration, including a magnetic assembly and enclosure combination1057,1051and1058,1053and1059,1055adjacent each connection edge1043,1045, and1047. Similar to previously described embodiments, magnetic assemblies1057,1058, and1059may be configured to rotate within and with respect to enclosures1051,1053, and1055. Alternatively, magnetic assemblies1057,1058, and1059may be fixed within enclosures1051,1053, and1055. In such an embodiment, enclosures1051,1053, and1055may be configured to rotate about their longitudinal axes. In still another embodiment, enclosures1051,1053, and1055may be omitted and magnetic assemblies1057,1058, and1059may be configured to rotate about their longitudinal axes within cavities or hollows adjacent sides1043,1045, and1047of triangular connection member1040.

FIG. 10Dillustrates a connection member1060comprising three connection edges1063,1065, and1067in a triangular framework. A magnetic assembly and enclosure combination1078,1073and1079,1075may be fixedly attached to each of connection edges1065and1067. According to the illustrated embodiment, enclosures1073and1075may be fixedly attached to an inner or outer portion of each side section1065and1067. Magnetic assemblies1078and1079may be configured to rotate within and with respect to enclosures1073and1075, so as to align the polarities of each magnetic section of each magnetic assembly1078and1079in order to magnetically link respective connection edges1065and1067with another object containing a similar magnetic assembly, such as another triangle similar to triangular connection member1060. Alternatively, a magnetic connector apparatus of another configuration, such as one having only a single edge or connection member, may be connected with the magnetic connector apparatus configured as triangular framework1060, or any of the other magnetic connector apparatus disclosed herein. As shown in the figure, connection edge1063comprises a connection rod1071that is attached to, and substantially parallel to, but offset from, connection edge1063. Multi-pole magnetic assembly1077may be configured to rotate about connection rod1071in order to magnetically link connection edge1063with a connection edge of another object.

FIG. 11illustrates a connection member1100comprising three connection edges or sides1103,1105, and1107in a triangular configuration, each connection edge1103,1105, and1107including a cylindrical enclosure1111,1113, and1115encasing a rectangular prismic multi-pole magnetic assembly1122,1124, and1126. According to various embodiments, rectangular prismic multi-pole magnetic assemblies1122,1124, and1126may not easily rotate within enclosures1111,1113, and1115or may be fixedly attached within enclosures1111,1113, and1115. Accordingly, enclosures1111,1113, and1115may be configured to rotate within each side1103,1105, and1107, so as to allow the polarities of each magnetic section of each multi-pole magnetic assembly1122,1124, and1126to align with the magnetic sections of other multi-pole magnetic assemblies.

FIG. 12illustrates a connection member comprising six connection edges1210-1215in a hexagonal configuration1200, including a magnetic assembly and enclosure combination1201-1206adjacent each connection edge1210-1215. As previously described, the multi-pole magnetic assembly within each magnetic assembly and enclosure combination1201-1206may be configured to rotate with or, alternatively, with respect to its corresponding enclosure.

FIG. 13Aillustrates a first connector apparatus1310comprising a first connection member having four connection edges arranged in a rectangular configuration, and a second connector apparatus1350comprising a second connection member having four connection edges1321-1324. As illustrated, each of the four connection edges, or sides, of first connector apparatus1310may encase a magnetic assembly and enclosure combination1311-1314. According to various embodiments, the multi-pole magnetic assemblies encased within each magnetic assembly and enclosure combination1311-1314may be may be cylindrical, prismic, and/or another suitable shape. Similarly, the enclosures themselves may be cylindrical, prismic and/or another shape.

Second connector apparatus1350may comprise four enclosures1321-1324, each encasing a multi-pole magnetic assembly1331-1334. Enclosures1321-1324may be shaped such that they can be connected end to end and form any number of polygonal shapes. Each multi-pole magnetic assembly1331-1334may rotate within its respective enclosure1321-1324about a longitudinal axis.

As illustrated inFIG. 13A, as first and second connector apparatus1310and1350approach one another, the multi-pole magnetic assembly within magnetic assembly and enclosure combination1314may rotate to align the respective magnetic sections of magnetic assembly and enclosure combination1314and multi-pole magnetic assembly1331. Once the magnetic sections are aligned, first and second connector apparatus1310and1350may be magnetically linked along longitudinally aligned outer perimeters1315and1325, as illustrated inFIG. 13B. Alternatively, either the multi-pole magnetic assembly1331alone, or the enclosure in magnetic assembly and enclosure combination1314, may rotate about a longitudinal axis in order to align the respective magnetic sections.

FIG. 14Aillustrates a multi-pole magnetic assembly1485rotating within a second connector apparatus1475in order to magnetically link with a first connector apparatus1450along longitudinally askew outer perimeters1455and1480. According to various embodiments, multi-pole magnetic assembly1485may rotate in order to align the respective magnetic sections of multi-pole magnetic assembly1485and the multi-pole magnetic assembly within magnetic assembly and enclosure combination1460. According to alternative embodiments, either the multi-pole magnetic assembly within the enclosure of magnetic assembly and enclosure combination1460or the enclosure of combination1460may rotate along a longitudinal axis instead of multi-pole magnetic assembly1485.

As illustrated inFIG. 14B, since each multi-pole magnetic assembly within each of first and second connector apparatus1450and1475includes multiple pairs of magnetic sections (as opposed to just one pair), first and second connector apparatus1450and1475may magnetically link along longitudinally askew outer perimeters1455and1480, which, as discussed above, results in four separate connection points along each of the sides of the two connector apparatus.

FIG. 15Aillustrates first and second connector apparatus1550and1575approaching one another. As illustrated, the magnetic sections within magnetic assembly and enclosure combination1560are not aligned with respect to those of multi-pole magnetic assembly1585. Accordingly, if first and second connector apparatus1550and1575were magnetically linked longitudinally aligned along outer perimeters1555and1580, one of the multi-pole magnetic assemblies would need to rotate. However, as illustrated inFIG. 15B, first connector apparatus1550may magnetically link with second connector apparatus1575such that their respective outer perimeters1555and1580are longitudinally askew by a single magnetic section without any need for magnetic rotation.

It should also be understood that embodiments are contemplated in which only one of the two connector apparatus that are to be connected together includes a rotatable multi-pole magnetic assembly. As long as one of the multi-pole magnetic assemblies can rotate, it can be connected with another apparatus comprising a multi-pole assembly that is fixed and not rotatable.

FIG. 16Aillustrates a connector apparatus1600comprising a rectangular connection member1650in the process of being magnetically linked to four triangular connection members1610-1640. Rectangular connection member1650and each of triangular connection members1610-1640may include a magnetic assembly or magnetic assembly and enclosure combination adjacent each connection edge of each respective connection member1610-1650. Each magnetic assembly or magnetic assembly and enclosure combination may be configured to rotate, so as to allow the polarities of each magnetic section of each multi-pole magnetic assembly to align with the magnetic sections of a multi-pole magnetic assembly in an adjacent connection member1610-1650. Accordingly, each connection edge of rectangular connection member1650may be magnetically linked to a connection edge of one of the triangular connection members1610-1640.

According to various embodiments, the magnetic assembly within each magnetic assembly and enclosure combination may be configured to rotate with or, alternatively, with respect to, its corresponding enclosure. Accordingly, since the magnetic assemblies are free to rotate, the connection edges of each of rectangular connection member1650and triangular connection members1610-1640may be magnetically linked at any angle, and may be pivoted with respect to one another once linked.

As illustrated in the transition fromFIG. 16AtoFIG. 16B, multi-pole magnetic assemblies1633and1643may rotate about their longitudinal axes in order to align the polarities of their respective magnetic sections in order to magnetically link with their respective adjacent multi-pole magnetic assemblies within rectangular connection member1650.

FIG. 16Billustrates a connector apparatus1600comprising rectangular connection member1650magnetically linked at each connection edge to a connection edge of each of triangular connection members1610-1640. Multi-pole magnetic assemblies1633and1643have rotated about their longitudinal axes in order to align and magnetically link with corresponding multi-pole magnetic assemblies in rectangular connection member1650.

According to various embodiments, each of triangular connection members1610-1640may be pivoted with respect to rectangular connection member1650about their respective magnetically linked sides. Accordingly, triangular connection members1610-1640may be brought together in order to form a pyramid having a rectangular base and four triangular faces. In such embodiments, each remaining unlinked connection member of each of triangular connection members1610-1640may be magnetically linked to a connection edge of another of triangular connection members1610-1640. The multi-pole magnetic assemblies in each connection edge of each of triangular connection member1610-1640may rotate about its longitudinal axis, either with or with respect to an enclosure, in order to align the polarities of the respective magnetic sections.

FIG. 17illustrates a connector apparatus1700comprising four triangular connection members1710,1720,1730, and1740. Each triangular connection members1710,1720,1730, and1740may include one or more multi-pole magnetic assembly and enclosure combinations. Each multi-pole magnetic assembly and enclosure combination may rotatably allow each connection edge of each of triangular connection members1710,1720,1730, and1740to magnetically link with another connection edge of another of triangular connection members1710,1720,1730, and1740, so as to form a tetrahedron. According to various embodiments, each connection edge of each triangular connection member1710,1720,1730, and1740may comprise an enclosure and encase a multi-pole magnetic assembly configured to rotate about its longitudinal axis.

Alternatively, each connection edge of each triangular connection member1710,1720,1730, and1740may secure, either rotatably or fixedly, an enclosure configured to encase one or more multi-pole magnetic assemblies. In embodiments in which the connection member fixedly secures an enclosure, the multi-pole magnetic assembly may be configured to rotate about its longitudinal axis within and with respect to the enclosure. In embodiments in which the connection member rotatably secures an enclosure, the multi-pole magnetic assembly may be configured to rotate about its longitudinal axis together with the enclosure as the enclosure rotates.

According to various embodiments, any polygonal shape may be used in place of triangular connection members1710,1720,1730, and1740and magnetically link in order to form a polyhedron having any number of faces. Similarly, any combination of various polygonal shapes may be magnetically linked in order to form any number of shapes and/or compositions of shapes. For example, four rectangular connection members may be linked together with four triangular connection members in order to form an obelisk. Moreover, some embodiments may comprise members extending generally in only a single dimension, such that polygonal shapes may be made using several separate magnetic connector apparatus, each making up one side of the polygon.

As previously described, a multi-pole magnetic assembly may be formed using a single continuous magnetic material, or alternatively, a multi-pole magnetic assembly may be formed by joining multiple pairs of oppositely polarized magnetic sections linked end to end, such that each magnetic section is magnetically polarized opposite that of each adjacent magnetic section.

FIG. 18Aillustrates a magnetizing apparatus1800configured with a bottom plate1801and a top plate1802configured to create a multi-pole magnetic assembly. As illustrated, top plate1802may be pivoted about hinge1812until top plate1802is positioned directly above bottom plate1801. In alternative embodiments, top plate1802may not be attached to bottom plate1801via hinge1812and may instead be pressed directly down against bottom plate1801. As illustrated, each of bottom1801and top1802plates may include one or more grooves1850configured to receive a magnetizable material. Adjacent each groove are magnetizing plates1820and1830configured to radiate a magnetizable material placed within groove1850with magnetic fields of alternating polarity.

FIG. 18Billustrates the magnetizing apparatus1800with two magnetizable cylinders1890and1891in place. Once magnetizable cylinders1890and1891are in place, top plate1802may be pivoted about hinge1812onto bottom plate1801. A current may be provided to cables1810and1812in order to create positive and negative magnetic fields along magnetizing plates1820and1830, respectively. The magnetizing plates1820and1830having alternating magnetic polarization may magnetize magnetizable cylinders1890and1891so as to create a multi-pole magnetic assembly including a first half and second half extending along a longitudinal axis. The first half may include magnetic sections of alternating polarity and the second half may include a corresponding number of magnetic sections each having a polarity opposite that of an adjacent magnetic section in the first half.

FIG. 18Cillustrates an exemplary embodiment of a multi-pole magnetic assembly1890created using the magnetizing apparatus described in conjunction withFIGS. 18A and 18B. As illustrated, multi-pole magnetic assembly1890includes a first half and second half extending along a longitudinal axis. The first half includes three magnetic sections with alternating polarity and the second half includes three corresponding magnetic sections each polarized opposite that of the adjacent magnetic section in the first half.

FIG. 19illustrates an exploded view of an embodiment of a magnetic connector apparatus1900. Magnetic connector apparatus1900comprises a first outer housing piece1910, an inner retainer piece1920, and a second outer housing piece1930. Four magnet housings1940are coupled with the inner retainer piece1920. Each of the magnet housings1940are configured to hold a respective magnet1945. Magnets1945may be positioned within their respective magnet housings1940such that the magnet1945can rotate within the magnet housing1940.

In some embodiments, one or more of the magnet housings1940may be configured to prevent or at least inhibit the magnets1945contained therein from being removed from the housing for safety purposes. Various features disclosed herein may facilitate this purpose. For example, one or more of the magnet housings1940may comprise a material that is of high strength and is difficult to break and/or deform. Examples of such materials include high-strength metals and other similar materials, such as a stainless steel metal, titanium, and/or related alloys, composite materials, such as carbon fiber, and other similar materials.

In some embodiments, other features may also, or alternatively, be provided to serve the purpose of inhibiting removal of the magnets. For example, as described in greater detail below, one or more magnet housing engaging members may be provided in order to at least substantially plug one or more openings in the magnet housings. Additionally, or alternatively, part of the magnetic connector apparatus, such as inner retainer piece1920, may comprise one or more recessed regions that may be configured to receive one or more portions of the magnet housing to make it more difficult to remove the magnet housing from the magnetic connector apparatus.

The magnet housing may also include one or more openings for receiving a fastener for coupling the magnet housing to another portion of the magnetic connector apparatus, as also described in greater detail below. The magnet housing may also comprise one or more reinforced regions wherein the material is thicker at locations that might otherwise be vulnerable to wear, tampering, and the like. For example, in embodiments comprising openings that may be plugged by magnet housing engaging members, regions of the magnet housing adjacent to such openings may be reinforced, appropriately bent, shaped, or otherwise configured to further ensure that the magnet contained therein cannot be removed.

Similarly, areas of the magnet housing adjacent to any opening for receiving a fastener may be reinforced, appropriately bent, shaped, or otherwise configured to further ensure that the magnet contained therein cannot be removed and/or that the magnet housing cannot be removed from the magnetic connector apparatus. For example, in the depicted embodiment, a cylindrical portion of the magnet housing that houses the magnet may be positioned relative to another portion of the magnet housing, such as a plate member, as a substantially perpendicular angle. This configuration is best seen inFIG. 21. In some preferred embodiments, the fasteners may comprise rivets or other such fasteners that cannot easily be removed by a user in order to further enhance the safety features of the apparatus.

In some embodiments, magnet1945may comprise one or more of the multi-pole magnetic assemblies discussed above. Such assemblies may comprise a first half and a second half extending substantially along a longitudinal axis. The first half may comprise at least two magnetic sections of alternating polarity and the second half may comprise a corresponding number of magnetic sections. Each magnetic section in the second half may have a polarity opposite that of an adjacent magnetic section in the first half such that the polarity of the magnet alternates along its length.

Each of the magnet housings1940, and therefore each of the magnets1940, is positioned along a connection edge of the apparatus1900. More particularly, connection edges1902,1904,1906, and1908of the square-shaped apparatus1900each has an accompanying magnet/magnet housing such that any of these connection edges may be used to magnetically couple the apparatus with another magnetic connector apparatus along one or more of the connection edges.

In the depicted embodiment, the first outer housing piece1910is positioned on an opposite side of the connector apparatus1900from the second outer housing piece1930such that the inner retainer piece1920is positioned in between the first outer housing piece1910and the second outer housing piece1930. In some preferred implementations of methods for manufacturing magnetic connector apparatus, inner retainer piece1920may be sonically welded to first outer housing piece1910and second outer housing piece1930, as described in greater detail below.

FIG. 20illustrates a close-up view of a portion of inner retainer piece1920of magnetic connector apparatus1900. More particularly,FIG. 20illustrates a magnet housing receiver1922that is configured to engage a magnet housing1940(not shown inFIG. 20) to couple the magnet housing1940to the inner retainer piece1920. Magnet housing receiver1922comprises a first magnet housing engaging member1923and a second magnet housing engaging member1924. First magnet housing engaging member1923is configured to engage a first end of a magnet housing1940and second magnet housing engaging member1924is configured to engage a second end of the magnet housing1940opposite from the first end.

In the depicted embodiment, the first and second magnet housing engaging members,1923and1924respectively, each comprise a magnet housing plug that is configured to at least substantially seal an opening in a magnet housing1940. In some embodiments, one or more of the magnet housing engaging members and/or at least a portion of one or more of the magnet housings may be made up of a flexible or resilient material that is configured to facilitate such a sealing function. For example, such material(s) may comprise one or more of a plastic, rubber, flexible graphite, elastomer, foam, cork, etc.

In the depicted embodiment, the first and second magnet housing engaging members,1923and1924respectively, are both formed with an at least substantially circular radius having a radius of curvature that matches a radius of curvature of a corresponding portion of a magnet housing1940. The corresponding portion of the magnet housing is best seen inFIG. 21, as described below.

FIG. 21illustrates a close-up view of an embodiment of a magnet housing1940that may be suitable for use in some embodiments of magnetic connector apparatus disclosed herein. As shown in this figure, magnet housing1940comprises a body member1947defining a cylindrical cavity. At opposite ends of the cylindrical cavity, body member1947defines openings1949. One or both of openings1949may be configured to receive a magnet housing engaging member, such as magnet housing engaging members1923and1924illustrated inFIG. 20. The cavity defined by body member1947is configured to receive a magnet therein, such as magnet1945.

In the depicted embodiment, the ends of magnet housing that define openings1949have a formed radius to add to the structural strength of the device and further prevent the magnet contained therein from being removed/accessed. Openings 1949 are at least substantially circular and are formed with a radius of curvature that at least substantially matches a radius of curvature of one or more corresponding magnet housing engaging members (in this embodiment magnet housing engaging members1923and1924). By providing matching radii of curvature between these components, access to the magnet1945housed within magnet housing1940may be prevented in order to enhance the safety of the device, as described elsewhere herein.

The one or more magnet housing engaging members may be coupled with another component of the device, such as the inner retainer piece1920, in a variety of different ways. For example, a coupling member1927may be provided to couple each of the magnet housing engaging members1923and1924to inner retainer piece1920, as illustrated inFIG. 20. Coupling member(s)1927may, in some embodiments, be an integral part of, and thus comprised of the same material as, the magnet housing engaging members. In other embodiments, the one or more coupling members may be made up of a different material. For example, in some embodiments, the coupling members may be integral with the inner retainer piece1920, and thus may comprise a metal, metal alloy, plastic, or other material that is used to make up inner retainer piece1920. In any event, it is preferable that the link between the retainer piece1920(or another portion of the device) and the magnet housing be strong enough to withstand any foreseeable tampering such that the magnet(s) housed within the magnet housing(s) are not capable of being removed with any foreseeable forces resulting from use of the device.

Magnet housing1940also comprises a first plate member1942extending from body member1947and a second plate member1944extending from an opposite end of body member1947. Both first plate member1942and second plate member1944comprise fastener openings1948. Fastener openings1948may be configured to receive a fastener for coupling the magnet housing1940to a retainer piece, such as inner retainer piece1920. The retainer piece may therefore include a similar fastener opening for receiving the fastener. For example, inner retainer piece1920includes a fastener opening1926that is configured to be aligned with fastener openings1948in first plate member1942and second plate member1944and receive a fastener1946therethrough, as illustrated inFIGS. 19-21. Various fasteners may be used, such as rivets, screws, bolts, and pins.

One or more regions on the magnet housing may also be reinforced, appropriately bent, shaped, or otherwise configured to further ensure that the magnet housing and/or the magnet contained therein cannot be removed. For example, in the magnet housing1940depicted inFIG. 21, the opposing ends of body member1947that are configured to receive the magnet housing engaging members have reinforced metal bent in a circular manner to enhance the strength, and therefore safety, of the magnet housing1940. Similarly, magnet housing2940comprises reinforced regions adjacent to fastener opening1948in order to serve similar ends. These reinforced regions may be configured to fit within a recessed region surrounding fastener opening1926on inner retainer piece1920.

The inner retainer piece may further comprise one or more recessed regions for receiving a plate member of a magnet housing. For example, inner retainer piece1920comprises recessed region1928that is configured to receive first plate member1942. A similar recessed region may be provided on a surface of inner retainer piece1920that is opposite from the surface shown inFIG. 20for receiving second plate member1944.

Other regions of the device may also include recessed regions. For example, as shown inFIG. 20, the area surrounding fastener opening1926is stamped or otherwise recessed such that an appropriate fastener, such as a rivet, may be received therein and such that, once received in the fastener opening, the fastener is rendered at least substantially inaccessible to a user of the apparatus for safety purposes. As discussed above, it may be preferably in some embodiments, also for safety reasons, to provide a fastener that is not easily removable, such as a rivet or the like.

Although the area of the recessed regions1928in the depicted embodiment is substantially rectangular, it should be appreciated that other shapes are contemplated as well. However, preferably the shape of the recessed region at least substantially matches the shape of the corresponding plate member that is received therein.

FIG. 22illustrates a perspective view of magnetic connector apparatus1900. As shown in this figure, magnetic connector apparatus1900includes four connection edges1902,1904,1906, and1908. Each of these connection edges includes a magnet housing1940within which is contained a respective magnet (not visible inFIG. 22). One or more of the connection edges can be coupled with a connection edge of another connector apparatus, as described above, in order to build an assembly comprising multiple connector apparatus.

FIGS. 23A and 23Billustrate cross-sectional views of the components used to manufacture another embodiment of a magnetic connector apparatus.FIG. 23Aillustrates these components at a stage prior to undergoing a welding process in one implementation of a method for manufacturing a magnetic connector apparatus.FIG. 23Billustrates a cross-sectional view of the components shown inFIG. 23Aafter undergoing a welding process, which, in some implementations, may comprise a sonic welding process.

The components illustrated inFIGS. 23A and 23Bthat may be used to manufacture a magnetic connector apparatus2300include a first outer housing piece2310, an inner retainer piece2320, and a second outer housing piece2330. One or more magnet housings may also be coupled with one or more of the first outer housing piece2310, the inner retainer piece2320, and the second outer housing piece2330, as described above. However, a magnet housing is not depicted in these figures.

First outer housing piece2310comprises a joint weld protrusion2311. As described above, joint weld protrusion2311comprises a V-shaped ridge. However, as described elsewhere herein, other shapes/configurations are also contemplated. Joint weld protrusion2311may extend around the entire perimeter of first outer housing piece2310. However, other embodiments are also contemplated in which one or more joint weld protrusions only extend partially around such a perimeter.

A similar joint weld protrusion2331may be provided on second outer housing piece2330, as shown in the figure. As with joint weld protrusion2311, joint weld protrusion2331may extend around the entire perimeter of second outer housing piece2330or, alternatively, joint weld protrusion2331may extend partially around the perimeter. Joint weld protrusion2331, like joint weld protrusion2311, comprises a V-shaped ridge. However, in some embodiments joint weld protrusion2331may comprise a different shape than joint weld protrusion2311.

Both first outer housing piece2310and second outer housing piece2330also comprise melt chambers,2302A and2302B, respectively. Both melt chamber2302A and melt chamber2302B are shaped with two sides that form a corner cutout shape. When the first outer housing piece2310is approximated with the second outer housing piece2330, as shown inFIG. 23B, a joint melt chamber2302is formed. As illustrated in this figure, half of a first side of joint melt chamber2302is formed with one side of melt chamber2302A and the other half of the first side of joint melt chamber2302is formed with one side of melt chamber2302B. A second side of joint melt chamber2302is formed with a separate side of joint melt chamber2302A and a third side of joint melt chamber2302opposite from the second side is formed with another side of joint melt chamber2302B. The fourth and final side of joint melt chamber2302is formed from a portion of inner retainer piece2320.

As also shown inFIG. 23B, a welding process may cause material from the joint weld protrusions and/or other portions of the components used to manufacture the apparatus to melt into joint melt chamber2302. Melted material is shown inFIG. 23Bat10. Melted material10may also surround a portion of inner retainer piece2320, as also shown inFIG. 23B.

FIG. 24Aillustrates a cross-sectional view of various components prior to undergoing a welding process in another implementation of a method for manufacturing another embodiment of a magnetic connector apparatus.FIG. 24Aillustrates these components at a stage prior to undergoing a welding process in one implementation of a method for manufacturing a magnetic connector apparatus.FIG. 24Billustrates a cross-sectional view of the components shown inFIG. 24Aafter undergoing a welding process, which, in some implementations, may comprise a sonic welding process.

The components illustrated inFIGS. 24A and 24Bthat may be used to manufacture a magnetic connector apparatus2400include, like magnetic connector apparatus2300, a first outer housing piece2410, an inner retainer piece2420, and a second outer housing piece2430. One or more magnet housings (not shown inFIGS. 24A and 24B) may also be coupled with one or more of the first outer housing piece2410, the inner retainer piece2420, and the second outer housing piece2430, as described above.

First outer housing piece2410comprises a joint weld protrusion2411. However, unlike joint weld protrusion2311, joint weld protrusion2411comprises a relatively flat top and relatively parallel sides, rather than the relatively pointed tip and slanted sides of a V-shaped ridge. Joint weld protrusion2411may extend around the entire perimeter of first outer housing piece2410.

A similar joint weld protrusion2431may be provided on second outer housing piece2430, as shown in the figures. As with joint weld protrusion2411, joint weld protrusion2431may extend around the entire perimeter of second outer housing piece2430or, alternatively, joint weld protrusion2431may extend partially around the perimeter. Joint weld protrusion2431, like joint weld protrusion2411, comprises a relatively flat top and parallel sides. However, in some embodiments joint weld protrusion2431may comprise a different shape than joint weld protrusion2411. In other embodiments, a joint weld protrusion may only be provided on one of first outer housing piece2410and second outer housing piece2430.

First outer housing piece2410also comprises a melt chamber2402. Melt chamber2402, unlike melt chambers2302A and2302B, comprises a rounded cutout or a substantially curvate cutout region. However, unlike melt chamber2302, melt chamber2402only formed within first outer housing piece2410. Second outer housing piece2430may also include a melt chamber, but does not in the embodiment depicted inFIGS. 24A and 24B.

Thus, when first outer housing piece2410is approximated with second outer housing piece2430, as shown inFIG. 24B, a joint melt chamber is formed that is defined in part by curvate cutout region2402and in part by a portion of inner retainer piece2420.

As also shown inFIG. 24B, a welding process may cause material from the joint weld protrusions and/or other portions of the components used to manufacture the apparatus to melt into the melt chamber. Melted material is shown inFIG. 24Bat10. Melted material10may also surround a portion of inner retainer piece2420, as also shown inFIG. 24B.

Those having skill in the art will appreciate that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. While the principles of this disclosure have been shown in various embodiments, many modifications of structure, arrangements, proportions, elements, materials, shapes, thicknesses, widths, heights, and components, may be used without departing from the principles and scope of this disclosure. These and other changes or modifications are intended to be included within the scope of the present disclosure.