Abstract:
An electrical connector, which may be a multi-pin connector, includes magnetic elements and mechanical alignment elements which provide connective forces and precision alignment and orientation. The magnetic elements permit a user to bring male and female connector portions only into “rough” alignment before magnetic forces bring the portions into the correct position. Pin contacts on the connector portions extend only a small amount beyond respective protective annular openings and are thereby protected. Spring-biased pin elements may be included on one of the connector portions to bias the contact pins into engagement and create conductive paths when the portions are in a connected position. Paramagnetic or non-magnetic sheaths may surround the magnetic elements to focus, or distribute, magnetic forces.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/744,432 titled “MAGNETIC-ENABLED CONNECTOR DEVICE,” filed on Sep. 26, 2012, the specification of which is incorporated in its entirety herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Technical Field 
         [0003]    The disclosure relates to connectors for electronic devices and data communication. More particularly, the disclosure relates to self-aligning, magnetically biased connectors, including multi-pin connectors. 
         [0004]    2. Prior Art 
         [0005]    It is generally known to provide magnetic coupling elements in electrical and non-electrical connectors. Examples of connectors that include magnetic coupling elements are disclosed in U.S. Pat. Nos. 4,484,761; 4,776,406; 7,277,013 and 7,334,433. Examples of magnetic breakaway connection devices for power lines or cables are disclosed in U.S. Pat. Nos. 5,315,064 and 5,623,122. 
         [0006]    Examples of other types of electrical connectors that include magnetic elements are described in U.S. Pat. Nos. 2,170,287; 3,363,214; 3,431,428; 3,521,216; 3,808,577; 4,844,582; 4,874,316; 5,401,175; 5,812,356; 5,816,825; 5,941,729; 5,954,520; 6,183,264; 6,250,931; 6,267,602; 6,478,614; 6,527,570; 6,561,815; 6,607,391; 6,623,276; 6,727,477; 6,988,897; 7,066,739; 7,264,479; 7,311,526; 7,351,066; 7,517,222; and in U.S. Patent Application Publication Nos. 2004/0209489; 2005/0208783 and 2005/0255718. 
         [0007]    U.S. Pat. No. 7,264,479 describes a connector for connecting two coaxial cables, wherein the holding forces between two connector or adapter portions are formed by means of magnetic forces. The mutually facing end faces of the two adapter portions are each provided with disks or plates for grounding. For this reason, connectors of this type require a user to orient and align the two adapter portions axially with respect to one another before the magnetic forces act and peg-shaped contact elements can latch into the corresponding annular mating contact elements. 
         [0008]    Multi-pin connectors are useful for connecting signal carriers, such as computer cables, to peripheral devices, such as printers or displays, or for connecting signal carriers or other cables to electronic equipment, such as medical equipment. Multi-pin connectors may incorporate elements for connecting a plurality of conductive paths. Known multi-pin connectors may include connectors known as “D-sub connectors.” A D-sub connector contains two or more parallel rows of pins or sockets usually surrounded by a D-shaped metal shield that provides mechanical support, ensures correct orientation, and may screen against electromagnetic interference. 
         [0009]    One problem with prior art connectors that utilize threaded fasteners, for example, or which are not readily connected or disconnected, is that in environments where many cables and connectors are utilized, cable management becomes challenging. The rigid coupling implements, i.e., threaded fasteners, of known connectors makes untangling and proper wire or cable routing time consuming. A related problem is that sudden forces on such prior art connectors may cause irreparable damage to the connector, cable or electronic device. For example, in a hospital environment where electronic devices providing vital patient support functions are connected with prior art “hardline” connectors, medical personnel or others tripping over a cable could result in medical equipment falling and being damaged from impact, or other consequences that could be catastrophic to equipment and patients. 
         [0010]    Another problem in the prior art is that connectors that utilize multiple pins are prone to damage from misalignment or attempting connection with respective portions in an improper orientation. Typical prior art multi-pin connectors utilize somewhat lengthy pins on the male connector portion, which may extend to a point that is generally flush with the connector shield. Because of their length, the pins are more prone to bending and deformation caused by damage when they are exposed, or by misalignment during the connection process. If connection is attempted before the connector portions are properly aligned, bending, deformation or other damage may result to one or more pin conductors, rendering the connector permanently damaged and useless. 
         [0011]    Yet another shortcoming in prior art connectors, such as those that are mechanically connected to a computer, peripheral or other device, for example, using threaded fasteners or other rigid connectors, is that they require dexterity and visibility for connection in hard to reach or confined places, such as in the case where a number of connectors are engaged in the back of a computer or server in a tightly confined space, such as a server rack. 
         [0012]    There is thus a need in the art for connectors that address the aforementioned problems in the prior art. The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above, and others. 
       SUMMARY OF THE INVENTION 
       [0013]    One aspect of the invention provides a multi-pin connector assembly that may be connected more quickly and precisely than prior art connectors and which avoids a “hardline” connection to an electrical or electronic source or target. This aspect is achieved through the use of magnetic elements on respective male and female connector portions, as well as alignment surfaces, which cooperate to allow the user to bring the connector portions only into “rough” alignment before the magnetic forces pull the respective connectors into precise alignment and a complete connection. According to a related aspect of the invention, a connector may be used in confined locations, which would not permit the use of conventional connectors that require tools or manual turning of mechanical screws to complete connections. 
         [0014]    Another aspect of the invention ensures proper orientation of the male and female portions of multi-pin connectors. This may be achieved through the use of a pair of magnetic elements on each of the male and female connector portions. The magnetic elements are oriented with opposite polarities, one of each pair having a north pole facing in a forward direction, and the other of each pair having a south pole facing in a forward direction. When the male and female connector portions are brought into proximity in the wrong orientation, the user experiences a tactilely-sensed repulsive force, indicating that the orientation is improper. When the connector portions are brought into proximity with the proper orientation, the attractive magnetic forces complete the connection and, in conjunction with alignment surfaces, bring the connectors and respective multiple pins into perfect alignment. According to another aspect of the invention, an audible “click” may be generated by the impact of respective connector surfaces to indicate to the user that the connector is in a completely connected state. 
         [0015]    According to another aspect of the invention, contact pins are provided in a unique configuration which reduces the risk of damage from misalignment or otherwise. Contact pins on the male and female connector elements extend only a small amount beyond respective protective surfaces, such that the pins cannot be damaged from bending or breaking due to lateral forces. A male connector portion includes contact pins that extend only slightly beyond a protective annular opening in the male connector. A female connector portion includes spring-biased connector pins that extend only slightly beyond a protective annular opening in an unconnected state. In a connected state, the male connector pins push spring-biased female connector pins back into the respective annular openings and extend therein, providing further alignment and complete conductive paths. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The above and other attendant advantages and features of the invention will be apparent from the following detailed description together with the accompanying drawings, in which like reference numerals represent like elements throughout. It will be understood that the description and embodiments are intended as illustrative examples and are not intended to be limiting to the scope of invention, which is set forth in the claims appended hereto. 
           [0017]      FIG. 1  is an exploded view of a male portion of a connector according to an aspect of the invention. 
           [0018]      FIG. 2  is an oblique exploded view of a female portion of a connector according to an aspect of the invention. 
           [0019]      FIG. 3  is an oblique view showing male and female connector portions in a disconnected position. 
           [0020]      FIG. 4  is an oblique view showing male and female connector portions in a connected position. 
           [0021]      FIG. 5  is an enlarged, oblique view showing male and female connector portions in a connected position. 
           [0022]      FIG. 6  is a planar, cross-sectional view taken on plane  6 - 6  in  FIG. 5 , but showing the male and female connectors in a disconnected position. 
           [0023]      FIG. 7  is a planar, cross-sectional view taken on plane  7 - 7  in  FIG. 5 , showing the male and female connectors in a connected position. 
           [0024]      FIG. 8  is an enlarged view of area “ 8 ” in  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0025]      FIG. 1  is an exploded view of a female connector  10 , according to an aspect of the invention. A plurality of conductive contact pins  28  are disposed within respective annular openings  56  formed in a main seat body  30  of female connector  10 . Conductive contact pins  28  may be spring-biased by cooperating with springs  26  and pegs  24 , which may be disposed in correspondingly-shaped recesses or cavities  36  formed in an adapter element  18 , which cooperates with the main seat body  30  via, for example, threaded fasteners  14 , to retain the pins  28 , springs  26  and pegs  24  in an assembled position. Pegs  24  may include crimped connectors to receive and secure the ends of respective conductors or wires (not shown) from an electrical source and form a conductive path with springs  24  and pins  28 . Referring additionally to  FIG. 6 , pins  28  may each include a narrow forward portion and a retaining collar or shoulder such that the forward portion is narrow enough to extend into the annular opening  56 , while the retaining collar or shoulder prohibits further passage of the pin  28  into the annular opening  56 , thereby retaining the pin  28  within the main seat body  30 . 
         [0026]    According to an aspect of the invention, pins  28 , springs  26  and pegs  24  may be replaced with pre-assembled, telescoping spring-biased contact pins  25 , which each include a spring element (not shown) disposed within telescoping conductive elements. Contact pins  25  may include any commercially available pre-assemble, telescoping contact pins suitable for use in connector environments. 
         [0027]    According to an aspect of the invention, connector  10  may be provided with magnetic elements  20 , disposed within complementary-shaped recesses formed in adapter  18 , which may be defined between posts or grip legs  19 . Sheaths  22  enclose magnets  20  and also partially or wholly enclose the length and depth of grip legs  19  and thereby cooperate with adapter  18 , recesses and grip legs  19  to secure the magnets thereon. In accordance with an aspect of the invention, sheaths  22  may be comprised of paramagnetic or non-magnetic material, such as copper, aluminum or bronze, which has the effect of distributing the magnetic field. Also in accordance with an aspect of the invention, sheaths  22  and grip legs  19  may be dimensioned so as to provide some movement of magnets while being retained therein to provide a “floating” mount of the magnets, which enhances the magnetic forces that secure the female connector to a counterpart. Sheaths  22  are received in elongated holes or recesses  36  in seat body  30  and retained therein when the seat body  30  and adapter  18  are in an assembled state. 
         [0028]    Housing halves  54  may be provided to enclose the assembled seat body  30  and adapter  18  and may include threaded fasteners  14 . A neck grip or tension relief collar  16  secures an electric source or target cable wire (not shown) against slippage within housing  54  and absorbs tension on the cable wire. Alternatively, housing  54  may be formed integrally with seat body  30  and adapter  18  using an injection molding process. 
         [0029]    In accordance with an aspect of the invention, seat body  30  is provided with notch recesses  34 , which, in a connected state, may receive a complementarily-shaped projection or protuberance, such as protuberances  48  on male connector  12  ( FIG. 2 ), which provides for vertical and lateral alignment of the female connector  10  with a counterpart male connector  12 . In accordance with an aspect of the invention, seat body  30  is provided with lateral ramps or inclined surfaces  100 , which may be at a 45-degree angle, which provide for lateral alignment of the female connector  10  with a counterpart. 
         [0030]      FIG. 2  shows an exploded view of a male connector  12  in accordance with an aspect of the invention. The male connector  12  may include a male contact plate  46  and a male foundation plate  40 , which cooperate to retain male connector magnets  21  and male conductive pins  42  therein. Male contact plate  46  includes a plurality of pinholes or annuluses  60  formed therein to receive a like plurality of male conductive pins  42  in an array, such as parallel rows. The back ends of the male pins  42  may be seated in concavities  58  in foundation plate  40 . The male pins  42  extend in a forward direction through the annuluses  60  to thereby provide a conductive path from foundation plate  40  thru contact plate  46 . Foundation plate  40  includes protuberances or raised portions  41  for supporting magnets  21  thereon. Male sheaths  44 , which may partially or completely cover or enclose magnets and secure magnets  21  against protuberances  41 , are also received in elongate openings  50  of male contact plate  46  and retained therein, also retaining magnets within the male connector  12  in an assembled state. As shown in the zoomed-in view in  FIG. 2 , male magnets  21  may be oriented such that a top magnet has a north polarity facing forward, toward a male connector counterpart (not shown in  FIG. 2 ), whereas a lower magnet has a south polarity facing forward, toward the male connector counterpart. Threaded fasteners  14  may secure the male contact plate  46  to the foundation plate  40  and may also secure the assembled contact plate  46  and foundation plate  40  to a male housing  38  via threaded holes  62 . 
         [0031]    Referring additionally to  FIG. 3 , according to an aspect of the invention, contact plate  46  is provided with ramped or angled surfaces  102 , which cooperate with the ramps  100  ( FIG. 1 ) on female connector body  30 , to provide for easy connection and positive alignment of the male connector  12  and female connector  10 . Protuberances  48  are also received within recesses  34  to provide for positive vertical and lateral alignment. Magnetic biasing forces are provided via female connector magnets  21  (situated behind sheath  44  in  FIG. 3 ) and male connector magnets (situated behind sheath  22  in  FIG. 3 ) such that the male and female connectors are magnetically attracted to one another. As will be appreciated by those of ordinary skill in the art, owing to the alignment elements, including protuberances  48 , recesses  34 , ramps  100  and surfaces  102 , as the male and female connector portions are roughly aligned by a user and put in close proximity to one another, the magnetic forces further pull the respective connectors into perfect alignment and together, without a user having to precisely align them, to a completely connected state shown in  FIGS. 4 and 5 . More specifically, the physical structure of male ramps  102  and female ramps  100  prevents the male connector  12  and female connector  10  from skipping one or more magnetic peaks and valleys to the right or to the left, prior to connecting, and thus prevents male pins  42  from misalignment or improper connection with female pins  28 . The cooperating ramp surfaces  100  and  102  sets up left to right, or lateral, physical centering, for approximate guidance at a gap distance, as well as precision guidance to final plug-in and contact as the connectors move to close proximity. The ramps set up a funneling effect to channel the connectors towards each other in the correct position. 
         [0032]    According to an aspect of the invention, vertical, or top to bottom centering, as well as proper orientation, is facilitated by the female magnets  20  and male magnets  21 , as well as the female notches  34  and protuberances  48 . With regard to orientation, the reverse polarities of the top and bottom male and female magnets results in repulsive forces if the male connector is improperly oriented, i.e., rotated 180-degrees from a proper orientation. Thus, tactile sensing of repulsive forces may indicate to a user that orientation is improper without the user having to view the actual the orientation of the connector. In this way, the user is prevented from connecting the connectors in an improper orientation. As a result, potential damage to the connector, or more catastrophic consequences, such as failure or misalignment of an electronic connector in a medical environment, is prevented. Also, in accordance with an aspect of the invention, the contact of forward surfaces of respective sheaths  44  and  42  may cause an audible signal, such as a “click,” to indicate to the user that the connector is completely connected and aligned. 
         [0033]      FIG. 6  is a planar cross-sectional view taken along lines  6 - 6  in  FIG. 5 , showing the male  12  and female  10  connectors in a disconnected configuration. It can be seen that, in the disconnected configuration, the contact pins  28  of female connector  10  extend beyond a front surface  55  of the female seat body  30 . Contact pins  28  are biased in this direction by springs  26 . Contact pins  42  on male connector  12  also extend beyond a front surface  49  of the male contact plate  46 . Thus, contact between pins  42  and pins  28  is ensured as the male and female connector portions move to a connected state. Moreover, it will be noted that the contact pins  42  do not extend significantly beyond the male contact plate, thus preventing deformation (i.e., lateral bending) or damage to the pins when exposed in the disconnected state. 
         [0034]      FIG. 7  is a planar cross-sectional view taken along lines  7 - 7  in  FIG. 5  showing the male  12  and female  10  connectors in a connected configuration. In this configuration, male connector  12  and female connector  10  are held together by magnetic forces and, as may be seen in the enlarged view in  FIG. 8 , female connector contact pins  28  are pushed back into annular openings  60  by male contact pins  42 , against the biasing force of springs  26 . Forward ends of male contact pins  42  may thus extend to some degree into the annular openings  60  on the female seat body  30 . Thus, each contact pin  28  is biased into contact with a respective contact pin  42  to make sufficient electrical contact and to allow for variances in pin length or wear that may occur. 
         [0035]    It should be understood that implementation of other variations and modifications of the invention in its various aspects may be readily apparent to those of ordinary skill in the art, and that the invention is not limited by the specific embodiments described herein. It is therefore contemplated to cover, by the present invention any and all modifications, variations or equivalents that fall within the spirit and scope of the claims that follow.