Electrical Connector Magnetic Module Noise Filtering

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Solution Overview

Problem

Existing electrical connectors with magnetic modules for noise filtering are either too large or costly to manufacture and assemble effectively, lacking a design that balances size, cost, and ease of manufacturing.

Innovation Solution

The design incorporates a transformer and common mode filter with a separated filter configuration, allowing for independent manufacturing and assembly, featuring a transformer with a center tap and a common mode filter with physically separated wires, enabling cost-effective and efficient noise filtering in electrical connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If magnetic elements are integrated into electrical connectors for noise filtering, then noise filtering capability is improved, but device size and manufacturing cost increase

Engineering Contradiction:

Improvenoise filtering capabilityVSAvoidconnector size

Core Design Contradiction:

Object-affected harmful factorsVSVolume of stationary object

Solution Approach 1:

The patent combines the transformer and common mode filter into a single integrated magnetic module within the electrical connector. The transformer includes a first wire and second wire with center tap, while the common mode filter includes a third wire and fourth wire, all housed together in one connector structure. This merging approach provides effective noise filtering without requiring separate discrete components, thereby controlling overall device size while maintaining filtering performance.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If magnetic elements are integrated into electrical connectors for noise filtering, then noise filtering capability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvenoise filtering capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

By integrating multiple magnetic elements (transformer and common mode filter) into a single connector housing, the patent reduces the total number of discrete components that need to be sourced, assembled, and tested. This consolidation simplifies the manufacturing process and reduces assembly steps, thereby lowering overall manufacturing cost despite the added noise filtering functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical connector is designed to perform multiple functions simultaneously: signal transmission through the transformer and noise filtering through the common mode filter. This multi-functionality is achieved within a single integrated structure, eliminating the need for separate noise filtering components and reducing overall system complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If transformer and common mode filter are integrated, then noise filtering is improved, but assembly complexity increases

Engineering Contradiction:

Improvenoise filtering capabilityVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The transformer and common mode filter are merged into a single integrated module within the connector housing. The transformer comprises a first wire with two opposite ends and a second wire with two opposite ends and a center tap, while the common mode filter comprises a third wire and a fourth wire. By integrating these elements into one assembly, the patent reduces the number of separate assembly operations required, thereby simplifying the overall assembly process while maintaining effective noise filtering.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration simplifies manufacturing, reduces costs, and maintains effective noise filtering capabilities, making it suitable for high-speed communication applications like network and Ethernet interfaces.

Implementation Method 1

Magnetic elements, including transformer and common mode filter, are often used to filter noises in high-speed communication

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS8251744B2Electrical connector with magnetic module

Publication Date: 2012.08.28 HON HAI PRECISION INDUSTRY CO LTD

AI summary

An electrical connector (100) to be mounted on a substrate provides signal channels between a first side and a second side. The electrical connector includes a transformer (210), a common mode filter (327) and a separated filter (328). The transformer includes a first wire (314) having two opposite ends electrically connected to said first side and a second wire (312) having two opposite ends and a center tap (313). The common mode filter includes a third wire (322) and a fourth wire (324), each of the third wire (322) and the fourth wire (324) having an end respectively electrically connected to the two opposite ends of the second wire (312). The separated filter (328) includes a fifth wire (326) separated from the common mode filter (327) and the transformer (310), the fifth wire (326) having an end electrically connected to the center tap (313) of the second wire (312). Opposite ends of the third, the fourth and the fifth wires (322, 324, 326) are electrically connected to the second side.