Electrical Connector Magnetic Module Segmentation
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Solution Overview
Problem
Existing electrical connector systems with magnetic modules for noise filtering are either too large or costly, making them difficult to manufacture and assemble efficiently.
Innovation Solution
The design incorporates a transformer and common mode filter with physically separated wires, allowing for independent manufacturing and assembly, where the transformer is integrated into a plastic container with conductive tails connected to the wires, and the common mode filter features a plastic container with magnetic cores and conductive tails, enabling convenient assembly and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic elements are integrated into a single assembly, then noise filtering effectiveness is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The magnetic element assembly is divided into separate components: the common mode filter and the transformer are manufactured independently and then assembled together. This segmentation allows each component to be optimized and manufactured separately using standard processes, improving ease of manufacture while maintaining the noise filtering effectiveness of the complete assembly.
2Reliability
If magnetic elements are integrated into a single assembly, then noise filtering effectiveness is improved, but assembly time and production efficiency decrease
Solution Approach 1:
The common mode filter and transformer are pre-assembled into a integrated magnetic element assembly before final installation into the electrical connector. This preliminary action allows the complex magnetic components to be prepared in advance using automated assembly processes, improving production efficiency while ensuring proper noise filtering performance.
3Ease of manufacture
If traditional electrical connector designs are used, then manufacturing is simpler, but noise filtering performance is insufficient
Solution Approach 1:
The common mode filter and transformer are merged into a single integrated magnetic element assembly that is then incorporated into the electrical connector. This merging provides effective noise filtering performance while maintaining manufacturing simplicity through the use of pre-assembled modules and standard manufacturing processes.
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 allows for a compact, cost-effective electrical connector system with improved noise filtering capabilities, facilitating easier manufacturing and assembly while maintaining effective signal transmission across network interfaces.
Implementation Method 1
a common mode filter having a third wire and a fourth wire that are physically separated from the second wire, wherein the third wire has an end electrically connected to one end of the second wire and an opposite end electrical connected to said second side, and wherein the fourth wire has an end electrically connected to the opposite end of the second wire and an opposite end electrical connected to said second side. The transformer is incorporated into a plastic container, the plastic container having a plurality of conductive tails electrically connected to opposite ends of the first and the second wires
Data Source
AI summary
An electrical connector system includes a substrate (1) connected to PHY side and an electrical connector (3) mounted on the substrate (1), a transformer (5) and a common mode filter (7). The electrical connector (3) is used to mate with a cable assembly and so forms a Cable side. The transformer (5) further includes a first wire (51) having two opposite ends electrically connected to the PHY side and a second wire (53) having two opposite ends. The common mode filter (7) has a third wire (73) and a fourth wire (75) that are physically separated from the second wire (53). The third wire (73) has an end electrically connected to one end of the second wire (53) and an opposite end electrically connected to the Cable side. The fourth wire (75) has an end electrically connected to the opposite end of the second wire (53) and an opposite end electrically connected to the Cable side.