Electrical Connector Magnetic Module Segmentation
Find Innovative SolutionsGenerate Solutions
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 effectively.
Innovation Solution
The design of an electrical connector system that includes a transformer and a common mode filter, where the second wire and the third and fourth wires are physically separated, allowing for independent manufacturing and assembly, and are integrated with a substrate and magnetic cores within a plastic container for convenient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic elements are integrated into electrical connector systems for noise-filtering, then noise-filtering capability is improved, but device size and manufacturing complexity increase
Solution Approach 1:
The patent divides the common mode filter into two separate filters, each handling one direction of signal transmission. This segmentation allows each filter to be independently manufactured and assembled, reducing overall manufacturing complexity while maintaining effective noise filtering in both directions.
Solution Approach 2:
The patent extracts the common mode filter from the traditional integrated transformer design, allowing it to be manufactured separately and then assembled into the electrical connector system. This extraction simplifies the manufacturing process by enabling specialized production of filter components independently from the connector housing.
2Reliability
If traditional integrated magnetic modules are used, then noise-filtering is achieved, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
By segmenting the common mode filter into two separate filters positioned on opposite sides of the second wire, the patent enables parallel manufacturing processes and simplified assembly operations, reducing both cost and complexity while maintaining effective noise filtering.
Solution Approach 2:
The patent creates a modular electrical connector system where the separated common mode filters can be manufactured using standardized processes and assembled into different connector configurations, improving manufacturing efficiency and reducing costs through universal manufacturing approaches.
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 design enables the creation of a smaller, cost-effective electrical connector system with improved noise-filtering capabilities, facilitating easier manufacturing and assembly while maintaining effective signal transmission between the PHY and Cable sides.
Implementation Method 1
an improved magnetic module, which includes a first wire, a second wire, a third wire and a fourth wire... the third wire and the fourth wire that are physically separated from the second wire
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 and electrically connected to opposite ends of the second wire (53).