Drum-Type Transformer Alignment in Electrical Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors with surface mount transformers lack a simple and effective construction for efficient signal transmission, particularly in differential signal channels.
Innovation Solution
The electrical connector features pairs of mating and foot terminals connected by a circuit board with drum-type transformers, where the primary and secondary winding wires are wound around a core with flanges, and terminal electrodes are strategically positioned to align transformers along the longitudinal direction, ensuring efficient signal transmission and preventing electric discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface mount transformers are used in electrical connectors, then the construction is simplified and manufacturing is easier, but signal integrity and reliability deteriorate due to improper transformer alignment and insufficient voltage distance
Solution Approach 1:
The patent transitions from conventional horizontal/planar transformer arrangement to a vertical arrangement where drum-type transformers are mounted perpendicular to the circuit board surface. This dimensional change allows transformers to be aligned along the longitudinal direction of signal channels while maintaining proper spacing, thereby improving signal integrity without compromising manufacturing simplicity.
Solution Approach 2:
The patent employs asymmetric positioning of terminal electrodes relative to the drum-type core, with first terminal electrodes on one lateral side and second terminal electrodes on the other lateral side. This asymmetric arrangement optimizes the voltage distance between adjacent transformers and ensures proper signal coupling while preventing electric discharge, thus enhancing reliability.
2Productivity
If transformers are aligned along the longitudinal direction of signal channels, then signal transmission efficiency is improved, but the risk of electric discharge increases due to reduced voltage distance between adjacent transformers
Solution Approach 1:
By mounting drum-type transformers vertically (perpendicular to the circuit board) rather than horizontally, the patent achieves alignment along the longitudinal direction of signal channels while utilizing the vertical dimension to maintain adequate voltage distance between adjacent transformers, thus preventing electric discharge while preserving signal transmission efficiency.
Solution Approach 2:
The patent applies different spatial arrangements to different parts of the transformer assembly: the drum-type core is positioned to align with signal channels for efficient transmission, while the terminal electrodes are strategically positioned on opposite lateral sides to maintain local voltage distance, thereby locally preventing electric discharge while maintaining overall signal efficiency.
3Reliability
If drum-type transformers with flanges are used, then transformer alignment and signal integrity are improved, but device complexity increases due to additional components
Solution Approach 1:
The patent integrates the mounting function directly into the drum-type transformer structure by incorporating flanges as part of the transformer body rather than as separate mounting components. This merging of functions reduces the number of discrete parts while achieving precise alignment along the longitudinal direction, thereby improving reliability without proportionally increasing device complexity.
Solution Approach 2:
The drum-type transformer with flanges serves multiple functions: it provides magnetic coupling for signal transmission, ensures precise alignment along the signal channel through its longitudinal orientation, and facilitates secure mounting on the circuit board. This multi-functionality reduces the need for additional specialized components, balancing reliability improvement with controlled complexity.
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 enhances signal integrity and reliability by aligning transformers perpendicular to the signal channels, maintaining a safe voltage distance to prevent electric discharge, thus improving the overall performance of differential signal channels.
Implementation Method 1
a primary winding wire and a secondary winding wire wound around the core
Data Source
AI summary
An electrical connector (10) includes plural pairs of mating terminals (24), plural pairs of foot terminals (26), and a number of circuit board component units. The circuit board component unit includes an upper inner circuit board (141), a lower inner circuit board (142), and a number of electronic components mounted onto the upper and lower inner circuit board (141,142). The electronic components include a number of transformers (15), each transformer (15) including a drum type core (161), a primary winding wire (171), and a secondary winding wire (172) wound around the drum type core (161). The primary winding wire (171) of one transformer (15) and the primary winding wire (171) of an adjacent transformer (15) or the secondary winding wire (172) of the one transformer (15) and the secondary winding wire (172) of the adjacent transformer (15) are disposed adjacent to each other to prevent electric discharge.