Integrated Magnetic Module for Electrical Connector Noise Filtering
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 inefficient for high-speed communication applications.
Innovation Solution
An electrical connector system comprising a substrate with conductive traces, a transformer, and a common mode filter, where the transformer and common mode filter are physically separated to allow independent manufacturing and assembly, utilizing a ringy magnetic core and conductive pads for efficient noise filtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If magnetic elements are used for noise filtering in high-speed communication, then noise filtering effectiveness is improved, but device size and manufacturing cost increase
Solution Approach 1:
The patent combines the transformer and common mode filter into a single integrated magnetic module. The transformer primary and secondary windings are formed on the same magnetic core, and the common mode filter windings are integrated around the same magnetic core structure. This merging of multiple magnetic elements into one unified module achieves effective noise filtering while reducing the overall device size compared to separate components.
Solution Approach 2:
The magnetic module serves multiple functions simultaneously: it provides transformation (transformer function) and noise filtering (common mode filter function) within a single integrated structure. The magnetic core and windings are designed to perform both signal transformation and common mode noise rejection, making the device multi-functional and reducing the need for separate magnetic components.
2Object-affected harmful factors
If magnetic elements are used for noise filtering in high-speed communication, then noise filtering effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The transformer and common mode filter are manufactured as a single integrated module rather than separate components. This consolidation reduces the number of assembly steps, minimizes the quantity of magnetic materials required, and simplifies the manufacturing process, thereby reducing overall manufacturing cost while maintaining effective noise filtering performance.
Solution Approach 2:
The magnetic module is designed with segmented windings where the transformer primary, transformer secondary, and common mode filter windings are physically separated but integrated on the same magnetic core. This segmentation allows for simplified manufacturing of each winding section independently while maintaining the magnetic coupling necessary for both transformation and noise filtering functions.
3Object-affected harmful factors
If transformer and common mode filter are integrated, then noise filtering effectiveness is improved, but assembly complexity increases
Solution Approach 1:
By integrating the transformer and common mode filter into a single magnetic module with a unified magnetic core and coordinated windings, the patent eliminates the need for separate assembly of multiple magnetic components. This merging reduces assembly complexity despite the enhanced noise filtering functionality, as the integrated structure requires fewer assembly steps and connections.
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
The solution enables convenient manufacturing and assembly of the electrical connector system, providing effective noise filtering while reducing size and cost, thus enhancing performance in high-speed communication applications.
Implementation Method 1
Magnetic elements, including transformer and common mode filter, are often used to filter noises in high-speed communication
Implementation Method 2
a transformer having a first wire having two opposite ends electrically connected to said first side and a second wire having two opposite ends
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) 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.