Integrated Magnetic Module for Electrical Connector Noise Filtering
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Solution Overview
Problem
Existing electrical connector systems with magnetic modules for noise filtering are either too large, costly, or difficult to manufacture and assemble effectively, particularly in high-speed communication applications.
Innovation Solution
The electrical connector system includes a substrate with conductive traces, a transformer with a magnetic core, and a common mode filter with physically separated wires, allowing for independent manufacturing and assembly, and featuring a design that integrates magnetic cores and conductive tails within a plastic container for convenient assembly and 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 positioned on opposite sides of a central leg of the magnetic core, while the common mode filter windings are positioned on the outer legs, all within one compact magnetic structure. This merging of functions into a single module achieves effective noise filtering while reducing overall device size compared to separate components.
Solution Approach 2:
The magnetic module serves multiple functions simultaneously: it provides transformer functionality for signal isolation and common mode filter functionality for noise suppression. The single magnetic core structure supports both the transformer windings (first and second wires) and common mode filter windings (third and fourth wires), making the component universal and eliminating the need for separate discrete magnetic elements.
2Object-affected harmful factors
If traditional magnetic modules are used for noise filtering, then noise filtering is achieved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The magnetic module is designed with distinct functional zones: the central leg contains the transformer windings while the outer legs contain the common mode filter windings. The magnetic core is divided into three legs with clear spatial separation of different winding types, making it easier to manufacture and assemble different winding sections independently before final integration.
Solution Approach 2:
The patent specifies that the first and second wires are wound around the central leg first to form the transformer, then the third and fourth wires are wound around the outer legs to form the common mode filter. This preliminary arrangement of windings around the magnetic core structure simplifies the manufacturing sequence and assembly process compared to attempting to assemble separate components.
3Ease of manufacture
If separate transformer and common mode filter components are used, then manufacturing flexibility is maintained, but assembly complexity and space requirements increase
Solution Approach 1:
The transformer and common mode filter are merged into a single magnetic module with a unified magnetic core structure. The three-legged magnetic core provides distinct positioning for transformer windings on the central leg and common mode filter windings on the outer legs, achieving functional integration while maintaining manufacturing flexibility through modular winding design.
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 efficient noise filtering, reduces manufacturing costs, and simplifies assembly, resulting in a compact and cost-effective electrical connector system suitable for high-speed communication applications.
Implementation Method 1
a transformer having a first wire having two opposite ends electrically connected to said first side and a second wire having two opposite ends, a common mode filter having a third wire and a fourth wire
Implementation Method 2
Magnetic elements, including transformer and common mode filter, are often used to filter noises in high-speed communication
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.