Planar Embedded Magnetics for High-Density Connectors
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Solution Overview
Problem
Current communication connectors face challenges with hand-wound magnetic components that are time-consuming, costly, and difficult to integrate, leading to poor repeatability and performance, especially in high-frequency applications, and are unable to support the increasing demand for compact and high-density connectors.
Innovation Solution
The integration of wideband planar transformers with ferrite material embedded in a rigid planar substrate, surrounded by an elastic non-conductive material, and inter-wound conductors with precise spacing to minimize parasitic inductance and leakage, along with thermal conduits for heat management and impedance-matched center taps for EMI control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hand-wound magnetic components are integrated into connector housing, then magnetic isolation and EMI suppression are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The magnetic component is segmented into discrete planar turns that are pre-formed on a substrate before integration into the connector housing. This segmentation allows for automated manufacturing of the magnetic elements separately from the connector assembly, reducing overall manufacturing time while maintaining EMI suppression functionality.
Solution Approach 2:
The magnetic windings are preliminarily formed on a substrate in a planar configuration before being integrated into the final connector assembly. This preliminary preparation enables automated manufacturing processes and reduces the time required for final assembly, while the pre-formed structure maintains the necessary magnetic properties for EMI suppression.
2Object-affected harmful factors
If hand-wound magnetic units are inserted into connector housing, then magnetic isolation is achieved, but spacing control and repeatability deteriorate
Solution Approach 1:
The magnetic windings are merged with the substrate to form an integrated planar magnetic structure. This combination eliminates the need for separate insertion and positioning steps, ensuring precise and repeatable spacing between magnetic turns through the substrate's inherent structural accuracy rather than relying on manual placement tolerances.
Solution Approach 2:
The magnetic windings are preliminarily positioned on the substrate during the substrate fabrication process itself, establishing precise spacing before the magnetic component is integrated into the connector housing. This preliminary positioning ensures consistent spacing control and repeatability across all manufactured units.
3Object-affected harmful factors
If hand-wound magnetics are used in connector integration, then basic magnetic functionality is achieved, but performance in high-frequency applications deteriorates
Solution Approach 1:
The magnetic windings are formed with smooth curved transitions between turns in the planar structure, eliminating sharp corners and discontinuities that cause signal reflection and interference at high frequencies. This curved geometry maintains basic magnetic functionality while significantly improving high-frequency performance through reduced electromagnetic discontinuities.
Solution Approach 2:
The manual hand-winding mechanical process is replaced with a planar fabrication process that uses photolithography or other precision deposition techniques to create the magnetic windings. This substitution eliminates the variability and imprecision of manual winding, providing consistent geometric parameters that are critical for reliable high-frequency operation.
4Object-affected harmful factors
If hand-wound magnetic components are integrated into connectors, then magnetic isolation is achieved, but manufacturing cost increases
Solution Approach 1:
The magnetic component is segmented into planar turns that can be manufactured using standard PCB fabrication processes. This segmentation allows the magnetic element to be produced using existing, cost-effective manufacturing infrastructure rather than requiring specialized hand-winding equipment and skilled labor, thereby reducing overall manufacturing cost while maintaining magnetic isolation functionality.
Solution Approach 2:
The expensive and time-consuming manual hand-winding process is replaced with automated planar fabrication processes such as photolithography and electroplating. This substitution dramatically reduces labor costs and increases manufacturing efficiency while maintaining the necessary magnetic isolation performance, making the connector more economically viable.
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 solution enables the creation of compact, high-performance communication connectors with improved repeatability, reduced manufacturing costs, and enhanced electromagnetic interference suppression, suitable for high-density applications such as 96 port Ethernet switches.
Implementation Method 1
a ferrite material embedded in the fully-cured and rigid planar substrate
Implementation Method 2
inter-wound conductors disposed around the embedded ferrite material, where the inter-wound conductors have top conductors bonded to a top surface of the fully-cured and rigid substrate
Data Source
AI summary
The current invention provides an integrated planar transformer and electronic component that includes at least one wideband planar transformer disposed in a planar substrate, where each wideband planar transformer includes a planar substrate in a fully-cured and rigid state, a ferrite material embedded in the planar substrate, where the ferrite material is enveloped in an elastic and non-conductive material, inter-wound conductors disposed around the embedded ferrite material, where top and bottom conductors are bonded by an insulating adhesive. The top and bottom conductors are connected in an inter-connected pattern by conductive vias disposed on each side of the ferrite material and span through the layers to the conductors. The planar transformer further includes at least one center tap connected to at least one inter-wound conductor. The integrated planar transformer and electronic component further includes at least one electronic component connected to at least one terminal of the wide-band planar transformer.