Plug Connector Integrated Transformer Shielding

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Solution Overview

Problem

Conventional M12 plug connectors require separate transformer components for galvanic separation, increasing construction space, complexity, crosstalk, and installation challenges, while RJ45 plugs are not reliable for industrial applications.

Innovation Solution

A plug connector design where the transformer unit is positioned behind the plug body and between the terminal contacts, with a contact element that connects the plug body to the transformer unit, allowing for compact integration and reduced crosstalk, and a shielding element with obliquely extending tabs for reliable electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate transformer components are used for galvanic separation, then galvanic separation between PHY and MDI sides is achieved, but construction space increases and device complexity increases

Engineering Contradiction:

Improvegalvanic separationVSAvoidconstruction space

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The transformer unit is integrated directly into the plug connector body, merging previously separate components (transformer and plug connector) into a single integrated unit. This eliminates the need for separate mounting space on the circuit board and reduces the overall construction space while maintaining galvanic separation functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transformer unit is positioned behind the plug body and nested within the plug connector structure. The contact element extends through the plug body to establish electrical connection, allowing the transformer to be housed within the existing plug connector footprint without requiring additional external space.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If separate transformer components are used, then galvanic separation is provided, but layout complexity increases due to air gaps and leakage clearances requirements

Engineering Contradiction:

Improvegalvanic separationVSAvoidlayout complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By integrating the transformer unit directly into the plug connector, the invention eliminates the need for separate layout planning with air gaps and leakage clearances between separate components. The integrated design simplifies the circuit board layout as the transformer is housed within the plug connector's own structure.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate transformer components are used, then galvanic separation is achieved, but additional crosstalk on the transceiver chip occurs

Engineering Contradiction:

Improvegalvanic separationVSAvoidcrosstalk

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The transformer unit is nested behind the plug body within the plug connector structure, positioning it closer to the plug contacts and away from the transceiver chip. This spatial arrangement reduces the length of conductor traces on the circuit board, thereby minimizing the potential for crosstalk to affect the sensitive transceiver chip while maintaining galvanic separation.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If separate transformer components are used, then galvanic separation is provided, but installation work increases

Engineering Contradiction:

Improvegalvanic separationVSAvoidinstallation work

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The transformer unit is integrated into the plug connector as a single assembly, eliminating the need for separate placement and wiring of transformer components during installation. The integrated design allows the entire plug connector with embedded transformer to be mounted as one unit, significantly reducing installation complexity and labor.

Inventive Principle:

Principle #5Merging (Combining)

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 compact design reduces crosstalk and installation complexity, enhances transmission characteristics, and provides a reliable shielding connection without requiring precise positional accuracy.

Implementation Method 1

the transformer unit (158) which connects the terminal contacts (112) under galvanic separation to base-side connecting contacts (113)

Methodology Applied

Scientific EffectGalvanic separation: Electromagnetic Induction

Implementation Method 2

a shielding element with obliquely extending tabs for reliable electrical connection

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentEP3411928B1Plug connector with integrated galvanic separation and shielding element

Publication Date: 2021.10.06 HARTING ZHUHAI MFG

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AI summary

To avoid the disadvantages of additionally required space, unwanted crosstalk and deterioration in transmission properties that are concomitant with a separate transformer, a plug connector (100) is proposed, comprising: a plug base (110) with terminal contacts (112) for external contacting of the plug connector (100), base-side connection contacts (113), and a transformer unit for galvanic separation in a conductive path between the terminal contacts (112) and the base-side connection contacts (113) and a plug body (130) with plug contacts (131), the plug base (110) and the plug body (130) enclosing a contact element (120) for connecting the base-side connection contacts (113) to the plug contacts (131) and the contact element (120) being planar in a plane perpendicular to a plug-in direction of the plug body (130). A shielding element (300) for the plug connector (100) is also proposed.