Surface Mount Device Chokes for Automatic SMT Assembly
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Solution Overview
Problem
Existing electrical connectors with manually wound magnetic wires around magnetic cores hinder automatic Surface-mount technology (SMT) manufacturing in high-speed signal transmission systems.
Innovation Solution
The use of Surface Mount Device (SMD) chokes with rectangular core portions and soldering portions, which can be directly soldered onto conductive pads without manual winding, allowing for automatic assembly and integration with transformer chokes in an electrical connector design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional common mode chokes with manually wound magnetic wires are used, then common mode filtering performance is achieved, but automatic SMT manufacturing cannot be implemented
Solution Approach 1:
The patent changes the physical form and mounting parameters of the common mode choke from a manual wire-wound component to an SMD component with standardized dimensions and mounting holes, enabling it to be processed by automatic SMT equipment. This parameter transformation allows the choke to be placed, soldered, and fixed automatically on the circuit board without manual intervention.
2Productivity
If manually wound magnetic wires are used around magnetic cores, then common mode choke functionality is achieved, but manufacturing time and labor costs increase
Solution Approach 1:
The patent replaces the manual mechanical wire-winding operation with an automated SMT process. The SMD choke is positioned and soldered by automated equipment, eliminating the need for manual wire winding around magnetic cores, thereby significantly reducing manufacturing time and labor costs while maintaining the common mode filtering functionality.
3Ease of manufacture
If SMD chokes are used instead of wire-wound chokes, then automatic manufacturing is enabled, but structural complexity of the choke component changes
Solution Approach 1:
The patent segments the common mode choke into distinct functional parts: the magnetic core, the winding structure, and the mounting structure with holes for mechanical attachment. This segmentation allows the choke to be manufactured as a standardized SMD component that can be automatically mounted, while the internal complexity is encapsulated within the component itself rather than requiring manual assembly operations.
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
Enables the automatic manufacture of electrical connectors with improved common mode choke functionality, enhancing manufacturing efficiency and reducing manual labor costs.
Implementation Method 1
The surface mount device chokes could be soldered to the daughter board directly without any manually wound wires. Compared to the traditional common mode choke having wires manually wound around the core portion, the surface mount device chokes are adapted for being applied in automatic manufacture.
Data Source
AI summary
An electrical connector (100) includes an insulative housing (10) and a terminal module (20) received in the insulative housing. The terminal module includes a daughter board (21), a choke group, a number of mating terminals (24) mounted on a first side of the daughter board, and a connecting module (22) mounted on a second side the daughter board and having a number of connecting terminals (221). The choke group has a number of transformer chokes (23) mounted to the second side of the daughter board, and a number of surface mount device chokes (25) adapted for being applied in automatic manufacture and mounted the second side of the daughter board.