Surface Mount Transformer Layout for Compact Electrical Connector
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Solution Overview
Problem
Existing electrical connectors face challenges in miniaturization while maintaining good electrical performance, as the arrangement of surface mount transformers on printed circuit boards (PCBs) often results in either excessive width or length, making it difficult to fit them within the limited space of an insulative housing.
Innovation Solution
The electrical connector features a magnetic module with a PCB that mounts four isolated transformers in a specific configuration, where two transformers are aligned transversely and overlap each other, allowing for a compact arrangement that fits within the housing's dimensions, along with common mode chokes and other components, optimizing space usage and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If four surface mount transformers are mounted on a PCB in a conventional arrangement, then good electrical performance is achieved, but the PCB width or length becomes excessive and cannot fit within the housing
Solution Approach 1:
The patent applies dimensional change by transitioning from a conventional linear arrangement of transformers to a folded layout where transformers are positioned on both sides of the PCB and connected via via holes. This utilizes the third dimension (depth/vertical connectivity) to reduce the footprint area, allowing four transformers to fit within compact housing dimensions while maintaining electrical performance through proper via connections
2Volume of moving object
If the PCB area is reduced to fit within the housing, then miniaturization is achieved, but it becomes difficult to maintain good electrical performance
Solution Approach 1:
The patent implements nesting by placing transformers on both the front and back sides of the PCB, with connections between layers achieved through via holes. This nested arrangement allows components to be distributed across multiple layers of the PCB, effectively utilizing the available space volume rather than just surface area, thereby maintaining electrical performance in a miniaturized connector
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 configuration enables a compact and efficient electrical connector design that maintains good electrical performance by minimizing the PCB's size and reducing the number of conductive through holes, allowing for a more compact and functional arrangement of transformers and chokes.
Implementation Method 1
The magnetic module includes a printed circuit board (PCB) and four isolated transformers surface mounted on a same face of the PCB... electrically connecting the mating contacts to corresponding mounting contacts
Data Source
AI summary
An electrical connector includes an insulative housing, a contact module, and a magnetic module. The insulative housing defines a receiving cavity forwardly communicating with an exterior plug and a mounting cavity located behind the receiving cavity. The contact module includes a set of mating contacts each having a contacting portion exposed within the receiving cavity and a set of mounting contacts for connecting to an exterior substrate. The magnetic module is received in the mounting cavity and electrically connecting the mating contacts to corresponding mounting contacts. The magnetic module includes a printed circuit board (PCB) and four isolated transformers surface mounted on a same face thereof. The four discrete transformers are arranged on a limited space of the PCB.