Patent Publication Number: US-7708595-B2

Title: Electrical connector system with magnetic module

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This patent application is related to a pending U.S. patent application Ser. No. 12/319,299, filed on Jan. 5, 2008, published in Document No. 2009 0176408 A1 on Jul. 9, 2009, and entitled “ELECTRICAL CONNECTOR HAVING AN IMPROVED MAGNETIC MODULE”, which is assigned to the same assignee with this application. This patent application is also related to two pending U.S. patent application Ser. Nos. 12/321,470 and 12/508,792, which are assigned to the same assignee with this application. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an electrical connector system, and more particularly, to an electrical connector system having magnetic module for noise-filter. 
   2. Description of the Prior Art 
   Magnetic elements, including transformer and common mode filter, are often used in noise-filter in the high frequency field. An electrical connector system having magnetic modules with more effective noise filtering, smaller size and lower cost is always a focus of the designers of the field. 
   OBJECTS OF THE INVENTION 
   A main object of the present invention is to provide an electrical connector system having transformer and common mode filter which is convenient to be manufactured and assembled. 
   The present invention provides an electrical connector system used for a network interface, said network interface providing signal channels between a first side and a second side. The electrical connector system comprising a substrate forming a plurality of conductive traces, an electrical connector mounted on the substrate; 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 that are physically separated from the second wire, wherein the third wire has an end electrically connected to one end of the second wire and an opposite end electrical connected to said second side, and wherein the fourth wire has an end electrically connected to the opposite end of the second wire and an opposite end electrical connected to said second side. The transformer is incorporated into a plastic container, the plastic container having a plurality of conductive tails electrically connected to opposite ends of the first and the second wires 
   The second wire and the third wire and the fourth wire are physically separated from each other, so that the transformer and the common mode filter could be independently manufactured and conveniently assembled. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features of this invention, which are believed to be novel, are set fourth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: 
       FIG. 1  is a perspective view of an electrical connector system of according to a prior design; 
       FIG. 2  is an exploded view of the electrical connector system shown in  FIG. 1 ; 
       FIG. 3  is a perspective view of a filter portion shown in  FIG. 2 ; 
       FIG. 4  is a perspective view of an electrical connector system of according to a second prior design; 
       FIG. 5  is an exploded view of the electrical connector system shown in  FIG. 4 ; 
       FIG. 6  is a perspective view of a filter portion shown in  FIG. 2 ; 
       FIG. 7  is a perspective view of an electrical connector system of according to a third prior design; 
       FIG. 8  is an exploded view of the electrical connector system shown in  FIG. 7 ; 
       FIG. 9  is a perspective view of a filter portion shown in  FIG. 8 ; 
       FIG. 10  is a perspective view of an electrical connector system of according to a fourth prior design; 
       FIG. 11  is an exploded view of the electrical connector system shown in  FIG. 10 ; 
       FIG. 12(   a )- 12 ( d ) are circuit diagrams according to present invention; 
       FIG. 13  is a perspective view of a filter portion according to a first embodiment of the present invention; 
       FIG. 14  is a perspective view of a filter portion according to a second embodiment of the present invention; 
       FIG. 15  is a perspective view of a filter portion according to a third embodiment of the present invention; 
       FIG. 16  is a perspective view of a filter portion according to a fourth embodiment of the present invention; 
       FIG. 17  is a perspective view of a filter portion according to a fifth embodiment of the present invention; 
       FIG. 18  is a perspective view of a filter portion according to a sixth embodiment of the present invention; 
       FIG. 19  is a perspective view of a filter portion according to a seventh embodiment of the present invention; 
       FIG. 20  is a perspective view of a filter portion according to an eighth embodiment of the present invention; 
       FIG. 21  is a perspective view of a filter portion according to a ninth embodiment of the present invention; 
       FIG. 22  is a perspective view of a filter portion according to a tenth embodiment of the present invention; 
       FIG. 23  is a perspective view of a filter portion according to a eleventh embodiment of the present invention; 
       FIG. 24  is a perspective view of a filter portion according to a twelfth embodiment of the present invention; 
       FIG. 25  is a perspective view of a filter portion according to a thirteenth embodiment of the present invention; 
       FIG. 26  is a perspective view of a filter portion according to a fourteenth embodiment of the present invention; 
       FIG. 27  is a perspective view of a filter portion according to a fifteenth embodiment of the present invention; 
       FIG. 28  is a perspective view of a filter portion according to a sixteenth embodiment of the present invention; 
       FIG. 29  is a perspective view of a filter portion according to a seventeenth embodiment of the present invention; 
       FIG. 30  is a perspective view of a filter portion according to an eighteenth embodiment of the present invention; 
       FIG. 31  is a perspective view of a filter portion according to a nineteenth embodiment of the present invention; and 
       FIG. 32  is a perspective view of a filter portion according to a twentieth embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference will now be made to the drawing figures to describe the present invention in detail. 
     FIGS. 1-12D  show prior designs disclosed four electrical connector systems embodying similar principle to the present invention. The electrical connector systems are used for a network interface for 10/100 based Ethernet. The network interface provides signal channels (referring to  FIGS. 12A-12D ) between a PHY side and a Cable side. 
   Referring to  FIGS. 1-3  and  12 A- 12 C, the electrical connector system comprises a substrate  1  forming a plurality of conductive traces connected to PHY side, an electrical connector  3  mounted on the substrate  1 , two transformers  5 , and a common mode filter module  7 . The electrical connector  3  is used to mate with a cable assembly and so forms a Cable side. The transformer  5  further comprises 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 module  7  comprises two common mode filters. Each common mode filter has a third wire  73  and a fourth wire  75  that are 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. 
   The common mode filter  7  further comprises a plastic container  71 , two magnetic cores received in the plastic container  71  and a plurality of conductive tails  77  molded together with the plastic container  71 . The third wires  73  and the fourth wires  75  wind around the magnetic cores. The ends of the third and the fourth wires  73 ,  75  are respectively electrically connected to said conductive tails  77 . So, the container  71  makes the common mode filter  7  an integrated common mode module that can be assembled conveniently. 
   The transformer  5  further comprises a ringy magnetic core and said first and said second wires  51 ,  53  are wound around the ringy magnetic core. 
   Referring to  FIGS. 12A-12C , circuit diagrams of the network interface are provided. It is shown that each of said first and said second wires  51 ,  53  forms a center tap  55 ,  57 . In one optional design, the center tap  55  of the first wire  51  is connected to ground, while the common mode module  7  further comprise a fifth wire  79  winding the magnetic core, the center tap  57  of the second wire  53  being electrically connected to ground through the fifth wire  79 , which is shown in  FIG. 12B . In another optional design, the fifth wire  79  is not provided and the center tap  57  of the second wire is electrically connected to ground directly, which is shown in  FIG. 12C . It is the same for other prior designs of that center taps and a fifth wire may be optionally used to further improve noise filter. 
   Referring back to  FIGS. 2 and 3 , the electrical connector  3  further comprises an interior PCB  33 , a plurality of mating contacts  35  and a plurality of transferring contacts  37  mounted on the interior PCB. The transformer  5  and the common mode module  7  are mounted on the interior PCB  33 . The interior PCB  33  forms a plurality of conductive traces  331  and a plurality of conductive pads  333 . The opposite ends of the first wire  51  are electrically connected to the PHY side through some of the conductive traces  331  of the interior PCB  33  and said transferring contacts  37 . The opposite ends of the second wire  53  are respectively electrically connected to ends of the third and the fourth wires  73 ,  75  sequentially through some of the conductive pads  333 , some of the conductive trace 331 of the interior PCB  33 , some other conductive pads  333 , some of the conductive tails  77  and some other of the conductive pads  333 . The opposite ends of the third and the fourth wires  73 ,  75  are electrically connected to the Cable side sequentially through some other of the conductive tails  77 , some of the conductive traces  331  of the interior PCB  33  and the mating contacts  35 . 
   Referring to  FIG. 12D , circuit diagram of an electrical connector system in 10-1000 based Ethernet application is shown, which is similar to the circuit diagram of 10/100 based Ethernet application except that there are four signal channels. 
   Referring to  FIGS. 4-6 , an electrical connector system according to a second prior design is shown. The electrical connector system comprises a substrate  1 ′ forming a plurality of conductive traces  11 ′ and an electrical connector  3 ′ mounted on the substrate  1 ′, a transformer  5 ′ and a common mode filter  7 ′. The transformer  5 ′ further comprises 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 ′ that are 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. 
   The common mode filter  7 ′ further comprises a plastic container  71 ′, a magnetic core received in the plastic container  71 ′ and a plurality of conductive tails  77 ′ molded together with the plastic container  71 ′. The third wire  73 ′ and the fourth wire  75 ′ wind around the magnetic core. The ends of the third and the fourth wires  73 ′,  75 ′ are respectively electrically connected to said conductive tails  77 ′. So, the container  71 ′ makes the common mode filter an integrated common mode module to be assembled conveniently. 
   Referring to  FIGS. 5 and 6 , the transformer  5 ′ and the common mode module  7 ′ are mounted on the substrate  1 ′. The opposite ends of the first wire  51 ′ are electrically connected to the PHY side by some said conductive traces  11 ′ of the substrate  1 ′. The opposite ends of the second wire  53 ′ are respectively electrically connected to one ends of the third and the fourth wires  73 ′,  75 ′ through some of the conductive pads  13 ′, some of the conductive trace  11 ′ of the substrate  1 ′, some other conductive pads  13 ′, some of the conductive tails  77 ′ and some other of the conductive pads  13 ′. 
   The electrical connector  3 ′ further comprises an interior PCB  33 ′. The interior PCB  33 ′ forms a plurality of conductive traces  331 ′. The electrical connector  3 ′ further comprises a plurality of mating contacts  35 ′ and a plurality of transferring contacts  37 ′ mounted on the interior PCB. The third and the fourth wires  73 ′,  75 ′ are electrically connected to the Cable side through some conductive tails  77 ′, some conductive traces  11 ′ of the substrate  1 ′, the transferring contacts  37 ′, the conductive traces  331 ′ and the mating contacts  35 ′. 
   Referring to  FIGS. 7-9 , an electrical connector system according to a third prior design is shown. The electrical connector system comprises a substrate  2  forming a plurality of conductive traces  21  and an electrical connector  4  mounted on the substrate  2 , a transformer  6  and a common mode filter  8 . The transformer  6  further comprises a first wire  61  having two opposite ends electrically connected to the Cable side and a second wire  63  having two opposite ends. The common mode filter  8  has a third wire  83  and a fourth wire  85  that are physically separated from the second wire  63 . The third wire  83  has an end electrically connected to one end of the second wire  63  and an opposite end electrically connected to the PHY side. The fourth wire  85  has an end electrically connected to the opposite end of the second wire  63  and an opposite end electrically connected to the PHY side. So PHY side and the Cable side are completely opposite to circuit diagram shown in  FIG. 12A . 
   The common mode filter  8  further comprises a plastic container  81 , a magnetic core received in the plastic container  81  and a plurality of conductive tails  87  molded together with the plastic container  81 . The third wire  83  and the fourth wire  85  wind around the magnetic core. The ends of the third and the fourth wires  83 , 85  are respectively electrically connected to said conductive tails  87 . So, the container  81  makes the common mode filter an integrated common mode module to be assembled conveniently. 
   Referring to  FIGS. 8 and 9 , the substrate  2  comprises a plurality of conductive traces  21  and a plurality of conductive pads  23 . The common mode module  8  is mounted on the substrate  2 . The electrical connector  4  further comprises an interior PCB  43 . The interior PCB  43  forms a plurality of conductive traces  431  and a plurality of conductive pads  433 . The transformer  6  is mounted on the interior PCB  43 . The electrical connector  4  further comprises a plurality of mating contacts  45  and a plurality of transferring contacts  47  mounted on the interior PCB. 
   Referring to  FIGS. 10-11 , an electrical connector system according to a fourth prior design is shown. The electrical connector system comprises a substrate  2 ′ forming a plurality of conductive traces  21 ′ and an electrical connector  4 ′ mounted on the substrate  2 ′, a transformer  6 ′ and a common mode filter  8 ′. The transformer  6 ′ further comprises a first wire  61 ′ having two opposite ends electrically connected to the PHY side and a second wire  63 ′ having two opposite ends. The common mode filter  8 ′ has a third wire  83 ′ and a fourth wire  85 ′ that are physically separated from the second wire  63 ′. The third wire  83 ′ has an end electrically connected to one end of the second wire  63 ′ and an opposite end electrically connected to the Cable side. The fourth wire  85 ′ has an end electrically connected to the opposite end of the second wire  63 ′ and an opposite end electrically connected to the Cable side. The circuit diagram of the fourth prior design is shown in  FIG. 12B . 
   The common mode filter  8 ′ further comprises a plastic container  81 ′, a magnetic core received in the plastic container  81 ′ and a plurality of conductive tails  87 ′ molded together with the plastic container  81 ′. The third wire  83 ′ and the fourth wire  85 ′ wind around the magnetic core. The ends of the third and the fourth wires  83 ′,  85 ′ are respectively electrically connected to said conductive tails  87 ′. So, the container  81 ′ makes the common mode filter an integrated common mode module to be assembled conveniently. 
   Referring to  FIG. 11 , the transformer  6 ′ is mounted on the substrate  2 ′. The electrical connector  4 ′ further comprises an interior PCB  43 ′. The interior PCB  43 ′ forms a plurality of conductive traces  431 ′ and a plurality of conductive pads  433 ′. The common mode filter  8 ′ is mounted on the interior PCB  43 ′. The electrical connector  4 ′ further comprises a plurality of mating contacts  45 ′ and a plurality of transferring contacts  47 ′ mounted on the interior PCB. 
   Referring back to the third and fourth prior designs, the opposite ends of the second wire  63 ,  63 ′ and the one ends of the third and the fourth wires are respectively electrically connected through some of the conductive pads  433 ,  433 ′ and conductive traces  431 ,  431 ′ of the interior PCB  43 ,  43 ′, the transferring contacts  47 ,  47 ′, some of the conductive traces  21 ,  21 ′ and conductive pads  23 ,  23 ′ of the substrate  2 ,  2 ′. According to the first to the fourth prior designs, the second wire  53 ,  53 ′,  63 ,  63 ′ of the transformer  5 ,  5 ′,  6 ,  6 ′ is physically separated from the wires of the common mode filter  7 ,  7 ′,  8 ,  8 ′, so that the transformer  5 ,  5 ′,  6 ,  6 ′ and the common mode filter  7 ,  7 ′,  8 ,  8 ′ could be separately manufactured conveniently. Furthermore, the common mode filter  7 ,  7 ′,  8 ,  8 ′ and the transformer  5 ,  5 ′,  6 ,  6 ′ could be optionally mounted onto the substrate  1 ,  1 ′,  2 ,  2 ′ or the interior PCB  33 ,  33 ′,  43 ,  43 ′. 
   Referring to  FIGS. 13-32 , twenty electrical connector systems according to first to twentieth embodiments are respectively shown. The twenty embodiments are designed with similar structures to the first to fourth prior designs except that the common mode filter  800  and the transformer  600  are differently designed. 
   In the twenty embodiments of the present invention, the electrical connector system provides two signal channels and accordingly has two transformers and two common mode filters. The two transformers are incorporated in a plastic container  603  to form an integral transformer module  600 . The plastic container  603  is insert-molded with a plurality of conductive tails  601 . The first and the second wires  61 ,  63  of the two transformers have opposite ends respectively electrically connected to said conductive tails  601 . 
   In the first to the fourth embodiments of the present invention (referring to  FIGS. 13-16 ), the connector system has two common mode filters  800  corresponding to the two signal channels. Each of the common mode filters  800  has a third and a fourth wires  83 ,  85  formed from printed circuit technology. The common mode filter  800  further comprises a plurality of conductive pads  801  respectively attached thereon and electrically connecting opposite ends of the third and the fourth wires  83 ,  85 . The conductive pads  801  are preferred to mount the common mode filter  800  onto corresponding PCB through SMT (surface-mount technology). This type of common mode filter  800  can improve the function of filtering noise. 
   In the fifth to the eighth embodiments of the present invention (referring to  FIGS. 17-20 ), the connector system has two common mode filters  840  corresponding to the two signal channels. Each of the common mode filters  840  comprises a circle-shaped magnetic core  842  and a third and a fourth wires  83 ,  85  winding around the magnetic core  842 . The third and the fourth wires  83 ,  85  having opposite ends directly mounted onto corresponding PCB. This type of common mode filter  840  has no container and conductive tail, and therefore the cost for making the same is comparatively low. 
   In the ninth to the twelfth embodiments of the present invention (referring to  FIGS. 21-24 ), the connector system has a common mode filter module  860 . The common mode filter module  860  comprises one plastic container  863  and two common mode filters received therein. The plastic container  863  is configured with a plurality of conductive tails  861 . Each of the common mode filter has a third and a fourth wires  83 ,  85  having opposite ends electrically connected to the conductive tails  861 . According to the ninth to the twelfth embodiments of the present invention, the two common mode filters of the two signal channels are both received in the container  863  and form the integral common mode filter module  860 , which is beneficial for mounting the filters to corresponding PCB. 
   In the thirteenth to the sixteenth embodiments of the present invention (referring to  FIGS. 25-28 ), the connector system has two signal channels and accordingly two transformers and two common mode filters  880 . Each of the common mode filter  880  comprises an “I” shaped magnetic core  882 , a plurality of conductive pads  881  attached thereon, a third and a fourth wires winding around the magnetic core  882 . The third and the fourth wires  83 ,  85  are electrically connected to the conductive pads  881 . The “I” shaped magnetic core make it easy to winding the third and the fourth wire  83 ,  85  around there. The conductive pads  881  are preferred to mount the common mode filter  880  onto corresponding PCB through SMT (surface-mount technology). This type of common mode filter  880  is the cheapest one in all the embodiments of present invention. 
   In the seventeenth to the twentieth embodiments of the present invention (referring to  FIGS. 29-32 ), the third wires  83  and the fourth wires  83  of the two common mode filters in the two signal channels wind around a common magnetic core  892  and thus form an integral common mode filter  890 . It should be understood that if more signal channels were needed, more wires of the common mode filter of the signal channels could be wound around the magnetic core  892 . The magnetic core  892  defines two holes  894  cutting there through. The third and the fourth wires  83 ,  85  wind around the magnetic core and get through the two holes  894 . The third and the fourth wires  83 ,  85  have opposite ends directly mounted onto corresponding PCB. 
   It is to be understood, however, that even though numerous, characteristics and advantages of the present invention have been set fourth in the foregoing description, together with details of the structure and function of the invention, the disclosed is illustrative only, and changes may be made in detail, especially in matters of number, shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.