Patent Publication Number: US-2022215999-A1

Title: Magnetic module and method of making the same and electrical connector including the magnetic module

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application relates to U.S. patent application Ser. No. 17/476,366, filed on Sep. 15, 2021, entitled “MAGNETIC MODULE AND ELECTRICAL CONNECTOR INCLUDING THE MAGNETIC MODULE” and U.S. patent application filed on even day herewith, entitled “MAGNETIC MODULE AND ELECTRICAL CONNECTOR INCLUDING THE MAGNETIC MODULE,” which are assigned to the same assignee as this application. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a magnetic module and an electrical connector including the magnetic module, and more particularly to the winding of the magnetic module. The present invention also relates to a method of making the magnetic module, and more particularly to a winding method of the magnetic module. 
     2. Description of Related Arts 
     China Patent No. 102832019 discloses a magnetic module including a magnetic core, a primary coil and a secondary coil wound on the magnetic core, each input end and output end of the primary coil and the secondary coil has two wire, and the resistance of each input end and output end is relatively large, which cannot guarantee the effective transmission of high-frequency signal transmission. However, in order to reduce the impedance, thickening the enameled wire will cause the enameled wire to have a greater tension during the winding and bending process, which will easily cause the outer layer of paint to rupture, and cause the flexibility of the enameled wire to deteriorate, which is inconvenient for winding operations. 
     SUMMARY OF THE INVENTION 
     A main object of the present invention is to provide a magnetic module suitable for high frequency signal transmission. Another main object of the present invention is to provide a manufacturing method of the magnetic module. A further main objective of the present invention is to provide an electrical connector using the magnetic module. 
     To achieve the above-mentioned object, a magnetic module comprises: a magnetic core; and a plurality of enameled wires wound on the magnetic core, the enameled wire being wound on the magnetic core to form a primary coil and a secondary coil, the primary coil including a first group of enameled wires and a second group of enameled wires, the secondary coil including a third group of enameled wires and a fourth group of enameled wires, wherein the respective parts of the first group of enameled wires and the fourth group of enameled wires wound around the magnetic core are twisted together to form a first stranded wire, the respective parts of the second group of enameled wires and the third group of enameled wires wound around the magnetic core are twisted together to form a second stranded wire, and the first stranded wire and the second stranded wire are twisted together to form a total stranded wire. 
     To achieve the above-mentioned object, a manufacturing method of a magnetic module comprises the steps of: providing a magnetic core; providing a plurality of enameled wires; dividing the enameled wires into a first group of enameled wires, a second group of enameled wires, a third group of enameled wires, and a fourth group of enameled wires, the first group of enameled wires and the second group of enameled wires being wound on the magnetic core to form a primary coil, the third group of enameled wires and the fourth group of enameled wires being wound on the magnetic core to form a secondary coil, wherein the first group of enameled wires and the fourth group of enameled wires are twisted to form a first stranded wire; the second group of enameled wires and the third group of enameled wires are twisted to form a second stranded wire; and the first strand and the second strand together are twisted to form a total strand wire. 
     To achieve the above-mentioned object, an electrical connector comprises a magnetic module, the magnetic module comprising: a magnetic core; and a plurality of enameled wires wound on the magnetic core, the enameled wire being wound on the magnetic core to form a primary coil and a secondary coil, the primary coil including a first group of enameled wires and a second group of enameled wires, the secondary coil including a third group of enameled wires and a fourth group of enameled wires, wherein the respective parts of the first group of enameled wires and the fourth group of enameled wires wound around the magnetic core are twisted together to form a first stranded wire, the respective parts of the second group of enameled wires and the third group of enameled wires wound around the magnetic core are twisted together to form a second stranded wire, and the first stranded wire and the second stranded wire are twisted together to form a total stranded wire. 
     Compared to prior art, the respective parts of the first group of enameled wires and the fourth group of enameled wires wound around the magnetic core are twisted together to form a first stranded wire, the respective parts of the second group of enameled wires and the third group of enameled wires wound around the magnetic core are twisted together to form a second stranded wire, and the first stranded wire and the second stranded wire are twisted together to form a total stranded wire. Through the combination and process design of the twisted wire, a better high-frequency characteristics to ensure effective transmission of high-frequency signals may be achieved. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a schematic diagram of magnetic module in accordance with the present invention and common mode choke coil connected with it; 
         FIG. 2  is a circuit schematic of magnetic module and the common mode choke coil connected to it in  FIG. 1 ; 
         FIG. 3  is a schematic diagram of the wire ends spreading out after the magnetic module is wound in  FIG. 1 ; 
         FIG. 4  is a schematic diagram of the first embodiment of the arrangement structure of the enameled wire of the magnetic module in accordance with the present invention; 
         FIG. 5  is a schematic diagram of the second embodiment of the arrangement structure of the enameled wire of the magnetic module in accordance with the present invention; and 
         FIG. 6  is a perspective view of an electrical connector including the magnetic module in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1-4 , the first embodiment of a magnetic module  100  in accordance with the present invention is shown. The magnetic module  100  is actually a transformer. The magnetic module  100  includes a toroid or magnetic core  1  and a plurality of enameled wires wound on the magnetic core  1 . The enameled wires are wound on the magnetic core  1  to form a primary coil  2  and a secondary coil  3 . 
     The magnetic core  1  has a circular ring shape with a central through hole or an oval shape with two through holes. Specifically, in this embodiment, the magnetic core  1  is a toroidal magnetic core  1  provided with a central through hole  11 . The primary coil  2  includes a first group of enameled wires  21  and a second group of enameled wires  22 . The first group of enameled wires  21  and the second group of enameled wires  22  respectively form the primary input end  211  and the primary output end  221  of the primary coil  2 , and a primary center tap  101  is formed between the primary input end  211  and the primary output end  221 . The secondary coil  3  includes a third group of enameled wires  33  and a fourth group of enameled wires  34 . The third group of enameled wires  33  and the fourth group of enameled wires  34  respectively form the secondary input end  331  and the secondary output end  341  of the secondary coil  3 , and form the secondary center tap  102 . The tail end of the second center tap  102  is immersed in tin and short-circuited. 
     The diameter of each enameled wire of the first group of enameled wires  21 , the second group of enameled wires  22 , the third group of enameled wires  33 , and the fourth group of enameled wires  34  ranges from AWG  42  to AWG  35 . Specifically, in this embodiment, the diameter of each enameled wire is AWG  40 . The respective parts of the first group of enameled wires  21  and the fourth group of enameled wires  34  wound around the magnetic core  1  are twisted together to form a first stranded wire  14 . The respective parts of the second group of enameled wires  22  and the third group of enameled wires  33  wound around the magnetic core  1  are twisted together to form a second stranded wire  23 . The first strand  14  and the second strand  23  are twisted together to form a total strand  50 . The total stranded wire  50  is wound around the magnetic core  1  in a manner that penetrates the central through hole  11  and exposes the end of each enameled wire. 
     In this embodiment, each of the first group of enameled wires  21  and the second group of enameled wires  22  has four enameled wires, and each of the third group of enameled wires  33  and the fourth group of enameled wires  34  has only one enameled wire. The range of the twisting degree of the first stranded wire  14 , the second stranded wire  23  and the total stranded wire  50  are all 0-35 strands per inch. Specifically, in this embodiment, the twisting degree of the first stranded wire  14 , the second stranded wire  23  and the total stranded wire  50  are all 10 strands per inch. 
     In another embodiment of the present invention, the first group of enameled wires  21  are twisted together and then twisted with the fourth group of enameled wires  34  to form a first stranded wire  14 . The second group of enameled wires  22  are twisted together and then twisted with the third group of enameled wires  33  to form a second stranded wire  23 . The range of the twisting degree of the first group of enameled wires  21 , the second group of enameled wires  22 , the first stranded wires  14 , the second stranded wires  23  and the total stranded wires  50  are all 0-35 twists/inch. Specifically, the twisting degree of the first group of enameled wires  21  and the second group of enameled wires  22  are both 10 stranded/inch, and the twisting degrees of the first stranded wires  14 , the second stranded wires  23  and the total stranded wires  50  are all 8 stranded/inch. The magnetic module  100  can support 6.25 Gbps signal transmission. 
     Each enameled wire has a first thread and a second thread. The first group of enameled wire  21  is natural. Each enameled wire in the first group of enameled wires  21  comprises a first thread N and a second thread n. The second group of enameled wire  22  is blue. Each enameled wire in the second group of enameled wires  22  comprises a first thread B and a second thread b. The third group of enameled wire  33  is red. Each enameled wire in the third group of enameled wires  33  comprises a first thread R and a second thread r. The fourth group of enameled wire  34  is green. Each enameled wire in the fourth group of enameled wires  34  comprises a first thread G and a second thread g. The color of the enameled wire is just for easy distinction, and other colors can also be used instead. 
     The first thread NNNN of the four enameled wires of the first group of enameled wires  21  collectively serves as the primary input end  211  of the primary coil  2  of the transformer. The second thread nnnn of the first group of enameled wires  21  and the first thread BBBB of the second group of enameled wires  22  together form the first center tap  101 . The second thread bbbb of the four enameled wires of the second group of enameled wires  22  are collectively used as the primary output end  221  of the primary coil  2  of the transformer. The first thread R of the enameled wire of the third group of enameled wires  33  is used as the secondary input end  331  of the transformer secondary coil  3 . The second thread g of the fourth group of enameled wire  34  is the secondary output end  341  of the transformer secondary coil  3 . The second thread r of the third group of enameled wires  33  and the first thread G of the fourth group of enameled wires  34  together form the second center tap  102 . The first center tap  101  is twisted into one bundle, and the second center tap  102  is twisted into another bundle. 
     The magnetic module  100  also includes a common mode choke  200 . The common mode choke coil  200  includes common mode core  201 . A natural enameled wire  40  is added and the natural enameled wire  40  includes the first thread N′ and the second thread n′. The natural wire  40  is twisted with the third group of enameled wires  33  and the fourth group of enameled wires  34  and then wound around the common mode core  201  to form windings RgN′ and rGn′. 
     Referring to  FIG. 5 , a schematic diagram of the second embodiment of the enameled wire arrangement of the magnetic module  100  in accordance with the present invention is shown. Compared with the previous embodiment, in this embodiment, each of the first group of enameled wires  21  and the second group of enameled wires  22  has five enameled wires, and each of the third group of enameled wires  33  and the fourth group of enameled wires  34  has only one enameled wire 
     Referring to  FIG. 6 , an electrical connector  600  in accordance with the present invention includes a housing  601 , an insulating body  602  housed in the housing  601 , and a magnetic module  100  housed in the housing  601 . The electrical connector  600  includes four magnetic modules  100 , and the electrical connector  600  can support 25 Gbps signal transmission. 
     The manufacturing method of the magnetic module  100  of the present invention includes the following steps: providing the magnetic core  1 ; providing a plurality of enameled wires; dividing the enameled wires into a first group of enameled wires  21 , a second group of enameled wires  22 , a third group of enameled wires  33 , and a fourth group of enameled wires  34 ; winding the first group of enameled wires  21  and the second group of enameled wires  22  around the magnetic core  1  to form a primary coil  2  and winding the third group of enameled wires  33  and the fourth group of enameled wires  34  around the magnetic core  1  to form a secondary coil  3 ; twisting the first group of enameled wires  21  and the fourth group of enameled wires  34  to form the first stranded wire  14 ; twisting the second group of enameled wires  22  and the third group of enameled wires  33  to form the second stranded wire  23 ; and twisting the first stranded wire  14  and the second stranded wire  23  to form a total stranded wire  50 . 
     During manufacturing the magnetic module  100 , the respective parts of the first group of enameled wires  21  wound around the magnetic core  1  may be twisted together, and then twisted with the fourth group of enameled wires  34  to form the first stranded wire  14 , and the respective parts of the third group of enameled wires  33  can be twisted together, and then twisted with the second group of enameled wires  22  to form a second stranded wire  23 . 
     In the present invention, the respective parts of the first group of enameled wires  21  and the fourth group of enameled wires  34  wound around the magnetic core  1  are twisted together to form a first stranded wire  14 . The respective parts of the second group of enameled wires  22  and the third group of enameled wires  33  wound around the magnetic core  1  are twisted together to form a second stranded wire  23 . The first strand  14  and the second strand  23  are twisted together to form a total strand  50 . The magnetic module of the present invention is designed through the special combination and process design of the twisted wire, and the multi-strand twisted wire makes it have lower impedance and higher inductance, so as to achieve better high-frequency characteristics, such as insertion loss, reflection loss, and crosstalk are smaller, especially the reflection loss is small, to meet the purpose of high-frequency signals.