Method and apparatus for terminating wire wound magnetic core

Patent metadata

Field	Value
Publication number	US-9385485-B2
Application number	US-201414570102-A
Country	US
Kind code	B2
Filing date	Dec 15, 2014
Priority date	Dec 13, 2013
Publication date	Jul 5, 2016
Grant date	Jul 5, 2016

Abstract

A modular jack has a magnetic assembly including insulative body, two rows of terminals retained to the insulative body, four transformers, and four common mode chokes. Each of the transformer and common mode choke includes a magnetic core and a plurality of conductive wires wound therearound. Each terminal has a recess for receiving an end portions of a corresponding wire and then the terminal is inserted into a through-hole of an internal printed circuit board for dip soldering. Guiding of the wire to the recess can be automated in contrast to manual winding operation.

First claim

What is claimed is:

1. An electrical connector comprising:
a magnetic assembly having:
an insulative body having a front wall, a rear wall, two oppositely facing side walls between the front wall and the rear wall, and a receiving slot surrounded by said walls;
a plurality of contacts each having a first retention portion retained in the front wall and a first connecting portion extending outwardly along the front wall;
a plurality of leads each having a second retention section retained in the rear wall and a second connecting portion extending outwardly along the rear wall;
a plurality of signal conditioning components each having a magnetic core and a plurality of conductive wires wound around the core, the magnetic cores received within the receiving slot, the conductive wires including a plurality of first distal portions connecting to the first connecting portions and a plurality of second distal portions connecting to the second connecting portions; and
a printed circuit board (PCB) defining a plurality of conductive apertures for the first and second connecting portions to insert through; wherein

each of the first and second connecting portions defines a recess to receive a corresponding one of the first and second distal portions of the conductive wires, the distal portions of the conductive wires extend across the conductive apertures, and the distal portions are soldered to corresponding connecting portions;
the PCB is disposed above the insulative body and disposed horizontally along a front-to-back direction;
said first and second connecting portions extend upwardly beyond the PCB, said recess of the connecting portion located on a top thereof; and
said recesses of the first and second connecting portions are recessed downwardly.

2. The electrical connector as claimed in claim 1 , wherein the insulative body has a set of middle walls within the receiving slot to divide the receiving slot into a plurality of container chambers, each container chamber receiving one transformer and one common mode choke.

3. A method of manufacturing an electrical connector, comprising the steps of:
providing a carrier, the carrier including an insulative body having a front wall and a rear wall with a receiving slot between the front and rear walls, a plurality of contacts retained on the front wall, and a plurality of leads retained on the rear wall, each of the contacts and the leads defining a recess;
providing a plurality of conditioning components each having a magnetic core and a plurality of conductive wires wound therearound;
disposing the magnetic cores into the receiving slot, routing first distal portions of the conductive wires across the recesses of the contacts, and routing second distal portions of the conductive wires across the recesses of the leads;
providing a printed circuit board (PCB) defining a plurality of conductive vias, and mounting the PCB to the contacts and leads so as to insert the distal portions of the conductive wires received in the recesses across corresponding vias from a side of the PCB to the other opposite side of the PCB; and
dipping the recesses of the contacts and the leads into a solder pool to solder and retain the distal portions to the contacts and the leads.

4. The method as claimed in claim 3 , further comprising a step of cutting excessive free ends of the distal portions.

5. The method as claimed in claim 3 , wherein the step of dipping comprises forming conductive pads onto the conductive apertures for electrically connecting the contacts and the leads with the PCB.

6. The method as claimed in claim 3 , wherein the step of mounting the PCB comprises disposing the PCB above the insulative body and horizontally along a front-to-back direction.

7. The method as claimed in claim 6 , wherein the step of providing the carrier comprises retaining each contact in the front wall and extending a first connecting portion of the contact upwardly from the front wall, retaining each lead in the rear wall and extending a second connecting portion of the lead upwardly from the rear wall, and disposing said recesses on top free ends of the connecting portions.

8. The method as claimed in claim 7 , wherein said first and second connecting portions extend upwardly beyond the PCB.

9. The method as claimed in claim 8 , wherein said recesses of the first and second connecting portions are recessed downwardly.

10. The method as claimed in claim 4 , wherein said magnetic assembly is mounted to an insulative housing to be a RJ45.

11. The method as claimed in claim 4 , wherein said magnetic assembly is functioned as a Lan transformer mounted to an exterior mother PCB or an inner PCB of a RJ45.

12. An electrical connector comprising:
an insulative housing defining a mating cavity forwardly communicating with an exterior in a front-to-back direction;
a magnetic assembly assembled into the housing and including:
an insulative body with therein a receiving slot located behind a connecting face to communicate with the exterior in a vertical direction perpendicular to said front-to-back direction;
a plurality of contacts forming corresponding mating sections extending into the mating cavity and corresponding connecting sections exposed around the connecting face;
a plurality of signal conditioning components disposed in the receiving slot, each of said signal conditioning components including a magnetic core and a plurality of conductive wires wound thereon, each of said wires including at least one end mechanically and electrically connected to the connecting section of the corresponding contact; and
an inner printed circuit board positioned upon the connecting face to veil the receiving slot and defining a plurality of through holes therein; wherein
the connecting section defines a recess, in which said end of the wire is snugly received, and extends through the corresponding through hole, and a secured fixation between the wire and the connecting section, and that between the connecting section and the inner printed circuit board are both implemented via only one dip-soldering process.

13. The electrical connector as claimed in claim 12 , further including a plurality of footer pins each including a corresponding recess around the connecting face to receive the other end of the corresponding wire and extending through the corresponding hole so as to have a secured fixation between the wire and the footer pin and that between the footer pin and the printed circuit board are both implemented via only one dip-soldering process.

14. The electrical connector as claimed in claim 12 , wherein the footer pins and the contacts are located by two opposite sides of the insulative body, respectively.

15. The electrical connector as claimed in claim 12 , wherein said magnetic core has a donut-like shape.

16. The electrical connector as claimed in claim 12 , wherein said signal conditioning components directly face the printed circuit board in said vertical direction.

17. The electrical connector as claimed in claim 12 , wherein each of said footer pins extend beyond a mounting face of the insulative body opposite to said connecting face in the vertical direction for mounting to a main body.

Assignees

• Foxconn Interconnect Technology Ltd

Inventors

• Hsu Chih-Ching
• Xu Yong-Chun
• Tang zhi-hui

Classifications

• H01R13/6461

  Means for preventing cross-talk · CPC title

• H01R24/64

  for high frequency, e.g. RJ 45 · CPC title

• H01R9/2608 Primary

  Fastening means for mounting on support rail or strip (H01R9/2691 takes precedence; for switch or other electrical device H02B1/042) · CPC title

• H01R13/02

  Contact members · CPC title

• H01R13/6633

  with inductive component, e.g. transformer · CPC title