Electrical isolation device capable of limiting magnetic saturation even upon receipt of high power D.C. bias and, method for making the same and connector incorporating the same
View Patent ↗An electrical device is produced by winding wires around a core. The device may be used as a transformer. Wires are inserted into, through and around a first hole and a first side of a core a desired number of times. Thereafter, the wires are extended along either a top or a bottom of the core and then passed through and around a second hole of the core. After the wires are wound around the second hole of the core and a second side of the core, the production of the device is complete.
1. An electrical isolation device comprising:
a core having a top surface, a bottom surface, first and second exterior sides spaced from each other and first and second elongate holes formed therethrough, said first and second holes being spaced from each other and having respective longitudinal axes extending substantially parallel to each other, said top and bottom core surfaces situated in planes which are substantially parallel to said longitudinal axes of said elongate holes; and
at least two pairs of wires, each of which is inserted through said first hole in said core, wrapped around said first side of said core, extended over said top or said bottom of said core, inserted through said second hole in said core and wrapped around said second side of said core.
2. A method for producing an electrical isolation device including a core having first and second elongate holes formed therethrough having respective longitudinal axes extending substantially parallel to each other, and at least one first wire pair and at least one second wire pair, comprising the steps of:
inserting said at least one first wire pair and said at least one second wire pair through said first elongate hole in said core,
wrapping said first and second wire pairs around a first exterior side of said core,
extending said first and second wire pairs over a top surface or a bottom surface of said core, said top and bottom core surfaces situated in planes which are substantially parallel to said longitudinal axes of said elongate holes,
inserting said first and second wire pairs through said second elongate hole in said core which is spaced from said first hole, and
wrapping said first and second wire pairs around a second exterior side of said core which is spaced from said first side of said core.
3. A connector comprising:
a set of contacts structured and arranged to engage the contacts of a mating connector;
a set of terminals; and
a circuit electrically coupling said contacts and said terminals to each other, said circuit including an electrical isolation device having,
a core having a top surface, a bottom surface, first and second exterior sides spaced from each other and first and second elongate holes formed therethrough, said first and second holes being spaced from each other and having respective longitudinal axes extending substantially parallel to each other, said top and bottom core surfaces situated in planes which are substantially parallel to said longitudinal axes of said elongate holes, and
at least two wire pairs, each of which is inserted through said first hole in said core, wrapped around said first side of said core, extended over said top or said bottom of said core, inserted through said second hole in said core and wrapped around said second side of the core which is spaced from said first side and said core.
4. A connector as recited in claim 3 wherein said connector is a modular connector.
5. A connector as recited in claim 4 wherein said connector is an RJ45 modular connector.
6. A connector as recited in claim 3 wherein said at least two wire pairs include at least one first wire pair and at least one second wire pair, and wherein said at least one first wire pair is electrically coupled to said connector contacts and said at least one second wire pair is electrically coupled to said connector terminals.
7. A connector as recited in claim 6 wherein said core and said wires constitute a transformer and wherein a first one of said at least two pairs of wires comprises a pair of first wires and another one of said at least two pairs of wires comprises a pair of second wires, and wherein said pair of first wires constitutes a first winding of the transformer and said pair of second wires constitutes a second winding of the transformer.
8. An electrical assembly comprising:
an electrical isolation device including,
a core having a top surface, a bottom surface, first and second exterior sides spaced from each other and first and second elongate holes formed therethrough, said first and second holes being spaced from each other and having respective longitudinal axes extending substantially parallel to each other, said top and bottom core surfaces situated in planes which are substantially parallel to said longitudinal axes of said elongate holes; and
at least two pairs of wires, each pair of wires inserted through said first hole in said core, wrapped around said first side of said core, extended over said top or said bottom surface of said core, inserted through said second hole in said core and wrapped around said second side of said core; and
a common mode choke coupled to said electrical isolation device including,
a choke core; and wherein
one pair of said at least two pairs of wires are wound around said choke core.
9. An electrical device as recited in claim 8 wherein said choke coil has a toroidal shape.
10. A connector comprising:
a set of contacts structured and arranged to engage the contacts of a mating connector;
a set of terminals; and
a circuit electrically coupling said contacts and said terminals to each other, said circuit including,
an electrical isolation device including,
core having a top surface, a bottom surface, first and second exterior sides spaced from each other and first and second elongate holes formed therethrough, said first and second holes being spaced from each other and having respective longitudinal axes extending substantially parallel to each other, said top and bottom core surfaces situated in planes which are substantially parallel to said longitudinal axes of said elongate holes; and
at least a pair two pairs of wires, each pair of wires inserted through said first hole in said core, wrapped around said first side of said core, extended over said top or said bottom surface of said core, inserted through said second hole in said core and wrapped around said second side of said core; and
a common mode choke coupled to said electrical isolation device including,
a choke core; and wherein
one pair of said at least two pairs of wires are wound around said choke core.
11. A connector as recited in claim 10 wherein said core and said wires constitute a transformer and wherein one of said two pairs of wire constitutes a first winding of the transformer and the other of said two pairs of wires constitutes a second winding of the transformer.
12. A connector as recited in claim 10 wherein said connector is a modular connector.
13. A connector as recited in claim 12 wherein said connector is an RJ45 modular connector.
14. A connector as recited in claim 10 wherein said contacts are electrically coupled to one of said pair of wires and said terminals are coupled to said pair of wires wound around said choke core.
15. A connector as recited in claim 14 wherein said isolation device comprises a transformer, and wherein one of said at least two pairs of wires constitute a first winding of the transformer and a second one of said two pairs of wires constitute a second winding of the transformer.