Ethernet magnetics package wire terminations

• US 9,881,725 B2
• Filed: 11/21/2014
• Issued: 01/30/2018
• Est. Priority Date: 11/21/2014
• Status: Active Grant

• Current Assignee: Cisco Technology, Inc. (Cisco Systems, Inc.)
• Original Assignee: Cisco Technology, Inc. (Cisco Systems, Inc.)
• Inventors: Edwards, William Frank, Chau, Ki-Yuen, Tharp, Keith Frank, Curtis, George, Lin, Kayen
• Primary Examiner(s): Hinson, Ronald
• Application Number:
  US14/550,256
• Publication Number:
  US 20160148743A1
• Time in Patent Office: 1,166 Days
• Field of Search: 336192
• CPC Class Codes: H01F 17/062 Toroidal core with turns of coil around it
• CPC Class Codes: H01F 2017/0093 Common mode choke coil
• CPC Class Codes: H01F 2027/065 Mounting on printed circuit boards
• CPC Class Codes: H01F 27/04 Leading of conductors or axles through casings, e.g. for tap-changing arrangements
• CPC Class Codes: H01F 27/06 Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H01R 13/00 Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
• CPC Class Codes: H01R 13/719 specially adapted for high frequency, e.g. with filters
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 4/027 comprising means for positioning or holding the parts to be soldered or welded
• CPC Class Codes: H01R 43/01 for connecting unstripped conductors to contact members having insulation cutting edges
• CPC Class Codes: H01R 43/0221 Laser welding H01R43/0228 takes precedence
• CPC Class Codes: Y10T 29/49194 Assembling elongated conductors, e.g., splicing, etc.

Abstract

In one implementation, an apparatus is configured to aid in the manufacturing or assembling of electronic surface mount packages. The apparatus includes a common mode choke base configured to support a common mode choke. The apparatus includes terminal contacts coupled to the common mode choke base. The terminal contacts are aligned with wires connected to the common mode choke. The apparatus includes a support member including a wire supporting portion aligned with the wires connected to the common mode choke and a central portion configured to support the common mode choke base.

Claims

1. An apparatus comprising:

a common mode choke base configured to support a common mode choke;

a plurality of terminal contacts coupled to the common mode choke base, wherein the plurality of terminal contacts are each aligned with a wire connected to the common mode choke, and wherein at least one of the plurality of terminal contacts includes a top surface with an alignment portion, the alignment portion configured to align and support the wire on the top surface and further support a weld within, securing the wire to the at least one of the plurality of terminal contacts; and

a support member including a wire supporting portion aligned with the wires connected to the common mode choke and a central portion configured to support the common mode choke base.

2. The apparatus of claim 1, wherein the plurality of terminal contacts are configured to receive a wire form tool that presses the wires against the plurality of terminal contacts.

3. The apparatus of claim 1, further comprising:

a plurality of grooves on the common mode choke base to aid in alignment of the wires.

4. The apparatus of claim 1, wherein a portion of the at least one of the plurality of terminal contacts extends vertically from the common mode choke base, the top surface of the at least one of the plurality of terminal contacts extending continuously from a first side of the at least one of the plurality of terminal contacts to a second side of the at least one of the plurality of terminal contacts, and

wherein the alignment portion of the top surface is concave.

5. The apparatus of claim 1, wherein the at least one of the plurality of terminal contacts supports the wire with which the at least one of the plurality of terminal contacts is aligned during a termination process, and a weld resulting from the termination process extends past and overhangs an edge of the at least one of the plurality of terminal contacts.

6. The apparatus of claim 1, wherein the common mode choke base is configured to receive a push tongue that presses the wires against the common mode choke base.

7. The apparatus of claim 6, wherein the wire supporting portion includes a friction holder configured to frictionally hold the wires in place.

8. The apparatus of claim 7, wherein the friction holder includes a triangular cross section to guide the wires.

9. The apparatus of claim 7, wherein the friction holder includes an elastic portion and a rigid portion.

10. The apparatus of claim 9, further comprising:

an adjustable tensioner configured to move the elastic portion with respect to the rigid portion.

11. An apparatus comprising:

a plurality of terminal contacts coupled to a common mode choke, wherein the plurality of terminal contacts are aligned with wires connected to the common mode choke;

a support member including a wire supporting portion aligned with the wires connected to the common mode choke and a central portion configured to support a base of the common mode choke; and

an adjustable tensioner configured to move a comb of the wire supporting portion to frictionally hold the wires.

12. The apparatus of claim 11, wherein the plurality of terminal contacts are configured to receive a wire form tool that presses the wires against the plurality of terminal contacts.

13. The apparatus of claim 12, wherein the base of the common mode choke is configured to receive a push tongue that presses the wires against the base of the common mode choke.

14. A method comprising:

coupling a plurality of terminal contacts to a common mode choke, wherein the plurality of terminal contacts are aligned with wires connected to the common mode choke;

connecting a support member including a wire supporting portion aligned with the wires to the common mode choke and a central portion configured to support a base of the common mode choke; and

adjusting a tensioner to move a comb of the wire supporting portion to frictionally hold the wires.

15. The method of claim 14, further comprising:

receiving, by the plurality of terminal contacts, a wire form tool that presses the wires against the plurality of terminal contacts.

16. The method of claim 14, further comprising:

receiving, by the common mode choke, a push tongue that presses the wires against the base of the common mode choke.

17. The method of claim 14, further comprising:

receiving, by the plurality of terminal contacts within a concave portion, at least one of the wires.

18. The method of claim 14, further comprising:

supporting, by at least one of the plurality of terminal contacts, at least one of the wires during a termination process, wherein a top surface of the at least one of the plurality of terminal contacts results in a weld that extends past and overhangs an edge of the at least one of the plurality of terminal contacts.

19. The method of claim 14, wherein the wire supporting portion includes a friction holder frictionally holding the wires in place.

20. The method of claim 19, wherein the friction holder includes a triangular cross section to guide the wires.