Compact encapsulated filter assembly for printed circuit boards and method of manufacture thereof

Claim 1

A filter assembly of the type having a single filter sleeve for providing RFI/EMI filtering on a printed circuit board, comprising three legs disposed substantially parallel to each other and including a first outer leg, a second outer leg, the first and second outer legs being joined by a bight portion, and a central leg disposed between the first and second outer legs, wherein the outer legs comprise the respective conductors of the filter assembly, and wherein the central leg comprises a ground pin of the filter assembly; a substantially cylindrical filter sleeve received over and mechanically secured and electrically engaged with one of the outer legs, such that the filter sleeve is disposed substantially parallel to the legs of the filter assembly and has an outer side surface closely adjacent a side surface of said central leg, said outer side surface being electrically engaged with said central leg by means of conductive joining material, and insulating material encapsulating the filter sleeve, bight portion and respective portions of the legs, whereby the spacing between the outer and central leg is minimized and the filter assembly is substantially compact.

Claim 5

The method of making a strip of respective filter assemblies, comprising the steps of: providing a ribbon of metal, blanking out the ribbon to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, such that the filter sleeve is substantially parallel to the respective legs, securing the filter sleeve in mechanical and electrical engagement with the one outer leg and with the central ground leg, respectively, and encapsulating the filter sleeve, bight portion, and respective portions of the legs with an insulating means.

Claim 6

The method of making a strip of respective filter assemblies, comprising the steps of: providing a ribbon of metal, blanking out the ribbon to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, such that the filter sleeve is substantially parallel to the respective legs, securing the filter sleeve in mechanical and electrical engagement with the one outer leg and with the central ground leg, respectively, and encapsulating the filter sleeve, bight portion, and respective portions of the legs with an insulating means.

Claim 10

The method of making a strip of respective filter assemblies, each of which may be cut off as desired, comprising the steps of: providing a continuous wire and bending the wire to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a first bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, and securing the filter sleeve to the one outer leg and to the central ground leg, respectively, in mechanical and electrical engagement therewith, and encapsulating the filter sleeve, first bight portion, and respective portions of the legs.

Claim 11

The method of making a strip of respective filter assemblies, each of which may be cut off as desired, comprising the steps of: providing a continuous wire and bending the wire to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a first bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, and securing the filter sleeve to the one outer leg and to the central ground leg, respectively, in mechanical and electrical engagement therewith, and encapsulating the filter sleeve, first bight portion, and respective portions of the legs.

Claim 15

The method of making a strip of respective filter assemblies, each of which may be cut off as desired, comprising the steps of: providing a continuous wire and bending the wire to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a first bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, bending the ground leg to provide an offset tang thereon, further bending the wire to form a second bight portion, providing a carrier strip and joining the carrier strip between the respective bight portions of the filter assembly segments, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, soldering the filter sleeve to the one outer leg and to the offset tang on the ground leg, respectively, in mechanical and electrical engagement therewith, and encapsulating the filter sleeve, first bight portion, and respective portions of the legs.

Claim 16

The method of making a strip of respective filter assemblies, each of which may be cut off as desired, comprising the steps of: providing a continuous wire and bending the wire to form a plurality of respective spaced-apart filter assembly segments, wherein each segment includes a pair of substantially-parallel outer legs, a first bight portion connecting the respective outer legs, such that the respective outer legs comprise the conductors of the filter assembly, and a central ground leg disposed between the respective outer legs and substantially parallel thereto, bending the ground leg to provide an offset tang thereon, further bending the wire to form a second bight portion, providing a carrier strip and joining the carrier strip between the respective bight portions of the filter assembly segments, providing a filter sleeve and slidably receiving the filter sleeve over one of the outer legs to a position substantially adjacent to the bight portion, soldering the filter sleeve to the one outer leg and to the offset tang on the ground leg, respectively, in mechanical and electrical engagement therewith, and encapsulating the filter sleeve, first bight portion, and respective portions of the legs.