Patent Application
20220384971
The subject matter herein relates generally to electrical devices.
Various types of electrical devices may include circuit boards that are electrically coupled to differential pairs of signal conductors or, more specifically, pairs of signal conductors that transmit differential signals. The signal conductor(s) are surrounded by a shield layer that, in turn, is surrounded by a cable jacket. At an end of the communication cable, the cable jacket, the shield layer, and insulation that covers the signal conductor(s) may be removed (e.g., stripped) to expose the signal conductor(s). The exposed portions of the conductor(s) may then be mechanically and electrically coupled (e.g., soldered) to contacts or a circuit card of an electrical device. However, signal integrity of the signal conductors is diminished at the transition area between the cable core and the circuit card.
Accordingly, there is a need for an electrical device that provides simple and reliable shielding at the termination between the signal conductors and the circuit card.
In one embodiment, a cable shield tunnel is provided for an electrical device that includes a ground bus and a floor shim configured to be coupled to a circuit card. The ground bus and the floor shim form a cable tunnel configured to receive an end of a cable. The ground bus includes an end wall extending along a first end of the cable tunnel, a first side wall extending from the end wall along a first side of the cable tunnel, and a second side wall extending from the end wall along a second side of the cable tunnel opposite the first side. The first and second side walls are configured to be coupled to the circuit card. The floor shim is discrete from the ground bus. The floor shim is separately coupled to the circuit card. The floor shim is provided at a second end of the cable tunnel opposite the first end. The floor shim is configured to be positioned between the cable and the circuit card.
In another embodiment, an electrical device is provided including a circuit card having cable contacts along a mounting surface at a cable end and a cable terminated to the mounting surface of the circuit card at the cable end. The cable has an inner signal conductor terminated to the corresponding cable contact and an outer conductor providing electrical shielding for the inner signal conductor. A cable shield tunnel is coupled to the circuit card at the mounting surface. The cable shield tunnel includes a ground bus and a floor shim coupled to a circuit card. The ground bus and the floor shim form a cable tunnel receive the end of the cable. The ground bus includes an end wall extending along a first end of the cable tunnel, a first side wall extending from the end wall along a first side of the cable tunnel, and a second side wall extending from the end wall along a second side of the cable tunnel opposite the first side. The first and second side walls are configured to be coupled to the circuit card. the floor shim is discrete from the ground bus. The floor shim is separately coupled to the circuit card. The floor shim is provided at a second end of the cable tunnel opposite the first end. The floor shim is configured to be positioned between the cable and the circuit card.
In a further embodiment, an electrical device is provided including a circuit card having cable contacts along a mounting surface at a cable end and a cable terminated to the mounting surface of the circuit card at the cable end. The cable has an inner signal conductor terminated to the corresponding cable contact and an outer conductor providing electrical shielding for the inner signal conductor. The end of the cable has a cable height. A cable shield tunnel is coupled to the circuit card at the mounting surface. The cable shield tunnel includes a ground bus and a floor shim coupled to a circuit card. The ground bus and the floor shim form a cable tunnel receive the end of the cable. The ground bus includes an end wall extending along a first end of the cable tunnel, a first side wall extending from the end wall along a first side of the cable tunnel, and a second side wall extending from the end wall along a second side of the cable tunnel opposite the first side. The first and second side walls are configured to be coupled to the circuit card. the floor shim is discrete from the ground bus. The floor shim is separately coupled to the circuit card. The floor shim is provided at a second end of the cable tunnel opposite the first end. The floor shim is configured to be positioned between the cable and the circuit card. The floor shim has a thickness selected based on the tunnel height and the cable height.
Embodiments described herein include electrical devices (e.g., electrical connectors, circuit board assemblies, and the like) that have a circuit board and cables terminated to the circuit board. The cables may have differential pairs of signal conductors and an outer conductor or shield layer providing shielding for the signal conductors. A cable jacket surrounds the shield layer and has an access opening that exposes the shield layer for electrical connection to a ground bus, which provides electrical shielding for the signal conductors at the end of the cable. Embodiments described herein include a floor shim that provides electrical shielding for the cable. The floor shim positions the cable relative to the ground bus to improve electrical performance. For example, the floor shim may be designed for impedance control of the signal conductors at the end of the cable.
The electrical device 100 has a mating end 104 and a cable end 106 opposite the mating end 104. The mating end 104 is configured to be plugged into a mating electrical device, such as a receptacle (not shown) of a communication system. The cable 110 extends from the cable end 106. The cable 110 has an insulative jacket 112 that surrounds one or more differential pairs of signal conductors and a shield layer. The insulative jacket 112 provides strain resistance and protection from the surrounding environment for the communication cable 110. The jacket 112 may include, for example, polyvinyl chloride (PVC), aluminized Polyethylene Terephthalate (PET), and/or shield tape.
The electrical device 100 includes a device housing 114 that has a housing cavity 116 that receives the circuit card 102. The cable 110 extends into the housing cavity 116. The circuit card 102 has electrical contacts 124 located at a mating edge 128 of the circuit card 102. In an exemplary embodiment, the mating edge 128 is configured to mate with a mating electrical connector (not shown) of the receptacle and establish a communicative connection through the electrical contacts 124. The electrical contacts 124 may be communicatively coupled to the signal conductors of the cable 110.
The circuit card 102 has a cable end 142, a mating end 144, and side edges 146, 148 extending between the cable end 142 and the mating end 144. The circuit card 102 includes an upper surface 150 and a lower surface 152. In an exemplary embodiment, the cables 110 are terminated to the circuit card 102 at the cable end 142 at both the upper surface 150 and the lower surface 152. However, the cables 110 may be terminated to only the upper surface 150 or the lower surface 152. The circuit card 102 may include a number of dielectric layers (e.g., FR-4 layers), traces, vias, and ground planes. The circuit card 102 includes mating contacts 154 at the mating end 144 for mating with the mating electrical connector. For example, the mating end 144 may be plugged into a card slot of the mating electrical connector. The circuit card 102 includes cable contacts 156 rearward of the mating contacts 154 (such as closer to the cable end 142). Optionally, the cable contacts 156 may be located closer to the cable end 142 than the mating end 144. The signal conductors of the cables 110 are terminated to corresponding cable contacts 156. In the illustrated embodiment, the contacts 154, 156 are contact pads and may include signal and ground contacts. The contacts 154, 156 may be communicatively coupled to one another through the circuit card 102. For example, the traces (not shown) of the circuit card 102 may communicatively couple the contacts 154, 156.
In the illustrated embodiment, the cables 110 are terminated to the circuit card 102 at the cable end 142. For example, eight cables 110 may be connected at the upper surface 150 (for example, in two rows) and eight cables 110 may be connected to the lower surface 152. In some embodiments, the cables 110 may be characterized as twin-axial or parallel-pair cables. In parallel-pair configurations, the cables 110 include differential pairs of signal conductors 160, 162 held by an insulator 164. An outer conductor 166, or shield layer, surrounds the insulator along the length of the cable 110 to provide electrical shielding for the signal conductors 160, 162. The outer conductor may be a braided shield, a foil wrap, or another type of shield layer. The jacket 112 of the cable 110 surrounds the outer conductor 166 to protect the outer conductor 166. The signal conductors 160, 162 of a single differential pair extend parallel to each other through the length of the cable 110. The external jacket 112, the outer conductor 166 and the insulator 164 are stripped at an end 168 of the cable 110. The signal conductors 160, 162 extend forward of the end of the insulator 164 and the outer conductor 166 at the end 168 of the cable 110. The exposed ends of the signal conductors 160, 162 are configured to be terminated to the cable contacts 156, such as by soldering to the cable contacts 156. In alternative embodiments, the signal conductors 160, 162 within the cable 110 may form a twisted pair of signal conductors. In other various embodiments, the communication cable 110 may be a single-ended cable having a single central conductor rather than the pair of signal conductors.
Each cable shield tunnel 200 includes a ground bus 202 and a floor shim 204, both of which are configured to be coupled to the circuit card 102. The ground bus 202 and the floor shim 204 form a cable tunnel 206 configured to receive the end 168 of the cable 110. The cable shield tunnel 200 is electrically connected to the circuit card 102 and is electrically connected to the outer conductor 166. For example, the cable shield tunnel 200 may be soldered to the circuit card 102 and soldered to the outer conductor 166.
In an exemplary embodiment, the cable shield tunnel 200 surrounds the cable 110 on all four sides (for example, top, bottom, right, left). In an exemplary embodiment, the cable shield tunnel 200 is provided at the end 168 of the cable 110 and at the termination to the circuit card 102. For example, the cable shield tunnel 200 extends both forward of and rearward of the end 168. The cable shield tunnel 200 extends along portions of both the exposed ends of the signal conductors 160, 162 and extends along a portion of the outer conductor 166. The cable shield tunnel 200 provides electrical shielding for the exposed portions of the signal conductors 160, 162 as the signal conductors 160, 162 transition from the end of the insulator 164 to the cable contacts 156.
The ground bus 202 (also shown in further detail in
The floor shim 204 (also shown in further detail in
The floor shim 204 includes a plate 250 having a base portion 252 and extensions 254 extending forward of the base portion 252. The base portion 252 electrically connects each of the extensions 254. Each extension 254 is configured to support a corresponding cable 110. In the illustrated embodiment, the extensions 254 have different lengths such that distal ends 256 of the extensions 254 are provided at different forward positions. For example, the distal ends 256 may be arranged in two rows, such as a forward row and a rearward row. In an exemplary embodiment, the floor shim 204 is generally planar. The floor shim 204 is configured to be electrically connected to the circuit card 102. For example, the floor shim 204 may be soldered corresponding circuits of the circuit card 102. For example, the floor shim 204 may be soldered to a ground plane of the circuit card 102. The floor shim 204 may be soldered to ground contact pads of the circuit card 102. The floor shim 204 may be mechanically and electrically connected to the circuit card 102 by other processes in alternative embodiments, such as being press-fit into plated vias of the circuit card 102 using press-fit pins extending from the plate 250.
The cables 110 are prepared by stripping the insulator 164, the outer conductor 166, and the outer jacket 112 from the end 168 of the cable 110. In an exemplary embodiment, a portion of the outer jacket 112 is removed to form a window 170 that exposes a length of the outer conductor 166 for electrical connection with the solder tab 214. For example, the window 170 may be provided at the top of the cable 110 for connection with the solder tab 214. The signal conductors 160, 162 extend forward of the end 168 of the cable 110. The exposed portions of the signal conductors 160, 162 may be soldered to the circuit card 102.
With additional reference to
In an exemplary embodiment, the side walls 220, 230 (
In an exemplary embodiment, the floor shim 204 is positioned rearward of the end 168 of the cable 110. The floor shim 204 extends along a length of the cable 110. The floor shim 204 is located between the cable 110 and the circuit card 102. The floor shim 204 elevates the cable 110 at a position or height above the surface of the circuit card 102. The thickness of the floor shim 204 controls the elevated position of the cable 110. In an exemplary embodiment, the floor shim 204 extends forward of the end 168 of the cable 110. For example, the floor shim 204 may extend along portions of the exposed signal conductors 160, 162 to provide shielding between the exposed signal conductors 160, 162 and the circuit card 102. The positioning of the floor shim 204 relative to the exposed signal conductors 160, 162 affects signal integrity, such as by lowering impedance of the signal transmission lines. Optionally, the floor shim 204 may extend into the space between the side walls 220, 230. The floor shim 204 may contact and thus electrically connect to the ground bus 202. Optionally, the floor shim 204 may engage the side walls 220, 230 by an interference fit or by using commoning features, such as slots, tabs, pins, and the like. The floor shim 204 may be soldered to the side walls 220, 230.
The floor shim 204 has a thickness 280 shown, for example, in
The raised section 290 positions the floor shim 204 closer to the signal conductors 160, 162, thus affecting the electrical characteristics of the system. For example, positioning the raised section 290 of the floor shim 204 closer to the signal conductors 160, 162 lowers impedance of the signal transmission lines as the signal conductors 160, 162 transition from the cable core to the circuit card 102.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
