Patent Grant
8007308
The present invention relates to high speed electrical connectors. In particular, the present invention relates to electrical connectors that provide high signal line density while also providing shielded controlled impedance (SCI) for the signal lines.
Interconnection of integrated circuits to other circuit boards, cables or electronic devices is known in the art. Such interconnections typically have not been difficult to form, especially when the signal line densities have been relatively low, and when the circuit switching speeds (also referred to as edge rates or signal rise times) have been slow when compared to the length of time required for a signal to propagate through a conductor in the interconnect or in the printed circuit board. As user requirements grow more demanding with respect to both interconnect sizes and circuit switching speeds, the design and manufacture of interconnects that can perform satisfactorily in terms of both physical size and electrical performance have grown more difficult.
Connectors have been developed to provide the necessary impedance control for high speed circuits, i.e., circuits with a transmission frequency of at least 5 GHz. Although many of these connectors are useful, there is still a need in the art for connector designs having increased signal line densities with closely controlled electrical characteristics to achieve satisfactory control of the signal integrity.
In one aspect, the present invention provides an electrical connector assembly having a carrier and a plurality of terminated cable assemblies retained by the carrier. The carrier includes a plurality of first alignment elements and each terminated cable assembly includes one or more second alignment elements. The first and second alignment elements are configured to cooperatively align the plurality of terminated cable assemblies in the carrier.
In another aspect, the present invention provides an electrical connector suitable for insertion into a carrier. The electrical connector includes an electrical cable, one or more electrical contacts, an insulator, an electrically conductive shield element, and at least one second alignment element. The electrical cable includes one or more conductors and a ground shield surrounding the one or more conductors. The insulator is disposed around the one or more electrical contacts, which are connected to the one or more conductors. The electrically conductive shield element is disposed around the insulator and connected to the ground shield. The at least one second alignment element is configured to cooperate with at least one first alignment element of the carrier to align the electrical connector in the carrier.
In another aspect, the present invention provides a carrier including a plurality of first alignment elements. The first alignment elements are configured to cooperate with a plurality of second alignment elements of a plurality of mating terminated cable assemblies to align the plurality of terminated cable assemblies in the carrier.
In another aspect, the present invention provides an electrical connector system having a carrier, a plurality of terminated cable assemblies retained by the carrier, and a header configured to mate with the carrier. The carrier includes a plurality of first alignment elements and the plurality of terminated cable assemblies includes a plurality of second alignment elements. The first and second alignment elements are configured to cooperatively align the plurality of terminated cable assemblies in the carrier.
The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and detailed description that follow below more particularly exemplify illustrative embodiments.
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof. The accompanying drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the invention is defined by the appended claims.
Exemplary embodiments of electrical connector assemblies are described and illustrated herein as used with a single type of electrical cable 8. However, these and other exemplary embodiments may have other types of electrical cables 8 having signal, power, and/or ground elements. Electrical cables 8 may be, but are not limited to, single wire cables (e.g., single coaxial cables and single twinaxial cables) and multi-wire cables (e.g., multiple coaxial cables, multiple twinaxial cables, and twisted pair cables). Further, different types and configurations of electrical cables 8 and electrical cable terminations 10 may be used simultaneously with the electrical connector assemblies. For example, a portion of electrical cables 8 and electrical cable terminations 10 retained by carrier 4 may be coaxial cables and terminations, while another portion of electrical cables 8 and electrical cable terminations 10 retained by carrier 4 may be twinaxial (or other) cables and terminations.
In one aspect, some elements of electrical connector assembly 2 may be constructed in a manner the same as or similar to what is taught in U.S. Patent Application Publication No. 2007-0197095 A1, published Aug. 23, 2007.
Electrical cable termination 10 includes a longitudinal electrically conductive shield element 32, an insulator 34, and a single electrical contact 30. Electrically conductive shield element 32 has a front end 36, a back end 38, and side surfaces 40a-40d (collectively referred to herein as “sides 40”) defining a non-circular transverse cross-section. Although the illustrated embodiment includes four sides 40 defining a substantially square transverse cross-section, shield element 32 may have other numbers of sides defining other generally rectangular or non-circular transverse cross-sections. In other embodiments, shield element 32 may have a generally curvilinear (such as, e.g., a circular) transverse cross-section.
As illustrated, shield element 32 includes laterally protruding resilient ground contact beams 42 disposed on opposed side surfaces 40a and 40c. In other embodiments, shield element 32 includes only a single ground contact beam 42.
A latch member 44 extends from at least one of sides 40. The latch member is configured to retain electrical cable termination 10 in a retainer or organizer plate (not shown) configured to receive, secure, and manage a plurality of electrical cable terminations. In one embodiment, latch member 44 is designed to yield (i.e., deform) at a lower force than required to break the attached electrical cable 8, so that an electrical cable termination 10 can be pulled out of the retainer or organizer plate for the purpose of replacing or repairing an individual electrical cable termination and cable assembly. In the illustrated embodiment of
Shield element 32 includes carrier rib receiving apertures 45 positioned in opposed side surfaces 40b and 40d and configured to receive at least a portion of a carrier rib 26 of carrier 4. Shield element 32 may include a single carrier rib receiving aperture 45, or it may include two or more carrier rib receiving apertures 45 having a different size, shape, and/or non-symmetric placement on shield element 32, whereby carrier ribs 26 may be configured to cooperate with the two or more carrier rib receiving apertures 45 to ensure that electrical cable termination 10 is inserted into carrier 4 in the correct predetermined orientation.
Shield element 32 may further include a keying member, in the form of tab 46, laterally extending from back end 38 of shield element 32. Tab 46 is configured to ensure that electrical cable termination 10 is inserted into the retainer or organizer plate in the correct predetermined orientation. If electrical cable termination 10 is not properly oriented within the retainer or organizer plate, electrical cable termination 10 cannot be fully inserted. In one embodiment, tab 46 is deformable (such as by the use of a tool or the application of excess force in the insertion direction) and may be straightened to allow a damaged or defective electrical cable termination 10 to be pushed completely through the retainer or organizer plate, such that the damaged or defective components can be replaced or repaired.
Although the figures show that shield element 32 includes ground contact beams 42, it is within the scope of the present invention to use other contact element configurations, such as Hertzian bumps, in place of contact beams 42.
Insulator 34 has a front end 48, a back end 50, and outer surfaces 52a-52d (collectively referred to herein as “outer surface 52”) defining a non-circular shape. Although the illustrated embodiment includes an outer surface 52 defining a substantially square shape, insulator 34 may have an outer surface 52 defining other suitable shapes, including generally rectangular, non-circular, or curvilinear (such as, e.g., circular) shapes.
In the exemplary embodiment of
In the exemplary embodiment of
In another embodiment, one or more spacer bars 58 are shaped to receive two electrical contacts 30 and are configured for slidable insertion into shield element 32, such that two electrical contacts 30 lie substantially parallel to a longitudinal axis of shield element 32. One or more spacer bars 58 are configured to guide two electrical contacts 30 during their insertion into insulator 34. In this configuration, electrical cable termination 10 can serve as a twinaxial cable termination, whereby two electrical contacts 30 can be connected, e.g., to a single twinaxial cable.
In other embodiments, insulator 34 may include two or more mating insulator parts (not shown). Each insulator part may be separately formed or may be integrally hinged in a clamshell fashion to facilitate injection molding or machining and to provide an ease of assembly of one or more electrical contacts 30. The two or more mating insulator parts can be assembled using any suitable method/structure, including but not limited to snap fit, friction fit, press fit, mechanical clamping, and adhesive. In one exemplary embodiment, insulator 34 may include two mating insulator parts, each insulator part extending longitudinally along the length of one or more electrical contacts 30. In another exemplary embodiment, insulator 34 may include two mating insulator parts, each insulator part, which may be hermaphroditic, encompassing substantially one-half the length of one or more electrical contacts 30.
In the embodiment illustrated in
In one embodiment, electrical cable termination 10 is configured for termination of an electrical cable 8, such that a conductor 64 of electrical cable 8 is attached to electrical contact 30 and ground shield 68 of electrical cable 8 is attached to shield element 32 of electrical cable termination 10 using conventional means, such as soldering. The type of electrical cable used in an aspect of the present invention can be a single wire cable (e.g., single coaxial or single twinaxial) or a multiple wire cable (e.g., multiple coaxial, multiple twinaxial, or twisted pair). In one embodiment, prior to attaching one or more electrical contacts 30 to one or more conductors 64 of electrical cable 8, ground shield 68 is stiffened by a solder dip process. After one or more electrical contacts 30 are attached to one or more conductors 64, the one or more electrical contacts 30 are slidably inserted into insulator 34. The prepared end of electrical cable 8 and insulator 34 are configured such that the stiffened ground shield 68 bears against back end 50 of insulator 34 prior to one or more electrical contacts 30 being fully seated against front end 48 of insulator 34. Thus, when insulator 34 (having one or more electrical contacts 30 therein) is next slidably inserted into shield element 32, the stiffened ground shield 68 acts to push insulator 34 into shield element 32, and one or more electrical contacts 30 are prevented from pushing against insulator 34 in the insertion direction. In this manner, one or more electrical contacts 30 are prevented from being pushed back into electrical cable 8 by reaction to force applied during insertion of insulator 34 into shield element 32, which may prevent proper connection of one or more electrical contacts 30 with header 400.
In one embodiment, electrical cable termination 10 includes two electrical contacts 30 and is configured for termination of an electrical cable 8 including two conductors 64. Each conductor 64 of electrical cable 8 is connected to an electrical contact 30 of electrical cable termination 10, and ground shield 68 of electrical cable 8 is attached to shield element 32 of electrical cable termination 10 using conventional means, such as soldering. The type of electrical cable used in this embodiment can be a single twinaxial cable.
In one embodiment, first and second insulative members 54, 56 and spacer bars 58 of insulator 34 are configured to provide an open path between the area of shield element 32 to be soldered to ground shield 68 and the area under latch member 44 of shield element 32, such that solder flux vapor may be vented during soldering.
In one aspect, some elements of terminated cable assembly 6 may be constructed in a manner the same as or similar to what is taught in U.S. Patent Application Publication No. 2008-0020615 A1, published Jan. 24, 2008.
Referring to
Longitudinal alignment ribs 118a and transverse alignment ribs 118b (collectively referred to herein as “alignment ribs 118”) extend from an internal surface 114a of the carrier and define substantially square shaped alignment boxes. Longitudinal alignment ribs 118a may facilitate injection molding of carrier 104. Alignment ribs 118 may extend from internal surface 114a substantially perpendicularly. Optionally, alignment ribs 118 may have a slope to provide guidance during insertion of terminated cable assemblies 106 and injection molding of carrier 104. Alignment ribs 118 may additionally include side chamfers or radii 120 and/or top chamfers or radii 122 to provide guidance and positioning during insertion of terminated cable assemblies 106 into carrier 104 and facilitate injection molding of carrier 104. In other embodiments, alignment ribs 118 may define other suitable shapes, such as, e.g. other rectilinear shapes or curvilinear shapes.
Second alignment element receiving apertures 176 are positioned in internal surface 114a of carrier 104 and configured to receive second alignment elements 116 of terminated cable assemblies 106. Second alignment elements 116 intersect internal surface 114a of carrier 104 when carrier 104 and terminated cable assemblies 106 are in an assembled configuration.
Electrical cable termination 110 includes a longitudinal electrically conductive shield element 132, an insulator 134, and a single electrical contact 30. Electrically conductive shield element 132 has a front end 136, a back end 138, and side surfaces 140a-140d (collectively referred to herein as “sides 140”) defining a non-circular transverse cross-section.
As illustrated, shield element 132 includes laterally protruding resilient ground contact beams 142 disposed on opposed side surfaces 140a and 140c.
A latch member 144 extends from at least one of sides 140. The latch member is configured to retain electrical cable termination 110 in a retainer or organizer plate (not shown) configured to receive, secure, and manage a plurality of electrical cable terminations.
Shield element 132 includes a second alignment element 116, such as, e.g., a tab, configured to be received by corresponding second alignment element receiving aperture 176 of carrier 104 (shown in
Shield element 132 may further include a keying member, in the form of tab 146, laterally extending from back end 138 of shield element 132. Tab 146 is configured to ensure that electrical cable termination 110 is inserted into the retainer or organizer plate in the correct predetermined orientation. If electrical cable termination 110 is not properly oriented within the retainer or organizer plate, electrical cable termination 110 cannot be fully inserted.
Although the figures show that shield element 132 includes ground contact beams 142, it is within the scope of the present invention to use other contact element configurations, such as Hertzian bumps, in place of contact beams 142.
Insulator 134 has a front end 148, a back end 150, and outer surfaces 152a-152d (collectively referred to herein as “outer surface 152”) defining a non-circular shape.
In the exemplary embodiment of
In the exemplary embodiment of
In other embodiments, front end 70 of one or more electrical contacts 30 may be set back from or set forward of front end 136 of shield element 132. One advantage of setting front end 70 of electrical contact 30 back from front end 136 of shield element 132 is that front end 148 of insulator 134, as opposed to front end 70 of electrical contact 30, may provide the initial guidance of contact pin 406 of header 400 into electrical contact 30. Because front end 148 of insulator 134 has a larger contact pin entry area than front end 70 of electrical contact 30, additional guidance of contact pin 406 during insertion into electrical cable termination 110 is then provided.
One advantage of setting front end 70 of electrical contact 30 forward of front end 136 of shield element 132 is that front end 70 of electrical contact 30, cooperating with a corresponding recess (not shown) in internal surface 114a of carrier 104, may guide and position electrical contact 30 independent of the guidance and positioning of terminated cable assembly 106 into carrier 104. Independent guidance and positioning of electrical contact 30 reduces tolerance stack-ups in the assembly and provides a more precise placement of electrical contact 30 in carrier 104. Another advantage of setting front end 70 of electrical contact 30 forward of front end 136 of shield element 132 is that a protective collar or spacer (not shown) may be placed around front end 70 of electrical contact 30, e.g., to protect front end 136 of shield element 132 and front end 148 of insulator 134 against damage.
In the embodiment illustrated in
Referring to
In the exemplary embodiment of
Compared with having a separate second alignment element receiving aperture 176 (as shown in
In other embodiments, first alignment elements 212 may include a portion of contact pin receiving aperture 272. Compared with having a separate second alignment element receiving aperture 176 (as shown in
Longitudinal alignment ribs 218a and transverse alignment ribs 218b (collectively referred to herein as “alignment ribs 218”) extend from an internal surface 214a of the carrier and define substantially square shaped alignment boxes. Longitudinal alignment ribs 218a may facilitate injection molding of carrier 204. Alignment ribs 218 may extend from internal surface 214a substantially perpendicularly or may have a slope to provide guidance during insertion of terminated cable assemblies 106 and injection molding of carrier 204. Alignment ribs 218 may additionally include side chamfers or radii 220 and/or top chamfers or radii 222 to provide guidance and positioning during insertion of terminated cable assemblies 106 into carrier 204 and facilitate injection molding of carrier 204.
First alignment elements 212 including a portion of contact pin receiving aperture 272 are positioned in internal surface 214a of carrier 204 and configured to receive second alignment elements 116 of terminated cable assemblies 106. Second alignment elements 116 intersect internal surface 214a of carrier 204 and are positioned in corresponding contact pin receiving apertures 272 when carrier 204 and terminated cable assemblies 106 are in an assembled configuration.
Referring to
In the exemplary embodiment of
Longitudinal alignment ribs 318a and transverse alignment ribs 318b (collectively referred to herein as “alignment ribs 318”) extend from an internal surface 314a of the carrier and define substantially square shaped alignment boxes. Longitudinal alignment ribs 318a may facilitate injection molding of carrier 304. Alignment ribs 318 may extend from internal surface 314a substantially perpendicularly or may have a slope to provide guidance during insertion of terminated cable assemblies 306 and injection molding of carrier 304. Alignment ribs 318 may additionally include side chamfers or radii 320 and/or top chamfers or radii 322 to provide guidance and positioning during insertion of terminated cable assemblies 306 into carrier 304 and facilitate injection molding of carrier 304.
Alignment tabs 378 extend substantially perpendicular from longitudinal alignment ribs 318a or side wall 315b, and extend from internal surface 314a of the carrier. Alignment tabs 378 may extend from internal surface 314a substantially perpendicularly or may have a slope to provide guidance during insertion of terminated cable assemblies 306 and injection molding of carrier 304. Alignment tabs 378 may additionally include top chamfers or radii 321 to provide guidance and positioning during insertion of terminated cable assemblies 306 into carrier 304 and injection molding of carrier 304. In one embodiment, alignment tabs 378 are positioned offset from transverse alignment ribs 318b to help reduce lateral and rotational movement of terminated cable assemblies 306 in an assembled configuration.
Electrical cable termination 310 includes a longitudinal electrically conductive shield element 332, an insulator 334, and a single electrical contact 30. Electrically conductive shield element 332 has a front end 336, a back end 338, and side surfaces 340a-340d (collectively referred to herein as “sides 340”) defining a non-circular transverse cross-section.
As illustrated, shield element 332 includes laterally protruding resilient ground contact beams 342 disposed on opposed side surfaces 340a and 340c.
A latch member 344 extends from at least one of sides 340. The latch member is configured to retain electrical cable termination 310 in a retainer or organizer plate (not shown) configured to receive, secure, and manage a plurality of electrical cable terminations.
Shield element 332 includes alignment apertures 380 positioned in opposed side surfaces 340b and 340d and configured to receive at least a portion of an alignment tab 378 of carrier 304 (shown in
In the illustrated embodiment, the arrangement of alignment aperture 380 positioned in side surface 340d of shield element 332 and alignment aperture 381 of insulator 334 (described below) define second alignment element 316 of terminated cable assembly 306 and facilitates alignment of terminated cable assembly 306 in carrier 304. Front end 336 of shield element 332 defines an outer plane 333 of terminated cable assembly 306 that is intersected by corresponding first alignment element 312 of carrier 304 when carrier 304 and terminated cable assembly 306 are in an assembled configuration. In other embodiments, second alignment element 316 may be defined by one of alignment aperture 380 of shield element 332 or alignment aperture 381 of insulator 334.
Shield element 332 may further include a keying member, in the form of tab 346, laterally extending from back end 338 of shield element 332. Tab 346 is configured to ensure that electrical cable termination 310 is inserted into the retainer or organizer plate in the correct predetermined orientation. If electrical cable termination 310 is not properly oriented within the retainer or organizer plate, electrical cable termination 310 cannot be fully inserted.
Although the figures show that shield element 332 includes ground contact beams 342, it is within the scope of the present invention to use other contact element configurations, such as Hertzian bumps, in place of contact beams 342.
Shield element 332 includes recesses 382, in the form of narrowed portions, disposed on opposed side surfaces 340a and 340c. Recesses 382 facilitate insertion of contact elements 408 of header 400. To further facilitate insertion of contact elements 408, shield element 332 includes contact element deflecting rails 384 and contact element deflecting tabs 386 disposed on opposed side surfaces 340a and 340c. While recesses 382 provide additional clearance for contact elements 408, deflecting rails 384 and deflecting tabs 386 eliminate any opportunity for contact elements 408 to stub onto shield element 332 during insertion by guiding contact elements 408 away from shield element 332. When electrical connector assembly 302 and header 400 are in a mated configuration, a portion of contact elements 408 of header 400 is positioned in the corresponding recess 382 of shield element 332 while making electrical contact with corresponding contact beam 342. In other embodiments, at least a portion of shield element 332 may be recessed as described above or in other suitable ways to facilitate insertion of a contact element 408 of header 400. For example, shield element 332 may include a single recess 382 disposed on one of sides 340. Shield element 332 may include one or both of at least one contact element deflecting rail 384 and at least one contact element deflecting tab 386.
Insulator 334 has a front end 348, a back end 350, and outer surfaces 352a-352d (collectively referred to herein as “outer surface 352”) defining a non-circular shape.
In the exemplary embodiment of
Insulator 334 includes recesses 390, in the form of narrowed portions, disposed on opposed outer surfaces 352a and 352c. Recesses 390 facilitate insertion of insulator 334 into shield element 332 in the correct predetermined orientation. Beneficially, if insulator 334 is improperly assembled into shield element 332 (i.e., such that recesses 390 of insulator 334 and recesses 382 of shield element 332 are not aligned), insulator 334 cannot be fully installed (i.e., such that front end 348 of insulator 334 is substantially coplanar with front end 336 of shield element 332), thereby preventing the installation and use of an improperly assembled electrical cable termination 110. In other embodiments, at least a portion of insulator 334 may be recessed as described above or in other suitable ways to facilitate insertion of insulator 334 into shield element 332 in the correct predetermined orientation. For example, insulator 334 may include a single recess 390 disposed on outer surface 352.
Insulator 334 includes an alignment aperture 381 positioned in outer surface 352d and configured to receive at least a portion of an alignment tab 378 of carrier 304 (shown in
In the exemplary embodiment of
In each of the embodiments and implementations described herein, one or both of the first and second alignment elements may be configured to guide and position the plurality of terminated cable assemblies in the carrier. For example, the first alignment elements may include various elements described herein, such as, e.g., opening 28, alignment ribs 118 and side chamfers or radii 120 and/or top chamfers or radii 122 thereof, second alignment element receiving aperture 176, and alignment tab 378 and top chamfers or radii 321 thereof, to name a few, to guide and position the terminated cable assemblies in the carrier. Also for example, the second alignment elements may include various elements described herein, such as, e.g., electrical contacts 30, second alignment elements 116 and/or chamfers or radii 123 thereof, and alignment apertures 380 and 381, to name a few, to guide and position the terminated cable assemblies in the carrier.
In each of the embodiments and implementations described herein, the first and second alignment elements, at least a portion of the carrier, and at least a portion of the terminated cable assemblies may be cooperatively configured in an impedance controlling relationship. An impedance controlling relationship means that the first and second alignment elements, at least a portion of the carrier, and at least a portion of the terminated cable assemblies may be cooperatively configured to control the characteristic impedance of the electrical connector assembly. For example, referring to the embodiment illustrated in
Referring to
In each of the embodiments and implementations described herein, the various components of the electrical connector assembly and elements thereof are formed of any suitable material. The materials are selected depending upon the intended application and may include both metals and non-metals (e.g., any one or combination of non-conductive materials including but not limited to polymers, glass, and ceramics). In one embodiment, carrier 4 and insulator 34 are formed of a polymeric material by methods such as injection molding, extrusion, casting, machining, and the like, while the electrically conductive components are formed of metal by methods such as molding, casting, stamping, machining, and the like. Material selection will depend upon factors including, but not limited to, chemical exposure conditions, environmental exposure conditions including temperature and humidity conditions, flame-retardancy requirements, material strength, and rigidity, to name a few.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the mechanical, electro-mechanical, and electrical arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
This application claims the benefit of U.S. Provisional Patent Application No. 60/980,512, filed Oct. 17, 2007.
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