Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/46—Bases; Cases
  • H01R13/514—Bases; Cases composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
  • H01R12/70—Coupling devices
  • H01R12/71—Coupling devices for rigid printing circuits or like structures
  • H01R12/712—Coupling devices for rigid printing circuits or like structures co-operating with the surface of the printed circuit or with a coupling device exclusively provided on the surface of the printed circuit
  • H01R12/716—Coupling device provided on the PCB
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
  • H01R12/70—Coupling devices
  • H01R12/71—Coupling devices for rigid printing circuits or like structures
  • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
  • H01R12/722—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits
  • H01R12/724—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures coupling devices mounted on the edge of the printed circuits containing contact members forming a right angle
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
  • H01R12/70—Coupling devices
  • H01R12/71—Coupling devices for rigid printing circuits or like structures
  • H01R12/72—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures
  • H01R12/73—Coupling devices for rigid printing circuits or like structures coupling with the edge of the rigid printed circuits or like structures connecting to other rigid printed circuits or like structures
  • H01R12/735—Printed circuits including an angle between each other
  • H01R12/737—Printed circuits being substantially perpendicular to each other
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/46—Bases; Cases
  • H01R13/516—Means for holding or embracing insulating body, e.g. casing, hoods
  • H01R13/518—Means for holding or embracing insulating body, e.g. casing, hoods for holding or embracing several coupling parts, e.g. frames
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/646—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00 specially adapted for high-frequency, e.g. structures providing an impedance match or phase match
  • H01R13/6473—Impedance matching
  • H01R13/6474—Impedance matching by variation of conductive properties, e.g. by dimension variations

Definitions

• This invention relates generally to electrical interconnection systems and more specifically to improved signal integrity in interconnection systems, particularly in high speed electrical connectors.
• PCBs printed circuit boards
• a traditional arrangement for interconnecting several PCBs is to have one PCB serve as a backplane.
• Other PCBs, which are called daughter boards or daughter cards, are then connected through the backplane by electrical connectors.
• One of the difficulties in making a high density, high speed connector is that electrical conductors in the connector can be so close that there can be electrical interference between adjacent signal conductors.
• shield members are often placed between or around adjacent signal conductors. The shields prevent signals carried on one conductor from creating "crosstalk" on another conductor. The shield also impacts the impedance of each conductor, which can further contribute to desirable electrical properties.
• Transmitting signals differentially can also reduce crosstalk.
• Differential signals are carried on a pair of conducting paths, called a "differential pair.”
• the voltage difference between the conductive paths represents the signal.
• a differential pair is designed with preferential coupling between the conducting paths of the pair.
• the two conducting paths of a differential pair may be arranged to run closer to each other than to adjacent signal paths in the connector. No shielding is desired between the conducting paths of the pair, but shielding may be used between differential pairs.
• Electrical connectors can be designed for differential signals as well as for single-ended signals.
• Signal integrity in an electrical connector may be improved by forming adjacent conductive elements with complimentary shapes.
• Conductive elements containing projections are positioned adjacent conductive elements with relieved portions.
• Such a configuration of conductive elements contributes to a more uniform conductor to conductor spacing, which may impart conductive elements carrying signals with desirable electrical properties.
• the complimentary portions are formed in the regions of the conductive elements containing barbs or other features that engage a housing into which the conductive elements are inserted.
• conductive elements may be inserted into the housing from two sides, with conductive elements having projections inserted from one side and conductive elements complimentary relieved portions inserted from an opposite side of the housing.
• FIG. 1 is a perspective view of an electrical interconnection system according to an embodiment of the present invention
• FIGs. 2A and 2B are views of a first and second side of a wafer forming a portion of the electrical connector of FIG. 1 ;
• FIG. 2C is a cross-sectional representation of the wafer illustrated in FIG. 2B taken along the line 2C-2C;
• FIG. 3 is a cross-sectional representation of a plurality of wafers stacked together according to an embodiment of the present invention
• FIG. 4 A is a plan view of a lead frame used in the manufacture of a connector according to an embodiment of the invention.
• FIG. 4B is an enlarged detail view of the area encircled by arrow 4B-4B in FIG. 4A;
• FIG. 5 A is a cross-sectional representation of a backplane connector according to an embodiment of the present invention
• FIG. 5B is a cross-sectional representation of the backplane connector illustrated in
• FIG. 5A taken along the line 5B-5B;
• FIGs. 6A-6C are enlarged detail views of conductors used in the manufacture of a backplane connector according to an embodiment of the present invention.
• FIG. 7A is a cross-section of a portion of a connector with complimentary conductive elements.
• FIG. 7B illustrates a process of manufacturing a connector with complimentary ⁇ conductive elements.
• the electrical interconnection system 100 includes a daughter card connector 120 and a backplane connector 150.
• FIG. 1 shows an interconnection system using a right-angle, backplane connector.
• the electrical interconnection system 100 may include other types and combinations of connectors, as the invention may be broadly applied in many types of electrical connectors, such as right angle connectors, mezzanine connectors, card edge connectors and chip sockets.
• Backplane connector 150 and daughter connector 120 each contains conductive elements.
• the conductive elements of daughter card connector 120 are coupled to traces, of which trace 142 is numbered, ground planes or other conductive elements within daughter card 140.
• the traces carry electrical signals and the ground planes provide reference levels for components on daughter card 140.
• Ground planes may have voltages that are at earth ground or positive or negative with respect to earth ground, as any voltage level may act as a reference level.
• backplane connector 150 is coupled to traces, of which trace 162 is numbered, ground planes or other conductive elements within backplane 160.
• Backplane connector 150 includes a backplane shroud 158 and a plurality conductive elements (see FIGs. 6A-6C). The conductive elements of backplane connector 150 extend through floor 514 of the backplane shroud 158 with portions both above and below floor 514.
• mating contacts 154 which are adapted to mate to corresponding conductive elements of daughter card connector 120.
• mating contacts 154 are in the form of blades, although other suitable contact configurations may be employed, as the present invention is not limited in this regard.
• Tail portions, shown collectively as contact tails 156, of the conductive elements extend below the shroud floor 514 and are adapted to be attached to backplane 160.
• the tail portions are in the form of a press fit, "eye of the needle" compliant sections that fit within via holes, shown collectively as via holes 164, on backplane 160.
• other configurations are also suitable, such as surface mount elements, spring contacts, solderable pins, etc., as the present invention is not limited in this regard.
• backplane shroud 158 is molded from a dielectric material such as plastic or nylon.
• suitable materials are liquid crystal polymer (LCP), polyphenyline sulfide (PPS), high temperature nylon or polypropylene (PPO).
• LCP liquid crystal polymer
• PPS polyphenyline sulfide
• PPO polypropylene
• Other suitable materials may be employed, as the present invention is not limited in this regard. All of these are suitable for use as binder materials in manufacturing connectors according to the invention.
• One or more fillers may be included in some or all of the binder material used to form backplane shroud 158 to control the electrical or mechanical properties of backplane shroud 150.
• thermoplastic PPS filled to 30% by volume with glass fiber may be used to form shroud 158.
• backplane connector 150 is manufactured by molding backplane shroud 158 with openings to receive conductive elements.
• the conductive elements may be shaped with barbs or other retention features that hold the conductive elements in place when inserted in the opening of backplane shroud 158.
• the backplane shroud 158 further includes side walls 512 that extend along the length of opposing sides of the backplane shroud 158.
• the side walls 512 include grooves 172, which run vertically along an inner surface of the side walls 512. Grooves 172 serve to guide front housing 130 of daughter card connector 120 via mating projections 132 into the appropriate position in shroud 158.
• Daughter card connector 120 includes a plurality of wafers 122 ⁇ ...122 6 coupled together, with each of the plurality of wafers 122j ...122 6 having a housing 260 (see FIGs. 2A-2C) and a column of conductive elements.
• each column has a plurality of signal conductors 420 (see FIG. 4A) and a plurality of ground conductors 430 (see FIG. 4A).
• the ground conductors may be employed within each wafer 122j ...122 6 to minimize crosstalk between signal conductors or to otherwise control the electrical properties of the connector.
• Wafers ⁇ 1 ⁇ ...122 6 may be formed by molding housing 260 around conductive elements that form signal and ground conductors.
• housing 260 may be formed of any suitable material and may include portions that have conductive filler or are otherwise made lossy.
• daughter card connector 120 is a right angle connector and has conductive elements that traverse a right angle. As a result, opposing ends of the conductive elements extend from perpendicular edges of the wafers 122i ... l22 6 .
• Each conductive element of wafers 122] ...122 6 has at least one contact tail, shown collectively as contact tails 126 that can be connected to daughter card 140.
• Each conductive element in daughter card connector 120 also has a mating contact portion, shown collectively as mating contacts 124, which can be connected to a corresponding conductive element in backplane connector 150.
• Each conductive element also has an intermediate portion between the mating contact portion and the contact tail, which may be enclosed by or embedded within a wafer housing 260 (see FIG. 2).
• the contact tails 126 electrically connect the conductive elements within daughter card and connector 120 to conductive elements, such as traces 142 in daughter card 140.
• contact tails 126 are press fit "eye of the needle" contacts that make an electrical connection through via holes in daughter card 140.
• any suitable attachment mechanism may be used instead of or in addition to via holes and press fit contact tails.
• each of the mating contacts 124 has a dual beam structure configured to mate to a corresponding mating contact 154 of backplane connector 150.
• the conductive elements acting as signal conductors may be grouped in pairs, separated by ground conductors in a configuration suitable for use as a differential electrical connector. However, embodiments are possible for single-ended use in which the conductive elements are evenly spaced without designated ground conductors separating signal conductors or with a ground conductor between each signal conductor.
• some conductive elements are designated as forming a differential pair of conductors and some conductive elements are designated as ground conductors. These designations refer to the intended use of the conductive elements in an interconnection system as they would be understood by one of skill in the art.
• differential pairs may be identified based on preferential coupling between the conductive elements that make up the pair. Electrical characteristics of the pair, such as its impedance, that make it suitable for carrying a differential signal may provide an alternative or additional method of identifying a differential pair.
• ground conductors may be identified by their positioning relative to the differential pairs. In other instances, ground conductors may be identified by their shape or electrical characteristics. For example, ground conductors may be relatively wide to provide low inductance, which is desirable for providing a stable reference potential, but provides an impedance that is undesirable for carrying a high speed signal.
• daughter card connector 120 is illustrated with six wafers 122]...122 6 , with each wafer having a plurality of pairs of signal conductors and adjacent ground conductors. As pictured, each of the wafers 122] ...122 6 includes one column of conductive elements. However, the present invention is not limited in this regard, as the number of wafers and the number of signal conductors and ground conductors in each wafer may be varied as desired.
• each wafer 122[...122 6 is inserted into front housing 130 such that mating contacts 124 are inserted into and held within openings in front housing 130.
• the openings in front housing 130 are positioned so as to allow mating contacts 154 of the backplane connector 150 to enter the openings in front housing 130 and allow electrical connection with mating contacts 124 when daughter card connector 120 is mated to backplane connector 150.
• Daughter card connector 120 may include a support member instead of or in addition to front housing 130 to hold wafers 122 ! ...122 6 .
• stiffener 128 supports the plurality of wafers 122i... l22 6 .
• Stiffener 128 is, in the embodiment illustrated, a stamped metal member. Though, stiffener 128 may be formed from any suitable material. Stiffener 128 may be stamped with slots, holes, grooves or other features that can engage a wafer.
• Each wafer 122i ...122 6 may include attachment features 242, 244 (see FIGs. 2A-2B) that engage stiffener 128 to locate each wafer 122 with respect to another and further to prevent rotation of the wafer 122.
• attachment features 242, 244 see FIGs. 2A-2B
• stiffener 128 engages stiffener 128 to locate each wafer 122 with respect to another and further to prevent rotation of the wafer 122.
• the present invention is not limited in this regard, and no stiffener need be employed.
• the stiffener is shown attached to an upper and side portion of the plurality of wafers, the present invention is not limited in this respect, as other suitable locations may be employed.
• FIGs. 2 A-2B illustrate opposing side views of an exemplary wafer 220 A.
• Wafer 220A may be formed in whole or in part by injection molding of material to form housing 260 around a wafer strip assembly such as 410A or 410B (FIG. 4).
• wafer 220A is formed with a two shot molding operation, allowing housing 260 to be formed of two types of material having different material properties.
• Insulative portion 240 is formed in a first shot and lossy portion 250 is formed in a second shot.
• any suitable number and types of material may be used in housing 260.
• the housing 260 is formed around a column of conductive elements by injection molding plastic.
• housing 260 may be provided with openings, such as windows or slots 264i...264 6 , and holes, of which hole 262 is numbered, adjacent the signal conductors 420. These openings may serve multiple purposes, including to: (i) ensure during an injection molding process that the conductive elements are properly positioned, and (ii) facilitate insertion of materials that have different electrical properties, if so desired.
• one embodiment of the present invention may employ regions of different dielectric constant selectively located adjacent signal conductors 31O]B, 31O 2 B...31O 4 B of a wafer.
• the housing 260 includes slots 264 1 ...264 6 in housing 260 that position air adjacent signal conductors 310 ⁇ B, 31O 2 B...31O 4 B.
• the ability to place air, or other material that has a dielectric constant lower than the dielectric constant of material used to form other portions of housing 260, in close proximity to one half of a differential pair provides a mechanism to de-skew a differential pair of signal conductors.
• the time it takes an electrical signal to propagate from one end of the signal connector to the other end is known as the propagation delay.
• each signal within a pair have the same propagation delay, which is commonly referred to as having zero skew within the pair.
• the propagation delay within a conductor is influenced by the dielectric constant of material near the conductor, where a lower dielectric constant means a lower propagation delay.
• the dielectric constant is also sometimes referred to as the relative permittivity.
• a vacuum has the lowest possible dielectric constant with a value of 1. Air has a similarly low dielectric constant, whereas dielectric materials, such as LCP, have higher dielectric constants. For example, LCP has a dielectric constant of between about 2.5 and about 4.5.
• Each signal conductor of the signal pair may have a different physical length, particularly in a right-angle connector.
• the relative proportion of materials of different dielectric constants around the conductors may be adjusted. In some embodiments, more air is positioned in close proximity to the physically longer signal conductor of the pair than for the shorter signal conductor of the pair, thus lowering the effective dielectric constant around the signal conductor and decreasing its propagation delay.
• the impedance of the signal conductor rises.
• the size of the signal conductor in closer proximity to the air may be increased in thickness or width. This results in two signal conductors with different physical geometry, but a more equal propagation delay and more inform impedance profile along the pair.
• FIG. 2C shows a wafer 220 in cross section taken along the line 2C-2C in FIG. 2B.
• a plurality of differential pairs 34Oi ...34O 4 are held in an array within insulative portion 240 of housing 260.
• the array, in cross-section, is a linear array, forming a column of conductive elements.
• slots 264] ...264 4 are intersected by the cross section and are therefore visible in FIG. 2C. As can be seen, slots 264] ...264 4 create regions of air adjacent the longer conductor in each differential pair 34O 1 , 34O 2 ...34O 4 . Though, air is only one example of a material with a low dielectric constant that may be used for de-skewing a connector. Regions comparable to those occupied by slots 264i ...264 4 as shown in FIG. 2C could be formed with a plastic with a lower dielectric constant than the plastic used to form other portions of housing 260. As another example, regions of lower dielectric constant could be formed using different types or amounts of fillers. For example, lower dielectric constant regions could be molded from plastic having less glass fiber reinforcement than in other regions.
• FIG. 2C also illustrates positioning and relative dimensions of signal and ground conductors that may be used in some embodiments. As shown in FIG. 2C, intermediate portions of the signal conductors 31O 1 A...31O 4 A and 310iB...310 4 B are embedded within housing 260 to form a column. Intermediate portions of ground conductors 33Oi • ..33O 4 may also be held within housing 260 in the same column.
• Ground conductors 330i , 33O 2 and 33O 3 are positioned between two adjacent differential pairs 340i, 34O 2 ...34O 4 within the column. Additional ground conductors may be included at either or both ends of the column.
• a ground conductor 33O 4 is positioned at one end of the column.
• each ground conductor 330i ...33O 4 is preferably wider than the signal conductors of differential pairs 340] ...34O 4 .
• the intermediate portion of each ground conductor has a width that is equal to or greater than three times the width of the intermediate portion of a signal conductor. In the pictured embodiment, the width of each ground conductor is sufficient to span at least the same distance along the column as a differential pair.
• each ground conductor has a width approximately five times the width of a signal conductor such that in excess of 50% of the column width occupied by the conductive elements is occupied by the ground conductors. In the illustrated embodiment, approximately 70% of the column width occupied by conductive elements is occupied by the ground conductors 330i • • .33O 4 . Increasing the percentage of each column occupied by a ground conductor can decrease cross talk within the connector. Other techniques can also be used to manufacture wafer 220A to reduce crosstalk or otherwise have desirable electrical properties.
• one or more portions of the housing 260 are formed from a material that selectively alters the electrical and/or electromagnetic properties of that portion of the housing, thereby suppressing noise and/or crosstalk, altering the impedance of the signal conductors or otherwise imparting desirable electrical properties to the signal conductors of the wafer.
• housing 260 includes an insulative portion 240 and a lossy portion 250.
• the lossy portion 250 may include a thermoplastic material filled with conducting particles. The fillers make the portion "electrically lossy.”
• the lossy regions of the housing are configured to reduce crosstalk between at least two adjacent differential pairs 340]...34O 4 .
• the insulative regions of the housing may be configured so that the lossy regions do not attenuate signals carried by the differential pairs 34O 1 ...34O 4 an undesirable amount.
• Lossy materials Materials that conduct, but with some loss, over the frequency range of interest are referred to herein generally as "lossy" materials. Electrically lossy materials can be formed from lossy dielectric and/or lossy conductive materials.
• the frequency range of interest depends on the operating parameters of the system in which such a connector is used, but will generally be between about 1 GHz and 25 GHz, though higher frequencies or lower frequencies may be of interest in some applications. Some connector designs may have frequency ranges of interest that span only a portion of this range, such as 1 to 10 GHz or 3 to 15 GHz.
• Electrically lossy material can be formed from material traditionally regarded as dielectric materials, such as those that have an electric loss tangent greater than approximately 0.003 in the frequency range of interest.
• the "electric loss tangent" is the ratio of the imaginary part to the real part of the complex electrical permittivity of the material.
• Electrically lossy materials can also be formed from materials that are generally thought of as conductors, but are either relatively poor conductors over the frequency range of interest, contain particles or regions that are sufficiently dispersed that they do not provide high conductivity or otherwise are prepared with properties that lead to a relatively weak bulk conductivity over the frequency range of interest. Electrically lossy materials typically have a conductivity of about 1 siemans/meter to about 6.I x IO 7 siemans/meter, preferably about 1 siemans/meter to about 1 x 10 7 siemans/meter and most preferably about 1 siemans/meter to about 30,000 siemans/meter. Electrically lossy materials may be partially conductive materials, such as those that have a surface resistivity between 1 ⁇ /square and 10 6 ⁇ /square.
• the electrically lossy material has a surface resistivity between 1 ⁇ /square and 10 3 ⁇ /square. In some embodiments, the electrically lossy material has a surface resistivity between 10 ⁇ /square and 100 ⁇ /square. As a specific example, the material may have a surface resistivity of between about 20 ⁇ /square and 40 ⁇ /square.
• electrically lossy material is formed by adding to a binder a filler that contains conductive particles.
• conductive particles that may be used as a filler to form an electrically lossy material include carbon or graphite formed as fibers, flakes or other particles.
• Metal in the form of powder, flakes, fibers or other particles may also be used to provide suitable electrically lossy properties.
• combinations of fillers may be used.
• metal plated carbon particles may be used.
• Silver and nickel are suitable metal plating for fibers.
• Coated particles may be used alone or in combination with other fillers, such as carbon flake.
• the conductive particles disposed in the lossy portion 250 of the housing may be disposed generally evenly throughout, rendering a conductivity of the lossy portion generally constant.
• a first region of the lossy portion 250 may be more conductive than a second region of the lossy portion 250 so that the conductivity, and therefore amount of loss within the lossy portion 250 may vary.
• the binder or matrix may be any material that will set, cure or can otherwise be used to position the filler material.
• the binder may be a thermoplastic material such as is traditionally used in the manufacture of electrical connectors to facilitate the molding of the electrically lossy material into the desired shapes and locations as part of the manufacture of the electrical connector. However, many alternative forms of binder materials may be used.
• Curable materials such as epoxies
• materials such as thermosetting resins or adhesives may be used.
• binder materials may be used to create an electrically lossy material by forming a binder around conducting particle fillers, the invention is not so limited.
• conducting particles may be impregnated into a formed matrix material or may be coated onto a formed matrix material, such as by applying a conductive coating to a plastic housing.
• the term "binder" encompasses a material that encapsulates the filler, is impregnated with the filler or otherwise serves as a substrate to hold the filler.
• the fillers will be present in a sufficient volume percentage to allow conducting paths to be created from particle to particle.
• the fiber may be present in about 3% to 40% by volume.
• the amount of filler may impact the conducting properties of the material.
• Filled materials may be purchased commercially, such as materials sold under the trade name Celestran® by Ticona.
• a lossy material such as lossy conductive carbon filled adhesive preform, such as those sold by Techfilm of Billerica, Massachusetts, US, may also be used.
• This preform can include an epoxy binder filled with carbon particles. The binder surrounds carbon particles, which acts as a reinforcement for the preform.
• Such a preform may be inserted in a wafer 220A to form all or part of the housing and may be positioned to adhere to ground conductors in the wafer. In some embodiments, the preform may adhere through the adhesive in the preform, which may be cured in a heat treating process.
• Non-woven carbon fiber is one suitable material.
• Other suitable materials such as custom blends as sold by RTP Company, can be employed, as the present invention is not limited in this respect.
• the wafer housing 260 is molded with two types of material.
• lossy portion 250 is formed of a material having a conductive filler
• the insulative portion 240 is formed from an insulative material having little or no conductive fillers, though insulative portions may have fillers, such as glass fiber, that alter mechanical properties of the binder material or impacts other electrical properties, such as dielectric constant, of the binder.
• the insulative portion 240 is formed of molded plastic and the lossy portion is formed of molded plastic with conductive fillers.
• the lossy portion 250 is sufficiently lossy that it attenuates radiation between differential pairs to a sufficient amount that crosstalk is reduced to a level that a separate metal plate is not required.
• insulative portion 240 formed of a suitable dielectric material, may be used to insulate the signal conductors.
• the insulative materials may be, for example, a thermoplastic binder into which nonconducting fibers are introduced for added strength, dimensional stability and to reduce the amount of higher priced binder used. Glass fibers, as in a conventional electrical connector, may have a loading of about 30% by volume. It should be appreciated that in other embodiments, other materials may be used, as the invention is not so limited.
• the lossy portion 250 includes a parallel region 336 and perpendicular regions 334j ...334 4 .
• perpendicular regions 334i ...334 4 are disposed between adjacent conductive elements that form separate differential pairs 34O 1 ...34O 4 .
• the lossy regions 336 and 334i ...334 4 of the housing 260 and the ground conductors 33O 1 ...33O 4 cooperate to shield the differential pairs 34O 1 ...34O 4 to reduce crosstalk.
• the lossy regions 336 and 334j ...334 4 may be grounded by being electrically connected to one or more ground conductors. This configuration of lossy material in combination with ground conductors 330 j...33O 4 reduces crosstalk between differential pairs within a column.
• ground conductors 33O 1 ...33O 4 may be electrically connected to regions 336 and 334] ...334 4 by molding portion 250 around ground conductors 34Oi ...34O 4 .
• ground conductors may include openings through which the material forming the housing can flow during molding.
• the cross section illustrated in FIG. 2C is taken through an opening 332 in ground conductor 33O 1 .
• other openings in other ground conductors such as 33O 2 ...33O 4 may be included.
• perpendicular portions 334] ...334 4 to extend through ground conductors even though a mold cavity used to form a wafer 220A has inlets on only one side of the ground conductors. Additionally, flowing material through openings in ground conductors as part of a molding operation may aid in securing the ground conductors in housing 260 and may enhance the electrical connection between the lossy portion 250 and the ground conductors.
• other suitable methods of forming perpendicular portions 334i ...334 4 may also be used, including molding wafer 320A in a cavity that has inlets on two sides of ground conductors 33Oi ...33O 4 .
• other suitable methods for securing the ground contacts 330 may be employed, as the present invention is not limited in this respect.
• Forming the lossy portion 250 of the housing from a moldable material can provide additional benefits.
• the lossy material at one or more locations can be configured to set the performance of the connector at that location.
• changing the thickness of a lossy portion to space signal conductors closer to or further away from the lossy portion 250 can alter the performance of the connector.
• electromagnetic coupling between one differential pair and ground and another differential pair and ground can be altered, thereby configuring the amount of loss for radiation between adjacent differential pairs and the amount of loss to signals carried by those differential pairs.
• a connector according to embodiments of the invention may be capable of use at higher frequencies than conventional connectors, such as for example at frequencies between 10-15 GHz or 3 to 6 GHz.
• wafer 220A is designed to carry differential signals.
• each signal is carried by a pair of signal conductors 310[A and 31O]B,... 31O 4 A and 31O 4 B.
• each signal conductor is closer to the other conductor in its pair than it is to a conductor in an adjacent pair.
• a pair 34Oi carries one differential signal
• pair 34O 2 carries another differential signal.
• signal conductor 31O 1 B is closer to signal conductor 310iA than to signal conductor 310 2 A.
• Perpendicular lossy regions 334 J ...334 4 may be positioned between pairs to provide shielding between the adjacent differential pairs in the same column.
• FIG. 3 illustrates a cross-sectional view similar to FIG. 2C but with a plurality of subassemblies or wafers 320A, 320B aligned side to side to form multiple parallel columns.
• the plurality of signal conductors 340 may be arranged in differential pairs in a plurality of columns formed by positioning wafers side by side. It is not necessary that each wafer be the same and different types of wafers may be used. It may be desirable for all types of wafers used to construct a daughter card connector to have an outer envelope of approximately the same dimensions so that all wafers fit within the same enclosure or can be attached to the same support member, such as stiffener 128 (FIG. 1). However, by providing different placement of the signal conductors, ground conductors and lossy portions in different wafers, the amount that the lossy material reduces crosstalk relative for the amount that it attenuates signals may be more readily configured. In one embodiment, two types of wafers are used, which are illustrated in FIG. 3 as subassemblies or wafers 320A and 320B.
• Each of the wafers 320B may include structures similar to those in wafer 320A as illustrated in FIGs. 2A, 2B and 2C. As shown in FIG. 3, wafers 320B include multiple differential pairs, such as pairs 34O 5 , 34O 6 , 34O 7 and 34O 8 . The signal pairs may be held within an insulative portion, such as 240B of a housing. Slots or other structures (not numbered) may be formed within the housing for skew equalization in the same way that slots 264 1 ...264 6 are formed in a wafer 220A.
• the housing for a wafer 320B may also include lossy portions, such as lossy portions 250B.
• lossy portions 250B may be positioned to reduce crosstalk between adjacent differential pairs.
• the lossy portions 250B may be shaped to provide a desirable level of crosstalk suppression without causing an undesired amount of signal attenuation.
• lossy portion 250B may have a substantially parallel region 336B that is parallel to the columns of differential pairs 34O 5 ...34O 8 .
• Each lossy portion 250B may further include a plurality of perpendicular regions 334 ! B...334 5 B, which extend from the parallel region 336B.
• the perpendicular regions 334jB...334 5 B may be spaced apart and disposed between adjacent differential pairs within a column.
• Wafers 320B also include ground conductors, such as ground conductors 33O 5 ...330 9 . As with wafers 320A, the ground conductors are positioned adjacent differential pairs 34O 5 ...34O 8 . Also, as in wafers 320A, the ground conductors generally have a width greater than the width of the signal conductors. In the embodiment pictured in FIG. 3, ground conductors 33O 5 ...33O 8 have generally the same shape as ground conductors 33O 1 ...33O 4 in a wafer 320A. However, in the embodiment illustrated, ground conductor 33O 9 has a width that is less than the ground conductors 33O 5 ...33O 8 in wafer 320B.
• Ground conductor 33O 9 is narrower to provide desired electrical properties without requiring the wafer 320B to be undesirably wide.
• Ground conductor 33O 9 has an edge facing differential pair 34O 8 . Accordingly, differential pair 34O 8 is positioned relative to a ground conductor similarly to adjacent differential pairs, such as differential pair 33O 8 in wafer 320B or pair 34O 4 in a wafer 320A. As a result, the electrical properties of differential pair 34O 8 are similar to those of other differential pairs.
• wafer 320B may be made with a smaller size.
• a similar small ground conductor could be included in wafer 320A adjacent pair 34O 1 .
• pair 34Oi is the shortest of all differential pairs within daughter card connector 120.
• the net effect of differences in ground configuration may be proportional to the length of the conductor over which those differences exist.
• differential pair 34O 1 is relatively short, in the embodiment of FIG. 3, a second ground conductor adjacent to differential pair 34O 1 , though it would change the electrical characteristics of that pair, may have relatively little net effect.
• a further ground conductor may be included in wafers 320A.
• FIG. 3 illustrates a further feature possible when using multiple types of wafers to form a daughter card connector. Because the columns of contacts in wafers 320A and 320B have different configurations, when wafer 320A is placed side by side with wafer 320B, the differential pairs in wafer 320A are more closely aligned with ground conductors in wafer 320B than with adjacent pairs of signal conductors in wafer 320B. Conversely, the differential pairs of wafer 320B are more closely aligned with ground conductors than adjacent differential pairs in the wafer 320A.
• differential pair 34O 6 is proximate ground conductor 33O 2 in wafer 320A.
• differential pair 34O 3 in wafer 320A is proximate ground conductor 33O 7 in wafer 320B.
• FIG. 4A illustrates a step in the manufacture of wafers 320A and 320B according to one embodiment.
• wafer strip assemblies each containing conductive elements in a configuration desired for one column of a daughter card connector, are formed.
• a housing is then molded around the conductive elements in each wafer strip assembly in an insert molding operation to form a wafer.
• signal conductors of which signal conductor 420 is numbered and ground conductors, of which ground conductor 430 is numbered, may be held together on a lead frame 400 as shown in FIG. 4A.
• the signal conductors 420 and the ground conductors 430 are attached to one or more carrier strips 402.
• the signal conductors and ground conductors are stamped for many wafers on a single sheet.
• the sheet may be metal or may be any other material that is conductive and provides suitable mechanical properties for making a conductive element in an electrical connector. Phosphor-bronze, beryllium copper and other copper alloys are example of materials that may be used.
• FIG. 4A illustrates a portion of a sheet of metal in which wafer strip assemblies 410A, 410B have been stamped.
• Wafer strip assemblies 410A, 410B may be used to form wafers 320A and 320B, respectively.
• Conductive elements may be retained in a desired position on carrier strips 402. The conductive elements may then be more readily handled during manufacture of wafers. Once material is molded around the conductive elements, the carrier strips may be severed to separate the conductive elements. The wafers may then be assembled into daughter board connectors of any suitable size.
• FIG. 4A also provides a more detailed view of features of the conductive elements of the daughter card wafers. The width of a ground conductor, such as ground conductor 430, relative to a signal conductor, such as signal conductor 420, is apparent. Also, openings in ground conductors, such as opening 332, are visible.
• the lead frame 400 includes tie bars 452, 454 and 456 that connect various portions of the signal conductors 420 and/or ground strips 430 to the lead frame 400. These tie bars may be severed during subsequent manufacturing processes to provide electronically separate conductive elements. A sheet of metal may be stamped such that one or more additional carrier strips are formed at other locations and/or bridging members between conductive elements may be employed for positioning and support of the conductive elements during manufacture. Accordingly, the details shown in FIG. 4A are illustrative and not a limitation on the invention.
• the lead frame 400 is shown as including both ground conductors 430 and the signal conductors 420, the present invention is not limited in this respect.
• the respective conductors may be formed in two separate lead frames. Indeed, no lead frame need be used and individual conductive elements may be employed during manufacture. It should be appreciated that molding over one or both lead frames or the individual conductive elements need not be performed at all, as the wafer may be assembled by inserting ground conductors and signal conductors into preformed housing portions, which may then be secured together with various features including snap fit features.
• FIG. 4B illustrates a detailed view of the mating contact end of a differential pair 424i positioned between two ground mating contacts 434i and 434 2 .
• the ground conductors may include mating contacts of different sizes.
• the embodiment pictured has a large mating contact 434 2 and a small mating contact 434j. To reduce the size of each wafer, small mating contacts 434j may be positioned on one or both ends of the wafer.
• FIG. 4B illustrates features of the mating contact portions of the conductive elements within the wafers forming daughter board connector 120.
• FIG. 4B illustrates a portion of the mating contacts of a wafer configured as wafer 320B.
• the portion shown illustrates a mating contact 434j such as may be used at the end of a ground conductor 33O 9 (FIG. 3).
• Mating contacts 424j may form the mating contact portions of signal conductors, such as those in differential pair 34O 8 (FIG. 3).
• mating contact 434 2 may form the mating contact portion of a ground conductor, such as ground conductor 33O 8 (FIG. 3).
• each of the mating contacts on a conductive element in a daughter card wafer is a dual beam contact.
• Mating contact 4341 includes beams 46O 1 and 46O 2 .
• Mating contacts 424 1 includes four beams, two for each of the signal conductors of the differential pair terminated by mating contact 4241.
• beams 46O 3 and 46O 4 provide two beams for a contact for one signal conductor of the pair and beams 46O 5 and 46O 6 provide two beams for a contact for a second signal conductor of the pair.
• mating contact 434 2 includes two beams 46O 7 and 46O 8 .
• each of the beams includes a mating surface, of which mating surface 462 on beam 46O 1 is numbered.
• each of the beams 460 ! ...46O 8 may be shaped to press against a corresponding mating contact in the backplane connector 150 with sufficient mechanical force to create a reliable electrical connection. Having two beams per contact increases the likelihood that an electrical connection will be formed even if one beam is damaged, contaminated or otherwise precluded from making an effective connection.
• Each of beams 460 1 ...46O 8 has a shape that generates mechanical force for making an electrical connection to a corresponding contact.
• the signal conductors terminating at mating contact 424 ⁇ may have relatively narrow intermediate portions 484] and 484 2 within the housing of wafer 320D.
• the mating contact portions 424 1 for the signal conductors may be wider than the intermediate portions 484j and 484 2 . Accordingly, FIG. 4B shows broadening portions 48O 1 and 48O 2 associated with each of the signal conductors.
• the ground conductors adjacent broadening portions 48O 1 and 48O 2 are shaped to conform to the adjacent edge of the signal conductors.
• mating contact 434 1 for a ground conductor has a complementary portion 482 ⁇ with a shape that conforms to broadening portion 48Oi .
• mating contact 434 2 has a complementary portion 482 2 that conforms to broadening portion 48O 2 .
• backplane connector 150 like daughter card connector 120, includes features for providing desirable signal transmission properties.
• Signal conductors in backplane connector 150 are arranged in columns, each containing differential pairs interspersed with ground conductors.
• the ground conductors are wide relative to the signal conductors.
• adjacent columns have different configurations. Some of the columns may have narrow ground conductors at the end to save space while providing a desired ground configuration around signal conductors at the ends of the columns.
• ground conductors in one column may be positioned adjacent to differential pairs in an adjacent column as a way to reduce crosstalk from one column to the next.
• lossy material may be selectively placed within the shroud of backplane connector 150 to reduce crosstalk, without providing an undesirable level attenuation for signals.
• adjacent signals and grounds may have conforming portions so that in locations where the profile of either a signal conductor or a ground conductor changes, the signal-to-ground spacing may be maintained.
• FIGs. 5A-5B illustrate an embodiment of a backplane connector 150 in greater detail.
• backplane connector 150 includes a shroud 510 with walls 512 and floor 514. Conductive elements are inserted into shroud 510. In the embodiment shown, each conductive element has a portion extending above floor 514. These portions form the mating contact portions of the conductive elements, collectively numbered 154. Each conductive element has a portion extending below floor 514. These portions form the contact tails and are collectively numbered 156.
• FIG. 5 A shows conductive elements in backplane connector 150 arranged in multiple parallel columns.
• each of the parallel columns includes multiple differential pairs of signal conductors, of which differential pairs 540 1 , 54O 2 ...54O 4 are numbered.
• Each column also includes multiple ground conductors. In the embodiment illustrated in FIG. 5A, ground conductors 53O 1 , 53O 2 ...53O 5 are numbered.
• Ground conductors 530i • • .53O 5 and differential pairs 540i ...54O 4 are positioned to form one column of conductive elements within backplane connector 150. That column has conductive elements positioned to align with a column of conductive elements as in a wafer 320B (FIG. 3). An adjacent column of conductive elements within backplane connector 150 may have conductive elements positioned to align with mating contact portions of a wafer 320A. The columns in backplane connector 150 may alternate configurations from column to column to match the alternating pattern of wafers 320A, 320B shown in FIG. 3.
• Ground conductors 53O 2 , 53O 3 and 53O 4 are shown to be wide relative to the signal conductors that make up the differential pairs 54Oi ...54O 4 .
• Narrower ground conductive elements which are narrower relative to ground conductors 53O 2 , 53O 3 and 53O 4 , are included at each end of the column.
• narrower ground conductors 530i and 53O 5 are including at the ends of the column containing differential pairs 54Oi ...54O 4 and may, for example, mate with a ground conductor from daughter card 120 with a mating contact portion shaped as mating contact 434i (FIG. 4B). .
• FIG. 5B shows a view of backplane connector 150 taken along the line labeled B-B in FIG. 5 A.
• an alternating pattern of columns of 560A-560B is visible.
• a column containing differential pairs 540i...540 4 is shown as column 560B.
• FIG. 5B shows that shroud 510 may contain both insulative and lossy regions.
• each of the conductive elements of a differential pair such as differential pairs 54Oi ...54O 4 , is held within an insulative region 522.
• Lossy regions 520 may be positioned between adjacent differential pairs within the same column and between adjacent differential pairs in adjacent columns. Lossy regions 520 may connect to the ground contacts such as 53Oi ...53O 5 .
• Side walls 512 may be made of either insulative or lossy material.
• FIGs. 6A, 6B and 6C illustrate in greater detail conductive elements that may be used in forming backplane connector 150.
• FIG. 6A shows multiple wide ground contacts 53O 2 , 53O 3 and 53O 4 .
• the ground contacts are attached to a carrier strip 620.
• the ground contacts may be stamped from a long sheet of metal or other conductive material, including a carrier strip 620.
• the individual contacts may be severed from carrier strip 620 at any suitable time during the manufacturing operation.
• each of the ground contacts has a mating contact portion shaped as a blade.
• one or more stiffening structures may be formed in each contact.
• a rib, such as 610 is formed in each of the wide ground conductors.
• Each of the wide ground conductors, such as 53O 2 ...53O 4 includes two contact tails.
• For ground conductor 53O 2 contact tails 65O 1 and 656 2 are numbered.
• Providing two contact tails per wide ground conductor provides for a more even distribution of grounding structures throughout the entire interconnection system, including within backplane 160 because each of contact tails 65O 1 and 656 2 will engage a ground via within backplane 160 that will be parallel and adjacent a via carrying a signal.
• FIG. 4A illustrates that two ground contact tails may also be used for each ground conductor in daughter card connector.
• FIG. 6B shows a stamping containing narrower ground conductors, such as ground conductors 530 1 and 53O 5 .
• narrower ground conductors of FIG. 6B have a mating contact portion shaped like a blade.
• the stamping of FIG. 6B containing narrower grounds includes a carrier strip 630 to facilitate handling of the conductive elements.
• the individual ground conductors may be severed from carrier strip 630 at any suitable time, either before or after insertion into backplane connector shroud 510.
• each of the narrower ground conductors such as 530i and 53O 2 , contains a single contact tail such as 656 3 on ground conductor 530) or contact tail 656 4 on ground conductor 53O 5 .
• a single contact tail such as 656 3 on ground conductor 530
• contact tail 656 4 on ground conductor 53O 5 Even though only one ground contact tail is included, the relationship between number of signal contacts is maintained because narrow ground conductors as shown in FIG. 6B are used at the ends of columns where they are adjacent a single signal conductor.
• each of the contact tails for a narrower ground conductor is offset from the center line of the mating contact in the same way that contact tails 656j and 656 2 are displaced from the center line of wide contacts. This configuration may be used to preserve the spacing between a ground contact tail and an adjacent signal contact tail.
• the narrower ground conductors such as 530
• 53O 5 are also shorter than the wider ground conductors such as 53O 2 ...53O 4 .
• the narrower ground conductors shown in FIG. 6B do not include a stiffening structure, such as ribs 610 (FIG. 6A). However, embodiments of narrower ground conductors may be formed with stiffening structures.
• FIG. 6C shows signal conductors that may be used to form backplane connector 150.
• the signal conductors in FIG. 6C like the ground conductors of FIGs. 6A and 6B, may be stamped from a sheet of metal. In the embodiment of FIG.
• the signal conductors are stamped in pairs, such as pairs 54O 1 and 54O 2 .
• the stamping of FIG. 6C includes a carrier strip 640 to facilitate handling of the conductive elements.
• the pairs, such as 54O 1 and 54O 2 may be severed from carrier strip 640 at any suitable point during manufacture.
• the signal conductors and ground conductors for backplane connector 150 may be shaped to conform to each other to maintain a consistent spacing between the signal conductors and ground conductors.
• ground conductors have projections, such as projection 660, that position the ground conductor relative to floor 514 of shroud 510.
• the signal conductors have complimentary portions, such as complimentary portion 662 (FIG. 6C) so that when a signal conductor is inserted into shroud 510 next to a ground conductor, the spacing between the edges of the signal conductor and the ground conductor stays relatively uniform, even in the vicinity of projections 660.
• signal conductors have projections, such as projections 664 (FIG. 6C).
• Projection 664 may act as a retention feature that holds the signal conductor within the floor 514 of backplane connector shroud 510 (FIG. 5A).
• Ground conductors may have complimentary portions, such as complementary portion 666 (FIG. 6A). When a signal conductor is placed adjacent a ground conductor, complimentary portion 666 maintains a relatively uniform spacing between the edges of the signal conductor and the ground conductor, even in the vicinity of projection 664.
• FIGs. 6A, 6B and 6C illustrate examples of projections in the edges of signal and ground conductors and corresponding complimentary portions formed in an adjacent signal or ground conductor. Other types of projections may be formed and other shapes of complementary portions may likewise be formed.
• backplane connector 150 may be manufactured by inserting signal conductors and ground conductors into shroud 510 from opposite sides. As can be seen in FIG. 5 A, projections such as 660 (FIG. 6A) of ground conductors press against the bottom surface of floor 514. Backplane connector 150 may be assembled by inserting the ground conductors into shroud 510 from the bottom until projections 660 engage the underside of floor 514. Because signal conductors in backplane connector 150 are generally complementary to the ground conductors, the signal conductors have narrow portions adjacent the lower surface of floor 514. The wider portions of the signal conductors are adjacent the top surface of floor 514.
• backplane connector 150 may be assembled by inserting signal conductors into shroud 510 from the upper surface of floor 514. The signal conductors may be inserted until projections, such as projection 664, engage the upper surface of the floor. Two-sided insertion of conductive elements into shroud 510 facilitates manufacture of connector portions with conforming signal and ground conductors.
• FIGs. 7 A and 7B illustrate schematically a connector with complementary conductive elements and a method of manufacturing such a connector.
• FIG. 7 A illustrates in cross-section a portion of an electrical connector.
• the connector illustrated may be a backplane connector 150 as shown in FIGs. 5 A and 5B.
• FIG. 7 A is a cross-section through a portion of one column of conductive elements in the connector.
• conductive elements 740, 740, 74O 2 , and 74O 3 have a similar shape.
• conductive elements 74O 2 and 74O 3 may serve as signal conductors. Accordingly, these conductive elements may be arranged in pairs.
• FIG. 7A shows conductive elements 74O 2 and 74O 3 arranged as a pair positioned to carry a differential signal.
• the portion of the connector illustrated in FIG. 7A does not show a second conductive element with which conductive element 740 is paired.
• an additional signal conductor adjacent conductive element 740 may be present. More generally, the pattern of conductive elements illustrated in FIG. 7 A may be extended to form a column of conductive elements of any suitable length with any suitable arrangement of conductive elements.
• the conductive elements in that column may be shaped like either conductive element 740 or conductive element 790. Accordingly, the shape are manufacture of FIGs. 7A and 7B is explained by reference to conductive elements 740 and 790. However, similar description applies to other conductive elements such as conductive elements 74O 2 , 74O 3 and 79O 2 .
• conductive elements 740 and 790 each contains a mating contact portion, 754 and 714, respectively. In the embodiment illustrated, each mating contact portion is shaped as a blade. However, the shape of the mating contact portion is not a limitation on the invention and conductive elements may be formed with mating contact portions of any suitable shape.
• FIG. 7 A also shows conductive element 790 and 79O 2 .
• a conductive element such as conductive element 790 or 79O 2 is shown adjacent each pair of conductive elements that acts as signal conductors.
• conductive element 790 is shown to be wider than conductive element 740.
• conductive element 790 is shown with two contact tails, 716A and 716B. As described above, such a configuration may be desirable for a ground conductor. Accordingly, conductive element 790 may represent a ground conductor.
• the invention is not limited by the type of signals or potentials carried by the conductive elements.
• a high-density connector it may be desirable to position the signal conductors, such as conductive elements 740, 74O 2 and 74O 3 close to adjacent ground conductors, such as 790 and 79O 2 .
• the signal conductors such as conductive elements 740, 74O 2 and 74O 3 close to adjacent ground conductors, such as 790 and 79O 2 .
• conductive element 740 is illustrated with projections 760.
• Projection 760 may be a barb or other retention feature that engages housing 758 when conductive element 740 is inserted into housing 758.
• Conductive element 790 also contains projections 730. Projections 730 may, like projections 760, serve to engage housing 758. Alternatively, projections 730 may allow separation between contact tails 716A and 716B so that current flows in a desired pattern though conductive element 790 or to position ground vias in a printed circuit board close to vias carrying signals. Regardless of the reason that conductive elements contain projecting portions, such as projections 730 and 760, when the conductive elements are positioned close together, the projecting portions can alter the electrical characteristics of a conductive element.
• FIG. 7A illustrates that conductive elements 740 and 790 are formed with relieved portions 766 and 736, respectively.
• Each relieved portion is configured to be complementary to a projection in an adjacent conductive element.
• relieved portion 736 is configured to be complementary to projection 760.
• relieved portion 766 is configured to be complementary to projection 730.
• conductive element 740 and conductive element 790 have an edge-to-edge spacing D 2 in a cross-section through mating contact portions 714 and 754.
• conductive element 740 and conductive element 790 In a cross-section through projection 760 and relieved portion 736, conductive element 740 and conductive element 790 have an edge-to-edge spacing of D 3 .
• conductive element 740 and conductive element 790 In a cross- section through relieved portion 766 and projection 730, conductive element 740 and conductive element 790 have an edge-to-edge spacing of Di. As can be seen from FIG. 7A, the separations D 1 , D 2 and D 3 may not be exactly the same.
• center line Cu of conductive element 740 may be spaced from center line CL 2 of conductive element 790 by a spacing on the order of one millimeter.
• the spacing between center line CLI and center line CL 2 may be between approximately 0.8 millimeters and 1.5 millimeters. In other embodiments, the spacing may be approximately 1.1 millimeter.
• the projecting portions of adjacent conductive elements may overlap. For example, as shown in FIG. 7A, projection 760 overlaps projection 730. Likewise, projection 73O 2 overlaps projection 76O 2 of an adjacent conductive element 74O 2 .
• FIG. 7A projection 760 overlaps projection 730.
• projection 73O 2 overlaps projection 76O 2 of an adjacent conductive element 74O 2 .
• FIG. 7B illustrates schematically a method by which a connector containing conductive elements with complementary portions may be assembled.
• FIG. 7B shows a portion of a connector, such as backplane connector 150 (FIG. 1).
• the connector is assembled by inserting conductive elements, such as conductive elements 740 and 790, into a housing, such as insulative housing 758.
• a housing may be formed with openings to receive conductive elements.
• the conductive elements may be inserted into openings in the housing 758. As shown, conductive element 740 is inserted into opening 712 and conductive element 790 is inserted into opening 722. Each of the openings 712 and 722, has a shape that generally matches the portions of the conductive element inserted into the opening. However, some portions of each of the conductive elements may be larger than the corresponding opening. For example, opening 712 may have a width smaller than the width of projection 760, such that when conductive element 740 is inserted into opening 712, projection 760 presses against the walls of opening 712.
• housing 758 may be plastic or other soft material that may be displaced by projections 760 when conductive element 740 is inserted into opening 712. Regardless of the specific mechanism by which conductive element 740 engages housing 758, the engaging mechanism may include projections such as projection 760.
• conductive element 740 is inserted from a top surface 710 housing 758.
• shaped conductive elements, such as 74O 2 and 74O 3 (FIG. 7A) may be inserted in the same operation as conductive element 740.
• Conductive element 790 is inserted through opening 722 in a lower surface 720 of housing 758. Similar conductive elements, such as conductive element 79O 2 (FIG. 7A) may be inserted in the same operation.
• the projections of adjacent conductive elements do not interfere with each other, even if they overlap
• the conductive elements inserted through lower surface 720 and the conductive elements inserted through upper surface 710 may be inserted in the same operation using a tool that can access two surfaces of housing 758 simultaneously.
• the conductive element inserted through upper surface 710 and the conductive element inserted through lower surface 720 may be inserted in separate, sequential operations.
• the specific timing of the insertion is not a limitation of the invention. Accordingly, the conductive element may be inserted in any suitable order.

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• 2008
  • 2008-04-04 WO PCT/US2008/004386 patent/WO2008124052A2/fr active Application Filing

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