WO2022118222A1

WO2022118222A1 - Cable assembly

Info

Publication number: WO2022118222A1
Application number: PCT/IB2021/061193
Authority: WO
Inventors: Saujit Bandhu; Yunlong Qiao; Kok Hoe LEE; Chin Hua Lim
Original assignee: 3M Innovative Properties Company
Priority date: 2020-12-02
Filing date: 2021-12-01
Publication date: 2022-06-09
Also published as: CN220253637U

Abstract

A connector system is disclosed. The connector system includes a mating connector, a cage forming a part of the mating connector, and a cable assembly. The cable assembly includes a printed circuit board having one or more conductive contact pads and an overmold encapsulating at least a portion of the printed circuit board. The overmold defines an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, and a mating face perpendicular to an X direction. A mating portion of the printed circuit board extends forwardly from the mating surface and one or more cables extend rearwardly from the printed circuit board along the X direction. A lateral projection extends along the X direction, and the lateral projection is adapted to be disposed below, along the Z direction, an upper portion of the cage when the cable assembly is connected to the mating connector.

Description

CABLE ASSEMBLY

Background

Servers in data centers have ever-increasing data rates. Improved and standardized connectors offer superior mechanical performance, electrical performance and cost characteristics over current PCB cable assemblies

Summary

In some aspects of the present disclosure, a connector system is disclosed. The connector system can include a mating connector, a cage forming a part of the mating connector, and a cable assembly. The cable assembly can include a printed circuit board having one or more conductive contact pads and an overmold encapsulating at least a portion of the printed circuit board. The overmold can define an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, and a mating face perpendicular to an X direction. A mating portion of the printed circuit board can extend forwardly from the mating surface along the X direction. One or more cables can extend rearwardly from the printed circuit board along the X direction, and a lateral projection can extend along the X direction. The lateral projection can be adapted to be disposed below, along the Z direction, an upper portion of the cage when the cable assembly is connected to the mating connector.

In some aspects of the present disclosure, a cable assembly is disclosed. The cable assembly system can include a printed circuit board having one or more conductive contact pads and an overmold encapsulating at least a portion of the printed circuit board. The overmold can define an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, opposed lateral retaining surfaces spaced apart along the Y direction, and a mating face perpendicular to an X direction. A mating portion of the printed circuit board can extend forwardly from the mating surface. One or more cables can extend rearwardly from the printed circuit board along the X direction, and a lateral projection can extend along the X direction. The lateral projection can be disposed between, along the Y direction, the opposed lateral surfaces.

In some aspects of the present disclosure, a cable assembly is disclosed. The cable assembly system can include a printed circuit board having one or more conductive contact pads, and an overmold encapsulating at least a portion of the printed circuit board. The overmold can define an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, opposed lateral retaining surfaces spaced apart along the Y direction, and a mating face perpendicular to an X direction. A mating portion of the printed circuit board can extend forwardly from the mating surface, and one or more cables can extend rearwardly from the printed circuit board along the X direction. The lateral retaining surfaces can be disposed between, as measured along the Y direction, the opposed lateral surfaces.

Brief Description of the Drawings

FIG. 1 is an upper perspective view of a connector system, showing a mating connector and a cable assembly in a separated position, according to exemplary embodiments of the present disclosure.

FIG. 2 is an upper perspective view of a mating connector, showing a mating connector and a cable assembly in a connected position, according to exemplary embodiments of the present disclosure.

FIG. 3 is an upper perspective view of a mating connector, according to exemplary embodiments of the present disclosure.

FIG. 4 is an upper perspective view of a mating connector, showing a mating connector and a cable assembly in a connected position, according to exemplary embodiments of the present disclosure.

FIG. 5 is an upper perspective view of a cable assembly, according to exemplary embodiments of the present disclosure.

FIG. 6 is an upper perspective view of a cable assembly, according to exemplary embodiments of the present disclosure.

FIG. 7 is a lower perspective view of a cable assembly, according to exemplary embodiments of the present disclosure.

FIG. 8 is a perspective cross-sectional view of a cable assembly connected to a mating connector, according to exemplary embodiments of the present disclosure.

FIG. 9 is a cross-sectional view of a cable assembly connected to a mating connector, according to exemplary embodiments of the present disclosure.

Detailed Description

In the following description, reference is made to the accompanying drawings that form a part hereof and in which various embodiments are shown by way of illustration. The drawings are not necessarily to scale. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present description. The following detailed description, therefore, is not to be taken in a limiting sense. All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure. Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

Spatially related terms, including but not limited to, “lower,” “upper,” “beneath,” “below,” “above,” and “on top,” if used herein, are utilized for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation in addition to the particular orientations depicted in the figures and described herein. For example, if an object depicted in the figures is turned over or flipped over, portions previously described as below or beneath other elements would then be above those other elements.

As used herein, when an element, component or layer for example is described as forming a “coincident interface” with, or being “on” “connected to,” “coupled with” or “in contact with” another element, component or layer, it can be directly on, directly connected to, directly coupled with, in direct contact with, or intervening elements, components or layers may be on, connected, coupled or in contact with the particular element, component or layer, for example. When an element, component or layer for example is referred to as being “directly on,” “directly connected to,” “directly coupled with,” or “directly in contact with” another element, there are no intervening elements, components or layers for example.

As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that the terms “consisting of’ and “consisting essentially of’ are subsumed in the term “comprising,” and the like.

The data center industry has created several data center consortiums in recent years to offer standardized data products and to encourage data/computer sever suppliers to build servers with higher data rates. Common printed circuit board (PCB) materials available today require improvements as data rates continue to increase. As a result, special high-performance materials are being developed, but these materials can be costly. For some applications, a costly repeater/retimer component may be necessary when using common PCB materials to improve signal quality over long circuit traces, connectors, and cables. Twinaxial cables, or “Twinax”, may be used to eliminate or minimize the need for costly PCB materials and repeater/retimers. A Mini Cool Edge IO (MCIO) application can be designed to work with a number of interfaces, and improved interface designs for a cable assembly and/or a mating connector can enhance connection security, mechanical rigidity, and ease of manual connection or disconnection. Disclosed embodiments of an MCIO cable assembly can be used in next generation server applications which support PCIe Gen4 / Gen5 speeds.

Turning to the figures, FIG. 1 is an upper perspective view of a connector system, showing a mating connector and a cable assembly in a separated position, according to exemplary embodiments of the present disclosure, FIG. 2 is an upper perspective view of a mating connector, showing a mating connector and a cable assembly in a connected position, according to exemplary embodiments of the present disclosure, FIG. 3 is an upper perspective view of a mating connector, according to exemplary embodiments of the present disclosure, and FIG. 4 is an upper perspective view of a mating connector, showing a mating connector and a cable assembly in a connected position, according to exemplary embodiments of the present disclosure. Together, the cable assembly 108 and the mating connector 104 can form a connector system 100, and the cable assembly 108 and the mating connector 104 can releasably connect to one another as exemplarily shown in FIGS. 2 and 4. It is to be understood that the disclosed mating connector 104 and/or board mount connector 107 are shown and described as merely exemplary elements, and that a wide range of mating connectors 104 and/or board mount connectors 107 are within the scope of this disclosure and can connect to the disclosed cable assembly 108 in the manners disclosed and shown.

FIG. 5 is an upper perspective view of a cable assembly, according to exemplary embodiments of the present disclosure, FIG. 6 is an upper perspective view of a cable assembly, according to exemplary embodiments of the present disclosure, and FIG. 7 is a lower perspective view of a cable assembly, according to exemplary embodiments of the present disclosure. The cable assembly 108 can include a latch 130, a Printed Circuit Board (PCB) 140 and an overmold 150. As will be described further below, the latch 130 can define a latch engagement portion 132 and the PCB 140 can define a mating portion 142 and one or more electrically conductive contact pads 144. The PCB can have a thickness of 1.57, or about 1.57, mm. As can be seen in the figures, an X direction can be orthogonal to a Y direction, and each of the X direction and the Y direction can be orthogonal to a Z direction. For clarity, moving rearwardly along the X direction can indicate moving from the overmold 150 along the cables 120 towards the upper-right in FIG. 1, while moving forwardly along the X direction can indicate the opposite direction. Further, moving upwardly along the Z direction can indicate moving upward vertically, as shown in FIG. 1, while moving downwardly along the Z direction can indicate the opposite direction. Moving to the lower right, from the perspective of FIG. 1, can indicate moving forwardly in the Y direction, whereas moving in the opposite direction can indicate moving rearwardly in the Y direction.

The mating connector 104, which in some embodiments can be a board mount connector 107, can releasably or permanently connect with the cable assembly 108 in an electrical and/or mechanical fashion. Such a connection is exemplary shown, as a connector system 100, in FIG. 3. The mating connector 104 can receive a portion of the PCB 140 and can electrically connect to one or more conductive contact pads 144 on the PCB 140. The mating connector 104 can include a cage 106. The cage 106 can provide structural support and an engagement interface for the mating connector 104, and can further define an upper cage portion 109. The cage 106, or upper cage portion 109, can also engage with latch engagement portions 132 of the latch 130 to thereby permanently or releasably connect the mating connector 104 to the cable assembly 108.

In some embodiments, the conductive pads 144 can be disposed on a forward portion 142, or a mating portion, of the PCB. One or more cables 120, which can be TwinAx cables, can extend rearwardly along the X direction. The cables 120 can be electrically connected to portions of the PCB 140, which can be rear portions of the PCB 140. In various embodiments, the PCB 140 extends farther forwardly along the X direction than do all portions of a mating face 172 below, as measured along the Z direction, the PCB 140.

The overmold 150 can be proximate and/or in contact with the PCB 140 and, in some embodiments, can circumscribe, encapsulate, partially circumscribe or partially encapsulate a portion of the PCB 140, such as a rear portion of the PCB 140 as measured along the X direction. The overmold 150 can include electrically insulating, or substantially insulating, materials such as, but not limited to, polymers, rubbers, ceramics, organic materials, metals, carbon, and metal alloys. As can be exemplarily seen in the figures, the overmold 150 can define an upper surface 160 perpendicular to the Z direction, a lower surface perpendicular to the Z direction, opposed lateral surfaces 168a, 168b perpendicular to the Y direction, opposed lateral retaining surfaces 180a, 180b perpendicular to the Y direction, and a mating face 172 perpendicular to the X direction. In various embodiments, one or more of the upper surface 160, lower surface 164, opposed lateral surfaces 168a, 168b, lateral retaining surfaces 180a, 180b, and mating face 172 need not be perpendicular to, or parallel with, any of the X, Y or Z directions. One or more shoulders 176 can be defined in the overmold 150 proximate the mating face 172, upper surface 160, opposed lateral surfaces 168a, 168b and/or lateral retaining surfaces 180a, 180b. In some embodiments, one or both of the lateral retaining surfaces 180a, 180b are disposed between, as measured along the Y direction, the opposed lateral surfaces 168a, 168b.

FIGS. 5-7 show various features of the overmold 150, including a central projection 200, a first lateral projection 220a, a second lateral projection 220b, a first upper projection 250a and a second upper projection 250b. The central projection 200 can extend from the overmold 150, and in some embodiments extends forwardly along the X direction. In some embodiments, the central projection 200 can extend from the mating face 172. The central projection 200 can define a central projection leading edge 202, which can be a forward-most portion of the central projection 200 as measured along the X-direction. The central projection 200 can also define an upper surface 203, which can be flush or co-planar with the upper surface 160. The upper surface 203 can also be perpendicular to the Z direction, and can define an upper-most surface of the central projection 200 along the Z direction. A central projection lower angled surface 204, a central projection upper angled surface 208 and central projection lateral angled surfaces 212a, 212b, can be formed towards the forward portion (along the X direction) of the central projection 200.

The central projection lower angled surface 204 can be angled to be non-parallel with the X and Z directions and parallel with the Y direction. The central projection upper angled surface 208 can be angled to be non-parallel with the X and Z directions and parallel with the Y direction. The central projection lateral angled surfaces 212a, 212b can be angled to be non-parallel with the X and Y directions and parallel with the Z direction. In various embodiments, a width of the central projection 200, as measured along the Y direction, is, is about, is at least, or is at most 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% or 50% of a distance between opposed lateral surfaces 168a, 168b and/or between opposed lateral retaining surfaces 180a, 180b.

The first lateral projection 220a can extend from the overmold 150, and in some embodiments extends forwardly along the X direction. The first lateral projection 220a can extend from the mating face 172. In some embodiments, the first lateral projection 220a is disposed between, along the Y direction, the opposed lateral surfaces 168a, 168b. The first lateral projection 220a can define a leading edge 228a, an outward lateral surface 230a, an upper surface 232a, a lower surface 234a, and an angled surface 236a. The leading edge 228a can define a forward-most surface of the first lateral projection 220a as measured along the X direction. The leading edge 228a can also be disposed forward of the mating face 172 as measured along the X direction.

The outward lateral surface 230a can define a lateral surface of the first lateral projection 220a. The outward lateral surface 230a can be perpendicular to, or substantially perpendicular to, the Y direction. In some embodiments, the outward lateral surface 230a is disposed closer to the latch 130, central projection 200, and/or a centerline (parallel to the X direction) of the cable assembly 108, as measured along the Y direction, than are one or more of the opposed lateral surfaces 168a, 168b. In some embodiments, the outward lateral surface 230a is parallel to, or substantially parallel to, one or more of the opposed lateral surfaces 168a, 168b. In some embodiments, the outward lateral surface 230a is parallel to, or substantially parallel to, one or more of the lateral retaining surfaces 180a, 180b. The outward lateral surface 230a can be flush with, or coplanar with, the lateral retaining surface 180a. Additionally, the outward lateral surface 230a can be an outer-most surface of the first lateral projection 220a as measured along the Y direction moving from the central projection 200, latch 130 and/or the centerline (parallel to the X direction) of the cable assembly 108 outwardly along the Y direction.

The upper surface 232a can be perpendicular to, or substantially perpendicular to, the Z axis. In some embodiments, the upper surface 232a is parallel to, or substantially parallel to, one or more of the upper surface 160, lower surface 164, central projection upper surface 203, first upper projection upper surface 266a and second upper projection upper surface 266b. The upper surface 232a can also be an uppermost portion of the first lateral projection 220a, as measured along the Z direction.

The lower surface 234a can be perpendicular to, or substantially perpendicular to, the Z axis. In some embodiments, the lower surface 234a is parallel to, or substantially parallel to, one or more of the upper surface 160, lower surface 164, central projection upper surface 203, first upper projection upper surface 266a and second upper projection upper surface 266b. The upper surface 232a can also be a lowermost portion of the first lateral projection 220a, as measured along the Z direction. In some embodiments, the lower surface 234a is parallel to, or substantially parallel to, the upper surface 232a.

In some embodiments, the first lateral projection 220a can define an angled surface 236a. Various portions of the angled surface 236a can be disposed between the leading edge 228a and the upper surface 232a, between the leading edge 228a and the lower surface 234a and/or between the leading edge 228a and the outward lateral surface 230a. The angled surface 236a can include portions that are non-perpendicular to the X, Y and/or Z directions, parallel to the X, Y and/or Z directions, perpendicular to the X, Y and/or X directions and/or substantially perpendicular to the X, Y and/or X directions. For example, portions of the angled surface 236a disposed between the leading edge 228a and the upper surface 232a can be parallel with the Y direction, and non-parallel with the X and Z directions. Portions of the angled surface 236a disposed between the leading edge 228a and the lower surface 234a can be parallel with the Y direction, and non-parallel with the X and Z directions. Portions of the angled surface 236a disposed between the leading edge 228a and the outward lateral surface 230a can be parallel with the Z direction, and non-parallel with the X and Y directions. In some embodiments, the angled surface 236a can include a rounded, curved or curvilinear portion.

In various embodiments, a width of the first lateral projection 220a, as measured along the Y direction, is, is about, is at least, or is at most 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65% or 70% of a distance between the opposed lateral surface 168a and the central projection 200. In various embodiments, a width of the first lateral projection 220a, as measured along the Y direction, is, is about, is at least, or is at most 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65% or 70% of a distance between the lateral retaining surface 180a and the central projection 200.

The first lateral projection 220a and the second lateral projection 220b can be identical, similar, and/or can be mirror images of each other as seen across a plane containing the X and Z directions between the first lateral projection 220a and the second lateral projection 220b. However, for clarity, the second lateral projection 220b will now be described in detail.

The second lateral projection 220b can extend from the overmold 150, and in some embodiments extends forwardly along the X direction. The second lateral projection 220b can extend from the mating face 172. In some embodiments, the second lateral projection 220b is disposed between, along the Y direction, the opposed lateral surfaces 168a, 168b. The second lateral projection 220b can define a leading edge 228b, an outward lateral surface 230b, an upper surface 232b, a lower surface 234b, and an angled surface 236b. The leading edge 228b can define a forward-most surface of the second lateral projection 220b as measured along the X direction. The leading edge 228b can also be disposed forward of the mating face 172 as measured along the X direction.

The outward lateral surface 230b can define a lateral surface of the second lateral projection 220b. The outward lateral surface 230b can be perpendicular to, or substantially perpendicular to, the Y direction. In some embodiments, the outward lateral surface 230b is disposed closer to the latch 130, central projection 200, and/or a centerline (parallel to the X direction) of the cable assembly 108, as measured along the Y direction, than are one or more of the opposed lateral surfaces 168a, 168b. In some embodiments, the outward lateral surface 230b is parallel to, or substantially parallel to, one or more of the opposed lateral surfaces 168a, 168b. In some embodiments, the outward lateral surface 230b is parallel to, or substantially parallel to, one or more of the lateral retaining surfaces 180a, 180b. The outward lateral surface 230b can be flush with, or coplanar with, the lateral retaining surface 180b. Additionally, the outward lateral surface 230b can be an outer-most surface of the second lateral projection 220b as measured along the Y direction moving from the central projection 200, latch 130 and/or a centerline (parallel to the X direction) of the cable assembly 108 outwardly along the Y direction. The upper surface 232b can be perpendicular to, or substantially perpendicular to, the Z axis. In some embodiments, the upper surface 232b is parallel to, or substantially parallel to, one or more of the upper surface 160, lower surface 164, central projection upper surface 203, first upper projection upper surface 266a and second upper projection upper surface 266b. The upper surface 232b can also be an uppermost portion of the second lateral projection 220b, as measured along the Z direction.

The lower surface 234b can be perpendicular to, or substantially perpendicular to, the Z axis. In some embodiments, the lower surface 234b is parallel to, or substantially parallel to, one or more of the upper surface 160, lower surface 164, central projection upper surface 203, first upper projection upper surface 266a and second upper projection upper surface 266b. The upper surface 232b can also be a lowermost portion of the second lateral projection 220b, as measured along the Z direction. In some embodiments, the lower surface 234b is parallel to, or substantially parallel to, the upper surface 232b.

In some embodiments, the second lateral projection 220b can define an angled surface 236b. Various portions of the angled surface 236b can be disposed between the leading edge 228b and the upper surface 232b, between the leading edge 228b and the lower surface 234b and/or between the leading edge 228b and the outward lateral surface 230b. The angled surface 236b can include portions that are non-perpendicular to the X, Y and/or Z directions, parallel to the X, Y and/or Z directions, perpendicular to the X, Y and/or X directions and/or substantially perpendicular to the X, Y and/or X directions. For example, portions of the angled surface 236b disposed between the leading edge 228b and the upper surface 232b can be parallel with the Y direction, and non-parallel with the X and Z directions. Portions of the angled surface 236b disposed between the leading edge 228b and the lower surface 234b can be parallel with the Y direction, and non-parallel with the X and Z directions. Portions of the angled surface 236b disposed between the leading edge 228b and the outward lateral surface 230b can be parallel with the Z direction, and non-parallel with the X and Y directions. In some embodiments, the angled surface 236b can include a rounded, curved or curvilinear portion.

In various embodiments, a width of the second lateral projection 220b, as measured along the Y direction, is, is about, is at least, or is at most 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% of a distance between the opposed lateral surface 168b and the central projection 200. In various embodiments, a width of the second lateral projection 220b, as measured along the Y direction, is, is about, is at least, or is at most 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65% or 70% of a distance between the lateral retaining surface 180b and the central projection 200. In various embodiments, the central projection 200 can extend along the X direction farther forwardly, or less far forwardly, than does one or more of the first lateral projection 220a and the second lateral projection 220b.

FIGS. 6 and 7, among others, also show the first upper projection 250a and the second upper projection 250b. The first upper projection 250a can include a base 254a and an upper projection member 258a. The upper projection member 258a can define an upper projection member angled surface 262a and an upper projection member leading edge 264a, which can be a forward-most portion of the first upper projection 250a as measured along the X direction. The base 254a can join to, or be in contact with, the upper surface 160, and the base 254a (and thus the first upper projection 250a) can be directly connected to the upper surface 160 at a location rearward of the mating face 172, as measured along the X direction. The upper projection member 258a can extend along the X direction. In some embodiments, the upper projection member 258a can extend forwardly along the X direction. In various embodiments, the upper projection member leading edge 264a is forward of, along the X direction, the mating face 172, central projection leading edge 202, first lateral projection leading edge 228a and/or second lateral projection leading edge 228b. In various embodiments, the upper projection member leading edge 264a is rearward of, along the X direction, the mating face 172, central projection leading edge 202, first lateral projection leading edge 228a and/or second lateral projection leading edge 228b.

As measured along the Z direction, the upper projection member 258a can be located above the upper surface 160. In some embodiments, a non-zero distance, or a gap, exists between the upper projection member 258a and the upper surface 160, between the upper projection member 258a and the first lateral projection 220a, and/or between the upper projection member 258a and the second lateral projection 220b, as measured along the Z direction. An upper projection member upper surface 266a can be parallel with, or substantially parallel with, the X and Y directions and can be perpendicular with, or substantially perpendicular with, the Z direction. The upper projection member upper surface 266a can be parallel with, or substantially parallel with, the upper surface 160, lower surface 164, upper surface 232a, upper surface 232b, lower surface 234a and/or lower surface 234b. The upper projection member angled surface 262a can be formed at, or proximate, the upper projection member leading edge 264a, and can be angled such that the upper projection member angled surface 262a is non-parallel with the X and Z directions and is parallel with the Y direction.

The first upper projection 250a and the second upper projection 250b can be identical, similar, and/or can be mirror images of each other as seen across a plane containing the X and Z directions located between the first upper projection 250a and the second upper projection 250b. However, for clarity, the second upper projection 250b will now be described in detail. FIGS. 6 and 7, among others, also show the second upper projection 250b. The second upper projection 250b can include a base 254b and an upper projection member 258b. The upper projection member 258b can define an upper projection member angled surface 262b and an upper projection member leading edge 264b, which can be a forward-most portion of the second upper projection 250b as measured along the X direction. The base 254b can join to, or be in contact with, the upper surface 160, and the base 254b (and thus the second upper projection 250b) can be directly connected to the upper surface 160 at a location rearward of the mating face 172, as measured along the X direction. The upper projection member 258b can extend along the X direction. In some embodiments, the upper projection member 258b can extend forwardly along the X direction. In various embodiments, the upper projection member leading edge 264b is forward of, along the X direction, the mating face 172, central projection leading edge 202, first lateral projection leading edge 228a and/or second lateral projection leading edge 228b. In various embodiments, the upper projection member leading edge 264b is rearward of, along the X direction, the mating face 172, central projection leading edge 202, first lateral projection leading edge 228a and/or second lateral projection leading edge 228b.

As measured along the Z direction, the upper projection member 258b can be located above the upper surface 160. In some embodiments, a non-zero distance, or a gap, exists between the upper projection member 258b and the upper surface 160, between the upper projection member 258b and the first lateral projection 220a, and/or between the upper projection member 258b and the second lateral projection 220b, as measured along the Z direction. An upper projection member upper surface 266b can be parallel with, or substantially parallel with, the X and Y directions and can be perpendicular with, or substantially perpendicular with, the Z direction. The upper projection member upper surface 266b can be parallel with, or substantially parallel with, the upper surface 160, lower surface 164, upper surface 232a, upper surface 232b, lower surface 234a and/or lower surface 234b. The upper projection member angled surface 262b can be formed at, or proximate, the upper projection member leading edge 264b, and can be angled such that the upper projection member angled surface 262b is non-parallel with the X and Z directions and is parallel with the Y direction.

In some embodiments, the first upper projection 250a and second upper projection 250b are disposed on opposed sides of the central projection 200, as measured along the Y direction. In various embodiments, the first upper projection 250a and second upper projection 250b are each disposed between opposed lateral surfaces 168a, 168b, as measured along the Y direction. Further, in some embodiments, one or more of the first upper projection 250a and second upper projection 250b directly connect to the overmold 150 at a location rearward, along the X direction, of a location where one or more of the first lateral projection 220a and second lateral projection 220b directly connect to the overmold 150.

As described above, the cable assembly 108 and the mating connector 104 can releasably connect to one another as exemplarily shown in FIGS. 2, 4, 8 and 9. FIG. 8 is a perspective cross- sectional view of a cable assembly connected to a mating connector, according to exemplary embodiments of the present disclosure, and FIG. 9 is a cross-sectional view of a cable assembly connected to a mating connector, according to exemplary embodiments of the present disclosure. Portions of the mating connector 104, such as the mating connector main body 105, cage 106, and cage upper portion 109, can be seen engaging portions of the cable assembly 108.

When the mating connector 104 and the cable assembly 108 are connected, as shown in the figures and described in this disclosure, various features and interactions between features enhance the mechanical security and rigidity of the connection between the mating connector 104 and the cable assembly 108 along the Z direction. In some embodiments, the first and second lateral projections 220a, 220b are below (as measured along the Z direction) the cage 106 and/or the cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. In some embodiments, the first and second lateral projections 220a, 220b are above (as measured along the Z direction) the mating connector main body 105 when the mating connector 104 is connected to the cable assembly 108.

The central projection 200 can be above (as measured along the Z direction), directly above (as measured along the Z direction) and/or in contact with the mating connector main body 105 and below the cage 106 and/or cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. In some embodiments, the upper surface 160 is above (as measured along the Z direction), directly above (as measured along the Z direction) and/or in contact with the mating connector main body 105 and is below (as measured along the Z direction), directly below (as measured along the Z direction) and/or in contact with the cage 106 and/or cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. In some embodiments, the upper projections 250a, 250b, and/or the upper projection members 258a, 258b are above (as measured along the Z direction), directly above (as measured along the Z direction) and/or in contact with the mating connector main body 105, the cage 106 and/or the cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. In various embodiments, the cage 106 and/or the cage upper portion 109 is above (as measured along the Z direction), directly above (as measured along the Z direction) and/or in contact with the upper surface 160, the first lateral projection 220a and/or the second lateral projection 220b, and is below (as measured along the Z direction), directly below (as measured along the Z direction) and/or in contact with the upper projections 250a, 250b and/or the upper projection members 258a, 258b when the mating connector 104 is connected to the cable assembly

108. Further, in some embodiments, a portion of the cage 106 and/or cage upper portion 109 can be located above (as measured along the Z direction), directly above (as measured along the Z direction) and/or in contact with a lower portion (as measured along the Z direction) of the shoulder 176 formed in the overmold 150. Thus, based on the embodiments described and shown, when the mating connector 104 is connected to the cable assembly 108, relative movement between the cable assembly 108 and the mating connector 104 in the Z direction is limited or prevented by contact between one or more of the cage 106, cage upper portion 109, and the mating connector main body 105, and one or more of the first and second lateral projections 220a, 220b, PCB 140, upper surface 160, central projection 200, upper projections 250a, 250b and/or upper projection members 258a, 258b.

When the mating connector 104 and the cable assembly 108 are connected, as shown in the figures and described in this disclosure, various features and interactions between features enhance the mechanical security and rigidity of the connection between the mating connector 104 and the cable assembly 108 along the Y direction. In various embodiments, as measured from a center of the cable assembly 108 along the Y direction, the first and second lateral projections 220a, 220b are laterally inside of or within (as measured along the Y direction), directly inside of or within (as measured along the Y direction) and/or in contact with the cage 106 and/or the cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. Additionally, as measured from a center of the cable assembly 108 along the Y direction, the first and second lateral retaining surfaces 180a, 180b can be laterally inside of or within (as measured along the Y direction), directly within (as measured along the Y direction) and/or in contact with the cage 106 and/or the cage upper portion 109 when the mating connector 104 is connected to the cable assembly 108. Thus, based on the embodiments described and shown, when the mating connector 104 is connected to the cable assembly 108, relative movement between the cable assembly 108 and the mating connector 104 in the Y direction is limited or prevented by contact between one or more of the cage 106, mating connector main body 105 and cage upper portion

109, and one or more of the first and second lateral projections 220a, 220b, PCB 140, central projection 200 and first and second lateral retaining surfaces 180a, 180b.

Furthermore, when the mating connector 104 is connected to the cable assembly 108, relative movement between the cable assembly 108 and the mating connector 104 in the X direction (when moving towards one another) is limited or prevented by contact between one or more of the cage 106, cage upper portion 109 and the mating connector main body 105, and one or more of the mating face 172, upper projections 250a, 250b, latch 130, and/or bases 254a, 254b. The disclosed embodiments provide numerous benefits and mechanisms for the efficient, secure and stable operation of a connector system 100. In particular, any of the above-mentioned features of the overmold 150, such as the first and second lateral projections 220a, 220b, central projection 200, upper surface 160, lateral retaining surfaces 180a, 180b, PCB 140, upper projections 250a, 250b, and/or the upper projection members 258a, 258b can contact, contact in a mechanically biased fashion so as to press two adjacent components together and/or be disposed proximate the mating connector 104, mating connector main body 105, cage upper portion 109 and/or cage 106 when the mating connector 104 is connected to the cable assembly 108. When the contact between the above-described elements is a biased contact, an enhanced mechanical securement can be provided.

Additionally, a board 300, or circuit board, can be seen in FIGS. 3 and 4. It can also be seen how the mating connector 104 has a mating direction substantially parallel with the board 300. As this can pose restrictions on a design of a cable assembly 108 compatible with the mating connector 104, and further these restrictions can hinder mechanical connection properties, disclosed cable assembly 108 embodiments enable both a connection compatibility with such a mating connector 104 and also offer superior mechanical connection security and stability.

In some embodiments, one or more of the overmold 150, PCB 140, cage 106, mating connector main body 105, or any constituent element thereof, can be cast, molded, machined or otherwise formed as a single, integral component. In some embodiments, the overmold 150, PCB 140, cage 106, mating connector main body 105, or any constituent element thereof, can be formed of or can include a metal, metal alloy, polymer, composite material, ceramic, organic material, electrically -conductive material, electrical insulator, or any other material known to those skilled in the art.

The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the embodiments of the present disclosure. Thus, it should be understood that although the present disclosure has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of embodiments of the present disclosure. The complete disclosures of the patents, patent documents, and publications cited herein are incorporated by reference in their entirety as if each were individually incorporated. To the extent that there is any conflict or discrepancy between this specification as written and the disclosure in any document that is incorporated by reference herein, this specification as written will control.

Claims

What is claimed is:

1. A connector system, comprising: a mating connector; a cage forming a part of the mating connector; a cable assembly, the cable assembly comprising: a printed circuit board having one or more conductive contact pads; an overmold encapsulating at least a portion of the printed circuit board, the overmold defining an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, and a mating face perpendicular to an X direction, a mating portion of the printed circuit board extending forwardly from the mating surface; one or more cables extending rearwardly from the printed circuit board along the X direction; and a lateral projection extending along the X direction, the lateral projection adapted to be disposed below, along the Z direction, an upper portion of the cage when the cable assembly is connected to the mating connector.

2. The connector system of claim 1, wherein the lateral projection is directly below, along the Z direction, the upper cage portion when the cable assembly is connected to the mating connector.

3. The connector system of claim 1, wherein the lateral projection is in contact with the upper cage portion when the cable assembly is connected to the mating connector.

4. The connector system of claim 1, further including an upper projection, wherein the upper projection is adapted to be disposed above, along the Z direction, an upper portion of the cage when the cable assembly is connected to the mating connector.

5. The connector system of claim 4, wherein the upper projection is directly above, along the Z direction, the upper cage portion when the cable assembly is connected to the mating connector.

6. The connector system of claim 4, wherein the upper projection is in contact with the upper cage portion when the cable assembly is connected to the mating connector.

7. The connector system of claim 4, wherein the upper projection extends farther forward, along the X direction, than does the lateral projection.

8. The connector system of claim 4, wherein the upper projection directly connects to the overmold at a location rearward, along the X direction, of a location where the lateral projection directly connects to the overmold.

9. The connector system of claim 1, wherein the lateral projection is disposed between, along the Y direction, the opposed lateral surfaces.

10. A cable assembly, comprising: a printed circuit board having one or more conductive contact pads; an overmold encapsulating at least a portion of the printed circuit board, the overmold defining an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, opposed lateral retaining surfaces spaced apart along the Y direction, and a mating face perpendicular to an X direction, a mating portion of the printed circuit board extending forwardly from the mating surface; one or more cables extending rearwardly from the printed circuit board along the X direction; and a lateral projection extending along the X direction, the lateral projection disposed between, along the Y direction, the opposed lateral surfaces.

11. The cable assembly of claim 10, wherein the lateral projection defines a lateral projection upper surface at an upper side, as measured along the Z direction, of the lateral projection, and wherein the lateral projection upper surface is co -planar with the upper surface of the overmold.

12. The cable assembly of claim 10, wherein the lateral projection defines an outward lateral surface at a lateral side, as measured along the Y direction, of the lateral projection, and wherein the outward lateral surface is co-planar with one of the lateral retaining surfaces of the overmold.

13. The cable assembly of claim 10, further including a central projection extending along the X direction, the central projection extending farther forwardly, along the X direction, than does the lateral projection.

14. The cable assembly of claim 10, wherein the PCB extends farther forwardly, along the X directions, than do all portions of the mating face below, as measured along the Z direction, the PCB.

15. The cable assembly of claim 10, further including an upper projection, wherein the upper projection directly connects to the overmold at a location rearward, along the X direction, of a location where the lateral projection directly connects to the overmold.

16. A cable assembly, comprising: a printed circuit board having one or more conductive contact pads; an overmold encapsulating at least a portion of the printed circuit board, the overmold defining an upper surface and a lower surface spaced apart along a Z direction, opposed lateral surfaces spaced apart along a Y direction, opposed lateral retaining surfaces spaced apart along the Y direction, and a mating face perpendicular to an X direction, a mating portion of the printed circuit board extending forwardly from the mating surface; and one or more cables extending rearwardly from the printed circuit board along the X direction; wherein the lateral retaining surfaces are disposed between, as measured along the Y direction, the opposed lateral surfaces.

17. The cable assembly of claim 16, further including a lateral projection extending along the X direction, wherein the lateral projection defines a lateral projection upper surface at an upper side, as measured along the Z direction, of the lateral projection, and wherein the lateral projection upper surface is co-planar with the upper surface of the overmold.

18. The cable assembly of claim 16, further including a lateral projection extending along the X direction, wherein the lateral projection defines an outward lateral surface at a lateral side, as measured along the Y direction, of the lateral projection, and wherein the outward lateral surface is co-planar with one of the lateral retaining surfaces of the overmold.

19. The cable assembly of claim 16, further including a lateral projection extending along the X direction and an upper projection extending along the X direction, wherein the upper projection directly connects to the overmold at a location rearward, along the X direction, of a location where the lateral projection directly connects to the overmold.

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20. The cable assembly of claim 16, wherein the PCB extends farther forwardly, along the X directions, than do all portions of the mating face below, as measured along the Z direction, the PCB.