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
  • H01R13/533—Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure
• • 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
  • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
  • H01R13/627—Snap or like fastening
  • H01R13/6271—Latching means integral with the housing
  • H01R13/6272—Latching means integral with the housing comprising a single latching arm
• • 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
  • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
  • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
  • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
  • H01R13/6592—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable
  • H01R13/6593—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable the shield being composed of different pieces
• • 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
  • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
  • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
  • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
  • H01R13/6594—Specific features or arrangements of connection of shield to conductive members the shield being mounted on a PCB and connected to conductive members
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
  • H01R24/20—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
  • H01R24/22—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable with additional earth or shield contacts
• • 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
  • H01R12/50—Fixed connections
  • H01R12/51—Fixed connections for rigid printed circuits or like structures
  • H01R12/55—Fixed connections for rigid printed circuits or like structures characterised by the terminals
  • H01R12/58—Fixed connections for rigid printed circuits or like structures characterised by the terminals terminals for insertion into holes
• • 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
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
  • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
  • H01R13/41—Securing in non-demountable manner, e.g. moulding, riveting by frictional grip in grommet, panel or base
• • 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
• • 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
  • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
  • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
  • H01R13/6581—Shield structure
• • 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
  • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
  • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
  • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
  • H01R13/65912—Specific features or arrangements of connection of shield to conductive members for shielded multiconductor cable
• • 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
  • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
  • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
  • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
  • H01R13/65912—Specific features or arrangements of connection of shield to conductive members for shielded multiconductor cable
  • H01R13/65915—Twisted pair of conductors surrounded by shield
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R2201/00—Connectors or connections adapted for particular applications
  • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

• This patent application relates generally to interconnection systems, such as those including electrical connectors, used to interconnect electronic assemblies, and more specifically to interconnection systems for harsh environments, such as in a vehicle.
• Electrical connectors are used in many electronic systems. It is generally easier and more cost effective to manufacture a system as separate electronic assemblies, which may be joined together with electrical connectors. Connectors may be used for interconnecting assemblies so that the assemblies may operate together as part of a system. Connectors, for example, may be mounted on printed circuit boards withing two assemblies that are connected by mating the connectors. In other systems, it may be impractical to join two printed circuit boards by directly mating connectors on those printed circuit boards. For example, when the system is assembled, those printed circuit boards may be separated by too great a distance for a direct connection between connectors mounted in the printed circuit boards.
• connections between assemblies may be made through cables.
• the cables may be terminated with connectors that mate with connectors mounted on a printed circuit board.
• connections between assemblies may be made by plugging a connector that is part of cable assembly into a connector that is mounted to printed circuit board.
• a connector terminating a cable may be mated with another connector terminating another cable.
• automotive vehicles include electronic control units (ECUs) for controlling various vehicle systems, such as the engine, transmission (TCUs), security systems, emissions control system, lighting, advanced driver assistance systems (ADAS), entertainment systems, navigation systems, and cameras.
• ECUs electronice control units
• These control units may be manufactured as separate assemblies and connected over one or more vehicle networks formed with cables routed between these assemblies.
• the assemblies may be formed separately and then connected via cables that are terminated with connectors that enable connections to mating connectors terminating other cables or attached to printed circuit boards within the assemblies.
• An automobile presents a harsh environment for an electrical connector. The automobile may vibrate, which can cause a connector to unmate and cease working entirely.
• vibration Even if the vibration does not completely prevent operation of the connector, it can cause electrical noise, which can interfere with operation of electronics joined through interconnects including connectors. Noise, for example, may result from relative movement of components within connectors, which can change the electrical properties of the connector. Variations in the electrical properties, in turn, cause variation in the signals passing through the interconnect, which is a form of noise that interferes with processing the underlying signal.
• an electrical connector comprising at least one electrical conductor and a shield comprising a sheet with a first edge and a second edge.
• the first edge may be joined to the second edge to at least partially encircle a cavity with a perimeter bounded by the sheet.
• At least a part of the at least one electrical conductor may be disposed within the cavity, and the sheet may comprise a tab extending away from the cavity in a direction orthogonal to the perimeter.
• Such an electrical connector may include one or more of the following features: [0009]
• the tab may comprise a latching feature.
• the first edge may be joined to the second edge via interlocking projections and openings at the first edge and the second edge.
• the tab may extend from the first edge of the sheet.
• the tab may comprise a first tab portion extending from the sheet and a second tab portion extending portion; and the first tab portion may be parallel to and adjacent to the second tab portion.
• the first tab portion extends from the sheet at the first edge
• the second tab portion extends from the sheet at the second edge.
• the electrical connector may comprise a mating end; the cavity may be open at the mating end of the connector; the tab may have a first edge facing the mating end and a second edge opposite the first edge; the first edge of the tab is tapered towards the mating end of the connector; and the second edge of the tab may be orthogonal to the perimeter
• the electrical connector may further comprise an insulative housing comprising an opening.
• the insulative housing may comprise a beam comprising a cantilevered end and a latch at the cantilevered end extending into the opening.
• the shield is inserted into the opening, and the beam is configured such that the latch is aligned with the second edge of the tab when the shield is fully inserted into the cavity.
• the latch may comprise a camming surface, and the beam may be configured such that the first edge of the tab is aligned with the camming surface of the latch when the shield is partially inserted into the cavity
• the at least one electrical conductor may comprise a pair of signal terminals.
• shield may comprise a first shield, and the tab may comprise a first tab.
• the electrical connector may comprise a second shield at least partially encircling the cavity, and the second shield may comprise a second tab extending away from the cavity in a direction orthogonal to the perimeter.
• the electrical connector may further comprise a position assurance device comprising a member extending into the cavity and engaging the second tab.
• concepts as disclosed herein may be embodied as an electrical connector, comprising a mating end and a cable termination end, opposite the mating end.
• the electrical connector may comprise at least one electrical conductor; a first shield comprising a first sheet, wherein the first sheet encircles a first portion of a cavity; and a second shield comprising a second sheet.
• the second sheet may encircle a second portion of the cavity, the second portion of the cavity overlapping the first portion of the cavity in a region of overlap.
• At least a part of the at least one electrical conductor may be disposed within the cavity.
• the second shield is inside the first shield and the second shield comprises an outwardly extending embossment.
• the beam may be cut in the first sheet; and the slot of the second shield is disposed in the first linear segment of the second shield.
• the beam may comprise a first segment parallel to the first sheet and a second segment transverse to the first segment, the second segment extends through the opening.
• an electrical connector may be terminated to a cable comprising a cable shield.
• An end of the cable with the cable shield exposed may be inserted in the cavity; the second shield may encircle the cable inserted in the cavity and electrically connect to the exposed cable shield; the first shield may comprise contact beams configured for mating with a ground structure of a complementary connector; and the contact beams of the first shield may be electrically coupled through the first shield, the embossment and the second shield to the cable shield.
• the first shield may comprise at least one beam;
• the second shield may comprise at least one slot, a distal portion of each beam of the at least one beam may extend through a respective slot of the at least one slot;
• concepts as disclosed herein may be embodied as a cable assembly comprising a cable terminated with an electrical connector.
• the electrical connector may comprise a connector shield at least partially encircling a first portion of a cavity; and a metal member within the cavity, the metal member comprising an opening therethrough.
• the cable may comprise a first portion outside the cavity comprising: a first insulated electrical conductor; a second insulated electrical conductor; and a cable shield at least partially surrounding the first and second insulated electrical conductors, with the first and second insulated conductors separated with a first center-to-center spacing.
• the cable may comprise a second portion disposed within the cavity, the second portion comprising the first insulated electrical conductor and the second insulated electrical conductor, with the first and second insulated conductors separated with a second center-to-center spacing.
• the second portion of the cable may pass through the opening of the metal member.
• Such a cable assembly may include one or more of the following features: [0030] The second center-to-center spacing may be larger than the first center-to-center spacing; and the metal member may be configured to match the impedance of the second portion of the cable to the first portion of the cable.
• the cable shield may be absent in the second portion.
• the connector shield is electrically connected to the cable shield.
• the connector may further comprise a ferrule comprising a first annular portion, a second annular portion, and a plurality of arms joining the first annular portion to the second annular portion.
• the cable may pass through the first annular portion and the second annular portion, and the second annular portion may be between the first annular portion and the metal member.
• the first annular portion may contact the cable shield.
• the connector shield may be crimped around the first annular portion; and the connector may further comprise first and second contacts crimped to respective conductors of the first and second insulated conductors.
• the metal member may be an impedance adaptor.
• the ferrule may comprise a first metal sheet formed into a tube; the impedance adapter comprises a second metal sheet formed into a tube; and the first metal sheet and the second metal sheet are of a same material and have a same thickness.
• the metal member may comprise a first end and a second end with the opening extending between the first end and the second end; the opening at the first end may be shaped as an oval; the opening, at the second end may be shaped as an oval with a major axis and embossments extending towards the major axis; and the embossments may be between the first and second insulated electrical conductors.
• concepts as disclosed herein may be embodied as an electrical connector, comprising a conductive housing comprising a chamber; a shield member within and electrically and mechanically engaged to the conductive housing; a terminal assembly disposed within the chamber, the terminal assembly comprising an insulative member and an electrical conductor held by the insulative member.
• the insulative member may comprise a spacer separating at least a portion of the electrical conductor and the shield member.
• Such an electrical connector may include one or more of the following features: [0041]
• the insulative member may comprise a body and the spacer comprises a rib extending from the body.
• the electrical conductor may comprise a terminal comprising a mating contact portion and a contact tail and an intermediate portion joining the mating contact portion and the contact tail; the mating contact portion and the contact tail may extend in perpendicular directions; and the spacer may separate the shield member and a portion of the electrical conductor parallel to the contact tail.
• the second portion of the electrical conductor may be disposed within the chamber of the conductive housing; and the first portion of the electrical conductor is separated from the shield member by the spacer.
• the chamber may be a first chamber, and the conductive housing may comprise a plurality of chambers, including the first chamber, disposed in a row extending in a row direction.
• the shield member may be a first shield member, and the electrical connector may comprise a plurality of shield members within and electrically and mechanically engaged to the conductive housing, the plurality of shield members may include the first shield member.
• Each of the plurality of shield members may comprise a planar portion extending in a direction parallel to the row direction.
• the terminal assembly may be a first terminal assembly, and the electrical connector may comprise a plurality of terminal assemblies, including the first terminal assembly.
• Each of the plurality of terminal assemblies may be disposed in a respective chamber of the plurality of chambers; and each of the plurality of terminal assemblies may comprise a spacer adjacent the planar portion of a respective shield member of the plurality of shield members.
• the row may be a first row.
• the plurality of chambers may be a first plurality of chambers.
• the conductive housing may comprise a second plurality of chambers disposed in a second row extending in the row direction; and the electrical connector may comprise a second plurality of shield members within and electrically and mechanically engaged to the conductive housing.
• the electrical connector may comprise a second plurality of terminal assemblies, each of the second plurality of terminal assemblies disposed in a respective chamber of the second plurality of chambers.
• Each of the second plurality of terminal assemblies may comprise a spacer adjacent a shield member of the second plurality of shield members.
• each terminal assembly of the first plurality of terminal assemblies and the second plurality of terminal assemblies may comprise one pair of electrical conductors, each electrical conductor of the pair being positioned the same distance from an adjacent shield member by the spacer of the terminal assembly.
• the electrical connector may be a board connector comprising a mounting interface configured for mounting to a printed circuity board.
• the conductive housing may comprise inward facing surfaces, and at least two of the inward facing surfaces may comprise grooves.
• the shield may comprise edges disposed within the grooves of the inward facing surfaces such that the shield is held perpendicular to the mounting interface.
• the channel may be a first channel and the insulative member comprises a second channel parallel to the first channel; and the electrical conductor is a first electrical conductor, and the terminal assembly comprises second electrical conductor disposed within the second channel.
• first electrical conductor and the second electrical conductor may be configured as a differential pair.
• first electrical conductor and the second electrical conductor may have the same shape; and the first channel and the second channel may have the same shape.
• FIG. l is a perspective view of an illustrative interconnection system, in accordance with some embodiments.
• FIG. 3D is a perspective view of an electrical contact of the board connector of FIG. 3 A, in accordance with some embodiments.
• FIG. 4A is a perspective view of an illustrative multiport board connector, in accordance with some embodiments.
• FIG. 6 is an exploded perspective view of the cable connector of FIG. 5, in accordance with some embodiments.
• FIG. 8 A is a perspective sectional view of the cable connector of FIG. 6 with the carrier contact position assurance device (CCPA) partially inserted, in accordance with some embodiments.
• CCPA carrier contact position assurance device
• FIG. 9A is a perspective view of an illustrative back shield of the cable connector of FIG. 6 connected to an illustrative front shield of the cable connector, in accordance with some embodiments.
• FIG. 9B is a sectional view of the cable connector of FIG. 9 A, in plane 262 in FIG. 9A, in accordance with some embodiments.
• FIG. 9C is a sectional view of the cable connector of FIG. 9 A, in plane 272 in FIG. 9A, in accordance with some embodiments.
• FIG. 9D is a perspective view of illustrative electrical conductors of the cable connector of FIG. 9A, in accordance with some embodiments.
• FIG. 10C is a cross sectional view of a portion, including the embossment, of the cable connector of FIG. 10A, in accordance with some embodiments.
• FIG. 10D is another cross sectional view of the cable connector of FIG. 10 A, in accordance with some embodiments.
• FIG. 11C is a perspective view of the cable of FIG. 1 IB with a ferrule assembled to the cable, in accordance with some embodiments.
• FIG. 1 ID is a perspective view of the cable of FIG. 11C with a braid of the cable bent over the ferrule, in accordance with some embodiments.
• FIG. 1 IE is a perspective view of the cable of FIG. 1 ID with an impedance adaptor assembled on the cable, in accordance with some embodiments.
• FIG. 1 IF is a perspective view of the cable of FIG. 1 IE with a contact carrier housing and a back shield in a state in which the back shield is partially attached to the cable, in accordance with some embodiments.
• FIG. 11G is a top perspective view of the cable of FIG. 1 IF with a portion of a front shield slid over a portion of the back shield, in accordance with some embodiments.
• FIG. 11H is a bottom perspective view of the cable of FIG. 11G before the front shield is latched to the back shield, in accordance with some embodiments.
• FIG. 1 II is a perspective view of the cable of FIG. 11H with the front shield latched into the back shield, in accordance with some embodiments.
• FIG. 11 J is a cross sectional view of a portion of the cable of FIG. II illustrating the front shield latched into the back shield in additional detail, in accordance with some embodiments.
• FIG. 13 is a perspective view of an illustrative cable connector components to configure a cable connector to mate with the cable connector of FIG. 5, in accordance with some embodiments.
• the inventors have recognized and appreciated techniques for making a connector for providing high data rate transmission that may be economically manufactured yet operates reliably in the harsh environment presented by an automobile. Such a connector would be suitable for interconnecting assemblies in an automotive network, for example. These techniques may be applied in a modular connector system in which a set of components may be combined to form connectors in any of multiple configurations. This modularity reduces costs associated with manufacturing connectors of the types described herein.
• Each connector configuration may be formed with an insulative outer housing that establishes at least a mating interface of the connector.
• the outer housing may be insulative and may also provide latching features.
• the set of components may include insulative outer housings in complementary configurations, which may be used to form two connector configurations that will mate and latch to each other.
• a conductive structure at least partially encircling a cavity may be positioned within the outer housing.
• the cavity may be open at a mating end extending into the mating interface.
• the set of components may include conductive structures in one or more configurations that mate to each other.
• a conductive structure for example, may be die cast with a cavity or may be one or more sheets of metal formed into a tube.
• a tube, forming one conductive structure of the set may be sized to fit within an opening into a cavity of another conductive structure such that the conductive structures can mate.
• the set may include tubes of one radius sized to fit within tubes of a larger radius.
• multiple conductive structures may be incorporated into the same insulative outer housing to configure connectors of different sizes.
• die cast conductive structures may be formed with different numbers of cavities.
• some connectors may be configured with a 1x1 mating interface and other connectors may be configured with mating interfaces of other sizes, such as a 2x2 mating interface or a 2x3 mating interface, for example.
• a terminal assembly may be inserted into the cavity.
• Each terminal assembly may have an insulative member, serving as a terminal carrier, that receives one or more electrical conductors, each of which may serve as a terminal of the connector.
• the set of connector components may include at least two styles of terminals configured to mate to one another, such as pin and receptacle style terminals. Terminals may also have different style tails, with tails configured to be attached to a printed circuit board or to be attached to a conductor of a cable.
• the different mating and mounting configurations may be used in combination to form board connectors or cable connectors with mating interfaces that allow intermating of the connectors.
• a board connector may mate with a cable connector, or two cable connectors may mate, for example.
• SI signal integrity
• a sheet may be stamped with a tab extending from an edge of the sheet.
• the tab may be bent in a direction away from the cavity enclosed by the shield.
• tab portions may extend from two edges of a metal sheet that abut when the sheet is formed into a tube.
• the tab portions may both be bent to be parallel and adjacent one another. In this position, they may be crimped to form a tab and to provide mechanical integrity to the resulting tube, which in turn increases signal integrity by reducing variations in the relative position of the shield and conductors in the cavity formed by the shield.
• a simply formed tab may provide multiple functions in some embodiments.
• securing edges of a sheet through the use of tab portions that extend from edges of the sheet allows secure joining of opposing sides of the sheet without cutting large openings in the portions of sheet encircling the cavity. As openings in the portion of the sheet intended to shield the cavity would reduce shielding effectivenessjoining ends of the sheet via a tab contributes to high signal integrity.
• a tubular shield may be formed as a first shield and a second shield that are reliably yet economically electrically and mechanically connected.
• the first shield for example, may be a front shield, for example, and may include the mating interface.
• the second shield may be a back shield and may be configured to be attached to a cable. A portion of the second shield may fit within a portion of the first shield, or vice versa.
• One of the shields may include an embossment in the region of overlap. The embossment may provide contact, friction and/or electrical connectivity between the shields.
• Mechanical coupling between the first shield and the second shield may be provided by one or more beams, cut into one of the shields, that have cantilevered ends bent to fit into slots in the other shield.
• a further technique may be applied in a connector terminating a cable as part of a cable assembly.
• an end of a cable may be inserted into a cavity at least partially encircled by a shield.
• the end of the cable may be prepared to be attached to the cable connector in ways that change the electrical properties of the cable in that portion compared to the bulk of the cable.
• the cable shield may be removed, and, for a twinax cable, the conductors of the cable may be separated to enable terminals to be attached the conductor.
• This manipulation of the cable structure may change the impedance of this portion of the cable, which may degrade signal integrity.
• a separate metal member may be placed over this portion of the cable and electrically coupled to the shield.
• the metal member reduces the spacing between the conductors of the cable and the shield, which may be connected to ground. As a result of this change in signal to ground spacing, the impedance in the termination portion of the cable may better match the impedance in the bulk cable. In this way, the separate metal member may serve as an impedance adapter.
• the impedance adapter may avoid the need for complex manufacturing operations required to shape the shield to provide a signal to ground spacing for impedance matching.
• connectors such as board connectors formed with a die cast conductive structure configured as a conductive housing.
• the terminal assembly may be inserted into a cavity in the conductive housing, which may form a portion of the shielding around the terminal assembly.
• a separate shield member may be inserted into the conductive housing.
• an insulative member of the terminal assembly may be formed with a spacer.
• the connector may be configured such that the spacer establishes the separation between the inserted shield member and one or more electrical conductors in the terminal assembly.
• the spacer may be a rib, for example. In this way, the components of the connector may be separately manufactured and easily assembled in a way that provides desired electrical properties as a result of establishing a desired signal to ground spacing.
• Another technique may provide for mechanical stability of the electrical conductors within a terminal assembly, without introducing changes of impedance that could lead to poor signal integrity.
• One or more retention features such as barbs, may be provided on the intermediate portions of electrical conductors that are held within the insulative member of a terminal assembly. Such retention features may be large enough to yield stable contact positioning, including by resisting forces and vibration during normal use of the connector in a harsh environment.
• the electrical conductor may be inserted into a channel in the insulative member, and the channel may be narrower in the section encompassing the barb than in other parts of the insulative member. Such a barb, however, may be large enough to appreciably change the impedance along the electrical conductor.
• An impedance compensation section may be included adjacent the barb. In the impedance compensation section, the electrical conductor may be narrowed.
• FIG. 1 is a perspective view of an illustrative interconnection system, in accordance with some embodiments.
• the interconnection system may be used to connect two electronic devices to one another.
• interconnection system 100 is used in high data rate transmission applications (e.g., in applications including ECUs of automotive vehicles).
• the interconnection system comprises a board connector 100 mounted to a printed circuit board 160 and a cable connector 200 terminating a cable 213.
• the interconnection system comprises a board connector 100 mounted to a printed circuit board 160 and a cable connector 200 terminating a cable 213.
• only a portion of printed circuit board 160 and of cable 213 are shown.
• FIG. 2 is an exploded perspective view of the illustrative board connector 100 of FIG. 1 when not mated to cable connector 200, in accordance with some embodiments.
• Board connector 100 includes an opening 158 of the housing 150, which may be arranged to allow passage of electrical conductors therethrough, the mating interface of board connector 100 may be disposed within opening 158.
• the mating interface of a second connector, such as cable connector, 200 may be inserted into opening 158 to mate with board connector 100.
• RECTIFIED SHEET (RULE 91) joined together or may be held together by an insulative housing or other structures of board connector 100.
• board connector 100 includes electrical conductors that may serve as signal conductors.
• a pair of electrical conductors is shown such that the illustrated terminal assembly is configured for passing a differential signal.
• the electrical conductors may have mating contact portions at one end, a tail at the opposite end and an intermediate portion therebetween. Accordingly, the electrical conductors may serve as contacts for the connector.
• the mating contact portions of the electrical conductors are shaped as pins such that board connector 100 is configured as a header.
• the mating contact portions of the electrical conductors in a header connector may be shaped as blades or have other shapes.
• a board connector may have electrical conductors with mating contact portions shaped as receptacles.
• FIG. 2 illustrates a plurality of electrical conductors, including signal conductors 110A and HOB.
• the mating contact portions of the signal conductors extend into opening 158.
• Tails of signal conductors 110A and HOB extend from a mounting interface of board connector 100 for mounting to a substrate, here illustrated as a printed circuit board 160.
• Signal conductors 110A and 110B may be electrically connected to traces or other conductive structures within printed circuit board 160 via conduct! vely plated holes 162 and 163, respectively, on a board 160.
• Opening 158 may be shaped and sized to receive a mating connector therein.
• the mating connector may similarly include electrical conductors configured to electrically connect to mating contact portions of signal conductors 110A and 110B when the interconnection system is in the mated configuration.
• Conductive housing 140 may include features to facilitate attachment to the substrate.
• one or more attachment posts 141 are configured to electrically and mechanically couple conductive housing 140 to the board 160.
• the one or more attachment posts 141 may extend into one or more holes 161, which may be ground vias on board 160.
• the conductive housing may serve as a shield for the terminal assembly and the pair of conductors in the terminal assembly.
• the board connector 100 may include one or more further shield members.
• shield 130 is also inserted into the cavity of conductive housing 140, to further encircle the terminal assembly.
• shield 130 is sized to close the back of the cavity and may be installed after the terminal assembly is inserted.
• Shield 130 is electrically and mechanically coupled to conductive housing 140 such that shield 130 may also be grounded.
• Shield 130 in conjunction with a spacer on insulator 120, may also serve to position the terminal assembly within the cavity and, in so doing, may establish signal to ground spacing for the electrical conductors within the terminal assembly. Such a configuration may provide a desired and stable impedance.
• FIG. 3 A is a sectional view of the illustrative board connector 100 of FIG. 1 and 2, taken along the line 3A-3A in FIG. 2.
• insulator 120 forming a portion of the terminal assembly, may include a spacer, which is here shaped as a rib 121.
• the rib 121 or other spacer, positions the terminal assembly with respect to shield 130.
• the spacer may be sized and arranged to establish a distance between shield 130 and signal conductors 110A and 110B within the terminal assembly.
• FIG. 3C is a sectional view of the board connector 100, along the 3C-3C line of FIG. 3B, in accordance with some embodiments.
• groove 131 configured to receive edges of shield 130, is visible, but shield 130 is not shown for simplicity.
• FIG. 3C the channel for signal conductor 110B has a first portion 343, having a first width, and a second portion 344, having a second width.
• the second width is narrowed than the first width.
• the narrower portions for example, may provide suitable retention, while the wider portions may provide desired electrical properties, such as impedance and/or loss.
• FIG. 3D is a perspective view of an electrical contact of the board connector of FIG. 3 A, in accordance with some embodiments.
• Electrical signal conductor 1 10A may comprise a mating contact portion 1 15, tail 1 13, and an intermediate segment 1 14 joining the mating contact portion 115 and the tail 113.
• the intermediate segment has a first width 117B for over 50% of its length within the channel and is disposed within the channel.
• FIG. 3D illustrates a signal conductor 110A shaped for use in a right angle, board mounted connector.
• barb 112 there is a second barb 112’ near a bend in the signal conductor and a further retention feature 112” near the tail.
• FIG. 4B illustrates a portion of the cross sectional view along the line 4B-4B of FIG. 4A, in accordance with some embodiments.
• a contact in each of two of the ports is visible.
• connector 400 has a pair of contacts in each port.
• the contacts in each port are held in a separate insulator, such that there are four terminal assemblies, one for each of the ports.
• a shield corresponding to each of the terminal assemblies may be inserted into conductive housing 440 blocking removal of the terminal assembly.
• the components forming structures of multiple ports may be combined.
• an insulator may hold signal conductors for two or more ports or a shield may be inserted behind insulators for two or more ports.
• RECTIFIED SHEET (RULE 91) (FIG. 9B) is open at the mating end 520.
• the connector terminates cable 213 at the cable termination end 522.
• the cable connector 200 further includes impedance adaptor 230 which may be disposed around the cable 213.
• the impedance adaptor may be metal and may be in electrical contact with the connector shield.
• Impedance adaptor 230 is closer to the insulated conductors of cable 213 than the connector shield and may substantially cover the portions of the insulated cable conductors from which the cable shield has been removed or folded back. Impedance adaptor may be spaced
• the cable end may be prepared for termination and inserted through ferrule 220 and impedance adapter 230.
• the cable shield may be folded over ferrule 220 and the conductors of cable 213 may be crimped to terminals 240. Terminals 240 may then be inserted into contact carrier housing 250.
• Back shield 260 may then be crimped around ferrule 220.
• Front shield 270 may then be engaged to back shield 260 and latched in place.
• These components may form a terminated cable subassembly that is inserted into housing 290.
• the housing 290 may include an opening 292 to receive the terminated cable subassembly.
• FIG. 8 A is a perspective sectional view of the cable connector of FIG. 6 with a contact carrier position assurance (CCPA) in a partially inserted state.
• the CCPA may comprise a member 282 that can be inserted into an opening 281 in the connector housing 290. In the partially inserted state, member 282 does not block opening 281, providing clearance for a terminated cable subassembly to be inserted properly into housing 290.
• the CCPA may also comprise a beam backing member 285 that can be block deflection of beam 294.
• a beam backing member 285 that can be block deflection of beam 294.
• contact carrier housing 250 extends into the cavity 279 of front shield 270.
• the front shield 270 encircles the mating ends of terminals 240.
• the front shield 270 comprises contact beams 310 configured for mating with a ground structure of a complementary connector, such as board connector 100.
• FIG. 9C is a sectional view of the cable connector of FIG. 9A, taken along the plane 262 in FIG. 9A, in accordance with some embodiments.
• the sheet 264 of the back shield 260 has a first edge 263a and a second edge 263b.
• the first edge 263a of the sheet 264 of the back shield 260 is joined to the second edge 263b of the sheet 264 to at least partially encircle a portion 269 of cavity 279, with
• RECTIFIED SHEET (RULE 91) a perimeter 268 bounded by the sheet.
• the tab 261 of the back shield 260 comprises a latching feature.
• the back shield has axis of elongation 301.
• the first and second insulated conductors 210A and 210B may be separated with a first center-to-center spacing 289 A, while in portion 288B, the first and second insulated conductors 210A and 210B may be separated with a second center-to-center spacing 289B. According to some examples, the spacing 289B may be larger than the spacing 289A.
• ferrule 220 comprises a first and second annular portion, 221 A and 22 IB.
• the first and second annular portions may be connected, for example, using one or more arms.
• Two annular portions provide reliable electrical connection among ground conductors of the terminated cable and also provides mechanical support, which together reduce noise in the cable assembly, even in an environment with substantial vibration.
• Ferrule 220 includes arms 222A and 222B connecting the annular portions 221 A and 22 IB.
• the annular portions 221 A and 22 IB though of different diameters, are concentric.
• the cable passes through the first and second annular portions 221 A and 22 IB.
• the second annular portion 22 IB is provided between the first annular portion and a metal member, such as impedance adaptor 230.
• a terminated cable subassembly may be shielded by a back shield 260 attached to a cable shield and a front shield 270 electrically and mechanically coupled to the back shield.
• a simple, yet robust mechanism may be provided to electrically and mechanically connect the front shield and the back shield. That mechanism may include an embossment on one of the shields and/or one or more beams of one shield that fit within a slot of the other shield.
• FIG. 10A is a top perspective view of an illustrative embossment 962 of the illustrative back shield of FIG. 9A, in accordance with some embodiments.
• An embossment 962 may be provided on an outer surface of the back shield 260.
• the embossment may protrude outward in a direction away from a cavity formed by joining the two edges of the sheet of back shield 260.
• the embossment may be seen in FIGs. 10A and 10B.
• FIG. 10C is a cross sectional view of a portion of the cable connector in FIG. 10A including embossment 962.
• the front shield 270 comprises a sheet 274 encircling a first portion of a cavity 279, and the second sheet encircles a second portion 269 of the cavity.
• the front shield and the back shield overlap in a region of overlap 259.
• the embossment 962 is formed in this region of overlap 259.
• the embossment 962 is configured to provide contact, friction and/or electrical connectivity with the front shield 270 such that the embossment electrically connects the front shield 270 and back shield 260.
• the embossment comprises a ridge extending around at least 40% of the perimeter of the back shield 260.
• FIG. 1 IB is a perspective view of terminals 240 of the cable connector 200, following a crimping operation, in accordance with some embodiments.
• the exposed conductors 210A and 210B may be inserted into terminals 240, and crimped to secure the conductors in the terminals 240.
• impedance adapter 230 may be annular and may be slid over the terminals 240 and the insulated portions of conductors 210A and 21 OB. Impedance adapter 230 may be held by the back shield or in any other suitable way.
• the distal portions 276a and 276b are configured to extend through respective slots (e.g., slots 215a and 215b) of the back shield 260 such that the first shield is mechanically connected to the second shield.
• the beam 272a may comprise a first segment 277aa parallel to the first sheet 274 and a distal portion comprising second segment 277ab that is transverse to the first segment.
• the beam 272b may comprise a first segment 277ba parallel to the first sheet 274 and a distal portion comprising a second segment 277bb that is transverse to the first segment.
• two or more beams and corresponding slots may be provided.
• Cable connector 200 is shown as a receptacle connector configured to mate with a board connector 100 configured as a pin header.
• the construction techniques described herein may be applied to a cable connector with mating contact portions configured with pins by substituting a small number of components for those shown in FIG. 6.
• FIG. 13 is perspective view of illustrative components that can be substituted for components shown in FIG. 6 to form a cable connector 1300 configured to mate with the cable connector 200 of FIG. 5, in accordance with some embodiments.
• the cable connector 1300 may be formed with housing 1390 in place of housing 290, front shield 1370 in place of front shield 270, and terminals 1340 in place of terminals 240.
• other components may alternatively or additionally be substituted.
• a contact carrier housing configured to hold terminals 1340, may be used in place of a contact carrier housing 250.
• the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements.
• This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

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• 2022
  • 2022-08-31 EP EP22865492.7A patent/EP4396909A4/en active Pending
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