Connector assembly

Abstract

An electrical connector assembly may include a plug connector and a receptacle connector that can be mated together. Conductive communication between the plug connector and the receptacle connector is established by mating signal terminals and ground terminals included in terminal assemblies housed in each connector. To align and support the signal terminals and the ground terminals, the terminals may be part of a terminal laminate body and the terminal sub-assembly may be assembled from more than one laminate body. The terminal laminate body may include ground features that improve electrical characteristics and data transmission through the electrical connector assembly.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 897,006, filed on Sep. 6, 2019, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to electrical connectors, and more particularly to input / output connectors suitable for high data rate applications. Background Art

[0004] Input / output (IO) connectors can be designed for various systems, including board-to-board systems, wire-to-wire-to-board systems, and wire-to-board systems. A wire-to-board system includes a free-end connector attached to a wire and a fixed-end connector attached to a substrate. Depending on the requirements and environment in which the connector is intended to be used, there are a wide range of suitable designs for each type of system.

[0005] However, for applications with high data rates and limited physical space, many competing requirements make connector design more challenging. High data rates (data rates equal to or higher than 25 Gbps) typically use differential coupled signal pairs, in which two conductors are electrically coupled and physically arranged in pairs to transmit a differential signal, and the transmitted signal is reflected by the measured electrical difference between the conductor pairs. Differential signals help to better resist stray signals and crosstalk, and preferably maintain sufficient spacing to avoid inadvertent signaling modes with adjacent differential coupled signal pairs. In a connector interface, ground terminals can be added to create a return path to electrical ground and provide shielding between differential pairs. However, if space is a concern, then it is desirable to reduce the connector pitch and bring all the terminals closer together (which increases crosstalk).

[0006] Accordingly, electrical connectors are typically designed to meet both mechanical and electrical requirements. High-speed or high-data-rate electrical connectors are commonly used, for example, in backplane applications that require very high conductor density and high data rates. To meet the required mechanical and electrical requirements, such connectors often incorporate multiple sheet body components having an insulating web that supports multiple conductive terminals. The use of sheet body components is often desired to create a structure that can achieve the required high data rate and is also robust enough to support the required assembly process. However, in situations where high data rates are required and physical space is minimized, the sheet bodies must be configured to minimize the physical footprint of the connector while maintaining sufficient electrical characteristics for data transmission. The present disclosure is directed to an electrical connector for use in such situations.

[0007] The foregoing background discussion is intended solely to assist the reader. It is neither intended to limit the inventions described herein nor to limit or expand the prior art discussed. Accordingly, the foregoing discussion should not be taken as an indication that any particular element of an existing system is not suitable for use with the inventions described herein, nor is it intended to indicate that any element is essential for the practice of the inventions described herein. The practice and use of the inventions described herein are defined by the appended claims. SUMMARY OF THE INVENTION

[0008] The present disclosure illustrates an electrical connector assembly for electrically interconnecting a substrate, such as a printed circuit board, and a plurality of electrical cables. The electrical connector assembly can include a plug connector that is capable of mating with a socket connector. A corresponding terminal subassembly made of a plurality of terminal laminations can be housed within each of the plug connector and the socket connector. The terminal laminations include an array of conductive terminals disposed in a non-conductive terminal support molding. The terminal array can include signal terminals for transmitting data signals and ground terminals. Each terminal can be elongate and have opposite ends configured to mate with or be mounted to corresponding terminals on another connector or a substrate or electrical cable, and a flat intermediate body portion extending between the opposite ends. The signal terminals and the ground terminals are typically aligned in a common array plane by the terminal laminations.

[0009] In one aspect, the terminal subassembly of the plug connector or the socket connector can be associated with a ground bar having a plurality of projecting blades that make mechanical and electrical contact with a plurality of ground terminals on a terminal lamination. The ground bar can be oriented perpendicular to the common array plane of the terminal array and can make contact with the ground terminals intermediate a mating end and a mounting end. One possible advantage of connecting the ground bar between the plurality of ground terminals is that the ground bar can shorten the ground path, which can advantageously affect the electrical characteristics of the terminal lamination.

[0010] In another aspect, the insulating housing of the plug and socket and the terminal subassembly within the insulating housing are capable of moving relative to one another between a first operating position and a second operating position. In the first operating position, the mounting ends of the signal terminals and the ground terminals in the terminal array can extend below a mounting surface defined by the insulating housing to contact conductive ground pads on a substrate. Spacing the mounting surface of the insulating housing above the substrate can facilitate soldering the mounting ends of the terminals to the substrate. In the second operating position, the insulating housing and the terminal subassembly can move relative to one another such that the mounting surface is adjacent to the substrate and coplanar with the mounting ends of the signal terminals and the ground terminals. A cantilevered latching arm and a latching recess can interact cooperatively to function as a pawl for moving the insulating housing and the terminal subassembly between the first operating position and the second operating position.

[0011] In yet another aspect, the terminal sheet body may include a ground shield that provides additional electrical grounding for the ground terminals. The ground shield may be located adjacent to the terminal support molding and extend coextensively with the remainder of the terminal sheet body. The ground shield may include a plurality of ground protrusions that may extend through the terminal support molding to mechanically and electrically connect to the ground terminals in the terminal array. The ground shield may provide additional shielding for conductors that extend into and terminate in the terminal sheet body.

[0012] The above features and advantages of the present disclosure, as well as other features and advantages, will become apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure is illustrated by way of example and not limited to the accompanying drawings, in which like reference numerals indicate like components, and in which:

[0014] Figure 1 is a perspective view of a connector system including a plug connector and a socket connector mounted on a substrate in accordance with the present disclosure.

[0015] Figure 2 is Figure 1 a perspective exploded view of the connector system of [reference to relevant figure] in an undocked state, where the plug connector is mounted on the substrate and not docked with the socket connector.

[0016] Figure 3 is Figure 1 a cutaway perspective view of the connector system of [reference to relevant figure], showing the plug connector and the socket connector docked together.

[0017] Figure 4 is Figure 1 a cutaway assembled view of the connector system of [reference to relevant figure], showing the plug connector not docked with the socket connector.

[0018] Figure 5 is from Figure 1 a perspective view from above of an embodiment of the plug connector of [reference to relevant figure], showing the plug housing and a terminal subassembly having signal terminals and ground terminals disposed in the plug housing.

[0019] Figure 6 is Figure 5 a top view of the plug connector of [reference to relevant figure], showing the plug housing together with the terminal subassembly having signal terminals and ground terminals disposed in the plug housing.

[0020] Figure 7 is a perspective view from the bottom of the plug connector of [reference to relevant figure], showing the surface mount tails from which the signal terminals and ground terminals extend.

[0021] Figure 8It is a three-dimensional assembly view observed from above the plug connector, showing the opposite terminal thin bodies of the terminal sub-assembly removed from the plug housing.

[0022] Figure 9 It is Figure 6 A sectional three-dimensional view of the plug connector taken along line A-A, showing the opposite terminal thin bodies of the terminal sub-assembly arranged in the plug housing.

[0023] Figure 10 It is a three-dimensional assembly view observed from below the plug connector, showing the opposite terminal thin bodies of the terminal sub-assembly removed from the plug housing.

[0024] Figure 11 It is along Figure 6 A sectional assembly view of the plug connector taken along line A-A, showing the opposite terminal modules of the terminal sub-assembly removed from the plug housing.

[0025] Figure 12 It is a three-dimensional view of a terminal thin body of the terminal sub-assembly of the plug connector, including signal terminals and ground terminals arranged in a terminal support molding.

[0026] Figure 13 It is a top view of a terminal thin body including signal terminals and ground terminals arranged in a terminal support molding.

[0027] Figure 14 It is along Figure 13 A sectional view of the terminal thin body taken along line A-A between two signal terminals arranged in the terminal support molding.

[0028] Figure 15 It is along Figure 13 A sectional view of the terminal thin body taken along line B-B passing through a ground terminal arranged in the terminal support molding.

[0029] Figure 16 It is a three-dimensional detail view of one end of the terminal thin body, showing signal terminals and ground terminals arranged in the terminal support molding.

[0030] Figure 17 It is a three-dimensional view of the terminal thin body of the terminal sub-assembly, showing the mechanical and electrical connection between the ground terminal and a ground bar.

[0031] Figure 18 It is a three-dimensional detail view of one end of the terminal thin body of the terminal sub-assembly, showing the mechanical and electrical connection between the ground terminal and the ground bar.

[0032] Figure 19Is a side view of a plug connector mounted on a substrate in a first operating position.

[0033] Figure 20 Is a side view of a plug connector mounted on a substrate in a second operating position.

[0034] Figure 21 Is a three-dimensional detail view of the plug connector, in which a part of the plug housing is removed to show the first operating position of the plug housing and the terminal sub-assembly.

[0035] Figure 22 Is a three-dimensional detail view of the plug connector, in which a part of the plug housing is removed to show the first operating position of the plug housing and the terminal sub-assembly.

[0036] Figure 23 Is from Figure 1 A perspective view seen from below of an embodiment of the socket connector, showing the socket housing and the terminal sub-assembly in the socket housing.

[0037] Figure 24 Is a three-dimensional assembled view seen from above the socket connector, showing the lower housing part and the upper housing part in an unassembled state.

[0038] Figure 25 Is a three-dimensional assembled view seen from above, showing the lower housing of the socket connector, where the terminal sub-assembly is removed from the lower housing.

[0039] Figure 26 Is a three-dimensional assembled view seen from above, showing the lower housing of the socket connector, where the terminal sub-assembly includes a first terminal sheet body and a second terminal sheet body.

[0040] Figure 27 Is a sectional assembled view of the lower housing of the socket connector, where the terminal sub-assembly includes a first terminal sheet body and a second terminal sheet body removed from the housing, and the first terminal sheet body is higher than the second terminal sheet body in the vertical direction.

[0041] Figure 28 Is a perspective view seen from the rear of the first terminal sheet body and the second terminal sheet body including a cable alignment structure for the terminal sub-assembly of the socket connector.

[0042] Figure 29 Is a perspective view seen from the front of the first terminal sheet body of the socket connector, and the first terminal sheet body includes a terminal array having a plurality of signal terminals and a plurality of ground terminals embedded in a terminal support molding.

[0043] Figure 30It is a perspective view observed from the rear of the first terminal sheet body of the socket connector. The first terminal sheet body includes a terminal array having a plurality of signal terminals and a plurality of ground terminals embedded in a terminal support molding.

[0044] Figure 31 It is a perspective assembly view observed from the front of the first terminal sheet body. The first terminal sheet body includes a conductive ground shield adjacent thereto.

[0045] Figure 32 It is a perspective assembly view of the first terminal sheet body observed from the rear. The first terminal sheet body includes a conductive ground shield adjacent thereto.

[0046] Figure 33 It is a perspective view of a terminal array including a plurality of signal terminals and a plurality of ground terminals for the first terminal sheet body.

[0047] Figure 34 It is a perspective view observed from the front of the second terminal sheet body of the socket connector. The second terminal sheet body includes a terminal array having a plurality of signal terminals and a plurality of ground terminals embedded in a terminal support molding.

[0048] Figure 35 It is a perspective view observed from the rear of the second terminal sheet body of the socket connector. The second terminal sheet body includes a terminal array having a plurality of signal terminals and a plurality of ground terminals embedded in a terminal support molding.

[0049] Figure 36 It is a perspective assembly view observed from the front of the second terminal sheet body. The second terminal sheet body includes a conductive ground shield adjacent thereto.

[0050] Figure 37 It is a perspective assembly view observed from the rear of the second terminal sheet body. The second terminal sheet body includes a conductive ground shield adjacent thereto.

[0051] Figure 38 It is a perspective view of a terminal array of the second terminal sheet body including a plurality of signal terminals and a plurality of ground terminals. Detailed Description

[0052] Refer to Figures 1 to 4, showing a connector assembly 100 for a line pair board. The connector assembly 100 includes a plug connector 102 and a socket connector 104. The plug connector 102 is configured to be mounted on a substrate 106, while the socket connector 104 is configured to terminate a plurality of conductive cables 108. The plug connector 102 is capable of docking with the socket connector 104 to establish electrical communication between the substrate 106 and the plurality of conductive cables 108. The plug connector 102 can be placed adjacent to a surface of the substrate 106, and the socket connector 104 can be arranged such that the cables 108 are parallel to the substrate and generally perpendicular to the docking or stacking direction of the plug connector 102 and the socket connector 104, and thus the connector assembly 100 has an orthogonal configuration. In addition, the vertical height of the plug connector 102 and the socket connector 104 can be minimized so that the connector assembly 100 maintains a low profile for spacing considerations.

[0053] The substrate 106 can be any type of generally flat element, such as a printed circuit board, a backplane substrate, or a flexible circuit board having conductive traces that are electrically connected to a plurality of conductive pads 110 on a mounting surface 112 of the substrate. As Figure 3 and Figure 4 best shown, the plug connector 102 and the socket connector 104 can include a plurality of conductive contacts or terminals respectively provided thereon that can conductively contact each other when the plug connector and the socket connector are docked. The connector assembly 100 can be configured such that the plug connector 102 and the socket connector 104 are releasable to facilitate the assembly and interchange of electrical components operably associated with the plug connector and the socket connector.

[0054] Referring to Figures 5 to 8, the plug connector 102 includes a plug housing 120 and a terminal subassembly 160. The plug housing 120 is generally rectangular and has a mating face 122 and parallel but opposite and spaced-apart mounting faces 124. When the plug connector 102 is mounted to a substrate, the mounting faces 124 of the plug housing are adjacent to the substrate, while the mating face 122 projects away from the substrate and is oriented to abut against a socket connector when mating with the socket connector. The plug housing 120 includes a pair of spaced-apart elongated sidewalls 126 that are integrally joined to a pair of spaced-apart shorter end walls 128 that extend between the sidewalls, the sidewalls and end walls being orthogonally arranged to provide the rectangular shape of the plug housing 120. The sidewalls 126 and end walls 128 join the mating face 122 and the mounting faces 124. The spaced-apart sidewalls 126 and end walls 128 may be integral with each other and define an enclosure or housing that can surround and protect the terminal subassembly 160. In one embodiment, the corners formed by the intersection of the sidewalls 126 and end walls 128 may include chamfers, rounded corners or bevels as shown, which can assist in mating the plug connector 102 with the socket connector. The plug housing 120 may be made of any suitable non-conductive material (such as molded thermoplastic) and may be referred to as an insulating housing.

[0055] In one embodiment, the plug housing 120 may include a plurality of standoffs 130 that are associated with the mounting faces 124 and are for contacting the substrate when the plug connector 102 is mounted on the substrate. The standoffs 130 define a mounting plane 132 (shown in dashed lines) that is adjacent to or coplanar with the surface of the substrate, and the mounting plane 132 serves as a lower extension of the plug housing 120. In the illustrated embodiment, the standoffs 130 may be included at the four corners of the intersecting sidewalls 126 and end walls 128. The standoffs 130 may be separated from each other by one or more gaps 134 that extend laterally along the lower edges of the sidewalls 126.

[0056] As Figures 7 to 9As shown, an opening 140 may be provided through the mounting surface 124 of the plug housing 120 at a position offset from the longitudinal centerline of the offset housing. The opening 140 is for receiving and fixing the terminal subassembly 160 in the plug connector 102. Thus, it can be understood that the terminal subassembly 160 is disposed within the plug housing 120 in a manner offset relative to the longitudinal center of the plug housing. The opening 140 is generally rectangular and is defined by spaced-apart elongated side edges 142 (corresponding to the elongated side walls 126) and spaced-apart shorter end edges 144 (corresponding to the shorter end walls 128) arranged orthogonally to each other. A central web 146 may extend across the opening 140 between the shorter end edges 144 and may be spaced apart from the elongated side edges 142. The opening 140 and the central web 146 spanning the opening 140 may have a transverse length extending within the transverse length of the plug housing 120. The central web 146 can divide the opening 140 into two independent sub-openings 148, which extend parallel to each other and provide access passages through the mounting surface 124 to the interior of the plug housing 120. The central web 146 may be integrally molded as a part of the plug housing 120.

[0057] To hold the terminal subassembly 160 within the plug housing 120, the plug housing may include a retaining structure for engaging and positioning the terminal assembly within the opening 140. For example, as Figure 10 and Figure 11 shown, the retaining structure may include a plurality of ribs 150 integrally formed along the elongated side edges 142 of the opening 140. The plurality of ribs 150 may vertically span the height of the side edges 142 and be spaced apart from each other. The plurality of ribs 150 may project inwardly from the side edges 142 towards the central web 146 such that the plurality of ribs 150 partially extend into the opening 140.

[0058] As Figure 10 and Figure 11 shown in another example, the retaining structure may include: a cantilever snap arm 152, which is disposed adjacent to the opening 140 provided on the mounting surface 124 and may be located on the shorter end edge 144 defining the opening 140. The cantilever snap arm 152 may be supported in a cantilever manner between opposite first and second support feet 154, and the first and second support feet 154 extend vertically from the end edge 144 of the opening 140 and are integrally adjacent to the end wall 128 of the plug housing 120. The cantilever snap arm 152 may be connected to the upwardly extending support feet 154 by a bridging elastic member 156 at the uppermost end of the support feet 154. The bridging elastic member 156 may be in the form of a movable hinge having elastic properties such that the cantilever snap arm 152 can flex elastically like a cantilever.

[0059] The cantilevered latching arm 152 can be oriented generally downward from the bridging spring 156 toward the opening 140 and can include at its distal end a barb or distal locking projection 158 oriented away from the edge 144 and into the opening 140. To facilitate the cantilevered flexure of the latching arm 152 relative to the opening 140, the first and second support feet 154 can support the latching arm 152 in a spaced-apart relationship relative to the end wall 128 of the plug housing 120. Accordingly, the downwardly directed distal locking projection 158 can flex in a cantilevered manner toward and away from the end wall 128 of the plug housing 120 and relative to the opening 140 defined in the mounting surface 124. In embodiments where the opening 140 is divided into first and second sub-openings 148 by a central web 146, a cantilevered latching arm 152 can be included for each sub-opening 148 and supported between a pair of first and second support feet 154 such that at least two cantilevered latching arms 152 are associated with each end wall 128. In another embodiment, the cantilevered latching arm 152 and support feet 154 can be formed along the longer side edges 142 of a rectangular opening 140.

[0060] Referring Figures 8 to 10 , the terminal subassembly 160 can be formed from two elongate terminal modules or terminal laminae 162. In one embodiment, the two terminal laminae 162 can be substantially identical to each other and can form a hermaphroditic pair that can be docked interchangeably with each other when aligned in a parallel, opposing arrangement to construct the terminal subassembly 160. When the terminal assembly 160 is installed in the plug housing 120, the terminal assembly 160 can be disposed generally within the opening 140 through the mounting surface 124, where each terminal lamina 162 is located within one of the sub-openings 148 such that the two terminal laminae can be located on the cross web 146 and separated by the cross web 146. Accordingly, as Figure 7 shown, the plug connector 102 can have a first row or column of inline terminal pins 164 and a parallel second row or column of inline terminal pins 166 that extend laterally relative to the plug housing 120 and parallel to the elongate side walls 126. The parallel rows of inline terminal pins 164, 166 increase the density of communication channels that can be established by the connector assembly. To assemble the terminal subassembly 160 within the plug housing 120, the terminal lamina 162 can have a lateral lamina length 168 that generally coextends with the opening 140.

[0061] As Figures 8 to 13As shown, each terminal laminate 162 may include a conductive terminal array 170 that is partially disposed and supported in a non-conductive terminal support molding 172. The terminal array 170 includes a plurality of signal or data terminals 174 for conducting data signals and a plurality of ground terminals 176. The signal terminals 174 and the ground terminals 176 can be arranged adjacent to each other in a side-by-side configuration such that the vertical extensions of the terminals are aligned in a common array plane 178. In one embodiment, in order to transmit differential signals, the plurality of signal terminals 174 can be arranged in terminal pairs disposed between adjacent ground terminals 176. Each pair of signal terminals 174 can be electrically coupled together and can transmit a portion of a differential signal; however, other configurations or patterns of signal terminals and ground terminals can also be considered. The terminal array 170 can be made of a stamped thin metal plate, where the flat signal terminals 174 and ground terminals 176 are stamped into a three-dimensional shape that is embedded or fitted within the terminal support molding 172. The terminal support molding 172 can partially enclose the terminal array 170 to maintain the spacing between the signal terminals 174 and the ground terminals 176.

[0062] As Figure 14 and Figure 16 shown, each signal terminal 174 may include a mating end 180, a mounting end 182 opposite the mating end 180, and a flat intermediate body portion 184 extending between the mating end and the mounting end. The mating end 180 is for sliding and making electrical contact with a corresponding signal terminal from a socket connector and thus is formed with an angled end to guide and prevent collision with the corresponding terminal. The angled end of the mating end 180 can be offset at an angle of approximately 30° relative to the flat intermediate body portion 184. In order to abut against a conductive pad on a substrate, the mounting end 182 is formed as a surface mount tail that is generally perpendicular to the flat intermediate body portion 184 and projects in a direction opposite to the angled end at the mating end 180.

[0063] The elongated and generally flat flat intermediate body portion 184 includes, in sequence from the docking end 184 to the mounting end 182, a first cantilever segment 190, a second docking segment 192, a third retaining segment 194, and a fourth connecting segment 196. The cantilever segment 190 that terminates at the docking end 180 at its distal end can be supported in the terminal support molding 172 in such a way that it can flex to some extent when in sliding contact with a corresponding terminal of the socket connector. The docking segment 192 is partially embedded in the terminal support molding 172 and is exposed along a flat docking surface 198 to physically and conductively contact the corresponding terminals during docking of the plug connector 102 and the socket connector 104. The retaining segment 194 is completely embedded within the terminal support molding 172 to hold and support the signal terminals 174. The connecting segment 196 extends between the lower edge of the terminal support molding 172 and the mounting end 182 and may include a bend at an approximately 90° angle such that the surface-mount tail projects orthogonally relative to the generally flat intermediate body portion 184 at the mounting end.

[0064] As Figure 15 and Figure 16 shown, each ground terminal 176 may include a docking end 200, a mounting end 202 opposite the docking end 200, and a flat intermediate body portion 204 extending between the docking end and the mounting end. The docking end 200 is for sliding and conductive contact relative to a corresponding ground terminal from the socket connector and can thus be formed with an inclined end to guide and prevent collision with the corresponding terminal. The inclined end forming the docking end 200 may be offset relative to the flat intermediate body portion 204 at an approximately 30° angle. In one embodiment, the plurality of ground terminals 176 included in the terminal array 170 may be interconnected with each other by an upper ground bridge or rail 207 that extends along the docking end 200 of each ground terminal 176 and connects the docking ends 200 of each ground terminal 176. More specifically, the upper ground rail 207 is integrally formed with the docking end 200 and extends in the same plane as the docking end 200 to electrically connect each ground terminal 176 at their docking ends 200. To abut against a conductive ground pad on the substrate, the mounting end 204 of the ground terminal 176 may be formed with a surface-mount tail that is generally perpendicular to a surface of the flat intermediate body portion 204.

[0065] The elongate and generally flat flat intermediate body portion 204 includes, in sequence from the mating end 200 to the mounting end 202, a first cantilever segment 210, a second mating segment 212, a third retaining segment 214, and a fourth connecting segment 216. The cantilever segment 210, which terminates at its distal end in the mating end 200, may be supported in the terminal support molding 172 in a manner that allows it to flex somewhat when in sliding contact with a corresponding terminal of the receptacle connector. The mating segment 212 is partially embedded in the terminal support molding 172 and is exposed along a flat mating surface 218 to physically and conductively contact the corresponding terminal during mating of the plug connector 102 and the receptacle connector 104. The retaining segment 214 is completely embedded within the terminal support molding 172 to retain and support the ground terminal 176. The connecting segment 216 extends between the lower edge of the terminal support molding 172 and the mounting end 202 and may include a bend of approximately 90° such that the surface mount tail projects orthogonally relative to the generally flat intermediate body portion 204 at the mounting end.

[0066] As Figures 14 to 16 shown, each ground terminal 176 is significantly wider than the signal terminals 174 along the plane 178 of the terminal array 170. Specifically, the flat intermediate body portion 204 of each ground terminal 176 can be wider than the corresponding flat intermediate body portion 184 of each signal terminal 174. Except for two ground terminals 176a at the ends of the terminal sheet body 162, the ground terminals 176 are significantly wider than the signal terminals 174 along their entire vertical length. As described above, each terminal array 170 may be formed from a stamped thin metal plate and is generally planar except at the mating and mounting ends. The flat intermediate body portions 184 of the signal terminals 174 and the flat intermediate body portions 204 of the ground terminals 176 can be aligned with the common array plane 178 of the terminal array 170.

[0067] As Figures 14 to 16As shown, the terminal support molding 172 of each terminal sheet body 162 is generally L-shaped and may include a vertical leg 220 and a horizontal leg 222 disposed at a right angle to the vertical leg 220. The vertical leg 220 can define a rear surface 224 of the terminal support molding 172 and the horizontal leg 222 can define a front surface 226 of the terminal support molding 172, wherein the distance between the rear surface 224 and the front surface 226 defines the width or thickness of the terminal sheet body 162. The vertical leg 220 extends adjacent to the rear portions of the mating segments 192 of each signal terminal 174 and the mating segments 202 of each ground terminal 176 and partially surrounds the mating segments 192 of each signal terminal 174 and the mating segments 202 of each ground terminal 176 on three sides so that the signal terminals 174 and the ground terminals 176 remain exposed along their respective mating surfaces 198, 218. The retaining segments 194 of each signal terminal 174 and the retaining segments 214 of each ground terminal 176 are surrounded by the horizontal leg 222 of the terminal support molding 172 and are completely embedded in the horizontal leg 222 of the terminal support molding 172 so that the signal terminals 174 and the ground terminals 176 are fixed as part of the terminal sheet body 162. In one embodiment, the terminal support molding 172 can be made of a non-conductive thermoplastic that is insert molded or over-molded around a stamped terminal array 170 by a suitable manufacturing process. In other embodiments, the terminal support molding 172 can be molded independently of the terminal array 170 and the signal terminals 174 and the ground terminals 176 can be assembled into the terminal support molding.

[0068] The terminal subassembly 160 can include retention features that interact cooperatively with corresponding retention features on the plug housing 120. For example, as Figure 12 , Figure 13 and Figure 16As shown, the terminal thin plate body 162 can extend between a first thin plate body end 230 and a second thin plate body end 232 which are separated by the length of the terminal thin plate body and defined by the opposite end surfaces 234 of the terminal support molding 172. To engage the cantilevered latching arm of the plug housing, a first latching recess 236 and a second latching recess 238 can be provided inside the end surface 234 of the terminal support molding 172 near the horizontal leg 222. The first latching recess 236 and the second latching recess 238 can extend between the rear surface 224 and the front surface 226 of the terminal support molding 172 such that they span the width of the terminal thin plate body 162. The first latching recess 236 can extend into the end surface 234 of the terminal support molding 172 and can be shaped as a triangular groove or a V-shaped groove. The second latching recess 238 can be located below the first latching recess 236, can be formed at the lower corner of the end surface 234 and can be shaped as a chamfer. As described below, the first recess 236 and the second recess 238 can be used as pawls when engaging the cantilevered latching arm 152 on the plug housing 120.

[0069] As Figures 8 to 11 shown, the two terminal thin plate bodies 162 can be hermaphroditic and configured to lock together in pairs to assemble into a terminal subassembly 160. To provide a hermaphroditic configuration, the two terminal support moldings 172 can be identical to each other and can include complementary locking structures 240 formed along the rear surface 224 of the vertical leg 220. The locking structure 240 can include a plurality of posts 242 that extend horizontally from the rear surface 224 in opposite directions along the horizontal leg 222. The plurality of posts 242 are laterally spaced apart along the length of the terminal support molding 172. The locking structure 240 can further include a plurality of recesses 244 provided on the rear surface 224 of the vertical leg 220, the plurality of recesses 244 being complementary in shape to the posts 240 and laterally spaced apart along the length of the terminal support molding 172. The number and configuration of the posts 242 can correspond to the number and configuration of the recesses 244. When two identical terminal thin plate bodies 162 are symmetrically placed in a relative parallel relationship with their respective rear surfaces 224 of the vertical legs 220 adjacent to each other, the plurality of posts 242 can be received respectively in the plurality of recesses 244. In an embodiment where a pair of terminal thin plate bodies 162 are locked or press-fitted together to form a terminal subassembly 160, an extrusion rib 246 can be formed along the surface of each post 240. When the post 242 is inserted into the corresponding recess 244, the extrusion rib 246 can contact the inner surface of the recess and be displaced by the inner surface of the recess, thereby forming a firm interlocking fit between the pair of terminal thin plate bodies 162 of the terminal subassembly 160.

[0070] In Figure 12 and Figures 16 to 18In one aspect of the present disclosure as shown, a conductive ground bar 250 may be mechanically and electrically connected to the ground terminals 176 of the terminal array 170. The ground bar 250 may be flat and generally planar, and may include an elongated common ridge 252 that generally coextends with the lateral length of the terminal array 170. Projecting from the common ridge 252 may be a plurality of fork-shaped blades 254 that are spaced apart from each other along the common ridge 252. The ends 256 of the blades may be tapered or pointed at their distal ends. The blades 254 may be flat and may be wider laterally than their thickness between the upper and lower surfaces, and the upper and lower surfaces of the blades 254 are coplanar with the upper and lower surfaces of the common ridge 252; however, in other embodiments, the blades may have different shapes. The common ridge 252 and the plurality of blades 254 may be aligned in a common blade plane 258. When assembled, the ground bar 250 is assembled to the terminal sheet body 162, and the blade plane 258 is perpendicular to the common array plane 178 of the signal terminals 174 and the ground terminals 176. The ground bar 250 may be made by stamping a conductive metal material.

[0071] To mechanically and electrically connect with the ground bar 250, the ground terminals 176 of the terminal array 170 may include a hole 260 disposed in a flat intermediate body 204 of each ground terminal. The hole 260 may extend partially or completely through the flat intermediate body portion 204 orthogonally to the common array plane 178. The hole 260 may be disposed vertically above the horizontal feet 222 of the terminal support molding 172 in the flat intermediate body portion 204 such that the hole 260 is exposed along the exposed flat docking surface 218 of the ground terminal 176. The blades 254 may project from the common ridge 252 a sufficient distance to extend through the flat intermediate body portion 204 of the ground terminal 176 and may be partially received adjacent to the terminal array 170 in the vertical legs 220 of the terminal support molding 172. The hole 260 may have any shape; however, in a particular embodiment, the hole 260 may be oval or elliptical to form an elongated slot. The hole 260 may thus have a major axis 262 that aligns with the dimensions of the oval or ellipse. The width and thickness of the hole 260 may be generally the same as the width and thickness of the blade 254 such that the hole and the blade are generally dimensionally complementary.

[0072] However, in one embodiment, the hole 260 of the ground terminal 176 and the blade 254 of the ground bar 250 may be non-complementary in alignment and configured to distort the blade relative to the blade plane 258. The major axis 262 of the hole 260 may be disposed at a non-vertical and non-parallel angle relative to the vertical extension of the flat intermediate body portion 204 of the ground terminal 276. The hole 260 is thus inclined or skewed relative to the lateral and vertical extensions of the terminal array 170, as Figures 17 to 18As shown. In addition, the offset angle of the main axis 262 of the hole 260 can alternate between adjacent ground terminals 176 within the terminal array 170. For example, if the main axis 262 of a hole 260 is tilted or offset 45° clockwise relative to the vertical extension of a ground terminal 176, the hole 260 of the adjacent ground terminal 176 can be tilted or offset 45° counterclockwise. A possible advantage of alternating the offset angles of the main axes 262 of the plurality of holes 260 is that it can balance the torsional forces applied between the terminal array 170 and the ground strip 250 caused by the twisting and distortion of the blades 254. In other embodiments, the non-complementary alignment between the blade and the hole can be provided by other arrangements (such as the offset feet described below), or by non-complementary shapes or profiles of the blade and the hole (such as circular, square, and / or diamond-shaped), or by setting the holes through the ground terminals along non-vertical directions.

[0073] To mechanically and electrically connect the ground strip 250 and the terminal array 170 to each other, the ground strip 250 and the terminal sheet body 162 are positioned such that the plurality of blades 250 are aligned with the plurality of holes 260. The ground strip 250 points vertically towards the terminal array 170 so that the protruding blades 254 enter the holes 260. To assist in alignment, the horizontal feet 222 of the terminal support molding 172 that extend in front of the terminal array 170 and are perpendicular to the common array plane 178 can be used as an upper shelf surface 266 to support the blades 254 of the ground strip 250. When inserting the blade 254 into the oval hole 260, the inclined main axis 262 will cause the blade 254 to contact the inclined inner circumference of the hole, rotating or twisting the blade 254 relative to the blade plane 258. The material and thickness of the ground strip 250 can be selected to facilitate or enable the twisting of the blades 254. The torsional force caused by the rotation of the blade 254 in the corresponding hole 260 provides good mechanical and electrical contact between the ground strip 250 and each ground terminal 176, because the ground strip and the ground terminal cannot be disengaged and at the same time maintain good conductivity. A possible advantage of establishing conductivity between the ground strip 250 among the plurality of ground terminals 176 is to shorten the electrical path between the docking end and the mounting end of the ground terminal, which can advantageously affect the resonant frequency in the grounding circuit. In one embodiment, an adhesive can be used to help fix the terminal array 170 and the ground strip 250.

[0074] In Figures 19 to 20 In one aspect of the present disclosure shown in, the plug housing 120 and the terminal subassembly 160 are capable of selectively moving between a first operating position for transporting and installing the plug connector 102 onto a substrate and a second operating position once the plug connector has been installed onto the substrate. As Figure 19As shown, in the first operating position, the plug housing 120 and the terminal subassembly 160 are relatively positioned such that the mounting ends 182 of the signal terminals 174 and the mounting ends 202 of the ground terminals 176 extend below the mounting plane 132 associated with the mounting surface 124 of the plug housing 120. In the first operating position, the respective mounting ends 182, 202 of the signal terminals 174 and the ground terminals 176 (which may be the surface-mount tails described herein) are aligned in a plane that is spaced below and parallel to the mounting plane 132 associated with the mounting surface 124. As Figure 20 shown, in the second operating position, the plug housing 120 and the terminal subassembly 160 are moved relative to each other such that the support 130 contacts the substrate 106 and the plane of the mounting ends 182, 202 and the mounting plane 134 associated with the mounting surface 124 are coplanar. As shown, the gaps 134 separating the plurality of supports 130 still exist above the substrate 106 such that an adhesive can be directed through the gaps to adhesively secure the plug connector 102 to the substrate. A possible advantage of configuring the plug connector 102 to move between the first and second operating positions is that the first operating position facilitates soldering the mounting ends 182, 202 to the substrate while the second operating position reduces the vertical profile of the plug connector 102.

[0075] To facilitate movement or shifting between the first and second operating positions, the retaining features on the plug housing 120 and the terminal subassembly 160 can be selectively engaged and disengaged. As Figures 8 to 11 shown, to begin assembling the plug connector 102, the terminal subassembly 160, which can be assembled from interlocking hermaphroditic first and second terminal laminates 162, can be positioned above the plug housing 120 with the first and second terminal laminates aligned with the two sub-openings 148. The terminal subassembly 160 is received in the opening 140 and the two terminal laminates 162 are received in the two sub-openings 148 separated by the cross-shaped web 146. The horizontal feet 222 of the terminal support molding 172 can span the width of the sub-openings 148 to maintain and possibly form a friction fit between the terminal laminates 162 and the ribs 150 disposed around the opening 140.

[0076] To achieve and maintain the first operating position during transportation and soldering, as Figures 19 to 21As shown, the terminal sub-assembly 160 moves downward relative to the plug housing 120, causing the cantilevered latching arm 152 to flex toward the end wall 128 of the plug housing. The chamfered second latching recess 238 below can slide over the latching projection 158 and cause the latching projection 158 to flex. The latching projection 158 slides vertically relative to the end surface 234 of the terminal support molding 172 until the cantilevered arm 152 forces the latching projection into the V-shaped groove-like first latching recess 236. The first latching recess 236 serves as a pawl for latching the latching projection 158 of the cantilevered latching arm 152 to maintain the first operating position. The planar surfaces of the corresponding mounting ends 182, 202 of the signal terminal 174 and the ground terminal 176 are spaced apart and are located below the mounting plane 132 associated with the mounting surface 124 of the plug housing 120.

[0077] To move the housing plug 120 and the terminal sub-assembly 160 to the second operating position, as Figure 20 and Figure 22 shown, the plug housing 120 moves downward relative to the terminal sub-assembly 160, causing the cantilevered latching arm 152 to flex toward the end wall 128 of the plug housing. The V-shaped groove-like first latching recess 236 is displaced and disengages from the latching projection 158. The latching projection 158 slides vertically relative to the end surface 234 of the terminal support molding 172 until the cantilevered latching arm 152 forces the latching projection into the lower second latching recess 238. The planar surfaces of the corresponding mounting ends 184, 204 of the signal terminal 174 and the ground terminal 176 are now coplanar with the mounting plane 132 associated with the mounting surface 124 of the plug housing 120. In an embodiment having the support 130, the adhesive can be guided through the gap 134 defined between the plurality of supports to adhesively secure the plug connector 102 to the substrate 106. In one embodiment, the locations of the cantilevered latching arm 152 and the first and second latching recesses 236, 238 can be reversed, with the cantilevered latching arm on the terminal sub-assembly 160 and the recesses provided in the plug housing 120.

[0078] Referring to Figures 23 to 24, the socket connector 104 includes a socket housing 300 made of a non-conductive material such as molded thermoplastic and a terminal sub-assembly 400 electrically connected to a plurality of conductive cables 108. The socket housing 300, which can also be referred to as an insulating housing due to its non-conductive properties, may include a lower housing part 302 and an upper housing part 304, both made of a non-conductive material such as molded plastic. The lower housing part 304 has a lower docking surface 322 and an assembly surface 324 spaced apart from and parallel to the docking surface 322. The lower housing 302 is generally rectangular in shape and includes two parallel longer side walls 326 and two parallel shorter end walls 328 orthogonal to the two side walls 316 to define a rectangular shape. The two side walls 326 and the two end walls 328 of the lower housing 302 are integral with each other and can define an enclosure or housing for receiving the terminal sub-assembly 400. The side walls 326 and the end walls 328 may have a stepped configuration such that the docking surface 322 has a reduced profile relative to the assembly surface 324 and provides a shoulder 329 that can abut against a corresponding docking surface of the plug connector.

[0079] As Figures 25 to 27 shown, the rear side wall 326 may include a cable opening 332 that extends downward from the assembly surface 334 toward an intermediate platform 330 disposed within the lower housing part 302. The intermediate platform 330 is located between the docking surface 322 and the assembly surface 324 and is generally parallel to the docking surface 322 and the assembly surface 324 and extends between the elongated side walls 326 and the shorter end walls 328. The intermediate platform 330 may include structures for organizing and arranging the plurality of cables 108 and the terminal sub-assembly 400 relative to each other. For example, to receive and mount the terminal sub-assembly 400, the intermediate platform 330 may have a first sheet body groove 334 and a second sheet body groove 336 provided therein that provide access channels through the intermediate platform. The first sheet body groove 334 and the second sheet body groove 336 are parallel to the elongated side walls 326 and span the lateral length of the lower housing part 302 between the spaced-apart end walls 328. The first sheet body groove 334 may be adjacent to the front side wall 326 while the second sheet body groove 336 may be adjacent to the rear side wall 326. The intermediate platform 330 may also include a plurality of recesses 338 provided therein that are parallel and close to the cable opening 332 provided in the rear side wall 326. The cable opening 332 laterally spans the rear side wall 326 and allows the plurality of cables 108 to enter the socket connector 104. To align and assemble the upper housing part 304, the lower housing part 302 may have a plurality of alignment protrusions 339 that project upward from the front side wall 326, and the plurality of protrusions 339 may be received in corresponding recesses provided in the upper housing part 304.

[0080] As Figures 23 to 24As shown, the upper housing member 304 is configured to be assembled with the lower housing member 302 and is likewise rectangular, including an assembly surface 342 and a parallel and opposite ceiling 344, the ceiling 344 being joined to parallel, elongated side walls 346 and parallel, shorter end walls 348 that are orthogonally arranged with respect to each other. To permit a plurality of cables 108 to pass therethrough, a cable opening 350 is provided through the rear side wall 346 and corresponds in lateral dimension to the cable opening 332 of the lower housing member 302. The ceiling 344 may extend between the orthogonally arranged side walls 326 and end walls 328 to cover the interior of the receptacle housing 300 when the upper housing member 304 and the lower housing member 302 are assembled together. Formed on the exterior of the ceiling 344 may be a recess 352 that is generally rectangular in shape and is circumscribed by the orthogonal profiles of the side walls 326 and end walls 328. Two slots 354 pass through the ceiling 344 and extend into the end walls 328. During the assembly of the lower housing member 302 and the upper housing member 304, the recess 352 and the two slots 354 are capable of receiving a pressure plate 356 that may be placed adjacent to the ceiling 344. The pressure plate 356 is dimensioned to fit within the recess 352 of the ceiling 344 and is capable of distributing the force applied to the ceiling 344 during the assembly of the receptacle connector 104. To retain the pressure plate 356 to the upper housing member 304, the pressure plate 356 may include two spaced-apart locking arms 358 that are perpendicular to the flat body of the plate and descend from the flat body of the plate and are dimensioned to be received within the two slots 354 provided in the ceiling 344.

[0081] As Figures 25 to 28 shown, the plurality of cables 108 may include signal conductors for transmitting electrical signals and a ground conductor for providing a return to electrical ground and that may be configured to reduce electromagnetic interference and isolate the signal conductors from other cables of the plurality. In a particular embodiment, the plurality of cables may each be a coaxial cable, where two signal conductors 360 made of a conductive material such as copper wire extend along the length of the cable 108 and are surrounded by an insulator 362. The two signal conductors 360 are capable of being configured to cooperatively transmit differential signals. A ground conductor 364 may also extend along the length of the cable 108 and is made of a conductive material such as metal foil. The plurality of cables 108 may be arranged as a plurality of first cables 366 above and an extended plurality of second cables 368 below the plurality of first cables. In other embodiments, the plurality of cables 108 may have different configurations or may be replaced by other conductors such as a ribbon cable.

[0082] To route and guide multiple cables 108 into the receptacle connector 104, the receptacle housing 300 may be associated with a cable alignment assembly 370. The cable alignment assembly may include an upper first cable alignment member 372 and a lower second cable alignment member 374. The first cable alignment member 372 and the second cable alignment member 374 may be elongated structures of a non-conductive material such as molded thermoplastic. The first cable alignment member 372 and the second cable alignment member 374 are generally rectangular and co-extend with each other in a lateral dimension extending between a first member end 376 and a second member end 378. A plurality of cable holes 380 are provided through the first cable alignment member 372 and the second cable alignment member 374. The plurality of cable holes 380 are sized to allow individual cables of the multiple cables 108 to pass therethrough. The upper first cable alignment member 372 may receive a plurality of first cables 366 and the lower second cable alignment member 374 may receive a plurality of second cables 368. To couple and form the cable alignment assembly 370, the first cable alignment member 372 and the second cable alignment member 374 may include mating protrusions 382 and recesses 384 provided at the ends of the cable alignment members 372, 376. The cable alignment assembly 370 is capable of aligning and maintaining the plurality of first cables 366 and the plurality of second cables 368 traveling perpendicular to the receptacle connector 104 in a lateral row. When installed in the receptacle housing 300, the cable alignment assembly 370 may be located in an opening formed by corresponding cable openings 332, 350 of the lower housing member 300 and the upper housing member 304. To hold the cable alignment assembly 370 in the cable openings 332, 350, the first cable alignment member 372 and the second cable alignment member 374 may include a plurality of alignment protrusions 386 that are laterally spaced apart and span their lower and upper surfaces. The plurality of alignment protrusions 386 may be received in recesses 338 provided on an intermediate platform 330 of the lower housing member 320 and in similar recesses provided in the upper housing member 322.

[0083] As Figures 25 to 28As shown, the terminal subassembly 400 may include a first terminal laminate body 402 and a second terminal laminate body 404. The first terminal laminate body 402 can be configured to be inserted into a first laminate body slot 334 adjacent to the front sidewall 326 of the lower housing member 302, while the second terminal laminate body 404 can be configured to be inserted into a second laminate body slot 336 adjacent to the rear sidewall 326. The first terminal laminate body 402 and the second terminal laminate body 404 may have a laminate body length dimensioned to span their respective laminate body slots 334, 336 between the spaced-apart end walls 328 of the lower housing member 302. In the illustrated embodiment, to enable a plurality of first cables 366 to extend above a plurality of second cables 368, the first terminal laminate body 402 has a first laminate body height 406 that is vertically higher or greater than a second laminate body height 408 associated with the second terminal laminate body 404.

[0084] As Figures 29 to 32 shown, the higher first terminal laminate body 402 includes a conductive terminal array 410 that is partially disposed in and supported by a terminal support molding 412 made of a non-conductive material such as molded thermoplastic. In the illustrated embodiment, the terminal array 410 may include a plurality of signal terminals 414 and a plurality of ground terminals 416 for conducting data signals that are arranged in an alternating arrangement adjacent to each other and are arranged side by side in a common array plane 418. In one embodiment, two signal terminals 414 may be electromagnetically coupled together as a differential signal pair and a ground terminal 416 may be located on either side of the differential pair to isolate the differential pair; however, in other embodiments, different configurations of signal terminals and ground terminals may also be considered. The signal terminals 414 and the ground terminals 416 of the terminal array 410 may be manufactured by stamping a flat blank of conductive thin metal sheet.

[0085] As Figure 33 shown, each signal terminal 414 may include a mating end 420, an end termination 422 opposite the mating end 420, and a flat intermediate body portion 424 that extends between the end termination and the mating end and interconnects the end termination and the mating end. The mating end 420 is for sliding and making electrical contact with a corresponding signal terminal from a plug connector and may thus be formed with a slanted end to guide and prevent collision with the corresponding terminal. The slanted end at the mating end 420 may be offset at an angle of approximately 30° relative to the flat intermediate body portion 424. The end termination 422 and the flat intermediate body portion 424 may be aligned in the common array plane 418. A conductor termination hole 428 may be provided that is perpendicular to the common array plane 418 and extends into the end termination 422.

[0086] The elongated and generally flat flat intermediate body portion 424 includes a first retaining section 430 extending adjacent to the termination end 422 and a second cantilever section 432 extending adjacent to the docking end 420. The retaining section 430 may be embedded in the terminal support molding 412 to fixedly hold the signal terminal 414 in the first terminal laminate 402. The cantilever section 432 includes a pair of docking surfaces 434 on its rear side that slidably contact a corresponding signal terminal of the plug connector. The cantilever section 432 is capable of exhibiting a flexure in the shape of an elastic member relative to the common array plane 418 to press against a pair of docked signal terminals and maintain electrical contact with the docked signal terminals.

[0087] The ground terminal 416 may include a docking end 440, a termination end 442 opposite the docking end 440, and a flat intermediate body portion 444 extending between the docking end 440 and the termination end 442 and interconnecting the docking end 440 and the termination end 442. The docking end 440 is for sliding and electrically contacting a corresponding ground terminal from the plug connector, and may thus be formed with an inclined end to guide and prevent collision with the corresponding terminal. The inclined end of the docking end 440 may be offset from the flat intermediate body portion 444 at an angle of approximately 30°. The elongated and generally flat flat intermediate body portion 444 is wider than the corresponding flat intermediate body portion 424 of the signal terminal 414. The flat intermediate body portion 444 includes a first retaining section 450 adjacent to and extending from the termination end 442 and a second cantilever section 452 adjacent to and extending from the docking end 440. The retaining section 450 may be embedded in the terminal support molding 412 to fixedly hold the ground terminal 416 in the first terminal laminate 402. The cantilever section 452 may include a pair of docking surfaces 454 on its rear side for sliding contact with a corresponding ground terminal of the plug connector. The cantilever section 452 may exhibit an elastomeric-like flexure relative to the common array plane 418 to press against a pair of docked ground terminals and maintain electrical contact with the docked ground terminals.

[0088] In the illustrated embodiment, the mating end 440 of the ground terminal 416 in the middle of the terminal array 410 forks at its distal end and is coupled to a conductive ground bridge 456. However, the ground terminals 416 at either end of the terminal array 410 do not fork but are only coupled to a single conductive ground bridge 456 that faces the middle of the terminal array 410. Each conductive ground bridge 456 extends beneath the mating ends 420 of the signal terminals 414 of two adjacent differential pairs and spans the mating ends 420 of the signal terminals 414 of two adjacent differential pairs to connect the two ground terminals 416 to each other. The conductive ground bridge 456 is formed as an extension of the mating end 440 and can be inclined relative to the common array plane 418 to facilitate sliding contact with a corresponding ground terminal of a plug connector. The conductive ground bridge 456 serves to electrically isolate each pair of differentially coupled signal terminals 414.

[0089] The termination ends 442 of the plurality of ground terminals 416 can be interconnected by a conductive ground rail 457 that extends across the terminal array 410 to electrically interconnect all of the ground terminals 416. The conductive ground rail 457 can extend above and span the termination ends 442 of the signal terminals 414 of the differential pairs. The plurality of ground terminals 416 interconnected by the conductive ground bridges 456 and the conductive ground rail 457 extend around the signal terminals 414 of their respective differential pairs and electrically isolate the signal terminals 414 of their respective differential pairs. A conductor termination hole 458 can be provided perpendicular to the common array plane 418 and into the conductive ground rail 457. The conductor termination hole 458 of the ground terminal 416 is located above and between the conductor termination holes 428 of the signal terminals 414 of the corresponding differential pair. The conductor termination holes 428 of the signal terminals 414 of the differential pair and the associated conductor termination holes 458 of the ground terminals 416 define a triangular profile.

[0090] As Figures 29 to 32As shown, the terminal support molding 412 can extend around the terminal array 410 and support the terminal array 410 and co - extend with the length of the first terminal sheet body 402. The terminal support molding 412 includes a front surface 460 and an opposite rear surface 462. Signal terminals 414 and ground terminals 416 can be disposed between the front surface 460 and the rear surface 462 of the terminal support molding 412, wherein the retention segments of the signal terminals 414 and the ground terminals 416 are embedded in the material of the terminal support molding 412. The terminal support molding 412 can also include a lower surface 464, and the mating ends 420 of the signal terminals 414 and the mating ends 440 of the ground terminals 416 extend from the lower surface 464. The mating surfaces 434 of the signal terminals 414 and the mating surfaces 454 of the ground terminals 416 are thus exposed below the lower surface 464 of the terminal support molding 412. The terminal support molding 412 can include opposite sheet body ends 466, 468 that delimit the sheet body length of the first terminal sheet body 402. The terminal support molding 412 can be made of a non - conductive material such as molded thermoplastic and can be disposed around the terminal array 410 by an insert molding or overmolding manufacturing process.

[0091] As Figures 26 to 29 shown, the cable 108 among the plurality of upper first cables 366 can be received by the first terminal sheet body 402 and terminated to the first terminal sheet body 402. In particular, the insulator 362 can be removed from the ends of the plurality of first cables 366 to expose the signal conductor 360 and the ground conductor 364. The signal conductor 360 can be inserted into the conductor termination holes 428 of the signal terminals 414 while the ground conductor 364 can be inserted into the conductor termination holes 458 of the ground terminals 416. The ends of the signal conductor 360 and the ends of the ground conductor 366 are thus arranged in a triangular configuration similar to the conductor termination holes 428, 458. The ends of the signal conductor 360 and the ends of the ground conductor 364 can be joined, for example, by laser welding in the corresponding conductor termination holes 428, 454 to establish an electrical connection between the plurality of first cables 366 and the terminal array 410. Since the plurality of ground terminals 416 are interconnected with each other through the ground rail 457 at their termination ends 442 and through the ground bridge 456 at their mating ends 440, the plurality of ground terminals are also conductively interconnected to establish a common electrical ground.

[0092] As Figures 33 to 36As shown, the second terminal thin body 404 with a shorter vertical length includes a conductive terminal array 510, and the conductive terminal array 510 is partially disposed in and supported by a terminal support molding 512 made of a non-conductive material such as molded thermoplastic. In the illustrated embodiment, the terminal array 510 may include a plurality of signal terminals 514 for conducting data signals and a plurality of ground terminals 516 that are arranged in an alternating arrangement adjacent to each other and aligned in a side-by-side configuration in an array plane 518. In one embodiment, two signal terminals 514 may be electromagnetically coupled together as a differential signal pair and a ground terminal 516 may be located on either side of the differential pair to isolate the differential pair; however, in other embodiments, different configurations of signal terminals and ground terminals may also be considered. The signal terminals 514 and ground terminals 516 of the terminal array 510 may be manufactured by stamping a flat blank of conductive thin metal sheet.

[0093] As Figure 38 shown, each signal terminal 514 may include a mating end 520, an end termination 522 opposite to the mating end 520, and a flat intermediate body portion 524 that extends between the mating end 520 and the end termination 522 and connects the mating end 520 and the end termination 522 to each other. The mating end 520 is for sliding and making conductive contact with a corresponding signal terminal from a plug connector, and thus may be formed with an inclined end to guide and prevent collision with the corresponding terminal. The inclined end at the mating end 520 may be offset from the flat intermediate body portion 524 at an angle of approximately 30°. The end termination 522 and the flat intermediate body portion 524 may be aligned in the common array plane 518. A conductor termination hole 528 may be provided perpendicular to the common array plane 518 and extending into the end termination 522.

[0094] The elongated and generally flat flat intermediate body portion 524 includes a first retaining section 530 that extends adjacent to the end termination 522 and a second cantilever section 532 that extends adjacent to the mating end 500. The retaining section 530 may be embedded in the terminal support molding 512 to fixedly hold the signal terminal 514 in the second terminal thin body 404. The cantilever section 532 includes a mating surface 534 on its rear side for sliding contact with a corresponding signal terminal of a plug connector. The cantilever section 532 may exhibit a resilient-like flexure relative to the array plane 518 to press against a mated signal terminal and maintain conductive contact with the mated signal terminal.

[0095] The ground terminal 516 may include a pair of docking ends 540, an end docking end 542 opposite the docking ends 540, and a flat intermediate body portion 544 extending between the docking ends 540 and the end docking end 542 and interconnecting the docking ends 540 and the end docking end 542. The docking ends 540 are adapted to slide and make electrical contact relative to a corresponding ground terminal from a plug connector, and may thus be formed with inclined ends to guide and prevent collision with the corresponding ground terminal. The inclined ends of the docking ends 540 may be offset relative to the flat intermediate body portion 544 at an angle of approximately 30°. The elongate and generally flat intermediate body portion 544 is wider than the corresponding flat intermediate body portion 524 of the signal terminal 514. The flat intermediate body portion 544 includes a first retaining section 550 adjacent to and extending from the end docking end 542 and a second cantilever section 552 adjacent to and extending from the docking ends 540. The retaining section 550 may be embedded in the terminal support molding 512 to fixedly hold the ground terminal 516 in the second terminal sheet body 404. The cantilever section 552 may include a flat docking surface 554 on its front side for sliding contact with a corresponding ground terminal of a plug connector. The cantilever section 552 may exhibit a flexure in the form of an elastic member relative to the array plane 518 to press against a docked ground terminal and maintain electrical contact with the docked ground terminal.

[0096] In the illustrated embodiment, the docking ends 540 of the ground terminals 516 in the middle of the terminal array 510 fork at their distal ends and are connected to a conductive ground bridge 556. However, the ground terminals 516 at either end of the terminal array 510 do not fork but are only connected to a single conductive ground bridge 556 towards the middle of the terminal array 516. Each conductive ground bridge 556 extends beneath the docking ends 520 of the signal terminals 514 of two adjacent differential pairs and spans the docking ends 520 of the signal terminals 514 of two adjacent differential pairs to interconnect the two ground terminals 516. The conductive ground bridge 556 is formed as an extension of the docking ends 540 and may be inclined relative to the common array plane 518 to facilitate sliding contact with a corresponding ground terminal of a plug connector. The conductive ground bridge 556 serves to electrically isolate each pair of differentially coupled signal terminals 514.

[0097] The termination ends 542 of the plurality of ground terminals 516 can be interconnected by a conductive ground rail 557 extending across the terminal array 510 to electrically interconnect all the ground terminals 516. The conductive ground rail 557 can extend above and across the termination ends 522 of the signal terminals 514 of the differential coupled pair. The ground terminals 516 interconnected by the conductive ground bridge 556 and the conductive ground rail 557 extend around the signal terminals 514 of the corresponding differential coupled pair and electrically isolate the signal terminals 514 of the differential coupled pair. A conductor termination hole 558 can be provided perpendicular to the common array plane 518 and into the conductive ground rail 557. The conductor termination holes 558 of the ground terminals 516 are located above and between the conductor termination holes 528 of the signal terminals 514 of the corresponding differential coupled pair. The conductor termination holes 528 of the signal terminals 514 of the differential pair and the conductor termination holes 558 of the associated ground terminals 516 define a triangular profile.

[0098] As Figures 34 to 37 shown, the terminal support molding 512 can extend around the terminal support array 510 and support the terminal support array 510 and co - extend with the length of the sheet body of the second terminal sheet body 404. The terminal support molding 512 includes a front surface 560 and an opposite rear surface 562. The signal terminals 514 and the ground terminals 516 can be disposed between the front surface 560 and the rear surface 562, wherein the signal terminals 514 and the ground terminals 516 are embedded in the non - conductive material of the terminal support molding 512. The terminal support molding 512 can further include a lower surface 564, and the mating ends 520 of the signal terminals 514 and the mating ends 540 of the ground terminals 516 extend from the lower surface 564. The mating surfaces 534 of the signal terminals 514 and the mating surfaces 554 of the ground terminals 516 are thus exposed below the lower surface 564 of the terminal support molding 512. The terminal support molding 512 can include opposite sheet body ends 566, 568 that define the length of the second terminal sheet body 404. The terminal support molding 512 can be made of a non - conductive material such as molded plastic and can be disposed around the terminal array 510 by an insert molding or overmolding manufacturing process.

[0099] As Figures 26 to 28 and Figure 35As shown, the cable 108 among the multiple second cables 368 below can be received by the second terminal sheet body 404 and terminated to the second terminal sheet body 404. In particular, the insulator 362 can be removed from the end of the multiple second cables 368 to expose the signal conductor 360 and the ground conductor 364. The signal conductor 360 can be inserted into the conductor termination hole 528 of the signal terminal 514, and the ground conductor 364 can be inserted into the conductor termination hole 558 of the ground terminal 516. The ends of the signal conductor 360 and the ground conductor 362 can be joined in the corresponding conductor termination holes 528, 558, for example, by laser welding, to establish an electrical connection between the multiple second cables 368 and the terminal array 510. Since the multiple ground terminals 516 are interconnected with each other at their docking ends 520 through the conductive ground bridge 556 and at their termination ends 542 through the conductive ground rail 557, the multiple ground conductors 366 are also conductively interconnected to establish a common electrical ground.

[0100] In one aspect of the present disclosure, as Figures 26 to 28 shown, the first terminal sheet body 402 and the second terminal sheet body 404 may respectively include a corresponding first conductive ground shield 600 and a second conductive ground shield 602 that provide additional electromagnetic shielding for the connector assembly. The first ground shield 600 and the second ground shield 602 are flat and planar structures that are disposed adjacent to the corresponding first terminal sheet body 402 and the second terminal sheet body 404 and can extend along with the lengths of the two terminal sheet bodies. In particular, the first ground shield 600 can extend between the corresponding sheet body ends 466, 468 of the first terminal support molding 412 and extend along with the corresponding sheet body ends 466, 468 of the first terminal support molding 412, and the second ground shield 602 can extend between the corresponding sheet body ends 566, 568 of the second terminal support molding 512 and extend along with the corresponding sheet body ends 566, 568 of the second terminal support molding 512. The first and second ground shields 600, 602 are adjacent to the rear surfaces 462, 562 of the terminal support moldings 412, 512 of the corresponding first and second terminal sheet bodies 402, 404, and the multiple first cables 366 and the multiple second cables 368 extend from the rear surfaces 462, 562.

[0101] In one embodiment, the conductive ground shields 600, 602 can be made by stamping a metal plate. In another embodiment, the conductive ground shields 600, 602 can be made by a metal injection molding process in which metal powder is mixed with a binder and cast into a finished part having conductive properties due to the metal powder. In another embodiment, the conductive ground shields 600, 602 can be formed of metallized plastic, where a molded plastic part is coated with metal to impart conductive properties.

[0102] As Figures 29 to 32 shown, the flat shape of the first ground shield 600 is parallel to the common array plane 418 of the first terminal laminate 402 when attached to the first terminal laminate 402. In one embodiment, the first ground shield 600 may be assembled from a relatively thin flat projection plate 610 and a relatively thick intermediate plate 640. For interconnecting with the terminal array 410, the projection plate 610 may include a plurality of ground projections 612 that extend perpendicular to the plane of the projection plate 610 and perpendicular to the common array plane 418. The ground projections 612 are laterally spaced along the lateral length of the first ground shield 600 and may be equal in number and aligned with the plurality of ground terminals 416 in the terminal array 410. In one embodiment, the ground projections 612 may be ground tabs aligned in a vertical orientation and thus have a vertical tab height 614. In one embodiment, the projection plate 610 may be made of a thin metal plate and the ground tabs forming the ground projections 612 may be tabs or flips punched out of and integral with the projection plate 610. The ground projections 612 punched out of the projection plate 610 create tab openings 616 formed in the projection plate 610 between adjacent ground projections 612. In other embodiments, the ground projections 612 may have other suitable shapes and configurations.

[0103] To allow the wires from multiple first cables to pass through the first ground shield 600, a plurality of wire openings 618 are provided through the projection plate 610. The wire openings 618 may be generally triangular or pear-shaped to match the triangular profile of the conductor termination holes 428, 458 provided in the signal terminals 414 and ground terminals 416 of the terminal array 410. The wire openings 618 thus accommodate the triangular arrangement of the signal conductor and the ground conductor of the twinaxial cable. The wire openings 618 may be located between laterally adjacent ground projections 612 extending from the projection plate 610.

[0104] In one embodiment, since the first terminal laminate 402 has a first laminate height that is greater than the height of the second laminate, the projection plate 610 may include a plurality of second ground projections 620 that extend from the plane of the projection plate 610 perpendicular to the common array plane 418 of the terminal array 410. The plurality of second ground projections 620 also correspond in number to the ground terminals 416 of the terminal array and the plurality of second ground projections 620 are aligned with the plurality of ground terminals 416 of the terminal array; however, the plurality of second ground projections 620 may be vertically located below the plurality of first ground projections 612, respectively. The plurality of second ground projections 620 may be formed as stamped tabs similar to the plurality of first ground projections 612 and may also create a plurality of rectangular holes 622 that are formed into the projection plate 610. The plurality of second ground projections 620 may also be aligned in a vertical direction and may have a vertical tab height 624 that is similar to the vertical tab height 614 of the first ground projections 612. In other embodiments, both the first ground projections 612 and the second ground projections 620 may be joined by a single vertically elongated tab that is punched out from the projection plate 610.

[0105] The thicker intermediate plate 640 may be made of a conductive material such as a stamped metal plate or a metal that may be sintered or cast. The intermediate plate 640 also extends coextensively with the length of the first terminal laminate 402 and extends between the first laminate end 466 and the second laminate end 468 of the terminal support molding 412. The intermediate plate 640 may have a thickness 642 that provides a relative volume of the intermediate plate that is thinner than the projection plate 610. To allow the passage of the cables of a plurality of first cables, the intermediate plate 640 includes a plurality of cable openings 644 that are aligned with and similar in shape to the plurality of cable openings 618 provided in the projection plate 610. To allow the ground projections 612 from the projection plate 610 to extend to and connect with the ground terminals 416 of the terminal array 410, the intermediate plate 640 may include a plurality of first slots 646 that are arranged in a lateral row across the intermediate plate. The plurality of slots 646 extend through the body of the intermediate plate 640 and are perpendicularly oriented toward the common array plane 418 of the terminal array 410. The slots 646 may correspond in number to the plurality of ground projections 612 and be aligned with the plurality of ground projections 612. In embodiments where the ground projections 612 are formed as vertical tabs having an associated vertical tab height 614, the slots 646 may have similar dimensions to allow the tabs to pass through the intermediate plate 640. In embodiments where the plurality of second ground projections 620 are vertically formed below the plurality of first ground projections 612 in the projection plate 610, the intermediate plate 460 may have a corresponding plurality of second slots 648 provided thereon and aligned with the plurality of second ground projections.

[0106] To mechanically and electrically connect with the ground protrusions 612 from the first ground shield 600, a plurality of ground holes 650 may be provided on the terminal array 410 of the first terminal sheet body 402. For example, as Figure 32 shown, the ground holes 650 may be provided just below the ground rail 457 extending across the terminal array at the termination ends 442 of each ground terminal 416 of the terminal array 410. The number and alignment of the ground holes 650 may correspond to the number and alignment of the plurality of first ground protrusions 612. Since the termination ends 442 of the ground terminals 416 are embedded in the terminal support molding 412, material may be removed from the terminal support molding adjacent to the termination ends to provide a protrusion opening 652 that exposes the ground slots 650 to the ground protrusions 612.

[0107] As Figure 33 shown, in one embodiment, the ground holes 650 may be non-complementary in shape or alignment with the ground protrusions 612 to cause the ground protrusions 612 to twist or distort. For example, the ground holes 650 may be formed as slots having first offset legs 654 and second offset legs 654 that are similar in size to the tabs forming the ground protrusions 612 but have a lateral offset relative to the vertical alignment of the ground protrusions. The first offset legs 654 and the second offset legs 654 may be disposed toward the lateral ends of the terminal sheet body such that the vertical alignment of the ground holes 650 is not aligned with the ground protrusions 612 extending from the protrusion plate 610. Further, the lateral direction of the offset in the offset legs 654 may alternate from ground terminal 416 to ground terminal 416 to provide an alternating arrangement of offset slots extending laterally across the terminal array. In other embodiments, the non-complementary alignment between the blades and the holes may be provided by other arrangements (such as the offset legs described below) or by non-complementary shapes or profiles of the blades and the holes (such as circular, square, and / or diamond shapes) or by passing the holes through the ground terminals in a non-vertical direction. In embodiments where the ground plate 610 includes a plurality of second ground protrusions 620 extending therebelow, a plurality of second ground holes 658 may be provided in the ground terminals 416 generally perpendicular to the flat intermediate body portion 442 to correspond to and align with the plurality of second ground protrusions.

[0108] As Figures 31 to 32As shown, in order to mechanically and electrically connect the first ground shield 600 and the terminal array 410 to each other, the protruding plate 610 is positioned relative to the remainder of the first terminal sheet body 402 such that the ground protrusions are aligned with a plurality of ground holes in the ground terminals 416. An intermediate plate 640 may be disposed between the terminal support molding 412 and the protruding plate 610 to align a slot 646 in the intermediate plate 640 with a corresponding molding opening 652 in the terminal support molding to allow the ground protrusions 612 to pass from the plane of the protruding plate 610 to the common array plane 418 of the terminal array 410. When inserting the ground protrusions 612 into the ground holes 650 of the ground terminals 416, the offset feet 654 will cause the tabular ground protrusions to rotate or twist relative to the vertical extension of the ground protrusions and the ground terminals. A plurality of lower second ground protrusions 620 may be similarly received in a plurality of second ground holes 658 provided in the ground terminals 416 and be twisted by the plurality of second ground holes 658 provided in the ground terminals 416. The material and thickness of the protruding plate 610 may be selected to facilitate the twisting of the ground protrusions 612. The torsional force caused by the rotation of the ground protrusions 612 in the corresponding ground holes 650 provides good mechanical and electrical contact between the first ground shield 600 and each ground terminal 416, because the ground shield and the ground terminals cannot be disengaged while maintaining good conductivity. One possible advantage of establishing conductivity between the plurality of ground terminals 416 through the conductive ground shield 600 is to shorten the electrical path between the docking end and the mounting end of the ground terminals, which can advantageously affect the resonant frequency in the ground circuit.

[0109] In one embodiment, the slot 646 provided in the intermediate plate 640 may also have an offset foot 660 that is laterally offset relative to the vertical extension of the tabular ground protrusion 612 to twist the ground protrusion as the ground protrusion is inserted through the intermediate plate. The twisting of the ground protrusion 612 within the slot 646 ensures that the protruding plate 610 and the intermediate plate 640 are mechanically and electrically connected together. Referring to Figure 27 , since the shield can be removed from a plurality of first cables 366 at the position where the signal conductors 360 are terminated in the conductor termination holes 428 of the terminal array 410, the thickness of the first ground shield 600 can contribute to the impedance at the termination point. Additionally, referring to Figure 31 , it will be appreciated that since the ground protrusions 612 are provided on either side of the cable opening 618 of the protruding plate 610 and the cable opening 644 of the intermediate plate 640, the tabular ground protrusions will extend to either side of the cable and be parallel to the cable when connected to the first terminal sheet body 402. The ground protrusions 612 thus further isolate and improve the coupling between the signal conductors within the first terminal sheet body.

[0110] As Figures 34 to 37As shown, the second ground shield 602 is similar in construction and arrangement to the first ground shield. The second ground shield 602 is parallel to the common array plane 518 when attached to the second terminal sheet body 404. The second ground shield 602 can also be assembled from a relatively thin flat protruding plate 710 and a relatively thick intermediate plate 740. Projecting perpendicularly from the plane of the protruding plate 710 to the common array plane 518 are a plurality of ground protrusions 712. The plurality of ground protrusions 712 can be laterally spaced along the lateral length of the second ground shield 602 and can be equal in number and aligned with the ground terminals 516 of the second terminal array 510. The ground protrusions 712 can be formed as ground tabs that are stamped from the protruding plate 710 which can be made of a metal plate and are integral with the protruding plate 710. The ground tabs can be vertically aligned and can have a vertical tab height 714 that is the same as the height and size of the ground tabs of the first ground shield. The stamping of the ground protrusions 712 creates rectangular tab openings 716 formed in the protruding plate 710. To allow the cables of multiple second cables to pass through the first ground shield 602, a plurality of cable openings 718 are also stamped in the protruding plate, and the plurality of cable openings 718 are similar in size and configuration to the cable openings of the first ground shield. The cable openings 718 can be triangular or pear-shaped to accommodate a twinaxial cable configuration. Since the second terminal sheet body 404 is shorter than the first terminal sheet body 402 in the vertical direction, only a single row of ground protrusions 712 is formed on the protruding plate 710.

[0111] The relatively thick intermediate plate 740 can also be made of a conductive material such as cast or sintered metal. The intermediate plate 740 has a thickness 742 that provides bulk or heft to the relatively thin protruding plate 710. To allow the cables of multiple second cables to pass through, the intermediate plate 740 includes a plurality of cable openings 744 that are aligned with and similar in shape to the cable openings 718 on the protruding plate 710. Similarly, to allow the ground protrusions 712 to extend from the protruding plate 710 to contact the ground terminals 516 of the second terminal array 518, a plurality of slots 746 are provided through the intermediate plate in a vertical direction toward the common array plane 518. The plurality of slots 746 are arranged in a lateral row across the intermediate plate 740 and are equal in number and aligned with the plurality of ground protrusions 712. In embodiments where the ground protrusions 712 are formed as stamped tabs, the slots 746 can be sized to accommodate the passage of the tabs.

[0112] To mechanically and electrically interconnect with the ground protrusions 712 from the second ground shield 602, a plurality of ground holes 750 can be provided on the terminal array 510 of the second terminal sheet body 404. For example, as Figure 38As shown, the ground holes 750 may be formed just below the ground rail 557 extending across the terminal array on the termination ends 542 of the respective ground terminals 516 of the terminal array 510. The number and alignment of the ground holes 750 may correspond to the number and alignment of the plurality of ground protrusions 712. In particular, since only a single horizontal row of ground protrusions 712 extends from the protrusion plate 710, only a single corresponding horizontal row of ground holes 750 is included in the terminal array 510. Since the termination ends 542 of the ground terminals 516 are embedded in the terminal support molding 512, the molding openings 752 may be provided by removing material from the terminal support molding to expose the ground holes 750 to the ground protrusions 612.

[0113] In Figure 38 the illustrated embodiment, the ground holes 750 are non-complementary in shape or alignment with the ground protrusions 712 to twist or distort the ground protrusions when the ground protrusions are inserted. For example, the ground holes 750 may include a first offset leg 754 and a second offset leg 754 that are horizontally offset relative to the vertical alignment of the ground protrusions 612. As Figures 36 to 37 shown, in order to attach the second ground shield 602 to the second terminal sheet body 404, the protrusion plate 710 is placed adjacent to the terminal support molding 512, and the plurality of ground protrusions 712 are aligned with the plurality of ground holes 750 on the ground terminals 516. The intermediate plate 740 may be located between the terminal support molding 512 and the protrusion plate 710 so that the ground protrusions are received in the intermediate plate and extend through the slots 746 in the intermediate plate. When the ground protrusions 712 are inserted into the ground holes 750, the offset legs 754 cause the tab-shaped ground protrusions to rotate or twist relative to the vertical extension of the ground protrusions and the ground terminals 516. The torque caused by the distortion of the ground protrusions 712 results in a good mechanical and electrical connection between the second ground shield 602 and each ground terminal 516. It will be appreciated that since the tab-shaped ground protrusions 712 extend on either side of the cable opening 718 of the protrusion plate 710 and the cable opening 744 of the intermediate plate 740, the ground protrusions may shield and isolate the signal conductors in the plurality of second cables within the second terminal sheet body 602.

[0114] It will be recognized that the foregoing description provides examples of the disclosed systems and techniques. However, it is contemplated that other embodiments of the present disclosure may differ in detail from the foregoing examples. All references to the present disclosure or its examples are intended to refer to the specific examples discussed at that time and are not intended to imply any limitation on the scope of the present disclosure more generally. All apparent and disparaging language with respect to certain features is intended to indicate that those features are not preferred, rather than to exclude them entirely from the scope of the present disclosure, unless otherwise stated.

[0115] Unless otherwise indicated herein, the recitation of numerical ranges herein is merely intended to be a shorthand method of referring individually to each separate value falling within the range, and each separate value is incorporated into the specification as if it were individually recited herein. Unless otherwise indicated herein or clearly contradicted by context, all methods described herein can be performed in any suitable order.

[0116] Accordingly, the present disclosure includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. In addition, unless otherwise indicated herein or clearly contradicted by context, the present disclosure covers any combination of the above elements in all possible variations thereof. Further, the advantages described herein may not apply to all embodiments covered by the claims.

Claims

1. A terminal sheet body for an electrical connector, comprising: A conductive terminal array including a plurality of signal terminals and a plurality of ground terminals. Each signal terminal includes a mating end, a mounting end, and a flat intermediate body portion extending between the mating end and the mounting end. Each ground terminal includes a mating end, a mounting end, and a flat intermediate body portion extending between the mating end and the mounting end. A terminal support molding made of non-conductive material, disposed around and supporting the signal terminals and ground terminals of the conductive terminal array. And A ground bar made of conductive material, including a plurality of blades protruding from a common ridge. Each of the plurality of blades is configured to be mechanically and electrically interconnected with a corresponding one of the plurality of ground terminals.

2. The terminal thin plate body according to claim 1, wherein, Each of the plurality of ground terminals includes a hole provided on the flat intermediate body portion, and each of the plurality of blades is received in a hole on a corresponding one of the plurality of ground terminals.

3. The terminal thin plate body according to claim 2, wherein, The flat intermediate body portions of the plurality of signal terminals and the flat intermediate body portions of the plurality of ground terminals are aligned in a common array plane.

4. The terminal thin plate body according to claim 3, wherein, When the plurality of ground terminals and the ground bar are mechanically and electrically connected, the plurality of blades are aligned in a common blade plane perpendicular to the common array plane.

5. The terminal thin plate body according to claim 4, wherein, The ground bar is configured to reduce the electrical path between the mating end and the mounting end of each of the plurality of ground terminals.

6. The terminal thin plate body according to claim 5, wherein, The terminal support molding has an L-shaped configuration, which includes a vertical leg partially extending adjacent to a rear side of the conductive terminal array and a horizontal leg partially extending in front of the conductive terminal array.

7. The terminal thin plate body according to claim 6, wherein, The horizontal leg includes an upper shelf surface that supports the plurality of blades and aligns the plurality of blades with the holes of each of the plurality of ground terminals respectively.

8. The terminal thin plate body according to claim 7, wherein, The terminal sheet body is hermaphroditic and configured to be locked with an identical terminal.

9. The terminal thin plate body according to claim 8, wherein, The terminal support molding includes a plurality of posts protruding from a rear surface of the vertical leg and a plurality of recesses provided on the rear surface of the vertical leg.

10. The terminal thin plate body according to claim 9, wherein, The plurality of posts are configured to be received in the plurality of recesses of a symmetrically arranged identical terminal sheet body.

11. The terminal thin plate body according to claim 10, wherein, Each of the plurality of posts includes a pressing rib provided thereon, and the pressing rib forms an interference fit with a corresponding one of the plurality of recesses.

12. The terminal thin plate body according to claim 11, wherein, The terminal support molding is overmolded on the terminal array.

13. The terminal thin plate body according to claim 2, wherein, The holes provided on the ground terminals and the blades are non-complementary and are configured to twist the blades when the blades are inserted into the holes.

14. The terminal thin plate body according to claim 13, wherein, The holes are oval holes and the blades are flat.

15. The terminal thin plate body according to claim 14, wherein, The plurality of blades are aligned in the common blade plane, and each of the oval holes includes a major axis non-parallel to the common blade plane.

16. The terminal thin plate body according to claim 15, wherein, The major axis of the oval hole forms a non-vertical and non-parallel offset angle with respect to the vertical extension of a corresponding one of the plurality of ground terminals.

17. The terminal thin plate body according to claim 16, wherein, The offset angle of the holes alternates between the plurality of ground terminals.

18. The terminal thin plate body according to claim 1, wherein, The plurality of signal terminals are arranged in differential pairs, with a ground terminal adjacent to each differential pair.

19. The terminal thin plate body according to claim 18, wherein, The docking ends of the multiple grounding terminals are interconnected by a grounding rail.

20. The terminal thin plate body according to claim 19, wherein, The flat intermediate body portion of each of the multiple grounding terminals is wider in the transverse direction than the flat intermediate body portion of each of the multiple signal terminals.

21. A terminal sheet body for an electrical connector, comprising: A conductive terminal array including a plurality of signal terminals and a plurality of grounding terminals, each grounding terminal including a grounding hole provided thereon; A terminal support molding made of a non-conductive material, disposed around the terminal array and supporting the terminal array, the terminal support molding including a plurality of molding openings provided thereon, each of the plurality of molding openings being aligned with one of the plurality of grounding holes; And A conductive grounding shield disposed adjacent to the terminal support molding, the conductive grounding shield including a plurality of grounding protrusions protruding therefrom, the plurality of grounding protrusions spanning the molding openings and being received by the plurality of grounding holes to mechanically and electrically connect with the plurality of grounding terminals.

22. The terminal thin plate body according to claim 21, wherein, The plurality of signal terminals and the plurality of grounding terminals are substantially aligned on a common array plane and the grounding protrusions are perpendicular to the common array plane.

23. The terminal thin plate body according to claim 22, wherein, The plurality of grounding protrusions are a plurality of grounding tabs stamped from a protrusion plate and integral with the protrusion plate.

24. The terminal thin plate body according to claim 23, wherein, The protrusion plate and the plurality of grounding tabs are stamped from a thin metal plate.

25. The terminal thin plate body according to claim 24, wherein, The terminal sheet body includes a first sheet body end and a second sheet body end defining a transverse sheet body length, and the grounding shield extends coextensively with the transverse sheet body length.

26. The terminal thin plate body according to claim 25, wherein, The grounding shield includes an intermediate plate between the protrusion plate and the terminal support molding, the intermediate plate being made of a conductive material and thicker than the protrusion plate.

27. The terminal thin plate body according to claim 26, wherein, The intermediate plate includes a plurality of grooves provided thereon for receiving the plurality of grounding protrusions.

28. The terminal thin plate body according to claim 21, wherein, The plurality of grounding holes and the plurality of grounding protrusions are non-complementary and configured to distort the grounding protrusions when the grounding protrusions are inserted into the grounding holes.

29. The terminal thin plate body according to claim 28, wherein, The terminal sheet body includes a first sheet body end and a second sheet body end defining a transverse sheet body length.

30. The terminal thin plate body according to claim 29, wherein, The grounding protrusions are grounding tabs having a vertical tab height aligned in the vertical direction.

31. The terminal thin plate body according to claim 30, wherein, The grounding holes are elongated slots corresponding to the vertical tab height.

32. The terminal thin plate body according to claim 31, wherein, The slots include a first offset leg and a second offset leg laterally offset relative to the transverse sheet body length.

33. The terminal thin plate body according to claim 21, wherein, The plurality of grounding terminals include a docking end, a termination end opposite the docking end, and a flat intermediate body portion extending between the docking end and the termination end.

34. The terminal thin plate body according to claim 33, wherein, The grounding holes are provided perpendicular to the termination end of the grounding terminal.

35. The terminal thin plate body according to claim 34, wherein, The grounding shield includes a plurality of second grounding protrusions protruding therefrom, the plurality of second grounding protrusions spanning the terminal support molding and being received by a plurality of second grounding holes provided on the plurality of grounding terminals to mechanically and electrically connect with the plurality of grounding terminals.

36. The terminal thin plate body according to claim 35, wherein, The plurality of second grounding holes are provided perpendicular to the flat intermediate body portion of the plurality of grounding terminals.

37. The terminal thin plate body according to claim 33, wherein, The terminal array includes at least one signal terminal located between a pair of ground terminals, the signal terminal including a pair of docking ends, an end terminal opposite to the docking ends, and a flat intermediate body portion extending between the docking ends and the end terminal.

38. The terminal sheet body according to claim 37, further comprising a wire cable having a signal conductor terminating at the docking ends of the signal terminals.

39. The terminal thin plate body according to claim 38, wherein, The plurality of ground protrusions are a plurality of ground tabs formed by stamping a protrusion plate and integral with the protrusion plate.

40. The terminal thin plate body according to claim 39, wherein, The ground tabs extend parallel to the signal conductor into the terminal sheet body.

41. An electrical connector assembly, comprising: A plug connector configured to dock with a socket connector, the plug connector including an insulating plug housing and a plug terminal subassembly, the plug housing having a mating face, a mounting face spaced from the mating face, wherein an opening is provided in the mounting face, and the terminal subassembly is partially received in the opening and includes: A conductive terminal array including a plurality of signal terminals and a plurality of ground terminals; A terminal support molding made of a non-conductive material, disposed around the signal terminals and the ground terminals of the conductive terminal array and supporting the signal terminals and the ground terminals of the conductive terminal array; and A ground strip having a plurality of blades protruding from a common ridge, each of the plurality of blades configured to be mechanically and electrically interconnected with a corresponding one of the plurality of ground terminals; The socket connector includes a socket insulating housing and at least one socket terminal sheet body, the socket terminal sheet body including: A terminal array having a plurality of signal terminals and a plurality of ground terminals, each ground terminal including a ground hole; A terminal support molding disposed around the signal terminals and the ground terminals of the terminal array and supporting the signal terminals and the ground terminals of the terminal array and including a plurality of molding openings aligned with the plurality of ground holes; and A ground shield adjacent to the terminal support molding, the ground shield including a plurality of ground protrusions protruding therefrom, the plurality of ground protrusions spanning the plurality of molding openings and received by the plurality of ground holes to be mechanically and electrically connected to the plurality of ground terminals.

42. The electrical connector assembly as claimed in claim 41, wherein, Each of the plurality of ground terminals of the plug terminal subassembly includes a hole provided in the flat intermediate body portion, and each of the plurality of blades is received in a corresponding one of the plurality of ground terminals' holes.

43. The electrical connector assembly according to claim 42, wherein, The hole and the blade are non-complementary and configured to twist the blade when the blade is inserted into the hole.

44. The electrical connector assembly as claimed in claim 43, wherein, The plurality of signal terminals and the plurality of ground terminals of the plug terminal subassembly are generally aligned in an array plane, and the plurality of blades of the ground strip are generally aligned in a blade plane perpendicular to the array plane.

45. The electrical connector assembly according to claim 44, wherein, The hole is oval and has a major axis not parallel to the blade plane.

46. The electrical connector assembly as claimed in claim 41, wherein, The plurality of signal terminals and the plurality of ground terminals of the socket terminal sheet body are generally aligned in an array plane; and the plurality of ground protrusions are perpendicular to the array plane.

47. The electrical connector assembly according to claim 46, wherein, The plurality of ground protrusions are formed by stamping a protrusion plate and integral with the protrusion plate.

48. The electrical connector assembly according to claim 47, wherein, The ground shield further includes an intermediate plate between the protruding plate and the terminal support molding, the intermediate plate being made of a conductive material and thicker than the protruding plate.

49. The electrical connector assembly according to claim 48, wherein, The intermediate plate includes a plurality of grooves formed thereon for receiving the plurality of ground protrusions.

50. The electrical connector assembly as claimed in claim 49, wherein, The ground holes and the ground protrusions of the socket terminal sheet body are non-complementary and configured to distort the ground protrusions when the ground protrusions are inserted into the ground holes.

51. The electrical connector assembly according to claim 50, wherein, The ground hole is a groove including a first leg and a second leg that are laterally offset.

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