Electrical connector system

Abstract

A connector system includes: a first connector assembly having a first insulating shell, wherein the first insulating shell is configured to hold an array of terminal modules; a second connector assembly having a second insulating shell, wherein the second insulating shell is configured to hold an array of plug connectors, wherein the first insulating shell includes a docking end and an opposite module mounting end, the docking end includes an opening for accommodating the second insulating shell; the module mounting end has a plurality of accommodating compartments formed therein, the terminal module array is held in the plurality of accommodating compartments, and a channel extends between the opening and the accommodating compartments.

Description

[0001] This application is a divisional application of the application whose applicant is "Morris Ltd.", whose application date is January 4, 2019, whose application number is 201980016680.7, and whose invention name is "Low-profile electrical connector system with differential pair cable interface". Technical Field

[0002] The present application relates to the field of electrical connectors, and more particularly to a multi-conductor shielded electrical connector and an unshielded electrical connector used in a cable harness of a vehicle. Background Art

[0003] Typically, conventional wiring harness manufacturing proposes a "single wire" approach to manufacturing wiring harnesses for vehicles (i.e., a single lead wire terminated at a terminal). As the volume and complexity of onboard electronics have increased significantly, network solutions that provide low-cost, high-speed transmission and bandwidth have become increasingly necessary. In many cases, certain applications require high data rate transmission and require the use of balanced or impedance-tuned differential pair transmission links. Summary of the invention

[0004] A connector system is provided for use with a wire harness to interconnect these various devices. The connector system includes a first connector and a second connector for completing mechanical and electrical connections, and uses a shielded twisted pair cable system or a twin-axial cable system. The two connectors include electrical terminals arranged in pairs in space and geometry, and the paired electrical terminals are configured in a shielded sub-connector or module and retained in the first connector and the second connector of the connector system.

[0005] According to one embodiment of the present application, a connector system is provided, comprising: a first connector assembly having a first insulating shell, the first insulating shell being configured to hold an array of terminal modules; a second connector assembly having a second insulating shell, the second insulating shell being configured to hold an array of plug connectors, wherein the first insulating shell comprises a docking end and an opposite module mounting end, the docking end comprising an opening for accommodating the second insulating shell; the module mounting end having a plurality of accommodating compartments formed therein, the terminal module array being held in the plurality of accommodating compartments, and a channel extending between the opening and the accommodating compartments.

[0006] Among them, each terminal assembly of the terminal module array includes a conductive terminal pair arranged in a vertical manner, and the terminal pair includes an upper terminal and a lower terminal that define an edge-coupled differential signal pair; it also includes an insulating shell arranged around each conductive terminal pair, and the shell includes transverse holes and through-holes that interact with the specific geometric shapes of each terminal pair.

[0007] Wherein, the upper terminal and the lower terminal each include a vertical section, a horizontal section and a corner section connecting the vertical section and the horizontal section, the shell includes a curved portion, the curved portion extends around the corner section of the lower terminal, and the corner section of the upper terminal is surrounded by air.

[0008] Wherein, the butt joint ends of the upper terminal and the lower terminal are configured as male pins of a low-force screw butt joint system.

[0009] Wherein, the terminal module array is a 4X1 array or a 2X2 array.

[0010] Wherein, each terminal assembly of the terminal module array includes an insulating shell arranged around each conductive terminal, and also includes a conductive shielding member arranged around the terminal assembly and its insulating shell.

[0011] Wherein, when the second connector assembly is docked with the first connector assembly, the second insulating shell is inserted into the opening of the first insulating shell, and when further inserted, the shielding part outside the terminal module array and the shielding part outside the plug connector array engage with each other, and after being fully inserted, the terminals of the terminal module array and the terminals of the plug connection array engage respectively.

[0012] The terminal module array includes a terminal assembly, which includes a pair of conductive terminals bent at right angles and aligned edge to edge, and each terminal assembly also includes an insulating shell configured to support the pair of conductive terminals, the insulating shell including: a lower shell element, which is insert-molded around a length of the vertical section of the terminal; a horizontal shell element, which is insert-molded around a length of the horizontal section of the terminal; and an intermediate shell element installed on the corner section of the terminal connecting the vertical section and the horizontal section.

[0013] Wherein, the first connector component includes a first locking device and a first positioning device, and the second connector component includes a second locking device and a second positioning device. When the first connector component is docked with the second connector component, the first positioning device and the second positioning device cooperate to locate the position of the second connector component, and when the first connector component is fully docked with the second connector component, the first locking device and the second locking device cooperate to lock the docking state.

[0014] In order to better understand the above-mentioned objects, features and advantages of the present invention, embodiments are provided for detailed description with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention is illustrated by way of example and not limitation, in the accompanying drawings, in which like reference numerals indicate similar parts, and in which:

[0016] Figure 1 A perspective view showing a vehicle wiring harness connector assembly according to a first embodiment of the present invention;

[0017] Figure 2 Shown with Figure 1 a similar perspective view, but with the vehicle harness connector assembly in an unmated state;

[0018] Figure 3 Show Figure 1 A perspective view of a connector in a vehicle wiring harness connector assembly;

[0019] Figure 4 Show Figure 3 An exploded rear perspective view of a portion of a connector;

[0020] Figure 5 Show Figure 3 An exploded front perspective view of a portion of a connector;

[0021] Figure 6 Shown for use with Figure 3 A rear perspective view of a terminal module used with a connector;

[0022] Figure 7 Show Figure 6 A front perspective view of a terminal module;

[0023] Figure 8 Show Figure 6 An exploded rear perspective view of a terminal module;

[0024] Fig. 9 Show Figure 6 An exploded front perspective view of a terminal module;

[0025] Fig.10 Show Figure 6 An exploded rear perspective view of a terminal assembly of a terminal module;

[0026] Fig.11 Show Fig.10 An exploded front perspective view of a terminal assembly;

[0027] Fig.12 Show Fig.11 A side view of a terminal assembly;

[0028] Fig.13 yes Figure 1 A front perspective view of a second connector of a vehicle wiring harness connector assembly;

[0029] Fig.14 yes Fig.13 A rear perspective view of the connector;

[0030] Fig.15 yes Fig.13 An exploded perspective view of a portion of a connector;

[0031] Fig.16 yes Fig.14 An exploded perspective view of a portion of a connector;

[0032] Fig.17 is used with Fig.13 A front perspective view of a cable connector assembly for use with a connector;

[0033] Fig.18 yes Fig.17 A rear perspective view of the cable connector assembly;

[0034] Fig.19 yes Fig.17 A partially exploded front perspective view of a cable connector assembly;

[0035] Fig. 20 yes Fig.18 A rear perspective view of a portion of an exploded cable connector assembly;

[0036] Fig.21 yes Fig.17 A top view of an assembled cable and terminal module of the cable connector assembly;

[0037] Fig. 22 A front perspective view showing a vehicle wiring harness connector assembly according to a second embodiment of the present invention;

[0038] Fig.23 Shown with Fig. 22 a similar perspective view, but with the vehicle harness connector assembly in an unmated condition;

[0039] Fig.24 Show Fig. 22 a rear perspective view of one of the connectors of the vehicle wiring harness connector assembly;

[0040] Fig.25 Show Fig.24 An exploded perspective view of a portion of a connector;

[0041] Fig.26 Show Fig.24 An exploded front perspective view of a portion of a connector;

[0042] Fig. 27 Shown for use with Fig.24An exploded rear perspective view of a first embodiment of a terminal module for use with a connector;

[0043] Fig.28 Show Fig. 27 An exploded front perspective view of a terminal module

[0044] Fig.29 Show Fig. 27 An exploded rear perspective view of a terminal assembly of a terminal module;

[0045] Fig.30 Show Fig.29 A rear view of the terminal assembly;

[0046] Fig.31 yes Fig.29 A partial bottom perspective view of an intermediate housing element and a terminal of the terminal assembly;

[0047] Fig.32 yes Fig.29 A top view of the terminal assembly;

[0048] Fig.33 Shown for use with Fig.24 An exploded rear perspective view of a second embodiment of a terminal module for use with a connector;

[0049] Fig.34 Show Fig.33 An exploded front perspective view of a terminal module;

[0050] Fig.35 Show Fig.33 An exploded rear perspective view of a terminal assembly of a terminal module;

[0051] Fig.36 Show Fig.35 A rear view of the terminal assembly;

[0052] Fig.37 yes Fig.35 A top view of the terminal assembly;

[0053] Fig.38 yes Fig. 22 A front perspective view of a second connector of a vehicle wiring harness assembly;

[0054] Fig.39 yes Fig.38 A rear perspective view of the connector;

[0055] Fig.40 yes Fig.39 An exploded perspective view of a portion of a connector;

[0056] Fig.41 is used with Fig.38 A front perspective view of a cable connector assembly for use with a connector;

[0057] Fig.42 yes Fig.41 A rear perspective view of a portion of an exploded cable connector assembly; and

[0058] Fig.43 yes Fig.42 A top view of an assembled cable and terminal module of a cable connector assembly. DETAILED DESCRIPTION

[0059] The following detailed description illustrates exemplary embodiments and is not intended to be limited to these explicitly disclosed combinations.Thus, unless otherwise stated, the features disclosed herein may be combined together to form additional combinations that are not presented for the sake of brevity.

[0060] Although the preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made thereto without departing from the spirit of the present invention, the scope of which is defined by the appended claims. Similar components are designated by similar reference numerals.

[0061] The term "connected car" is an umbrella term used to cover many components of in-car connectivity, from infotainment to auxiliary vehicle technologies and full autonomy. Other uses include vehicles communicating with each other and the associated external infrastructure combined with the increasing use of mobile devices and other new driver assistance technologies. The use of Ethernet technology ties all automotive electronic systems together, including the instrument cluster system, infotainment system, and telematics system.

[0062] As shown in the accompanying drawings, specifically, Figure 1 to Figure 2 , discloses a connector system 10 for an in-vehicle Ethernet network system. The connector system 10 includes: a first connector assembly 15 having a first insulating housing 16, the first insulating housing 16 holding a plurality of terminal modules 25 in an array; and a second connector assembly 70, configured to mate with the first connector assembly 15 along a mating axis M, having a second insulating housing 71, the second insulating housing 71 holding a corresponding plurality of cable plug connectors 80 in a similar array. As shown, an embodiment of the connector system 10 is shown as a right-angle arrangement, but other arrangements such as a vertical arrangement or a line-to-line arrangement may be considered.

[0063] like Figures 3 to 12, a first connector assembly 15 is shown. The first connector includes a housing 16 formed of an insulating material, the housing 16 being configured to hold a plurality of terminal modules 25. The embodiment shows four independent terminal modules 25, but any number of modules may be used. The housing 16 is generally rectangular in shape and includes a docking end 17 and an opposite module mounting end 18. The docking end 17 includes an opening 20 for receiving a corresponding docking housing 71 of a second connector 70. The mounting end 18 has a plurality of bays 21 formed therein, and a plurality of terminal modules 25 are held in the plurality of bays 21. A passage extends between the opening 20 and the bays 21. Each bay 21 also includes a second downward opening 22 that communicates with a circuit substrate 100 to facilitate mounting each terminal module 25 on a suitable contact pad 102 and associated traces on the circuit substrate 100.

[0064] Figure 4 1 shows an exemplary printed circuit substrate layout or footprint 101. The footprint 101 includes a combination of contact pads 102 and plated through holes 103. The footprint 101 corresponds to the termination structure of the array of modules 25 held within the housing 16 and is arranged along a longitudinal direction perpendicular to the mating axis M. The two contact pads 102 engage the tails 45, 55 formed by the terminals 37, 38 of each module 25 and are spaced apart and adjacent to each other along a line parallel to the mating direction. The plated through holes 103 are configured to receive integrally formed tabs 32 formed on the shield 26 of each module 25. The plated through holes 103 are arranged adjacent to each contact pad 102 and are located on alternating sides of each corresponding contact pad 102. The size and geometry of the contact pads 102 and the traces can be adjusted to tune the signal integrity in the launch area or the area where each module 25 is connected to the circuit substrate 100.

[0065] like Figures 6 to 12 , details of the terminal module 25 are shown. The terminal module 25 includes a conductive shield 26 disposed around a terminal assembly 35. The shield 26 includes a butt end 27 and a substrate mounting end 28. Figure 8 As shown, the shield 26 includes a U-shaped base 30 and a cover 31, which interlock together to completely enclose the terminal assembly 35 except for the butt end 27 and the substrate mounting end 28. The butt end 27 of the shield 26 is configured to engage a butt portion of a butt plug connector 85. The cover 31 may include a downwardly extending tail 32, which is configured to be inserted into and fixed in the plated through hole 103 on the circuit substrate 100. The shield 26 may include a structure for retaining the terminal assembly 35 within the shield 26.

[0066] Reference Figures 10 to 12, the terminal assembly 35 includes a conductive terminal pair 36 arranged in a vertical manner and aligned in an edge-to-edge manner. The terminal pair 36 includes an upper terminal 37 and a lower terminal 38 that define an edge-coupled differential signal pair. Other terminal configurations are contemplated, such as the terminal pair 36 being electrically coupled in a horizontal arrangement in a broadside or body-to-body manner or any combination of various terminal configurations.

[0067] Each terminal assembly 35 also includes an insulating housing 40 disposed around each conductive terminal pair 36. In one embodiment, the insulating housing 40 can be molded around the terminal insert. To this end, a lead frame (not shown) can be formed on which the terminals are stamped and held together by a strip (not shown). The housing 40 can then be molded over or around portions of the terminals to form the terminal assembly 35. In another embodiment, the housing can be formed separately from the terminals located therein. Figures 10 to 12 As shown, the terminals 37, 38 of each pair 36 include specific spacing and geometric shapes, including but not limited to different cross-sections, cutouts, radii and spacing gaps. The configuration and position of each geometric shape can be specifically arranged to optimize the signal integrity ("SI") performance of each differential signal pair. An example of optimized SI tuning includes adjusting the spacing between the contact portions of the terminals to increase impedance. Notches can be formed along the terminals to match impedance and produce balanced signal transmission. Further, the housing 40 can also be specifically formed to tune the SI performance of each terminal module 25. For example, the housing 40 may include cross holes and apertures that interact with the specific geometric shapes of each terminal or terminal pair to affect the optimized SI performance. Therefore, a portion of each terminal can be exposed to the air, or a portion of each terminal is completely enclosed by the insulating material of the housing 40 and the material thickness is additionally adjusted by increasing or reducing the material in a specific area or a specific part. The dielectric constant strategy of the insulating housing 40 and the air is used to further improve the SI performance.

[0068] In the illustrated embodiment, the connector system 100 has been configured to have an impedance of 100 ohms along its entire length. Although the impedance at any particular location along the electrical path may not be 100 ohms, the system is configured to optimize performance around the 100 ohm target. Therefore, as described above, the shield 26, terminals 37, 38, and housing 40 are formed to optimize SI performance along with mechanical performance and manufacturability.

[0069] Reference Figures 10 to 12, each terminal 37, 38 includes a tail section, a vertical section, an angled transition section, a horizontal section, and a mating interface section in sequence. The terminals 37, 38 each include: a surface mounting tail 45, 55, each configured to be mechanically and electrically connected to one of the contact pads 102 on the circuit substrate 100, such as by welding. The surface mounting tails 45, 55 are configured the same, but extend in opposite directions from their respective horizontal sections.

[0070] The amount of conductive material from the surface mount tails 45, 55, contact pads, and solder reduces impedance, while the spacing of the contact pads 102 of the circuit substrate 100 in the illustrated embodiment increases impedance in this area. Further, the shield 26 may not extend all the way down to the circuit substrate 100 to facilitate soldering of the tails 45, 55 to the contact pads 102. The lack of shielding coupled with the geometry of the contact pads 102 increases impedance at the circuit substrate termination area. The spacing of the contact pads 102 and the lack of shielding compensate to some extent for the clustering of conductive material (such as contact pads, surface mount tails 45, 55, and solder material). In addition, the housing 40 can be further optimized to 100 ohms by providing a downward protrusion 41 extending between the lower portions 46, 56 of the horizontal sections of the terminals 37, 38, respectively. Further, the protrusion 41 also ensures that the terminals 37, 38 do not contact each other in the area of ​​the adjacent tails 45, 55.

[0071] The protrusion 41 serves to reduce the impedance between the lower portions 46, 56 of the vertical sections 47, 57 of the terminals 37, 38 to compensate for the increased impedance at the interconnection between the surface mount tails 45, 55 and the two contact pads 102. In some embodiments, there may be a minimum spacing between the lower surface 42 of the housing 40 and the contact pads 102 to facilitate the soldering process. By including only one protrusion 41 extending from the lower surface 42 between the terminals 37, 38, the effect of the housing 40 on the soldering process may be minimized while improving the electrical performance of the adjacent circuit substrate termination area.

[0072] The remaining vertical portion 47 of the upper terminal 37 has a constant width that is the same width as the lower portion 46. However, the remaining vertical portion 57 of the lower terminal 38 has a stepped width that is narrower than the lower vertical portion 56. The vertical portions 47, 57 are both enclosed in the housing 40. A through hole 43 is provided on the housing 40 between the vertical portions 47, 57 to help fix the terminals 37, 38 in a mold (not shown) during the molding process. The through hole 43 along the vertical portions 47, 57 increases the impedance along the vertical portion. Therefore, by providing an insulating portion of the housing 40 above and below the through hole 43 but between the vertical portions 47, 57, a reduction in impedance is provided on both sides of the through hole 43 along the electrical path to electrically compensate for the through hole 43 on the housing 40.

[0073] The corner transition sections 48, 58 of the terminals 37, 38 serve to interconnect the vertical sections 47, 57 and the horizontal sections 49, 59. Due to the configuration of the corner transition sections 48, 58, the electrical path of the corner section 48 of the upper terminal 37 is longer than the electrical path of the corner section 58 of the lower terminal 38. In order to reduce signal skew and compensate for the difference in path length between the corner section 48 and the corner section 58, a curved portion 44 of the housing 40 extends around the corner section 58 of the lower terminal, while the corner section 48 of the upper terminal 37 is surrounded by air. Since the dielectric constant of air is low compared to the insulating material of the portion 44, the propagation speed of the signal propagating along the corner section 48 of the upper terminal 37 is faster than that of the signal propagating along the corner section 58 of the lower terminal 38, thereby compensating for the difference in path length.

[0074] Furthermore, since the portion 48a of the transition section 48 adjacent to the vertical portion 47 of the upper terminal 37 is surrounded by air, the impedance of the terminal pair 36 increases as it moves away from the housing 40. Therefore, the portion 48a of the transition section 48 adjacent to the vertical portion 47 has a reduced width to achieve a desired distance between the transition section 48 of the upper terminal 37 and the transition section 58 of the lower terminal 38 to control the impedance of the terminal pair 36.

[0075] In one embodiment, a portion 50 of the transition section 48 adjacent to the horizontal portion 49 of the upper terminal 37 may be wider than other portions of the transition section and the horizontal section. This width variation may be configured to compensate for changes in impedance as a signal propagates from the transition section 48 in the air to the horizontal section 49 within the insulating housing 40.

[0076] The distance between the horizontal portion 49 of the upper terminal 37 and the horizontal portion 59 of the lower terminal 38 is set to provide a desired impedance of 100 ohms based on the dielectric properties of the insulating housing 40. The distance between the docking interface sections 51, 61 of the terminals 37, 38 is set to provide a desired distance or spacing between the terminals to optimize docking and electrical performance. In the illustrated embodiment, the docking ends 52, 62 of the terminals 37, 38 are configured as male pins of a low force helix ("LFH (low force helix)") docking system. Terminals 37, 38 having other configurations are contemplated.

[0077] like Figure 13 to Figure 14 As shown, a second connector assembly 70 is shown. The second connector assembly 70 includes an insulating housing 71 configured to hold a plurality of independent cable plug connector assemblies 80. The housing 71 is configured to engage the opening 20 at the mating end 17 of the first housing 16 of the first connector assembly 15. Figure 15 to Figure 16As best shown, the housing 71 includes: a plurality of openings 72 on a mating face 73 corresponding to the number of terminal modules 25 in the first connector assembly 15; and an insertion opening 74 opposite the plurality of openings on the mating face. A plurality of independent mounting areas are formed in the insertion opening 74 by a plurality of ridges 75 and are configured to receive each plug connector assembly 80 therein along the mating axis M.

[0078] like Figures 17 to 21 , a plug connector assembly 80 of the second connector assembly 70 is shown. Each plug connector assembly 80 includes a cable 81 and a cable connector assembly 85. The cable 81, such as a shielded twisted pair cable or a twinaxial cable, has a pair of signal conductors 82 and an integral shield layer 83.

[0079] The cable connector assembly 85 includes a conductive shield 86 disposed around a terminal module 95. The shield 86 is generally elongated and includes: a first clamping portion 87 configured to clamp around a portion of the cable 81; and a second clamping portion 88 configured to clamp around to mechanically and electrically connect the shield 86 to the shield layer 83 of the cable 81. A connector portion 89 of the shield 86 has a generally rectangular configuration with a mating end 90 opposite the clamping portions 87, 88. The connector 89 may include a U-shaped first portion 91 configured to engage a mating U-shaped second segment 92 to connect the terminal module 95 ( Fig.21 ) is completely enclosed within the shielding member 86.

[0080] The terminal module 95 includes a pair of conductive terminals 96 configured in an edge-to-edge relationship and arranged in a vertical manner to mate with the terminals 37, 38 of the first connector assembly 15. The two terminals 96 (except for their docking interface section 105) are identical except that they are mirror image configurations about a centerline between the two terminals 96. In other embodiments with different docking interfaces, the first and second terminals can be symmetrically configured along their entire lengths. The two terminals 96 are configured to define edge-coupled differential signal pairs in the same manner as the terminals 37, 38 of the first connector assembly 15.

[0081] The terminal module 95 also includes an insulating main housing member 106 disposed around each pair 97 of terminals 96. In one embodiment, the main housing member 106 can be insert molded around the terminals 96 in a manner similar to that described above with respect to the terminals 37, 38. In addition, a separate docking housing member 107 is disposed within and supported by the shield 86 in a manner spaced from the main housing member 106 and adjacent to the docking ends 90 of the terminals. Further, the terminals 37, 38 and the docking housing member 107 are configured such that the docking ends 105 of the two terminals 96 are disposed in the docking housing member 107 and are spaced apart in the docking housing member. More specifically, the docking housing member 107 has an opening at an end to allow flexing of the docking ends 105 without contacting the docking housing member 107.

[0082] Like the terminals 37, 38 of the first connector assembly 15, the terminals 96 of the second connector assembly 70 include specific spacing and geometry and interact with the housing components 106, 107 and the shield 86 to optimize the SI performance of each differential signal pair. The two terminals 96 are also configured to maintain an impedance of 100 ohms for the entire connector system 10. In an embodiment, it may be desirable to minimize the size of the housing components 106, 107 in the mating direction to reduce the impact of the housing components and the mating interface on achieving the 100 ohm target. More specifically, by providing a gap or spacing 109 ( Fig.21 ), the impedance along the gap 109 increases to compensate for the reduction in capacitance due to the housing components and the docking interface.

[0083] Reference Fig.21 The terminal 96 includes, in sequence, a termination section 97, a body section 100, and a mating interface section 105. The termination section 97 is configured to be welded or otherwise mechanically and electrically connected to the signal conductor 82 of the cable 81. The termination section 97 includes: a first enlarged portion or first protrusion 98 at a first end of the terminal 96 opposite the mating interface section; and a second enlarged portion or second protrusion 99 spaced apart from the first protrusion 98. In one embodiment, the first protrusion 98 can be larger than the second protrusion 99.

[0084] The first protrusion 98 is configured to reduce the impedance at the first end of the terminal 96. This is desirable because the length of the signal conductor 82 immediately adjacent the first end of the terminal 96 is unshielded and therefore has a relatively high impedance as it is distal from the cable 81. Therefore, by providing a relatively low impedance for the relatively large first protrusion 98, the first protrusion 98 will compensate or cancel the relatively high impedance along the unshielded portion of the signal conductor 82.

[0085] The second protrusion 99 may be provided to increase the strength of the solder connection between the signal conductor 82 and the terminating section 97 of the terminal 96 .

[0086] The body section 100 is shown as having two spaced apart flat sections 101, 102 with a curved section 103 located between the flat sections 101, 102. Due to the body housing component 106 molded onto the body section 100, the curved section 103 can be narrower than the flat sections 101, 102 to control impedance.

[0087] The mating interface section 105 of the terminal 96 is configured as a receptacle of a low-force screw-on mating system to mate with the terminals 37 , 38 of the first connector assembly 15 .

[0088] During assembly of the plug portion of the plug connector 85, the terminals 96 are soldered to the signal conductors 82 of the cable 81. A dispensed or molded insulator 108 is then formed around the terminating portion of the signal conductor 82 and the terminating section 97 of the terminal 96. The terminated cable 81 and the terminal module 95 can be inserted into the shield 86 and the clamping portions 87, 88 that clamp the cable 81. The second section 92 can be secured to the first portion 91 of the shield 86 to completely enclose the terminal module 95.

[0089] In one embodiment, the mating housing component 107 may be inserted into the mating end 90 of the shield 86 before positioning the terminated terminal module 95 in the mating housing component 107. In another embodiment, the mating housing component 107 may be inserted after the shield 86 and terminal module 95 are assembled.

[0090] In operation, the fully assembled first connector 15 is secured to a printed circuit substrate 100 by appropriate connections between the terminals and shields of each module 25 to maintain proper electrical connection with corresponding traces on the printed circuit substrate. The second connector 70 is mated to the first connector 15 by inserting the mating portion of the second housing into the opening formed in the first housing. Upon further insertion, the shield of the terminal module and the shield of the plug portion engage with each other, and after full insertion, the terminals of the terminal module and the terminals of the plug portion engage, respectively.

[0091] Reference Figure 22 to Figure 23 , a second embodiment of a connector system 110 is shown. The connector system 110 includes a first connector assembly 115 and a second connector assembly 170. The connector system 110 is similar to the connector system 10 described above in terms of the number of conductors and the operation of multiple 100 ohm differential pair transmission lines. Similar components may be indicated by similar reference numerals, and the description of some components may not be repeated here.

[0092] The first connector assembly 115 includes a housing 116 formed of an insulating material, and a plurality of terminal modules 125, 225 are disposed within the housing 116. Although any number of modules may be used, the embodiment shows four separate terminal modules 125, 225. The housing 116 is similar to the housing 16 described above, except that the housing 116 is configured in a manner to receive the terminal modules 125, 225. Thus, the housing 116 is taller than the housing 16 but narrower.

[0093] The circuit substrate 200 includes a layout or footprint 201 having a combination of contact pads 202 and plated through holes 203, which corresponds to the footprint of the array of modules 125, 225 held within the housing 216. As shown, the footprint 201 includes pairs of contact pads 202 and plated through holes 203, which are spaced apart and aligned along a longitudinal line parallel to the mating axis M.

[0094] The first connector assembly 115 includes two relatively short right-angle terminal modules 125 and two relatively tall right-angle terminal modules 225 disposed within the housing 116. Figure 25 to Figure 26 As best shown, a short module 125 and a tall module 225 form a pair of nested modules aligned parallel to the docking axis M.

[0095] Reference Figures 27 to 32 , showing details of the terminal module 125. The terminal module 125 includes a two-piece conductive shield 126 disposed around a terminal assembly 135. The conductive shield 126 has a first part 127 and a second part 128, and is similar to the conductive shield 26 described above, except that the two tails 132 of the conductive shield 126 are aligned in a direction transverse to the mating axis M.

[0096] The terminal assembly 135 includes a pair of conductive terminals 137, 138 bent at right angles and aligned edge to edge. The terminal pair includes a first terminal 137 and a second terminal 138 defining an edge-coupled differential signal pair. The first terminal 137 and the second terminal 138 (except for their docking interface section 158) are configured identically, except that the first terminal 137 and the second terminal 138 are symmetrical about a centerline extending between each pair of terminals. In other embodiments with different docking interfaces, the first terminal and the second terminal can be configured symmetrically along their entire length.

[0097] Each terminal assembly 135 also includes an insulative housing 140 configured to support the pair of conductive terminals. In one embodiment, the insulative housing 140 includes: a first or lower housing member 141, insert molded around a length of vertical sections 146 of the terminals 137, 138; and a second or horizontal housing member 142, insert molded around a length of horizontal sections 155 of the terminals. An intermediate housing member or cover 143 is mounted on the corner sections 150 of the terminals. In other words, the intermediate housing member 143 is formed separately from the lower housing member 141 and the horizontal housing member 142, and then mounted on the terminals.

[0098] The intermediate housing element 143 includes a right angle bend that follows the bend of the terminals 137, 138 and a pair of spaced apart internal channels 143a ( Fig.31 ). A central protrusion 143b extends downwardly from an upper inner surface of the intermediate housing element 143 between the terminals 137, 138 to help position the housing element relative to the terminals. Other configurations of the housing 140 are contemplated. For example, if desired, each of the housing elements can be molded around a terminal insert, or each housing element can be formed as a separate component and secured to the terminal.

[0099] As described above, the terminals 137, 138 and housing 140 are configured to optimize SI performance with a target of 100 ohms.

[0100] Reference Fig.29 , the terminal pair 137, 138 includes, in sequence, a tail section 145, a vertical section 146, a corner section 150, a horizontal section 155, and a docking interface section 158. Unlike the above-mentioned terminals 37, 38, the terminals 137, 138 are arranged side by side in the horizontal direction, and are therefore edge-coupled and have equal path lengths. Each of the terminals 137, 138 includes a surface mount tail 145, which is configured to be mechanically and electrically connected to one of the contact pads 202 on the circuit substrate 200, such as by welding. The vertical section 146 includes, in sequence, a first relatively narrow lower portion 147 and a second relatively wide upper portion 148.

[0101] There is a relatively large horizontal gap between the contact pads 202, which results in a relatively high impedance at the termination between the surface mount tail 145 and the contact pad 202. Although the lower housing member 141 may extend downwardly near the contact pads 202 to facilitate soldering of the surface mount tail 145 to the contact pad, the lower surface 141a of the lower housing member 141 must be at least a specified distance from the contact pad 202. Due to the lack of surrounding insulating material and to offset or compensate for the high impedance at the surface mount tail 145, the lower portion 147 of the vertical section 146 of the terminals 137, 138 is relatively wide to provide the required gap between the adjacent edges of the terminals.

[0102] The upper portions 148 of the vertical sections 146 of the terminals 137, 138 are relatively wide to reduce the distance between adjacent edges of the terminals as the terminals move from the vertical section to the corner section. The relatively narrow gap between the two upper portions 148 serves to reduce the impedance along the two portions.

[0103] Corner section 150 includes, in order, a vertical portion 151, a corner portion 152, a first horizontal portion 153, and a second horizontal portion 154. Vertical portion 151 extends continuously from upper portion 148 and has the same width. Corner portion 152 is slightly narrower than vertical portion 151, which results in lower impedance. The width of first horizontal portion 153 is even narrower than corner portion 152. It has been found that the narrower width of portion 153 is desirable to avoid an increase in impedance, which is believed to be caused by the change in direction occurring at corner portion 152. In other words, it is believed that without the reduction in the width of horizontal portion 153 and the corresponding increase in the distance between the two terminals 137, 138 at first horizontal portion 153, the impedance would otherwise be significantly reduced.

[0104] Second horizontal portion 154 is wider than first horizontal portion 153 to reduce the impedance of terminals 137 , 138 as terminals 137 , 138 transition from being partially enclosed in insulating material along intermediate housing member 143 to being fully enclosed in insulating material within horizontal housing member 142 .

[0105] Horizontal section 155( Fig.32 ) has: a first portion 156 that is the same width as the second horizontal portion 154 of the corner section 150 and is completely enclosed in the insulating material of the horizontal housing element 142; and a second portion 157 that is narrower and serves as a transition to the docking interface section 158 of the terminal. The docking interface section 158 of the terminals 137, 138 is configured to provide a desired distance or spacing between the terminals to optimize the docking and electrical performance of the connector system 110. In one embodiment, the docking interface section 158 of the terminals 137, 138 is configured with a low-force screw configuration. Terminals 137, 138 having other configurations are contemplated.

[0106] Reference Figure 33 to Figure 37 , showing details of a terminal module 225. The terminal module 225 includes a conductive shield 226 disposed around a terminal assembly 235. The conductive shield 226 has a first portion 227 and a second portion 228, and is similar to the conductive shield 126 described above, except that the vertical and horizontal legs of the conductive shield 226 are longer to accommodate the longer path length of the terminal module 225.

[0107] The terminal assembly 235 includes: a pair of conductive terminals 237, 238, similar to the terminals 137, 138, bent at right angles and aligned edge to edge. The terminal pair 237, 238 defines an edge-coupled differential signal pair. In addition to the first and second terminals being symmetrical about a centerline extending between each pair of terminals, the first and second terminals (except for their docking interface section 265) are configured identically. In other embodiments having different docking interfaces, the first and second terminals can be configured symmetrically along their entire length.

[0108] Each terminal assembly 235 also includes an insulating housing 240 configured to support the pair of conductive terminals 237, 238. The insulating housing 240 is similar to the housing 140 and includes: a first or lower housing element 241, insert molded around a length of the vertical section 246 of the terminals 237, 238; and a second or horizontal housing element 242, insert molded around a length of the horizontal section 257 of the terminals. An intermediate housing element or cover 243 is mounted on the corner section 251 of the terminals. The lower housing element 241 is similar to the lower housing element 141 and the horizontal housing element 242 is similar to the horizontal housing element, except that the two housing elements of the terminal assembly 235 are longer along the path of the terminals 237, 238. In other words, the lower housing element 241 is taller than the lower housing element 141, and the horizontal housing element 242 is longer in the horizontal direction than the horizontal housing element 142. The intermediate housing element 243 and the intermediate housing element 143 can be configured the same. As described above, other configurations of the housing 240 are contemplated.

[0109] The terminal pair 237, 238 includes, in order, a tail section 245, a vertical section 246, a corner section 251, a horizontal section 257, and a docking interface section 258. As described above, except that the terminals 237, 238 are symmetrical about the centerline extending between each pair of terminals, the terminals 237, 238 (except for their docking interface sections 265) are arranged side by side and have equal path lengths and are therefore configured identically. The surface mount tail 245 is the same as the surface mount tail 145 described above. The vertical section 246 includes, in order, a first relatively wide lower portion 247, a relatively narrow lower middle portion 248, an upper middle portion 249, and a fourth relatively wide upper portion 250.

[0110] As described above, there is a relatively large horizontal gap between the two contact pads 202, which results in a relatively high impedance at the termination between the surface mount tail 145 and the contact pad. The constraints of the configuration of the lower housing element 141 result in the lower portion 247 of the vertical section 246 of the terminals 237, 238 being relatively wide to provide the required distance between the adjacent edges of the terminals to offset or compensate for the high impedance at the surface mount tail.

[0111] The lower middle portion 248 of the terminals 237, 238 is relatively narrow to increase the distance between adjacent edges of the terminals because both portions are completely enclosed in the plastic of the lower housing element 241. The upper middle portion 249 of the terminals 237, 238 is slightly narrower than the lower middle portion 248 because one length of the middle portion is surrounded by the plastic of the lower housing element 241 and the other length is surrounded by air.

[0112] The upper portion 250 is relatively wide to reduce the distance between the terminals and thus increase the impedance of the terminal pair in this area. It has been found that this is desirable because the corner sections of the terminals 237, 238 are configured in the same manner as the corner sections 251 of the terminals 137, 138. Therefore, the upper portion 250 of the vertical section 246 is configured to compensate for the configuration of the corner sections.

[0113] As described above, the corner section 251 of the terminals 237, 238 is configured in the same manner as the corner section 150 of the terminals 137, 138. Thus, the corner section 251 includes, in sequence, a vertical portion 252, a corner portion 253, a first horizontal portion 254, and a second horizontal portion 255. The function of each of these portions and their interaction with the intermediate housing element 243 are the same as the corner section 150 of the terminals 137, 138 and the intermediate housing element 143, and therefore their description will not be repeated here.

[0114] Horizontal section 257( Fig.37 ) is completely enclosed in the insulating material of the horizontal housing element 242 and has five continuous sections of different widths. The first section 258 has the same width as the horizontal portion 255 of the corner section 251. A second section 260 is narrower and serves as a transition to a narrower third section 261. A fourth section 262 is wider and serves to reduce impedance before the terminal at the fifth section 263 becomes narrower. The width of the fifth section 263 is narrower than the width of the docking interface section 265 of the terminals 237 and 238. The docking interface section 265 of the terminals 237 and 238 provides a desired distance or spacing between the terminals to optimize the docking and electrical performance of the connector system 110. The docking interface section 265 of the terminals 237 and 238 is configured to dock with the docking interface section 158 of the terminals 137 and 138.

[0115] Reference Figures 38 to 40 , details of the second connector assemblies 170 are shown. Each second connector assembly 170 has a connector housing 171 configured to mate with a receptacle or opening of the first connector housing 116. The connector housing 171 holds four plug connector assemblies 185 therein.

[0116] Reference Figure 41 to Figure 43, each cable connector assembly 185 includes a conductive shield 186 disposed around a terminal module 195. The shield 186 is generally elongated and includes a first member 187 and a second member 191. The first member 187 includes: a first clamping portion 188 configured to clamp around a portion of the cable 81; a second clamping portion 189 configured to clamp around to mechanically and electrically connect the shield 186 to the shield layer 83 of the cable; and a housing retaining segment 190 configured to mechanically engage the housing member 210. The second shield member 191 has a generally rectangular configuration, having a first rectangular portion 192 configured to be fixed to the housing retaining segment 190 and a second rectangular portion 193 having a mating end 194.

[0117] The terminal block 195 includes a pair of conductive terminals 196 configured in an edge-to-edge relationship and arranged in a horizontal manner to mate with the terminals 137, 138 of the first connector assembly 115. The two terminals 196 (except for the mating interface section 205) are configured identically, except that the two terminals are mirror images about a centerline between the two terminals. The two terminals 196 are configured to define an edge-coupled differential signal pair in the same manner as the terminals 137, 138 of the first connector assembly 15.

[0118] The terminal module 195 also includes an insulating main body housing component 210 disposed around each pair of terminals 196. In one embodiment, the insulating main body housing component 210 can be insert molded around the terminals 196 in a manner similar to that described above with respect to the terminals 137, 138. In addition, a separate insulating docking housing component 211 is disposed and supported within the shield 186 in a manner spaced apart from the main body component 210 and adjacent to the docking end 194 of the second rectangular portion 193. Further, the two terminals 196 and the docking housing component 211 are configured such that the docking ends 205 of the two terminals are disposed and spaced apart in the docking housing component. More specifically, the docking housing component 211 has two openings at the ends to allow flexing of the docking ends 205 without contacting the docking housing component.

[0119] Like the terminals 137, 138 of the first connector assembly 115, the terminals 196 of the second connector assembly 170 include specific spacing and geometry, and interact with the insulating housing components 210, 211 and the shield 186 to optimize the SI performance of each differential signal pair. The two terminals 196 are also configured to maintain an impedance of 100 ohms for the entire connector system 10. In an embodiment, it is desirable to minimize the size of the housing components 210, 211 in the mating direction to reduce the impact of the housing components and the mating interface on achieving the 100 ohm target. More specifically, by providing a gap or spacing 213 ( Fig.43), the impedance along the gap 213 increases to compensate for the reduction in capacitance due to the housing components and the docking interface.

[0120] Reference Fig.43 , the terminal 196 includes, in sequence, a termination section 197, a body section 201, and a mating interface section 205. The termination section 197 is configured to be welded or otherwise mechanically and electrically connected to the signal conductor 82 of the cable 81. The termination section 197 includes a first portion 198 at a first end 199 of the terminal 196 and a second portion 200 of reduced width spaced apart from the first end of the terminal.

[0121] The body section 201 is shown as having two spaced apart flat sections 202, 203 with a curved section 204 between the flat sections 202, 203. The curved section 204 and portions of the flat sections 202, 203 include a narrow length to control impedance due to the insulating housing 210 molded onto the body section 201.

[0122] The docking interface section 205 of the terminal 196 is configured as a receptacle of a low-force screw docking system to mate with the terminals 137 , 138 of the first connector assembly 115 .

[0123] During assembly of the cable connector assembly 185 of the second connector assembly 170, the terminal 196 is soldered to the signal conductor 82 of the cable 81. A dispensed or molded insulator 212 is then formed around the terminating portion of the signal conductor 82 and the terminating section 197 of the terminal 196. The terminated cable 81 and the terminal module 195 can be inserted into the first part 187 of the shield 186 and the clamping portions 188, 189 of the clamped cable 81. The second shielding part 191 can be fixed to the first shielding part 187 to completely enclose the terminal module 195.

[0124] In one embodiment, the docking housing 211 may be disposed in the docking end of the second shielding member 191 before the first shielding member 187 and the second shielding member 191 are connected to each other. In another embodiment, the docking housing 211 may be inserted after the first shielding member 187 and the second shielding member 191 are assembled together.

[0125] The disclosure given herein illustrates various features in terms of its preferred and exemplary embodiments. After reading this disclosure, those skilled in the art will come to many other embodiments, modifications and variations within the scope and spirit of the appended claims.

Claims

1. A connector system, comprising: A first connector assembly having a first insulating housing configured to hold an array of terminal modules; a second connector assembly having a second insulating housing configured to hold an array of plug connectors, The first insulating housing comprises a butt joint end and a module mounting end which are arranged opposite to each other, the butt joint end comprises an opening for receiving the second insulating housing; the module mounting end has a plurality of receiving compartments formed therein, the terminal module array is held in the plurality of receiving compartments, a channel extends between the opening and the receiving compartments, Among them, each terminal assembly of the terminal module array includes a conductive terminal pair arranged in a vertical manner, and the terminal pair includes an upper terminal and a lower terminal that define an edge-coupled differential signal pair; it also includes an insulating shell arranged around each conductive terminal pair, and the shell includes transverse holes and through-holes that interact with the specific geometric shapes of each terminal pair.

2. The connector system according to claim 1, wherein: The upper terminal and the lower terminal each include a vertical section, a horizontal section and a corner section connecting the vertical section and the horizontal section, the shell includes a curved portion, the curved portion extends around the corner section of the lower terminal, and the corner section of the upper terminal is surrounded by air.

3. The connector system according to claim 1, wherein: The butt ends of the upper terminal and the lower terminal are configured as male pins of a low-force screw butt system.

4. The connector system according to claim 1, wherein: The terminal module array is a 4X1 array or a 2X2 array.

5. The connector system of claim 1, wherein: Each terminal assembly of the terminal module array includes a conductive shielding member disposed around the terminal assembly and its insulating housing.

6. The connector system of claim 1, wherein: When the second connector assembly is docked with the first connector assembly, the second insulating shell is inserted into the opening of the first insulating shell. When further inserted, the shielding part outside the terminal module array and the shielding part outside the plug connector array engage with each other, and after being fully inserted, the terminals of the terminal module array and the terminals of the plug connection array engage respectively.

7. The connector system of claim 1, wherein: The first connector component includes a first locking device and a first positioning device, and the second connector component includes a second locking device and a second positioning device. When the first connector component is docked with the second connector component, the first positioning device and the second positioning device cooperate to locate the position of the second connector component, and when the first connector component is fully docked with the second connector component, the first locking device and the second locking device cooperate to lock the docking state.

8. A connector system comprising: A first connector assembly having a first insulating housing configured to hold an array of terminal modules; a second connector assembly having a second insulating housing configured to hold an array of plug connectors, The first insulating housing comprises a butt joint end and a module mounting end which are arranged opposite to each other, the butt joint end comprises an opening for receiving the second insulating housing; the module mounting end has a plurality of receiving compartments formed therein, the terminal module array is held in the plurality of receiving compartments, a channel extends between the opening and the receiving compartments, The terminal module array (125) includes a terminal assembly, the terminal assembly includes a pair of conductive terminals bent at right angles and aligned edge to edge, each terminal assembly also includes an insulating shell configured to support the pair of conductive terminals, the insulating shell includes: a lower shell element, which is insert-molded around a length of the vertical section of the terminal; a horizontal shell element, which is insert-molded around a length of the horizontal section of the terminal; and an intermediate shell element installed on the corner section of the terminal connecting the vertical section and the horizontal section.

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