Contact assembly with ground bus

Abstract

A contact assembly (100) includes a leadframe (110) having signal contacts (114) and ground contacts (116). The contacts (112) include a midsection (130, 140) extending between a mating end and a termination end. The ground termination end (144) has a leadframe ground bus (150) connecting each ground contact. An electrical connector (10) includes a contact retainer (120) holding the contacts. The electrical connector includes a cable (122) terminated to the leadframe, the cable including signal conductors (210) terminated to corresponding signal termination ends (134). The leadframe ground bus is terminated to each ground shield (212) to co-potentialize the ground shields. The electrical connector includes an external ground bus (124) separate and distinct from the leadframe ground bus, the external ground bus terminated to each ground shield on an opposite side of the cable from the leadframe ground bus to co-potentialize the ground shields.

Description

Technical Field

[0001] This article mainly deals with electrical connectors. Background Technology

[0002] Electrical connectors are commonly used to electrically connect various types of electrical devices to transmit signals between them. At least some known electrical connectors include cable assemblies having cables connecting the electrical device and the connector. Each cable has a signal conductor or a differential pair of signal conductors surrounded by a shielding layer, which in turn is surrounded by a cable sheath. The shielding layer includes conductive foil, which is used to shield the signal conductor(s) from electromagnetic interference (EMI) and improve overall performance. At the ends of the communication cable, the cable sheath, shielding layer, and insulation covering the signal conductor(s) can be removed (e.g., stripped) to expose the signal conductor(s). However, the exposed portions of the conductor(s) can be mechanically and electrically coupled (e.g., soldered) to corresponding components of the electrical device. However, the lack of shielding in the exposed portions can lead to high impedance mismatch and degrade the overall performance of the device.

[0003] Therefore, there is a need for an electrical connector with improved electrical shielding. Summary of the Invention

[0004] According to the present invention, a contact assembly for an electrical connector is provided. The electrical connector includes a lead frame having an array of contacts, the contacts including signal contacts and ground contacts. Ground contacts are interposed with signal contacts to provide electrical shielding between corresponding signal contacts. Each signal contact includes a signal intermediate portion extending between a signal mating end and a signal terminating end. Each ground contact includes a ground intermediate portion extending between a ground mating end and a ground terminating end. A ground terminating end has a lead frame ground bus connected to each ground contact. The electrical connector includes a contact retainer holding the array of contacts. The contact retainer is made of a dielectric material. The contact retainer holds each signal intermediate portion and each ground intermediate portion. The signal mating end and the ground mating end extend forward of the contact retainer. The signal terminating end and the ground terminating end extend rearward of the contact retainer. The electrical connector includes a cable terminated to the lead frame. The cable includes a signal conductor and a ground shield surrounding a corresponding signal conductor to provide electrical shielding to the signal conductor. The signal conductor terminates to a corresponding signal terminating end. The leadframe ground bus terminates to each ground shield to make the ground shield and the leadframe ground bus common potential. The electrical connector includes a separate and independent external ground bus. The external ground bus terminates to each ground shield on the side of the cable opposite to the leadframe ground bus to make the ground shield and the external ground bus common potential. Attached Figure Description

[0005] Figure 1This is a perspective view of an electrical connector formed according to one embodiment.

[0006] Figure 2 This is a perspective view of an electrical connector formed according to one embodiment.

[0007] Figure 3 This is a perspective view of a contact assembly formed according to one embodiment.

[0008] Figure 4 This is a side view of a contact assembly according to one embodiment.

[0009] Figure 5 This is a side view of a contact assembly according to one embodiment.

[0010] Figure 6 This is a top view of the contact assembly according to an exemplary embodiment.

[0011] Figure 7 This is a bottom view of the contact assembly according to an exemplary embodiment. Detailed Implementation

[0012] Figure 1 This is a perspective view of an electrical connector 10 formed according to one embodiment. The electrical connector 10 is configured to mate with a mating electrical connector 30. In an exemplary embodiment, the electrical connector 10 has a mating end 20, a cable end 22, and one or more cables 24 extending from the cable end 22. The electrical connector 10 includes a housing 26 configured to retain a contact assembly 100. In an exemplary embodiment, the housing 26 includes a slot 28 at the mating end 20. In the illustrated embodiment, the electrical connector 10 is a communication device, such as a Serial Affinity SCSI (SAS) connector. However, in alternative embodiments, the electrical connector 10 may be another type of electrical connector. For example, the electrical connector 10 may define a receptacle or socket connector, such as a ferrule receptacle connector.

[0013] The mating electrical connector 30 is configured to mate with the electrical connector 10. In an exemplary embodiment, the mating electrical connector 30 has a circuit card 32 at its mating end 34. The circuit card 32 includes mating contacts 36 at its edge 38. Connectors 10 and 30 can be high-speed connectors that transmit data signals at speeds exceeding 10 gigabits per second (Gbps), such as exceeding 25 Gbps. Connectors 10 and 30 can be input-output (I / O) connectors.

[0014] Figure 2This is a perspective view of an electrical connector 50 formed according to one embodiment. The electrical connector 50 is configured to mate with a mating electrical connector 70. In an exemplary embodiment, the electrical connector 50 has a mating end 60, a cable end 62, and one or more cables 64 extending from the cable end 62. The electrical connector 50 includes a housing 66 configured to retain a contact assembly 100. In an exemplary embodiment, the housing 66 includes a slot 68 at the mating end 60. In an exemplary embodiment, the mating electrical connector 70 has a circuit card 72 at the mating end 74 of the mating electrical connector 70. The circuit card 72 includes mating contacts 76 at its edge 78.

[0015] Figure 3 This is a perspective view of a contact assembly 100 formed according to one embodiment. In an exemplary embodiment, the contact assembly 100 includes an upper contact subassembly 102 and a lower contact subassembly 104 connected to a frame 106. The frame 106 supports the upper contact subassembly 102 and the lower contact subassembly 104. Optionally, the upper contact subassembly 102 and the lower contact subassembly 104 may be identical to each other and inverted by 180°. In an alternative embodiment, the contact assembly 100 may not have a frame 106, but instead have upper and lower contact subassemblies directly connected to each other without an intermediate support structure. In other alternative embodiments, the contact assembly 100 may have a single contact subassembly, for example, without a lower contact subassembly 104.

[0016] This description may be made specifically for the "upper" contact subassembly 102 having the qualifier "upper" and specifically for the "lower" contact subassembly 104 having the qualifier "lower," or may generally be made for both the upper contact subassembly 102 and the lower contact subassembly 104 that do not use the qualifiers "upper" or "lower." Contact assembly 100 includes a lead frame 110 having an array of contacts 112, the contacts 112 including signal contacts 114 and ground contacts 116. Contact assembly 100 includes a contact holder 120 holding the array of contacts 112. Contact assembly 100 includes a cable 122 terminating to the lead frame 110. Contact assembly 100 includes an external ground bus 124 configured to make the ground contacts 116 and the cable 122 common potential.

[0017] A contact retainer 120 is used to retain contacts 112, including a signal contact 114 and a ground contact 116. The contact retainer 120 is made of a dielectric material to electrically isolate the contacts 112 from each other. In an exemplary embodiment, the contact retainer 120 is overmolded onto the lead frame 110 to enclose a portion of the contacts 112 and maintain the relative position of the contacts 112. The contact retainer 120 extends between a front portion 126 and a rear portion 128.

[0018] In an exemplary embodiment, contacts 112 are arranged in one or more rows. For example, upper contacts 112 are arranged in an upward row configured to abut the upper surface of a circuit card (e.g., circuit card 32), and lower contacts 112 are arranged in a downward row configured to abut the lower surface of the circuit card. In an exemplary embodiment, signal contacts 114 are arranged in pairs, such as differential pairs. Ground contacts 116 are interposed between signal contacts 114, such as between pairs of signal contacts 114, to provide electrical shielding between corresponding signal contacts 114.

[0019] Each signal contact 114 includes a signal intermediate portion 130 extending between a signal mating end 132 and a signal termination end 134. A contact retainer 120 holds the signal intermediate portions 130 relative to each other. The contact retainer 120 maintains the spacing between the signal contacts 114. The signal mating end 132 is located in front of the contact retainer 120. The signal termination end 134 is located behind the contact retainer 120. In an exemplary embodiment, the signal contact 114 includes a spring beam 136 at the signal mating end 132. The spring beam 136 is a deflectable spring beam. The spring beam 136 includes a separable mating interface at or near its proximal end. The distal end of the spring beam 136 may be curved or cup-shaped to prevent stubbing during mating with a circuit card. In an exemplary embodiment, the signal contact 114 includes a solder pad 138 at the signal termination end 134. The solder pad 138 is configured to be soldered to a conductor of the cable 122.

[0020] Each ground contact 116 includes a ground intermediate portion 140 extending between a ground mating end 142 and a ground terminal end 144. A contact retainer 120 holds the ground intermediate portions 140 relative to each other and relative to a signal intermediate portion 130. The ground mating end 142 is located in front of the contact retainer 120. The ground terminal end 144 is located behind the contact retainer 120. In an exemplary embodiment, the ground contact 116 includes a spring beam 146 at the ground mating end 142. The spring beam 146 is a deflectable spring beam. The spring beam 146 includes a separable mating interface at or near its proximal end. The distal end of the spring beam 146 may be curved or cup-shaped to prevent shorting during engagement with a circuit card. In an exemplary embodiment, the ground contact 116 includes a lead frame ground bus 150 at the ground terminal end 144 (in... Figure 4 (As shown in the diagram). The lead frame ground bus 150 makes each of the ground contacts 116 common potential with the cable 122 and with each other. The lead frame ground bus 150 is separate and independent from the external ground bus 124.

[0021] During assembly, the upper contact subassembly 102 and the lower contact subassembly 104 are coupled to the frame 106. The frame 106 includes a platform 200 at the front of the frame 105. Upper and lower contact retainers 120 are coupled to the platform 200, for example, to the upper and lower surfaces of the platform 200, respectively. The frame 106 includes a cable support tray 202 at the rear of the platform 200. The cable support tray 202 supports the cable 122, for example, along the upper and lower surfaces of the cable support tray 202. The cable support tray 202 includes a partition wall 204 that forms a cable channel 206 for receiving the corresponding cable 122. In an exemplary embodiment, the frame 106 includes a strain relief element 208 that provides strain relief for the cable 122. The strain relief element 208 is coupled to the cable support tray 202. During assembly, the cable 122 is received in the cable channel 206 and terminated to the lead frame 110. The signal conductor 210 of the cable 122 (e.g., Figure 4 (As shown) terminated to signal contact 114. External ground bus 124 and lead frame ground bus 150 terminated to ground shield 212 of cable 122.

[0022] External ground bus 124 is separate and independent from lead frame ground bus 150. Both external ground bus 124 and lead frame ground bus 150 are electrically connected to the ground shield 212 of cable 122 to make the ground shield 212 common potential. In an exemplary embodiment, external ground bus 124 and lead frame ground bus 150 are coupled to opposite sides of the ground shield 212 of cable 122 to provide shielding above and below cable 122. External ground bus 124 includes a connection portion 162 between ground fingers 160 and ground fingers 160. Ground fingers 160 are aligned and coupled to corresponding ground contacts 116. Connection portion 162 is aligned with cable 122 and terminates on the side of cable 122 opposite to lead frame ground bus 150 to the corresponding ground shield 212 of cable 122. External ground bus 124 makes each ground shield 212 common potential. An external ground bus 124 is coupled to ground contact 116 to make the external ground bus 124 common potential with lead frame ground bus 150. In an exemplary embodiment, the external ground bus 124 includes a connecting beam 164 that extends between and connects each ground finger 160. The connecting beam 164 makes each ground finger 160 common potential. The connecting beam 164 is spaced apart from connection portion 162. The connecting beam 164 may span each ground finger 160, for example, at the front of the external ground bus 124. The connecting beam 164 may be abutted against contact holder 120 to position the external ground bus 124 relative to contact holder 120. The connecting beam 164 extends generally perpendicular to the ground fingers 160. For example, the connecting beam 164 may extend vertically and the ground fingers 160 may extend horizontally.

[0023] Figure 4This is a side view of the contact assembly 100 according to an exemplary embodiment. Figure 4 The upper contact subassembly 102 and lower contact subassembly 104 are shown connected to frame 106. Contact holder 120 is connected to frame 106. Upper signal contact 114 and ground contact 116 are aligned with each other in the upward direction, and lower signal contact 114 and lower ground contact 116 are aligned with each other in the downward direction. For example, signal and ground mating terminals 132, 142 are aligned with each other. Signal and ground intermediate portions 130, 140 are aligned with each other. At ground terminal 144, lead frame ground bus 150 extends in a plane relative to signal terminal 134.

[0024] In an exemplary embodiment, cable 122 is located between external ground bus 124 and lead frame ground bus 150. Cable 122 may be clamped between external ground bus 124 and lead frame ground bus 150. Both external ground bus 124 and lead frame ground bus 150 are electrically connected to ground shield 212. For example, external ground bus 124 and lead frame ground bus 150 may be soldered to ground shield 212. External ground bus 124 and lead frame ground bus 150 provide multiple contact points with ground shield 212. Electrical shielding is provided above and below ground shield 212 to enhance the shielding and electrical performance of electrical connector 10. In the illustrated embodiment, upper external ground bus 124 extends above cable 122 and is coupled to the top side of cable 122, and upper lead frame ground bus 150 extends below cable 122 and is coupled to the bottom side of cable 122. In the illustrated embodiment, the lower lead frame ground bus 150 extends above the cable 122 and is connected to the top side of the cable 122, and the lower external ground bus 124 extends below the cable and is connected to the bottom side of the cable 122.

[0025] A grounding finger 160 is positioned at the front of the external ground bus 124 and extends along the grounding contact 116, for example, along the grounding middle portion 140. The grounding finger 160 is electrically connected to the grounding contact 116. For example, the grounding finger 160 may be soldered to the grounding contact 116. The electrical connection between the grounding finger 160 and the grounding contact 116 provides a separate contact point.

[0026] Figure 5 This is a side view of the contact assembly 100 according to an exemplary embodiment. Figure 5 The upper contact subassembly 102 and lower contact subassembly 104, connected to the frame 106, are shown. In the illustrated embodiment, the external ground bus 124 and the lead frame ground bus 150 are relative to... Figure 4The orientation is reversed in the illustrated embodiment. In the illustrated embodiment, the upper lead frame ground bus 150 extends above the cable 122 and is connected to the top side of the cable 122, and the upper external ground bus 124 extends below the cable and is connected to the bottom side of the cable 122. In the illustrated embodiment, the lower external ground bus 124 extends above the cable 122 and is connected to the top side of the cable 122, and the lower lead frame ground bus 150 extends below the cable and is connected to the bottom side of the cable 122.

[0027] Figure 6 This is a top view of the contact assembly 100 according to an exemplary embodiment. Figure 7 This is a bottom view of the contact assembly 100 according to an exemplary embodiment. The contact holder 120 holds the contacts 122 relative to each other. External ground bus 124 ( Figure 6 ) and lead frame ground bus 150 ( Figure 7 A grounding shield 212 is connected to each cable 122. For example, an external ground bus 124 is soldered to the top side of the grounding shield 212 to mechanically and electrically connect the external ground bus 124 to the grounding shield 212. A lead frame ground bus 150 is soldered to the bottom side of the grounding shield 212 to mechanically and electrically connect the lead frame ground bus 150 to the grounding shield 212. The external ground bus 124 and the lead frame ground bus 150 enhance the electrical performance of the electrical connector 10. For example, the shielding on both sides of the cable 122 improves broadband crosstalk.

[0028] In an exemplary embodiment, the connection portion 162 of the external ground bus 124 ( Figure 6 Align and connect to the grounding shield 212. The connection portion 152 of the lead frame grounding bus 150 extends between the grounding contacts 116. Figure 7 Align and connect to grounding shield 212. Connections 152 and 162 can be soldered to grounding shield 212. (Reference) Figure 6 Connecting beam 164 extends between grounding fingers 160 to make each grounding finger 160 common potential. Connecting beam 164 is spaced apart from connecting portion 162. (Reference) Figure 7 The grounding contact 116 extends in front of the lead frame ground bus 150. The grounding contact 116 is located between the signal contacts 114.

Claims

1. A contact assembly (100) for an electrical connector (10), comprising: A lead frame (110) having an array of contacts (112) including signal contacts (114) and ground contacts (116), the ground contacts being interposed with the signal contacts to provide electrical shielding between the corresponding signal contacts, each signal contact including a signal intermediate portion (130) extending between a signal mating end (132) and a signal terminating end (134), each ground contact including a ground intermediate portion (140) extending between a ground mating end (142) and a ground terminating end (144), the ground terminating end having a lead frame ground bus (150) connecting each of the ground contacts. A contact holder (120) holds an array of contacts, the contact holder is made of dielectric material, the contact holder holds each of the signal intermediate portions and holds each of the ground intermediate portions, the signal mating terminal and the ground mating terminal extend in front of the contact holder, and the signal termination terminal and the ground termination terminal extend behind the contact holder; A cable (122) terminated to the lead frame, the cable including a signal conductor (210) and a ground shield (212), the ground shield surrounding a corresponding signal conductor to provide electrical shielding to the signal conductor, the signal conductor terminating to a corresponding signal termination, and the lead frame ground bus terminating at each of the ground shields to make the ground shield and the lead frame ground bus common potential; as well as An external ground bus (124) is separate from and independent of the lead frame ground bus. The external ground bus is terminated on the side of the cable opposite to the lead frame ground bus to each of the ground shields (212) so that the ground shields and the external ground bus are at the same potential. The external ground bus (124) includes a ground finger (160) and a connection portion (162) located between the ground fingers. The ground fingers are aligned and soldered to the corresponding ground contacts (116), and the connection portion is aligned and connected to the ground shield (212) of the cable (122). The external ground bus (124) includes a connecting beam (164) that extends between and connects each of the ground fingers (160) to make each of the ground fingers common potential, and the connecting beam is spaced apart from the connecting portion (162).

2. The contact assembly (100) as claimed in claim 1, wherein, The grounding shield (212) of the cable (122) is sandwiched between the external grounding bus (124) and the lead frame grounding bus (150).

3. The contact assembly (100) as claimed in claim 1, wherein, The external ground bus (124) is soldered to the ground shield (212) to mechanically and electrically connect the external ground bus to the ground shield, and wherein the lead frame ground bus (150) is soldered to the ground shield to mechanically and electrically connect the lead frame ground bus to the ground shield.

4. The contact assembly (100) as claimed in claim 1, wherein, The lead frame ground bus (150) includes a connection portion between the ground contacts (116) that is aligned with and connected to the ground shield (212) of the cable (122).

5. The contact assembly (100) as claimed in claim 1, wherein, The lead frame ground bus (150) extends above the cable (122) and is connected to the top side of the cable, and the external ground bus (124) extends below the cable and is connected to the bottom side of the cable.

6. The contact assembly (100) as claimed in claim 1, wherein, The external ground bus (124) extends above the cable (122) and is connected to the top side of the cable, and the lead frame ground bus (150) extends below the cable and is connected to the bottom side of the cable.

7. The contact assembly (100) of claim 1 further includes a strain relief element (208) that encloses portions of the signal termination (134), the ground termination (144), the lead frame bus (150), and the external ground bus (124).

8. The contact assembly (100) as claimed in claim 1, wherein, The signal mating end (132) and the ground mating end (142) are aligned with each other in a single row, the signal intermediate portion (130) and the ground intermediate portion (140) are aligned with each other in a single row, and wherein the signal termination end (134) is aligned with each other in a single row, and the lead frame bus (150) extends out of the plane relative to the signal termination end to connect to the ground shield (212) of the cable.

9. The contact assembly (100) as claimed in claim 1, wherein, Each signal contact (114) includes a spring beam (136) at its signal mating end, the spring beam including a separable interface configured to be electrically connected to a mating signal contact of a mating connector, and wherein each ground contact (116) includes a spring beam (146) at its ground mating end, the spring beam including a separable interface configured to be electrically connected to a mating ground contact of the mating connector.

10. The contact assembly (100) as claimed in claim 1, wherein, Each signal contact (114) includes a signal termination (134) with a welding protrusion that is welded to the signal conductor of the corresponding cable.

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