Electrical connectors, subassemblies, modules, cable assemblies, electrical assemblies, and circuit boards

Abstract

Electrical connectors, subassemblies, modules, cable assemblies, electrical assemblies, and circuit boards are provided. An electrical connector includes a plurality of cables, each cable of the plurality of cables including first and second conductive wires extending from a mounting interface of the electrical connector to a mating interface of the electrical connector, and a plurality of termination components manufactured separately from the plurality of cables, wherein: for each cable of the plurality of cables, the plurality of termination components includes first and second termination components attached to the first and second conductive wires, respectively, of the cable at the mounting interface.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 202010825662.8, filed August 17, 2020, entitled “Electrical Connectors, Cable Assemblies, Electrical Assemblies, and Printed Circuit Boards,” which is a divisional application of PCT Application No. PCT / US2015 / 012463, filed January 22, 2015, entitled “High Speed, High Density Electrical Connector with Shielded Signal Paths,” which entered the Chinese national phase on September 19, 2016, as Application No. 201580014851.4, and which has a priority date of January 22, 2014.

[0002] Cross Reference to Related Applications

[0003] This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 61 / 930,411, filed January 22, 2014, entitled “High Speed, High Density Electrical Connector with Shielded Signal Paths,” and U.S. Provisional Application No. 62 / 078,945, filed November 12, 2014, entitled “Very High Speed, High Density Electrical Interconnection System with Impedance Control in Mating Region,” the entire contents of both of which are incorporated herein by reference. TECHNICAL FIELD

[0004] The present invention relates generally to electrical connectors for interconnecting electronic assemblies. BACKGROUND

[0005] Electrical connectors are used in many electronic systems. It is often easy and more cost effective to manufacture a system as separate electronic assemblies, such as printed circuit boards (“PCBs”), that can be mated together with electrical connectors. A known arrangement for mating some printed circuit boards is to have one printed circuit board that serves as a backplane. Other printed circuit boards, called “daughter boards” or “daughter cards,” can be connected through the backplane.

[0006] Known backplanes are printed circuit boards on which a number of connectors can be mounted. Conductive traces in the backplane can be electrically connected to signal conductors in the connectors so that signals can be routed between the connectors. Daughter cards can also have connectors mounted thereon. The connectors mounted on the daughter cards can be plugged into the connectors mounted on the backplane. In this manner, signals can be routed between the daughter cards through the backplane. The daughter cards can be plugged into the backplane at right angles. Thus, the connectors used for these applications include right angle bends and are commonly referred to as "right angle connectors."

[0007] In other configurations, connectors can also be used for interconnection of printed circuit boards and for interconnection of other types of devices such as cables to printed circuit boards. At times, one or more smaller printed circuit boards can be connected to another larger printed circuit board. In such configurations, the larger printed circuit board can be referred to as a "motherboard" and the printed circuit boards connected to the motherboard can be referred to as daughter boards. In addition, printed circuit boards of the same size or similar size can at times be aligned in parallel. Connectors used in these applications are commonly referred to as "stacking connectors" or "mezzanine connectors."

[0008] Regardless of the exact application, the design of electrical connectors reflects trends in the electronics industry. Electronic systems are generally becoming smaller, faster and more complex. As a result of these changes, the number of circuits in a given area of an electronic system and the frequency at which these circuits operate has increased significantly in recent years. Current systems transfer more data between printed circuit boards and require electrical connectors that can electrically handle more data at higher speeds than connectors of even a few years ago.

[0009] In high density, high speed connectors, the electrical conductors can be in close proximity to one another so that electrical interference can exist between adjacent signal conductors. To reduce interference or to provide desirable electrical properties, a shielding member is often placed between or around adjacent signal conductors. The shield can prevent a signal carried on one conductor from creating "cross-talk" on another conductor. The shield can also affect the impedance of each conductor, which can further contribute to desirable electrical properties.

[0010] Examples of shielding can be seen in U.S. Patent No. 4,632,476 and U.S. Patent No. 4,806,107, which show connector designs that use a shield between multiple columns of signal contacts. These patents describe connectors in which the shield runs parallel to the signal contacts through the daughterboard connector and the backplane connector. Cantilever beams are used to make electrical contact between the shield and the backplane connector. U.S. Patent Nos. 5,433,617, 5,429,521, 5,429,520, and 5,433,618 show similar arrangements, however the electrical connection between the backplane and the shield is made through spring contacts. The connector described in U.S. Patent No. 6,299,438 uses a shield with torsion beam contacts. Other shields are shown in U.S. Published Application No. 2013-0109232.

[0011] Other connectors have a shield plate that is only within the daughterboard connector. Examples of such connector designs can be seen in U.S. Patent Nos. 4,846,727, 4,975,084, 5,496,183, and 5,066,236. Other connectors with a shield that is only within the daughterboard connector are shown in U.S. Patent No. 5,484,310. U.S. Patent No. 7,985,097 is another example of a shielded connector.

[0012] Other techniques can be used to control the performance of a connector. For example, differentially passing signals can also reduce crosstalk. A differential signal is carried on a pair of conductive paths called a "differential pair." The difference in electrical potential between the conductive paths represents the signal. Typically, a differential pair is designed to have a preferred coupling between the conductive paths of the differential pair. For example, the two conductive paths of a differential pair can be arranged to run closer to each other than to adjacent signal paths in the connector. It is undesirable to have a shield between the conductive paths of a differential pair, but a shield can be used between differential pairs. Electrical connectors can be designed for differential signals as well as single-ended signals. Examples of differential electrical connectors are shown in U.S. Patent Nos. 6,293,827, 6,503,103, 6,776,659, 7,163,421, and 7,794,278.

[0013] Another modification made to connectors to accommodate changing requirements is that connectors have become much larger in some applications. Increasing the size of a connector can result in tighter manufacturing tolerances. For example, the allowable mismatch between a conductor in one half of a connector and a socket in the other half can be constant regardless of the size of the connector. However, this constant mismatch or tolerance can become a percentage of the entire length of the connector when the side length of the connector is considered. Thus, the manufacturing tolerances for large connectors can be tighter, which increases manufacturing costs. One way to avoid this problem is to use modular connectors. Teradyne Connector Systems of Nashua, New Hampshire has developed a modular connector system called The system has a plurality of modules, each module having a plurality of columns of signal contacts, such as 15 or 20 columns. The modules are held together on a metal stiffener.

[0014] Another modular connector system is shown in U.S. Patent Nos. 5,066,236 and 5,496,183. These patents describe "module terminals," each module terminal having a single column of signal contacts. The module terminals are held in place in a plastic housing module. The plastic housing module is held together with an integral metal shield member. The shield can also be placed between the module terminals. SUMMARY

[0015] In one aspect, an electrical connector includes a plurality of modules arranged in a two-dimensional array, the modules having a shield material separating adjacent modules.

[0016] In some embodiments, the modules include cables.

[0017] In another aspect, an electrical connector can include a conductive wall adjacent to a mating contact of a conductive element within the connector. The wall has a flexible member and a contact surface.

[0018] According to some embodiments, there is provided an electrical connector comprising: a plurality of modules, each module of the plurality of modules comprising an insulating portion and at least one conductive element; and an electromagnetic shield material, wherein: the insulating portion separates the at least one conductive element from the electromagnetic shield material; the plurality of modules are arranged in a two-dimensional array; and the shield material separates adjacent modules of the plurality of modules.

[0019] In some embodiments, the shield material comprises a metal.

[0020] In some embodiments, the shield material comprises a lossy material.

[0021] In some embodiments, the lossy material comprises an insulating matrix holding conductive particles.

[0022] In some embodiments, the lossy material is overmolded on at least a portion of the plurality of modules.

[0023] In some implementations, the plurality of modules includes a plurality of first-type modules, a plurality of second-type modules, and a plurality of third-type modules, wherein the second-type modules are longer than the first-type modules, and the third-type modules are longer than the second-type modules.

[0024] In some implementations, the first type of modules are arranged in the first row; the second type of modules are arranged in the second row, which is parallel to and adjacent to the first row; and the third type of modules are arranged in the third row, which is parallel to and adjacent to the second row.

[0025] In some implementations, multiple modules are assembled into multiple sheets positioned side by side, each sheet including a first type of module, a second type of module, and a third type of module.

[0026] In some embodiments, the electromagnetic shielding material includes a plurality of shielding members; each of the plurality of shielding members is attached to a module of a plurality of modules; and for each of the plurality of sheets, a first shielding member attached to a first module of a sheet is electrically connected to at least one second shielding member attached to a second module of a sheet.

[0027] In some embodiments, the electromagnetic shielding material includes a plurality of shielding members; and each of the plurality of shielding members is attached to a module in a plurality of modules.

[0028] In some implementations, at least one conductive element is a pair of conductive elements configured to carry differential signals.

[0029] In some implementations, at least one conductive element is a single conductive element configured to carry a single-ended signal.

[0030] In some implementations, the shielding material includes metallized plastic.

[0031] In some embodiments, the electrical connector also includes a support member, wherein multiple modules are supported by the support member.

[0032] In some embodiments, at least one conductive element passes through an insulating portion.

[0033] In some embodiments, at least one conductive element is pressed onto the insulating portion.

[0034] In some embodiments, at least one conductive element includes a conductive wire; the insulation includes a passage; and the conductive wire is routed through the passage.

[0035] In some embodiments, the insulating portion is formed by molding; and after the insulating portion has been molded, the conductive wire passes through the passage.

[0036] In some embodiments, the shielding material includes a first shielding member and a second shielding member arranged on opposite sides of the module.

[0037] In some embodiments, the electrical connector further includes at least one lossy portion arranged between the first shielding member and the second shielding member.

[0038] In some embodiments, the at least one lossy portion is elongated and extends along an entire length of the first shielding member.

[0039] In some embodiments, the at least one conductive element of the module includes a contact tail, a mating interface portion, and an intermediate portion electrically connecting the contact tail and the mating interface portion; and the shielding material includes at least two shielding members arranged adjacent to the module, the at least two shielding members together covering four sides of the module along the intermediate portion.

[0040] In some embodiments, the shielding material includes a shielding member having a U-shaped cross-section.

[0041] In some embodiments, for each module, the at least one conductive element of the module includes a contact tail adapted to be inserted into a printed circuit board; the contact tails of the plurality of modules are aligned in a plane; and the electrical connector further includes an organizer having a plurality of openings sized and arranged to receive the contact tails.

[0042] In some embodiments, the organizer is adapted to occupy a space between the electrical connector and a surface of the printed circuit board when the electrical connector is mounted to the printed circuit board.

[0043] In some embodiments, the organizer includes a flat surface for mounting against the printed circuit board and an opposite surface having a profile adapted to match a profile of the plurality of modules.

[0044] According to some embodiments, there is provided an electrical connector comprising: a plurality of modules held in a two-dimensional array, each module of the plurality of modules comprising: a cable having a first end and a second end, the cable including a pair of conductive elements extending from the first end to the second end and a ground structure arranged around the pair of conductive elements; a contact tail attached to each of the pair of conductive elements at the first end of the cable; and a mating contact portion attached to each of the pair of conductive elements at the second end of the cable.

[0045] In some embodiments, the electrical connector further includes an insulating portion at the first end of the cable, wherein the contact tails of the pair of conductive elements are attached to the insulating portion.

[0046] In some embodiments, the contact tails of the pair of conductive elements are positioned for edge coupling.

[0047] In some embodiments, the electrical connector further comprises a conductive structure at the first end of the cable, wherein the conductive structure surrounds the insulating portion.

[0048] In some embodiments, the electrical connector further comprises a loss member attached to the conductive structure.

[0049] In some embodiments, the electrical connector further comprises an insulating portion at the second end of the cable, wherein the mating contact portions of the pair of conductive elements are attached to the insulating portion.

[0050] In some embodiments, each of the mating contact portions of the pair of conductive elements comprises a tubular mating contact.

[0051] In some embodiments, the electrical connector further comprises a conductive structure at the second end of the cable, wherein the conductive structure surrounds the insulating portion.

[0052] In some embodiments, the electrical connector further comprises a plurality of flexible members at the second end of the cable, wherein the plurality of flexible members are attached to the conductive structure.

[0053] According to some embodiments, there is provided an electrical connector comprising: a plurality of conductive elements, each of the plurality of conductive elements comprising a mating contact portion, wherein the mating contact portions are arranged to define a mating interface of the electrical connector; a plurality of conductive walls adjacent to the mating contact portions of the plurality of conductive elements, each of the plurality of conductive walls comprising a front edge adjacent to the mating interface, and the plurality of conductive walls are arranged to define a plurality of regions, each of the plurality of regions containing at least one mating contact portion and being separated from an adjacent region by a wall of the plurality of conductive walls, a plurality of flexible members attached to the plurality of conductive walls, the plurality of flexible members being positioned adjacent to the front edge, wherein: the wall defining each of the plurality of regions comprises at least two of the plurality of flexible members; and the wall defining each of the plurality of regions comprises at least two contact surfaces disposed rearward from the front edge and adapted to electrically contact a flexible member in a mating electrical connector.

[0054] In some embodiments, the electrical connector is a first electrical connector; the plurality of conductive elements is a first plurality of conductive elements, the mating contact is a first mating contact, the mating interface is a first mating interface, the plurality of conductive walls is a first plurality of conductive walls, the front edge is a first front edge, the plurality of regions is a first plurality of regions, and the contact surface is a first contact surface; the first electrical connector is combined with a second electrical connector, and the second electrical connector includes: a second plurality of conductive elements, each second conductive element of the second plurality of conductive elements including a second mating contact, wherein the second mating contact is arranged to define a second mating interface of the second electrical connector; a second plurality of conductive walls adjacent to the second mating contact, each second conductive wall of the second plurality of conductive walls including a second front edge adjacent to the second mating interface, and the second plurality of conductive walls are arranged to define a second plurality of regions, each second region of the second plurality of regions containing at least one second mating contact and separated from an adjacent second region by the walls of the second plurality of conductive walls; and a second plurality of flexible members attached to the second plurality of conductive walls, the second plurality of flexible members positioned adjacent to the second front edge, wherein: the walls defining each second region of the second plurality of regions include at least two second flexible members of the second plurality of flexible members; the walls defining each second region of the second plurality of regions include at least two contact surfaces disposed rearward from the second front edge; each first region of the first plurality of regions corresponds with a respective second region when the first electrical connector is mated with the second electrical connector; and for each first region and respective second region, a first flexible member of the first region is in contact with a second contact surface of the second region, and a second flexible member of the second region is in contact with a first contact surface of the first region.

[0055] In some embodiments, the plurality of flexible members attached to the plurality of conductive walls includes discrete flexible members joined to the conductive walls.

[0056] According to some embodiments, there is provided a method for manufacturing an electrical connector, the method comprising the acts of: forming a plurality of modules, each module of the plurality of modules including an insulating portion and at least one conductive element; arranging the plurality of modules in a two-dimensional array, including separating adjacent modules of the plurality of modules using an electromagnetic shielding material, wherein the insulating portion separates the at least one conductive element from the electromagnetic shielding material.

[0057] In some embodiments, the shielding material includes a lossy material, and the method further comprises the act of: overmolding the lossy material on at least a portion of the plurality of modules.

[0058] In some embodiments, the plurality of modules includes a plurality of first type modules, a plurality of second type modules, and a plurality of third type modules, and wherein the second type modules are longer than the first type modules, and the third type modules are longer than the second type modules.

[0059] In some embodiments, the act of arranging the plurality of modules includes: arranging the first type modules in a first row; arranging the second type modules in a second row, the second row being parallel and adjacent to the first row; and arranging the third type modules in a third row, the third row being parallel and adjacent to the second row.

[0060] In some embodiments, the method further includes the acts of: assembling the plurality of modules into a plurality of sheets; and arranging the plurality of sheets side-by-side, each sheet of the plurality of sheets including a first type module, a second type module, and a third type module.

[0061] In some embodiments, the at least one conductive element includes a conductive wire and the insulating portion includes a passage, and wherein the method further includes the act of: passing the conductive wire through the passage.

[0062] In some embodiments, the method further includes the act of: forming the insulating portion by molding prior to passing the conductive wire through the passage.

[0063] According to some embodiments, there is provided an electrical connector comprising: a plurality of modules arranged in a two-dimensional array along a first direction and a second direction orthogonal to the first direction, each module of the plurality of modules including an insulating portion and at least one conductive element, wherein: at least one module of the plurality of modules includes at most two conductive elements; and an electromagnetic shielding material separating adjacent modules of the plurality of modules, wherein: in at least one module of the plurality of modules, the at least one conductive element is separated from the electromagnetic shielding material by the insulating portion.

[0064] According to some embodiments, there is provided an electrical connector comprising: a plurality of cables, each cable of the plurality of cables including a first conductive wire and a second conductive wire extending from a mounting interface of the electrical connector to a mating interface of the electrical connector; and a plurality of termination components manufactured separately from the plurality of cables, wherein: for each cable of the plurality of cables, the plurality of termination components includes a first termination component and a second termination component respectively attached to the first conductive wire and the second conductive wire of the cable at the mounting interface.

[0065] According to some embodiments, there is provided a cable assembly comprising: a cable including a first end and a second end, the cable including at least one conductive element extending from the first end to the second end; an insulating portion; and a contact tail extending from the insulating portion and configured to make an electrical connection with a circuit board, wherein the contact tail is attached to the at least one conductive element at the first end of the cable.

[0066] According to some embodiments, a cable assembly configured for connection to a circuit board is provided, the cable assembly comprising: a housing comprising a surface configured for mounting adjacent to the circuit board; a plurality of cables, each cable of the plurality of cables comprising at least one electrically conductive wire; and a plurality of termination components attached to the electrically conductive wires of the plurality of cables, wherein the plurality of termination components are configured to make electrical connections with the circuit board.

[0067] According to some embodiments, an electrical connector is provided, comprising: a plurality of modules arranged in a two-dimensional array along a row direction and a column direction substantially perpendicular to the row direction, each module of the plurality of modules comprising: a pair of electrically conductive elements configured to carry a differential signal, each electrically conductive element of the pair of electrically conductive elements having a mating contact, a contact tail, and a middle portion extending between the mating contact and the contact tail; a shield surrounding the pair of electrically conductive elements; and a housing member separating the pair of electrically conductive elements and the shield, wherein: for modules in each column, the contact tails of the electrically conductive elements are aligned in the column direction such that a routing channel between the contact tails of two adjacent columns allows traces of the pairs of electrically conductive elements.

[0068] According to some embodiments, an electrical assembly is provided, comprising: a printed circuit board comprising a routing layer and a plurality of traces on the routing layer; and an electrical connector mounted to the printed circuit board, the electrical connector comprising a mounting interface facing the printed circuit board, the mounting interface comprising: a plurality of pairs of signal contact tails arranged in a plurality of first columns, and a plurality of ground contact tails arranged in a plurality of second columns, wherein: the first columns are separated by one or more second columns, the plurality of traces are between the first columns and the second columns adjacent to the first columns, and connected to respective signal contact tails in the first columns, and the connector comprises a plurality of modules arranged in a two-dimensional array, each module of the plurality of modules comprising a shield, and the pairs of signal contact tails are within the modules, and the plurality of ground contact tails extend from the shields of the plurality of modules.

[0069] According to some embodiments, a printed circuit board for mounting a connector is provided, the printed circuit board comprising: a plurality of routing layers; and a connector footprint comprising: a plurality of first type via columns, each first type via column comprising a differential pair of a plurality of signal vias, a plurality of second type via columns, each second type via column comprising a plurality of ground vias associated with the differential pair of signal vias, a plurality of routing channels between adjacent first type columns and second type columns, and a plurality of traces from at least two of the differential pairs of signal vias, the plurality of traces routed in one routing channel on one routing layer.

[0070] According to some embodiments, an electrical connector is provided, comprising: a plurality of lamellas, each of the plurality of lamellas comprising a plurality of pairs of electrically conductive elements in a column, and the plurality of lamellas being arranged side-by-side so as to form an array of pairs along a first direction and a second direction orthogonal to the first direction, wherein the plurality of lamellas comprises an insulating portion and an electromagnetic shielding material, and in at least one of the plurality of lamellas, the plurality of pairs of signal conductors are separated from the electromagnetic shielding material by the insulating portion.

[0071] According to some embodiments, an electrical connector is provided, comprising: a plurality of cables, each of the plurality of cables comprising a first electrically conductive wire and a second electrically conductive wire extending from a mounting interface of the electrical connector to a mating interface of the electrical connector; and a plurality of termination components manufactured separately from the plurality of cables, wherein: for each of the plurality of cables, the plurality of termination components comprises a first termination component and a second termination component respectively attached to the first electrically conductive wire and the second electrically conductive wire of the cable at the mounting interface.

[0072] According to some embodiments, a subassembly for an electrical connector is provided, comprising: a plurality of electrically conductive elements, each of the plurality of electrically conductive elements comprising a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail, wherein: the plurality of electrically conductive elements are arranged in pairs, the intermediate portion of each pair of electrically conductive elements is at least partially surrounded by a shielding member of an electromagnetic shielding material, and the shielding members of adjacent pairs of electrically conductive elements are electrically coupled within the subassembly.

[0073] According to some embodiments, a connector module is provided, comprising: a plurality of electrically conductive elements, each of the plurality of electrically conductive elements comprising a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail, at least the intermediate portion comprising a wide side joined by an edge, the plurality of electrically conductive elements being arranged in pairs such that wide sides are aligned with wide sides; and an electromagnetic shielding material at least partially surrounding each pair of electrically conductive elements and separating adjacent pairs of electrically conductive elements, wherein the mating contacts of the each pair of electrically conductive elements are aligned in a pair direction at an angle to a column direction.

[0074] According to some embodiments, a connector module is provided, comprising: a pair of electrically conductive elements, each comprising a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail; a first shielding member and a second shielding member at least partially enclosing the pair of electrically conductive elements, the first shielding member and the second shielding member separated by a gap, and a lossy material at least at a portion of the gap and electrically coupling the first shielding member and the second shielding member.

[0075] According to some embodiments, a cable assembly is provided, comprising: a cable comprising a first end and a second end, the cable comprising at least one conductive element extending from the first end to the second end; an insulation portion; and a contact tail extending from the insulation portion and configured to electrically connect with a circuit board, wherein the contact tail is attached to the at least one conductive element at the first end of the cable.

[0076] According to some embodiments, a cable assembly is provided, the cable assembly configured for connection to a circuit board, the cable assembly comprising: a housing comprising a surface configured for mounting adjacent to the circuit board; a plurality of cables, each cable of the plurality of cables comprising at least one conductive wire; and a plurality of termination components attached to the conductive wires of the plurality of cables, wherein the plurality of termination components are configured to electrically connect with the circuit board.

[0077] According to some embodiments, an electrical connector is provided, comprising: a plurality of modules arranged in a two-dimensional array along a row direction and a column direction substantially perpendicular to the row direction, each module of the plurality of modules comprising: a pair of conductive elements configured to carry a differential signal, each conductive element of the pair of conductive elements having a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail; a shield surrounding the pair of conductive elements; and a housing member separating the pair of conductive elements from the shield, wherein: for modules in each column, the contact tails of the conductive elements are aligned in the column direction such that a routing channel between contact tails of two adjacent columns allows passage of traces of a plurality of pairs of conductive elements.

[0078] According to some embodiments, an electrical assembly is provided, comprising: a printed circuit board comprising a routing layer and a plurality of traces on the routing layer; and an electrical connector mounted to the printed circuit board, the electrical connector comprising a mounting interface facing the printed circuit board, the mounting interface comprising: a plurality of pairs of signal contact tails arranged in a plurality of first columns, and a plurality of ground contact tails arranged in a plurality of second columns, wherein: the first columns are separated by one or more second columns, the plurality of traces are between a first column and a second column adjacent to the first column, and connected to respective signal contact tails in the first column, and the connector comprises a plurality of modules arranged in a two-dimensional array, each module of the plurality of modules comprising a shield, and the pairs of signal contact tails are within the modules, and the plurality of ground contact tails extend from the shields of the plurality of modules.

[0079] According to some embodiments, a printed circuit board mounting a connector is provided, the printed circuit board comprising: a plurality of routing layers; and a connector package comprising: a plurality of first type via columns, each first type via column comprising a differential pair of a plurality of signal vias, a plurality of second type via columns, each second type via column comprising a plurality of ground vias associated with the differential pair of signal vias, a plurality of routing channels between adjacent first type columns and second type columns, and a plurality of traces from at least two of the differential pairs of signal vias, the plurality of traces routed in one routing channel on one routing layer.

[0080] According to some embodiments, an electrical assembly is provided, comprising: a first electrical connector comprising a first mating interface, the mating interface comprising a plurality of first box-shaped first conductive members; and a second electrical connector comprising a second mating interface, the mating interface comprising a plurality of box-shaped second conductive members, wherein the first box-shaped first conductive members fit within the second conductive members such that the first electrical connector and the second electrical connector mate.

[0081] According to some embodiments, an electrical connector is provided, comprising: a plurality of conductive elements, each conductive element comprising a mating contact, wherein the mating contacts are arranged to define a mating interface of the electrical connector; and a plurality of box-shaped conductive members adjacent to the mating interface, wherein each conductive member surrounds one or more pairs of mating contacts or one or more single-ended signal mating contacts.

[0082] The foregoing is a summary of the present invention, which is defined by the appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0083] In the drawings:

[0084] FIG. 1A is an isometric view of an exemplary electrical interconnection system according to some embodiments;

[0085] FIG. 1B is an exploded view of the exemplary electrical interconnection system shown in FIG. 1A

[0086] FIG. 2A-2B shows a view of opposite sides of an exemplary wafer according to some embodiments;

[0087] FIG. 3 is a plan view of an exemplary pin frame for manufacturing a connector according to some embodiments;

[0088] FIG. 4A-4B ​A plurality of example module flaps of a counter-stacked example are shown according to some embodiments;

[0089] FIG. 5A-5B An example organizer according to some embodiments is shown, wherein the organizer is adapted to fit in a FIG. 4A-4B example of the example flap of

[0090] FIG. 6A-6B are a perspective view and an exploded view, respectively, of an example module flap according to some embodiments;

[0091] FIG. 7A and FIG. 7C is a perspective view of an example module of a flap according to some embodiments;

[0092] FIG. 7B is an example module according to some embodiments of FIG. 7A is an exploded view of an example module according to some embodiments of

[0093] FIG. 8A and FIG. 8C is a perspective view of an example module according to some embodiments of FIG. 7A is a perspective view of an example housing of a module according to some embodiments of

[0094] FIG. 8B is a front view of an example housing according to some embodiments of FIG. 8A

[0095] FIG. 9A and FIG. 9B are a front view and a perspective view, respectively, of an example housing according to some embodiments of FIG. 8A with an electrically conductive element inserted therein;

[0096] FIG. 9C and FIG. 9D are a perspective view and a front view, respectively, of an example electrically conductive element according to some embodiments adapted to be inserted in a housing of FIG. 8A

[0097] FIG. 10A and FIG. 10B are a perspective view and a front view, respectively, of an example shielding member of a module according to some embodiments of FIG. 7A

[0098] FIG. 11A and FIG. 11B are a perspective view and a cross-sectional view, respectively, of an example shielding member of a module for a connector according to some embodiments;

[0099] FIG. 12A-12C , FIG. 13A-13C ​​​are perspective views of a tail and mating contact of an exemplary module of a connector according to some embodiments at different stages of manufacture;

[0100] FIG. 14A-14C is a perspective view of a mating contact of another exemplary module of a connector according to some embodiments;

[0101] FIG. 15 is an exploded view of a portion of a pair of exemplary connectors adapted to mate with one another according to some embodiments;

[0102] FIG. 16 is an exploded view of a pair of exemplary connectors adapted to mate with one another according to some embodiments;

[0103] FIG. 17 is an exploded view of another pair of exemplary connectors adapted to mate with one another according to some embodiments;

[0104] FIG. 18A-18B shows vias arranged in columns on an exemplary printed circuit board, routing channels between the columns of vias, and traces running in the routing channels according to some embodiments. DETAILED DESCRIPTION

[0105] Described herein is a design for an electrical connector that improves signal integrity for high frequency signals such as frequencies including the GHz range up to about 25 GHz or up to about 40 GHz while maintaining high density such as a pitch between adjacent mating contacts on the order of 2 mm or less, for example including a center-to-center pitch between adjacent contacts in a column of between 0.75 mm and 1.85 mm, 1 mm and 1.75 mm, or 2 mm and 2.5 mm (e.g., 2.40 mm). The pitch between columns of mating contacts can be similar, however it is not required that the pitch between all mating contacts in a connector be equal.

[0106] The present disclosure is not limited to the details of construction or the arrangement of components set forth in the following description and / or illustrated in the drawings. The various embodiments are provided for purposes of illustration only and described herein with the understanding that the concepts described herein are capable of other embodiments and implementations. Moreover, the language used in this disclosure has been principally selected for readability and instructional purposes and can not have been selected to delineate or circumscribe the patent rights realm. Use of terms such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is meant to encompass the items listed thereafter and / or equivalents thereof as well as additional items.

[0107] FIG. 1A-1BAn electrical interconnect system in a form that can be used in an electronic system is shown. In this example, the electrical interconnect system includes a right angle connector and can be used, for example, to electrically connect a daughter card to a backplane. The figures show two mating connectors, one designed to attach to a daughter card and one designed to attach to a backplane. As FIG. 1A As can be seen in

[0108] FIG. 1A is an isometric view of an exemplary electrical interconnect system 100 according to some embodiments. In this example, the electrical interconnect system 100 includes a backplane connector 114 and a daughter card connector 116 adapted to mate with one another.

[0109] FIG. 1B is shown according to some embodiments. FIG. 1B is an exploded view of the exemplary electrical interconnect system 100 shown in FIG. 1A As shown in

[0110] Although not shown, the backplane 110 can have many other backplane connectors attached thereto in some embodiments such that the backplane 110 can be connected with multiple daughter cards. Additionally, multiple backplane connectors can be aligned end-to-end such that the connectors can be used to connect to one daughter card. However, for clarity, FIG. 1B only a portion of the backplane 110 and a single daughter card 112 are shown in

[0111] In the example of FIG. 1B In this example, the backplane connector 114 can include a shroud 120 that can serve as a base for the backplane connector 114 and as a housing for the conductors within the backplane connector. In various embodiments, the shroud 120 can be molded from a dielectric material such as plastic or nylon. Examples of suitable materials include, but are not limited to, liquid crystal polymer (LCP), polyphenylene sulfide (PPS), high temperature nylon, or polypropylene (PP), or polyphenylene oxide (PPO). Other suitable materials can be employed as the aspects of the present disclosure are not limited in this regard.

[0112] All of the above materials are suitable for use as the adhesive material in the manufacture of the connector. According to some embodiments, one or more fillers are included in some or all of the adhesive material used to form the backplane shroud 120 to control the electrical and / or mechanical properties of the backplane shroud 120. As a non-limiting example, a thermoplastic PPS filled volumetrically with 30% glass fiber can be used.

[0113] In some embodiments, the backplane of the shroud 120 can have multiple columns of openings 126, and the conductors 122 can be inserted into the openings 126 by extending the tails 124 through the lower surface of the shroud 120. The tails 124 can be adapted to attach to the backplane 110. For example, in some embodiments, the tails 124 can be adapted to be inserted into corresponding signal holes 136 on the backplane 110. The signal holes 136 can be plated with some suitable conductive material and can be used to electrically connect the conductors 122 to signal traces (not shown) in the backplane 110.

[0114] In some embodiments, the tails 124 can be a "pin eye" style flexible section that press fits within the signal holes 136. However, other configurations can also be used, such as surface mount elements, spring contacts, solderable pins, etc., as aspects of the present application are not limited to the use of any particular mechanism for attaching the backplane connector 114 to the backplane 110.

[0115] For the sake of clarity, FIG. 1B Only one of the conductors 122 is shown in FIG. 1. However, in embodiments, the backplane connector can include any suitable number of parallel columns of conductors and each column can include any suitable number of conductors. For example, in one embodiment, there are eight conductors in each column.

[0116] The spacing between the conductors of adjacent columns is not critical. However, higher densities can be achieved by placing the conductors close together. As a non-limiting example, the conductors 122 can be stamped from 0.4 mm thick copper alloy, and the conductors within each column can be spaced 2.25 mm apart and the columns of conductors can be spaced 2 mm apart. However, in other embodiments, smaller dimensions can be used to provide higher densities, such as thicknesses between 0.2 mm and 0.4 mm, or spacing between columns or between conductors within a column of 0.7 mm to 1.85 mm.

[0117] In FIG. 1BIn the example shown in FIG. 1, the shield 120 has a recess 132 formed in the bottom plate thereof. The recess 132 runs parallel to the columns of openings 126. The shield 120 also has recesses 134 formed in the inner side walls thereof. In some embodiments, the shield plate 128 is adapted to fit into the recesses 132 and 134. The shield plate 128 can have a tail 130 that is adapted to extend through an opening (not shown) in the bottom of the recess 132 and engage a ground hole 138 in the bottom plate 110. Like the signal holes 136, the ground hole 138 can be plated with any suitable conductive material, but the ground hole 138 can be connected to a ground trace (not shown) on the bottom plate 110 as opposed to a signal trace.

[0118] In FIG. 1B In the example shown in FIG. 1, the shield plate 128 has some torsion beam contacts 142 formed therein. In some embodiments, each contact can be formed by stamping arms 144 and 146 out of the shield plate 128. The arms 144 and 146 are then bent out of the shield plate 128 and can be long enough that the arms 144 and 146 can flex when pressed back into the plane of the shield plate 128. Additionally, the arms 144 and 146 can be resilient enough to provide a spring force when pressed back into the plane of the shield plate 128. The spring force created by each arm 144 or 146 can create a contact point between the arm and the shield plate 150 of the daughter card connector 116 when the backplane connector 114 is mated with the daughter card connector 116. The spring force created can be enough to ensure such contact even after the daughter card connector 116 has been repeatedly mated and unmated from the backplane connector 114.

[0119] In some embodiments, the arms 144 and 146 can be coined during manufacture. Coining can reduce the thickness of the material and increase the flexibility of the beam without weakening the shield plate 128. To improve electrical performance, it is also desirable that the arms 144 and 146 be short and straight. Thus, in some embodiments, the arms 114 and 146 are only manufactured to the length necessary to provide sufficient spring force.

[0120] In some embodiments, an alignment or gathering feature can be included on a backplane connector or mating connector. A complementary feature can be included on the other connector that engages the alignment or gathering feature on one connector. In FIG. 1B In the example shown in FIG. 1, the inner side walls of the shield 120 have recesses 140 formed therein. These recesses can be used to align the daughter card connector 116 with the backplane connector 114 during mating. For example, in some embodiments, the tabs 152 of the daughter card connector 116 can be adapted to fit into corresponding recesses 140 to align and / or prevent lateral movement of the daughter card connector 116 relative to the backplane connector 114.

[0121] In some embodiments, the daughter card connector 116 can include one or more blades. In FIG. 1B In the example shown in FIG. 1, only one blade 154 is shown for clarity, but the daughter card connector 116 can have multiple blades in an opposing stack. In some embodiments, the blade 154 can include a column of one or more receptacles 158, where each receptacle 158 can be adapted to engage a corresponding one of the connectors 122 of the backplane connector 114 when the backplane connector 114 and the daughter card connector 116 are mated. Thus, in such embodiments, the daughter card connector 116 can have as many blades as there are columns of connectors in the backplane connector 114.

[0122] In some embodiments, the blades can be held in or attached to a support member. In FIG. 1B In the example shown in FIG. 1, the blades of the daughter card connector 116 are supported in a stiffener 156. In some embodiments, the stiffener 156 can be stamped and formed from a metal strip. However, it should be appreciated that other materials and / or manufacturing techniques can also be suitable, as aspects of the present disclosure are not limited to the use of any particular type of stiffener or the complete lack of any stiffener. Moreover, other structures including a housing portion to which individual blades can be attached can alternatively or additionally be used to support the blades. In some embodiments, if the housing portion is insulating, the housing portion can have cavities that house mating contact portions of the blades to electrically isolate the mating contact portions. Alternatively or additionally, the housing portion can contain materials that affect the electrical performance of the connectors. For example, the housing can include shielding and / or electrically lossy materials.

[0123] In embodiments having a stiffener, the stiffener 156 can be stamped with features (e.g., one or more attachment points) to hold the blades 154 in a desired position. As a non-limiting example, the stiffener 156 can have a slot 160A formed along a front edge thereof. The slot 160A can be adapted to engage a tab 160B of the blade 154. The stiffener 156 can also include holes 162A and 164A that can be adapted to engage hub portions 162B and 164B, respectively, of the blade 154. In some embodiments, the hub portions 162B and 164B are sized to provide an interference fit in the holes 162A and 164A, respectively. However, it should be appreciated that other attachment mechanisms can also be suitable, such as adhesives.

[0124] Although FIG. 1BThe particular combination and arrangement of slots and holes on the stiffener 156 is shown in the example, but it should be understood that aspects of the present disclosure are not limited to any particular method of attaching a wafer to the stiffener 156. For example, the stiffener 156 can have one set of slots and / or holes for a wafer to be supported by the stiffener 156, such that the pattern of slots and / or holes repeats along the length of the stiffener 156 at each point where a wafer is to be attached. Alternatively, the stiffener 156 can have a different combination of slots and / or holes, or can have different attachment mechanisms for different wafers.

[0125] In FIG. 3 In the example shown in FIG. 2, the wafer 154 includes two pieces, a shield piece 166 and a signal piece 168. In some implementations, the shield piece 166 can be formed by insert molding a housing 170 around the front portion of the shield plate 150, and the signal piece 170 can be formed by insert molding a housing 172 around the one or more conductive elements. The formation of these housings is described in more detail below in connection with FIGS. 3 and 4. FIG. 2A-2B Examples of such conductive elements are described in more detail below.

[0126] FIG. 2A-2B Views of opposite sides of an example wafer 220A according to some implementations are shown. The wafer 220A can be formed entirely or partially by injection molding material to form a housing 260 around a wafer strip assembly. In FIG. 3 In the example shown in FIG. 2, the wafer 220A is formed in a two-shot injection molding operation, allowing the housing 260 to be formed from two materials having different properties. The insulating portion 240 is formed in the first shot and the loss portion 250 is formed in the second shot. However, any suitable number and type of materials can be used in the housing 260. For example, in some implementations, the housing 260 is formed from injection molded plastic around a column of conductive elements.

[0127] In some implementations, the housing 260 can be provided with holes and openings such as windows or slots 2641...2646, the holes of which are numbered, adjacent signal conductors are enclosed in the housing 260. These openings can be used for a number of purposes, including: (i) to ensure proper positioning of the conductive elements during the injection molding process, and / or (ii) to facilitate the insertion of materials that require different electrical properties.

[0128] The time it takes for an electrical signal to propagate from one end of a signal conductor to the other is known as the "propagation delay." In some implementations, it is desirable for signals within a pair of signal conductors to have the same propagation delay, which is often referred to as having "zero skew" within the pair.

[0129] Wafers having various configurations can be formed in any suitable manner, as aspects of the present disclosure are not limited to any particular manufacturing method. In some embodiments, wafers or wafer modules can be formed using insert molding. Such components can be formed by an insert molding operation in which a housing material is molded around the conductive elements. The housing can be integrally insulating or can include an electrically lossy material, which can be positioned depending on the desired use of the conductive elements in the formed wafer or wafer module.

[0130] FIG. 1B Wafer strip assemblies 410A and 410B suitable for use when manufacturing wafers according to some embodiments are shown. For example, wafer strip assemblies 410A and 410B can be used to manufacture wafers 154 in the example of FIG. 1 by insert molding a housing around the middle portion of the conductive elements of the wafer strip assemblies. However, it should be understood that the conductive elements disclosed herein can be incorporated into electrical connectors whether or not insert molding is used in the manufacturing. FIG. 3

[0131] In the example of FIG. 1, wafer strip assemblies 410A and 410B each include conductive elements in a configuration suitable for use as a column of conductors in a daughter card connector (e.g., daughter card connector 116 in the example of FIG. 1). A housing can then be molded around the conductive elements in each wafer strip assembly in an insert molding operation to form a wafer. FIG. 1B FIG. 3

[0132] To facilitate manufacturing of wafers, signal conductors (e.g., signal conductors 420) and ground conductors (e.g., ground conductors 430) can be held together on a pin frame such as exemplary pin frame 400 in the example of FIG. 1. For example, the signal conductors and ground conductors can be attached to one or more carrier tapes, such as exemplary carrier tape 402 shown in the example of FIG. 1. FIG. 3 FIG. 3

[0133] In some embodiments, conductive elements (e.g., in single-ended or differential configurations) can be punched out of a sheet of conductive material for a number of wafers. The sheet material can be made of metal or other electrically conductive material and provide suitable mechanical properties for the conductive elements in an electrical connector. Phosphor bronze, beryllium copper, and other copper alloys are non-limiting examples of materials that can be used.

[0134] FIG. 3 A portion of a sheet of conductive material from which wafer strip assemblies 410A and 410B have been punched out is shown. The conductive elements in wafer strip assemblies 410A and 410B can be held together by one or more retention features (e.g., retention features 412A and 412B). FIG. 3 ​​​​​The retaining features (e.g., connecting bars 452, 454, and 456 in the example of FIG. 4) are held in a desired position to facilitate easy handling during wafer fabrication. Once the material is molded around the conductive elements to form the housing, the retaining features can be disengaged. For example, the connecting bars 452, 454, and 456 can be used to provide electrically separate conductive elements and / or to separate the wafer strip assemblies 410A and 410B from the carrier tape 402. The final individual wafers can then be assembled into a daughter card connector.

[0135] In FIG. 3 In the example of FIG. 4, the ground conductors (e.g., ground conductors 430) are wider than the signal conductors (e.g., signal conductors 420). Such a configuration can be suitable for carrying differential signals, where it can be desirable to have two signal conductors within a differential pair that are disposed close to one another to facilitate preferential coupling. However, it should be understood that aspects of the present disclosure are not limited to the use of differential signals. The various concepts disclosed herein can alternatively be used for connectors that are suitable for carrying single-ended signals.

[0136] Although FIG. 3 While the example pin frame 400 in the example of FIG. 4 has both ground conductors and signal conductors, such a construction is not necessary. In alternative implementations, the ground conductors and signal conductors can be formed in two separate pin frames, respectively. In still other implementations, no pin frame can be used, and separate conductor elements can be employed instead during fabrication. Additionally, in some implementations, no insulating material can be molded over the pin frame or separate conductive elements, as the wafers can be assembled by inserting the conductive elements into one or more pre-formed housing portions. If there are multiple housing portions, the housing portions can be secured together with any suitable one or more attachment features, such as snap-fit features.

[0137] FIG. 3 The wafer strip assemblies shown in FIG. 4 provide just one example example of components that can be used for the fabrication of wafers. Other types and / or configurations of components can also be suitable. For example, a sheet of conductive material can be stamped to include one or more additional carrier tapes and / or bridge members between the conductive elements for positioning and / or supporting the conductive elements during fabrication. Thus, FIG. 1B The details shown in FIG. 4 are illustrative only and are not limiting. It should be understood that some or all of the concepts discussed above in connection with the daughter card connector can also be employed in a backplane connector. For example, in some implementations, the backplane connector (e.g., backplane connector 500) can include a carrier tape (e.g., carrier tape 502) that includes one or more retaining features (e.g., connecting bars 504, 506, and 508) that are configured to hold the conductive elements in a desired position to facilitate easy handling during wafer fabrication. Once the material is molded around the conductive elements to form the housing, the retaining features can be disengaged. For example, the connecting bars 504, 506, and 508 can be used to provide electrically separate conductive elements and / or to separate the wafer strip assemblies from the carrier tape. The final individual wafers can then be assembled into a backplane connector. FIG. 4AThe signal conductors in the backplane connector 114 in the example can be arranged in columns, each column containing differential pairs interspersed with ground conductors. In some embodiments, the ground conductors can partially or completely surround each pair of signal conductors. This configuration of signal conductors and ground shields can provide desirable electrical characteristics, which can facilitate the connector operating at higher frequencies between about 25 GHz and 40 GHz or higher.

[0138] However, the inventors have recognized and appreciated that incorporating a fully grounded structure into a connector using conventional connector manufacturing techniques can increase the size of the connector to such an extent that the number of signals that the connector can carry per inch is undesirably reduced. In addition, the inventors have recognized and appreciated that using conventional connector manufacturing techniques to provide a ground structure around signal pairs introduces a great deal of complexity and expense in the manufacture of a commercially available connector family. Such a family includes a range of connector sizes, such as 2-pair, 3-pair, 4-pair, 5-pair, or 6-pair to accommodate a range of system configurations. Here, the number of pairs refers to the number of pairs in a column of conductive elements, which means that the number of rows of conductive elements is different for each connector size. The tools to manufacture all of the desired sizes increase the cost of providing a family of connectors.

[0139] In addition, the inventors have recognized and appreciated that conventional methods for reducing "skew" in a signal pair are not as effective at higher frequencies between about 25 GHz and 40 GHz or higher. In this context, skew refers to a difference in the electrical propagation time between a pair of signals operating as a differential signal. This difference can be caused by a difference in the physical length of the conductive elements forming a pair. Such a difference can occur, for example, in a right angle connector where the conductive elements forming a pair are close to each other within the same column. Since the signal conductors bend over the right angle, one conductive element will have a larger radius of curvature than the other conductive element. Conventional methods require selectively positioning a material of low dielectric constant around the longer conductive element, which makes the signal propagate faster through the longer conductive element, thereby compensating for the longer distance that the signal travels through that conductive element.

[0140] In some embodiments, the connector can be formed from modules, each module carrying a pair of signals. The modules can be individually shielded, such as by attaching a shielding member to the module, and / or by inserting the module into an organizer or other structure that can provide electrical shielding between multiple pairs and / or around the conductive elements carrying the signals.

[0141] Modules can be assembled into a wafer or other connector structure. In some embodiments, different modules can be formed for each row of positions in a right angle connector that are to be populated with a pair of conductive elements. These modules can be manufactured to be used together to build a connector with as many rows as desired. For example, one shaped module can be formed for a pair of conductive elements to be positioned at the shortest row (sometimes referred to as the a-b row) of a connector. Separate modules can be formed for the conductive elements in the next shortest row (sometimes referred to as the c-d row). The interior of the c-d row module can be designed to conform to the exterior of the a-b row module.

[0142] This pattern can be repeated for any number of pairs. Each module can be shaped to be used with modules of shorter rows and / or longer rows that carry multiple pairs of conductive elements. To manufacture connectors of any suitable size, a connector manufacturer can assemble multiple modules into a wafer to provide the desired number of pairs in the wafer. In this way, a connector manufacturer can offer a widely used connector size, such as 2 pairs, for a series of connectors. When customer demand changes, the connector manufacturer can acquire tools for each additional pair or acquire tools for modules that contain multiple pairs, groups of multiple pairs, to produce larger size connectors. Tools used to produce modules for smaller connectors can be used to produce modules for shorter rows of even larger connectors.

[0143] FIG. 4B and FIG. 4A-4B Such modular connectors are shown in U.S. Patent Application Publication No. 2013 / 0283398, which is incorporated herein by reference in its entirety. FIG. 1B Oppositely stacked multiple example wafers 754A-754D according to some embodiments are shown. In this example, the example wafers 754A-754D have a right angle configuration and can be adapted for use in a right angle electrical connector (e.g., a daughter card connector 116 of the example of FIG. 4A However, it should be understood that the concepts disclosed herein can also be used with other types of connectors, such as backplane connectors, cable connectors, stacked connectors, mezzanine connectors, I / O connectors, chip sockets, etc.

[0144] In the example of FIG. 4B and FIG. 4B The wafers 754A-754D are adapted to be attached to a printed circuit board, such as the daughter card 712, which can allow the conductive elements in the wafers 754A-754D to form electrical connections with respect to corresponding traces in the daughter card 712. Any suitable mechanism can be used to connect the conductive elements in the wafers 754A-754D to the traces in the daughter card 712. For example, as shown in the example of FIG. 5AAs shown, the conductive elements in sheets 754A to 754D may include a plurality of contact tails 720 adapted to be inserted into through-holes (not shown) formed in daughter card 712. In some embodiments, the contact tails 720 may press-fit into "pinhole" type flexible sections fitted into the through-holes of daughter card 712. However, other configurations may also be used, such as other types of flexible members, surface mount elements, spring-loaded contacts, solderable pins, etc., because aspects of the invention are not limited to the use of any particular mechanism for attaching sheets 754A to 754D to daughter card 712.

[0145] In some embodiments, the sheets 754A to 754D may be attached to components that hold the sheets together or support the connector. For example, an organizer configured to hold the contact ends of multiple sheets may be used. FIG. 5B and FIG. 4A An exemplary organizer 756 according to some embodiments is shown, wherein the organizer 756 is adapted to be fitted in FIG. 4B and FIG. 4B The example is on sheets 754A to 754D. In this example, organizer 756 includes a plurality of openings, such as opening 762. These openings can be sized and arranged to receive contact tails 720 of the exemplary sheets 754A to 754D. In some embodiments, exemplary organizer 756 may be made of a rigid material and may facilitate alignment and / or reduce relative movement between the exemplary sheets 754A to 754D. Additionally, in some embodiments, exemplary organizer 756 may be made of an insulating material (e.g., insulating plastic) and may support contact tails 720 or prevent contact tails 720 from shorting together when the connector is mounted to a printed circuit board.

[0146] Furthermore, in some embodiments, the organizer 756 may have a dielectric constant matching that of the housing material used for the sheet. The organizer may be configured to occupy the space between the sheet housing and the surface of the printed circuit board on which the connector is mounted. To provide such functionality, for example, the organizer 756 may have... FIG. 4A The visible flat surface is used for mounting against the printed circuit board. The opposing surface facing the sheet may have any other protrusions to match the profile of the sheet. In this way, the organizer 756 can help to equalize the impedance along the signal conductors that pass through the connector and into the printed circuit board.

[0147] although FIG. 4B and FIG. 5A or FIG. 5B and FIG. 2AOther support members not shown can alternatively or additionally be used to hold the sheets together. The sheets can be held close to their mating interfaces using, for example, metal stiffeners or plastic organizers. As yet another possible attachment mechanism, the sheets can include features that can engage complementary features on other sheets, thereby holding the sheets together.

[0148] Each sheet can be constructed in any suitable manner. In some embodiments, the sheet can be constructed from a plurality of modules, each module carrying one or more conductive elements shaped to carry signals. In the exemplary embodiments described herein, each module carries a pair of signal conductors. These signal conductors can be aligned in the column direction, as in the sheet assembly shown in FIG. 2A or 2B. Alternatively, these signal conductors can be aligned in the row direction, such that each module carries signal conductors in at least two adjacent rows. As yet another alternative, a pair of signal conductors can be offset relative to one another in the row direction and the column direction such that each module contains signal conductors in two adjacent rows and two adjacent columns. FIG. 6A

[0149] In other embodiments, the signal conductors can be aligned in the column direction in one portion of their length and aligned in the row direction in other portions of their length. For example, the signal conductors can be aligned in the row direction in the middle portion of their sheet housing. Such a configuration enables a wide-side coupling, which results in approximately equal lengths of the signal conductors even for right-angle connectors and avoids an offset. The signal conductors can be aligned in the column direction at the contact tails and / or the mating interfaces. Such a configuration enables an edge coupling at the contact tails and / or the mating interfaces. Such a configuration can help to route traces within a printed circuit board to vias that plug into the contact tails. Different alignments in different portions of the conductive elements can be achieved by using a transition region where a portion of the conductive element is bent or curved to change its relative position.

[0150] FIG. 6B FIG. 6A are perspective exploded views of an exemplary sheet 754A according to some embodiments. As shown in these figures, the exemplary sheet 754A has a modular construction. In this example, the exemplary sheet 754A includes three modules 910A-C sized and shaped to fit together in a right-angle configuration. For example, the module 910A can be positioned on the outside of the right-angle turn, forming the longest row of the sheet. The module 910B can be positioned in the middle, and the module 910C can be positioned on the inside, forming the shortest row. Thus, the module 910A can be longer than the module 910B, which in turn can be longer than the module 910C.

[0151] The inventors have recognized and appreciated that a modular construction, such as that of the exemplary sheet 754A, can be used to construct a sheet assembly with a desired number of rows and columns. For example, the exemplary sheet 754A can be used to construct a sheet assembly with two rows and two columns, as shown in FIG. 2A, or a sheet assembly with three rows and three columns, as shown in FIG. 2B. The inventors have recognized and appreciated that a modular construction can be used to construct a sheet assembly with a desired number of rows and columns. FIG. 6B FIG. 6A ​​​The configurations shown in the middle can advantageously reduce tooling costs. For example, in some embodiments, a single set of tooling can be configured to manufacture a corresponding one of the modules 910A-C. If a new wafer design requires four modules (e.g., by adding one module to the outside of the modules 910A-C), all three existing sets of tooling can be reused, such that only one new set of tooling is needed to manufacture the fourth module. This can be less costly than a new set of tooling to manufacture an entire wafer.

[0152] The modules 910A-C can be held together to form a wafer in any suitable manner (e.g., by pure friction). In some embodiments, additional mechanisms can be used to hold two or more modules 910A-C together. For example, FIG. 6B and FIG. 6A In the example of FIG. 9B, the module 910A includes a protrusion 912A adapted to be inserted into a recess 914B formed in the module 910B. The protrusion 912A and the corresponding recess 914B can have a dovetail shape, such that when the protrusion 912A and the corresponding recess 914B are assembled together, they can reduce rotational motion between the modules 910A and 910B. However, other suitable attachment mechanisms can alternatively or additionally be used. The attachment mechanisms can include snaps or latches. As yet another example, the attachment mechanisms can include a hub extending from one module that engages via an interference fit or other suitable engagement with a hole or other complementary structure on the other module. Examples of other suitable structures can include adhesives or welds.

[0153] Any number of such attachment mechanisms can be used to hold the modules 910A and 910B together. For example, two attachment mechanisms can be used on each side of the modules 910A and 910B, with one attachment mechanism oriented perpendicular to the other, which can further reduce rotational motion between the modules 910A and 910B. However, it should be understood that aspects of the present disclosure are not limited to the use of dovetail-shaped attachment mechanisms, nor to any particular number of attachment mechanisms between any two modules or arrangement of attachment mechanisms between any two modules.

[0154] In embodiments, the modules 910A-C of the example wafer 754A can include any suitable number of conductive elements that can be configured to carry differential signals and / or single-ended signals, and / or that are configured as ground conductors. For example, in some embodiments, the module 910A can include a pair of conductive elements configured to carry differential signals. These conductive elements can have contact tails 920A and 930A, respectively.

[0155] In some embodiments, the modules 910A-C of the example sheet 754A can include a ground conductor. For example, the enclosure of module 910A can be made of a conductive material and serve as a shield member 916A. The shield member 916A can be formed from a sheet of metal shaped to fit the module. Such an enclosure can be made by stamping forming techniques known in the art. Alternatively, the shield member 916A can be formed from a conductive or partially conductive material plated onto or overmolded onto the exterior of the module housing. The shield member 916A can be, for example, a moldable matrix material mixed with a conductive filler to form a conductive or conductive loss material. In such embodiments, the attachment mechanism of the shield member 916A and the module can be the same, formed by overmolding the material around the module.

[0156] In some embodiments, the shield member 916A can have a U-shaped cross-section, such that the conductive elements in module 910A can be surrounded on three sides by the shield member 916A for that module. In some embodiments, module 910B can also have a U-shaped shield member 916B, such that when modules 910A and 910B are assembled together, the conductive elements in module 910A can be surrounded on three sides by shield member 916A and on the remaining side by shield member 916B. This can provide a fully shielded signal path, which can improve signal quality, for example, by reducing cross-talk.

[0157] In some embodiments, the innermost module can include an additional shield member to provide a fully shielded signal path. For example, in the example of FIG. 9B, module 910C includes a U-shaped shield member 916C and an additional shield member 911C, such that the conductive elements in module 910C are surrounded on all four sides. However, it should be understood that aspects of the present disclosure are not limited to using shield members to fully enclose a signal path, as a desired amount of shielding can be achieved by selectively placing shield members around a signal path without fully enclosing the signal path. FIG. 6B and FIG. 6A In some embodiments, the shield members 916A-C can be formed from a single piece of material (e.g., some suitable metal alloy) and stamped, and similarly for shield members 916B-C. One or more suitable attachment mechanisms can be formed during the stamping process. For example, the tabs 912A and recesses 914B described above can be formed on the shield members 916A and 916B, respectively, by stamping. However, it should be understood that aspects of the present disclosure are not limited to forming shield members from a single piece of material by stamping. In some embodiments, a shield member can be formed by assembling multiple component parts together (e.g., by welding or otherwise attaching the parts together).

[0158] In some embodiments, the shield members 916A-C can be formed from a single piece of material (e.g., some suitable metal alloy) and stamped, and similarly for shield members 916B-C. One or more suitable attachment mechanisms can be formed during the stamping process. For example, the tabs 912A and recesses 914B described above can be formed on the shield members 916A and 916B, respectively, by stamping. However, it should be understood that aspects of the present disclosure are not limited to forming shield members from a single piece of material by stamping. In some embodiments, a shield member can be formed by assembling multiple component parts together (e.g., by welding or otherwise attaching the parts together).

[0159] In some embodiments, one or more of the contact tails of the example sheet 754A can be contact tails of ground conductors. For example, the contact tails 940A and 942A of the module 910A can be electrically coupled to the shield member 916A, and the contact tail 944B of the module 910B can be electrically coupled to the shield member 916B. In some embodiments, these contact tails can be integrally connected to the respective shield members (e.g., stamped out of the same piece of material), although this is not required as in other embodiments the contact tails can be formed as separate pieces and connected to the respective shield members in any suitable manner (e.g., by soldering). Moreover, aspects of the disclosure are not limited to electrically coupling contact tails to shield members. In some embodiments, any of the contact tails 940A, 940B, and 944B can be connected to a ground conductor that is not configured as a shield member.

[0160] In some embodiments, the contact tails of the ground conductors can be arranged to space apart the contact tails of adjacent signal conductors. In FIG. 6B and FIG. 4A In the example of the sheet 954A, the ground contact tail 942A can be positioned immediately adjacent to the signal contact tail 930A such that when the example sheet 954A is stacked against a similar sheet (e.g., the sheet 954B in the example of FIG. 4B and FIG. 6B In the example of the sheet 954B, the ground contact tail 942B can be positioned immediately adjacent to the signal contact tail 930B such that when the example sheet 954B is stacked against a similar sheet (e.g., the sheet 954A in the example of

[0161] In FIG. 7AIn the example of FIG. 1, the modules 100 include at least three ground contact tails coupled to the shield member 116. Such a configuration positions the contact tails symmetrically with respect to each pair of signal contact tails. The symmetric positioning of the ground contact tails also positions the ground contact via symmetrically with respect to the signal vias within the printed circuit board to which the connector is attached. In this example, each module 100 includes two ground contact tails that are bent to a position near the signal contact tails and provide shielding between the wafers. At least some of the modules 100 include additional ground contact tails that separate pairs of modules when the modules are positioned in the wafer. The longest and shortest modules do not have ground contact tails on the outside and inside, respectively, of their signal pairs. In some embodiments, however, such additional ground contact tails can be included. Further, other configurations of ground contact tails can be used to position the ground contact tails symmetrically around the signal conductors, and these configurations can have more or fewer ground contact tails per module than three.

[0162] FIG. 7C and FIG. 7B is a perspective view of an exemplary module 910A according to some embodiments. FIG. 7A is a partial exploded view of an exemplary module 910A according to some embodiments. As shown in these figures, the exemplary module 910A includes two conductive elements 925A and 935A that are inserted into a housing 918A. The conductive elements can be secured in the housing 918A in any suitable manner. In the illustrated embodiment, the conductive elements are inserted into slots formed in the housing 918A. The conductive elements can be held in place using any suitable retention mechanism, such as an interference fit; retention features that act as latches, adhesives; or material that is molded or inserted into the slots after the conductive elements are inserted to lock the conductive elements in place. In other embodiments, however, the housing can be molded around the conductive elements. The housing 918A can be sized and shaped to fit within the shield member 916A.

[0163] In FIG. 7C and FIG. 8AIn the embodiment shown in FIG. 9, the conductive elements 925A and 935A have substantially the same size and shape. Each conductive element has a contact tail exposed in one surface of the housing. In this example, the contact tails are shown as press-fit pinhole contacts, but any suitable contact tail can be used. Each conductive element also has a mating contact exposed in another surface of the housing. In this example, the mating contacts are shown as flat portions of the conductive elements. However, the mating contacts can have other shapes, which can be created by attaching another member or by forming the end of the conductive element into the desired shape. In this example, the conductive elements 925A and 935A are shown with the same thickness and width. In this example, however, the conductive element 935A is shorter than the conductive element 925A. In such an embodiment, to reduce skew within a pair of conductive elements, the conductive elements can be formed in different shapes to provide faster propagation speed in the longer conductor.

[0164] FIG. 8C and FIG. 8B is a perspective view of an example housing 918A according to some embodiments. FIG. 7B is a front view of an example housing 918A according to some embodiments. The housing 918A can be formed in any suitable manner, including by shaping using conventional insulating materials and / or conductive lossy materials. As shown in these figures, the example housing 918A includes two elongated slots 926A and 936A. These slots can be adapted to receive a pair of conductive elements (e.g., the conductive elements 925A and 935A of the example of FIG. 9). FIG. 9A

[0165] However, other housing configurations can be used. For example, the housing 918A can have a hollow portion. The hollow portion can be positioned to provide air between the conductive elements 925A and 935A. This approach can adjust the impedance of the pair of conductive elements. Alternatively or additionally, the hollow portion of the housing 918A can enable insertion of a lossy material or other material that enhances the electrical performance of the connector.

[0166] FIG. 9B and FIG. 9C are a front view and a perspective view, respectively, of an example housing 918A according to some embodiments, in which the conductive element 925A is inserted in the slot 926A and the conductive element 955A is inserted in the slot 936A. FIG. 9D and FIG. 9A-9D ​are perspective and front views of exemplary conductive elements 925A and 935A according to some embodiments. In this example, the conductive elements 925A and 935A and slots 926A and 936A are configured such that when the conductive element 925A is inserted into the slot 926A and the conductive element 925A is inserted into the slot 936A, the middle portions of the conductive elements 925A and 935A bend toward each other. As a result, the radius of curvature of the middle portion of the conductive element 925A decreases while the radius of curvature of the middle portion of the conductive element 935A increases. Thus, the difference in length between the conductive elements 925A and 935A is greatly reduced relative to a configuration in which the conductive elements are not bent.

[0167] In some embodiments, the conductive elements can be bent toward each other such that an edge of one conductive element is adjacent to an edge of another conductive element. In the illustrated embodiment, the conductive elements have wide surfaces that lie in different but parallel planes. Each conductive element can be bent toward the other conductive element in a plane that is parallel to its width dimension. Thus, even when the edges of the conductive elements are adjacent, they do not touch because they lie in different planes.

[0168] In other embodiments, the conductive elements can be bent toward each other to a point at which one conductive element overlaps the other conductive element in a direction that is perpendicular to the wide surfaces of the conductive elements. In this configuration, the middle portions of the conductive elements 925A and 935A are wide-side coupled.

[0169] The inventors have recognized and appreciated that a wide-side coupled configuration can provide a low skew right angle connector. When a connector is operated at lower frequencies, the skew of a pair of edge-coupled right angle conductive elements can be a relatively small fraction of a wavelength and thus can not significantly affect a differential signal. However, when a connector is operated at higher frequencies (e.g., 25 GHz, 30 GHz, 35 GHz, 40 GHz, 45 GHz, etc.), such skew can become a relatively large fraction of a wavelength and can negatively affect a differential signal. Thus, in some embodiments, a wide-side coupled configuration can be employed to reduce skew. However, wide-side coupling is not necessary because various techniques can be used to compensate for skew in alternative embodiments, such as by changing the profile of the edge of a conductive element on the inside of a turn (e.g., changing to a scalloped shape) to increase the electrical path along that edge.

[0170] The inventors have also recognized and appreciated that while a wide-side coupled configuration can be desirable for the middle portions of the conductive elements, a full or mostly edge-coupled configuration can be desirable at a mating interface with another connector or at an attachment interface with a printed circuit board. Such a configuration can facilitate, for example, routing of signal traces within a printed circuit board that connect to vias of a contact tail of a receiving connector.

[0171] Thus, in FIG. 9C example, the conductive elements 925A and 935A can have transition regions at one or both ends, such as transition regions 1210A and 1210B. In the transition regions, the conductive elements can be bent out of the plane parallel to the width dimension of the conductive elements. In some embodiments, each transition region can have a bend toward the transition region of the other conductive element. In some embodiments, the conductive elements each bend toward the plane of the other conductive element such that the ends of the transition regions are aligned in the same plane parallel but between the planes of the respective conductive elements. To avoid contact of the transition regions, the conductive elements can also be bent away from each other in the transition regions. Thus, the conductive elements in the transition regions can be aligned edge-to-edge in a plane parallel but between the planes of the respective conductive elements. For example, the contact tails such as 920A and 930A can be edge coupled. In some embodiments, similar transition regions can be used instead of or in addition to at the mating contact of the conductive elements.

[0172] FIG. 9C Both ends of each conductive element are shown bent in the same direction. This approach results in the ends of the conductive element 925A being outboard relative to the ends of the conductive element 935A. In other embodiments, the ends of a pair of conductive elements can be bent in opposite directions. For example, the contact tail 920A can be bent in the direction of the shorter row of the connector, while the contact tail 930A is bent in the direction of the longer row. Such a bend at the circuit board interface of the connector will lengthen the conductive element 925A relative to the conductive element 935A in the transition region. If the conductive elements have a bend near their mating contact as shown in the transition region, the element 925A will be longer in the transition region. By forming the transition regions symmetrically relative to each other, the relative lengthening in one transition region can be largely or completely offset by the relative shortening in the other transition region. This configuration of the conductive elements can reduce the misalignment within the pair of conductive elements 925A and 935A.

[0173] In FIG. 10A example, when the conductive elements 925A and 935A exit the housing 918A at one end of the housing, the conductive elements can be bent away from each other, for example, to conform to the desired arrangement of the conductive elements at the mating interface with the backplane connector, or to match the desired arrangement of the through holes on the daughter card. Whether or not the middle portions of the conductive elements are bent toward each other, transition regions at the ends of the conductive elements can be used. For example, the slot 926A can be deeper than the slot 936A at either end of the housing 918A to adjust the desired spacing between the ends of the conductive elements 925A and 935A.

[0174] In some embodiments, the housing 918A may be made of an insulating material (e.g., plastic or nylon) through a molding process. The housing 918A may be formed as a single piece or may be assembled from separate manufactured parts. Additionally, a loss-inducing material may be incorporated into the housing 918A either uniformly or at one or more selected locations to provide any desired electrical properties (e.g., to reduce crosstalk).

[0175] In some embodiments, slots 926A and 936B may be filled with additional insulating material after conductive elements 925A and 935A have been inserted. The additional insulating material may be the same as or a different material from the insulating material used to form housing 918A. Filling slots 926A and 936B can prevent displacement of conductive elements 925A and 935A and thus maintain signal quality. However, other methods of securing conductive elements 925A and 935A may also be possible, such as using one or more fasteners configured to hold conductive elements 925A and 935A at a desired distance from each other.

[0176] FIG. 10B and FIG. 6A These are based on some implementation methods. FIG. 6B and FIG. 6A The figures show a perspective view and a front view of an example shielding member 916A. As shown in these figures, a contact tail 940A is connected to the shielding member 916A via a bent segment 941A, such that the contact tail 940A is offset from the sidewall of the shielding member 916A from which the contact tail 940A extends. As shown in these figures, a contact tail 942A is connected to the shielding member 916A via a bent segment 943A, such that the contact tail 942A is offset from the sidewall of the shielding member 916A from which the contact tail 940A extends. This configuration allows contact tails 940A and 942A to be aligned with signal contact tails 920A and 930A, as... FIG. 11A and 6B As shown in the image.

[0177] FIG. 11B and FIG. 6A These are perspective and cross-sectional views of an exemplary shielding member 1400 according to some embodiments. As shown in these figures, the exemplary shielding member 1400 is formed by assembling at least two components 1410A and 1410B together. In this example, components 1410A and 1410B form the top and bottom halves of the shielding member 1400, respectively. However, it should be understood that other configurations are also possible (e.g., left and right halves, a top plate with a U-shaped bottom channel, a bottom plate with an inverted U-shaped top channel, etc.), because aspects of this disclosure are not limited to shielding member components of any particular configuration.

[0178] and FIG. 6B andFIG. 11A The shield members 916C and 911C in the example of FIG. 9 are similar to those of FIG. 8, FIG. 11B and FIG. 11B The example shield member 1400 also provides a fully shielded signal path, advantageously reducing crosstalk between conductive elements enclosed by the shield member 1400 and conductive elements outside the shield member 1400. However, the inventors have recognized and appreciated that enclosing a signal path within a shielded cavity can create undesirable resonances that negatively impact signal quality. Accordingly, in some embodiments, one or more portions of lossy material can be electrically coupled to the shield member to reduce undesirable resonances. For example, in the example of FIG. 14, lossy portions 1430A and 1430B can be placed between the shield members 1410A and 1410B. The lossy portions can be held in place by the same features that attach the shield members to the wafer module and by being captured between the shield members. FIG. 7A-12C

[0179] In some embodiments, the lossy portions 1430A and 1430B can be elongated and can extend along the entire length of the shield member 1400. For example, the lossy portion 1430A can extend along the joint between the shield members 1410A and 1410B. However, it should be appreciated that the lossy portion 1430 need not extend continuously along the dashed line 1420. Rather, in alternative embodiments, the lossy portion 1430 can include one or more discontinuous portions placed at selected locations along the dashed line 1420. Moreover, aspects of the disclosure are not limited to using lossy portions on both sides of the shield member 1400. In alternative embodiments, one or more lossy portions can be incorporated on only one or more sides of the shield member 1400. For example, one or more lossy portions can be placed on the bottom of the U-shaped channel within the shield member 1410A, and the same for the shield member 1410B.

[0180] As another variation, lossy material can be coupled to the shield member at selected locations along the signal path. For example, lossy material can be coupled to the shield member adjacent to the above-mentioned adjacent transition regions or adjacent to the mating contact or contact tail. Such regions of lossy material can be attached to the shield member, for example, by pushing a hub portion through an opening in the shield member onto the lossy member. In this case, an electrical connection can be made through direct contact between the lossy material and the shield member. However, the lossy member can be electrically coupled in other ways, such as using capacitive coupling.

[0181] ​Alternatively or additionally, the lossy material may be placed on the outside of the shielding member, for example, by applying a lossy conductive coating to the shielding member or by overmolding the lossy material. In some embodiments, one or more lossy members may hold sheet modules together within a sheet, or sheet modules together within a sheet assembly. Lossy members of this configuration may, for example, be overmolded around a sheet module or sheet. However, connections between shielding assemblies do not necessarily need to be formed through lossy members. In some embodiments, conductive members may electrically connect shielding members in different sheet modules or different sheets. Other configurations of the lossy material may also be suitable, as aspects of this disclosure are not limited to any particular configuration, or are not at all limited to the use of lossy materials.

[0182] exist FIG. 12A-12C In the sheet module shown, a pair of conductive elements are inserted into a housing. The housing is rigid. In some embodiments, the pair of conductive elements can be routed through the sheet module using cables. In some embodiments, each cable can be in a biaxial configuration including a pair of signal conductors and an associated grounding structure. The grounding structure can include foil or braid wrapped around an insulator in which the signal conductors are embedded. In this embodiment, the cable insulator can function the same as the molded housing. However, cable manufacturing techniques can allow for more precise control over the positioning of the signal conductors and / or shielding components, thereby providing better electrical performance for the connector.

[0183] FIG. 4A This is a perspective view of an exemplary module 1500 at various manufacturing stages, based on some embodiments using this cable configuration. The exemplary module 1500 can be used alone in an electrical connector, or in combination with other modules to form a sheet of the electrical connector (similar to...). FIG. 4B and FIG. 12A Exemplary sheets 754A to 754D shown.

[0184] like FIG. 12A As shown, the exemplary module 1500 includes two conductive elements 1525 and 1535 extending through a cable insulator 1518. The cable insulator 1518 can be made of an insulating material in any suitable manner. For example, in some embodiments, the cable insulator 1518 can be extruded around the conductive elements 1525 and 1535. A single cable insulator can surround multiple conductors within a cable. In alternative embodiments, the cable insulator 1518 can include two component parts, each surrounding a respective conductor element of the conductor elements 1525 and 1535. The separate component parts can be held together in any suitable manner, such as by an insulating sheath and / or a conductive structure such as a foil.

[0185] In some embodiments, the cable insulation 1518 can extend along the entire length of the conductive elements 1525 and 1535. Alternatively, the cable insulation 1518 can include discontinuous portions arranged at selected locations along the conductive elements 1525 and 1535. The space between two discontinuous shell portions can be occupied by air, which is also an insulator. Furthermore, the cable insulation 1518 can have any suitable cross-sectional shape, such as circular, rectangular, oval, etc.

[0186] In some embodiments, the conductive elements 1525 and 1535 can be adapted to carry differential signals and the shielding member can be provided to reduce crosstalk between the pair of conductive elements 1525 and 1535 and other conductive elements in the connector. For example, in the example of FIG. 6A the shielding element 1516 can be provided to enclose the cable insulation 1518 in which the conductive elements 1525 and 1535 are inserted. In some embodiments, the shielding member 1516 can be a foil made of a suitable conductive material (e.g., metal) that can be wrapped around the cable insulation 1518. Other types of shielding members, such as rigid structures configured to receive the cable insulation 1518, can also be suitable.

[0187] As discussed above in connection with FIG. 6B and FIG. 12A the signal quality can be improved by providing a shield that completely encloses the signal path. Thus, in the example of FIG. 12A the shielding 1516 can completely wrap around the cable insulation 1518. However, it should be appreciated that a completely shielded signal path is not necessary, as in alternative embodiments the signal path can be partially shielded or completely unshielded. For example, in some embodiments, a lossy material can be placed around the signal path instead of a conductive shielding member to reduce crosstalk between different signal paths.

[0188] In some embodiments, each conductive element in the connector can have a contact tail attached thereto. In the example of FIG. 12B the conductive elements 1525 and 1535 can have contact tails 1520 and 1530, respectively, attached thereto by soldering, brazing, or compression fitting, or in some other suitable manner. Each contact tail can be adapted to be inserted into a corresponding hole in a printed circuit board to form an electrical connection with a corresponding conductive trace in the printed circuit board. The contact tails can be held within an insulating member, which can provide support to the contact tails and ensure that the contact tails remain electrically insulated from each other.

[0189] FIG. 12A Fig. 16 shows the connector of Fig. 15 in a subsequent manufacturing stage. FIG. 12CAn exemplary module 1500 includes an insulating portion 1528 formed around conductive elements 1525 and 1535 that are attached to contact tails 1520 and 1530. In some embodiments, the insulating portion 1528 can be formed by molding non-conductive plastic around the conductive elements 1525 and 1535 and the contact tails 1520 and 1530 to maintain a certain spacing between the contact tails 1520 and 1530. This spacing can be selected to match the spacing between corresponding holes on a printed circuit board suitable for inserting the contact tails 1520 and 1530. Such a spacing can be on the order of 1 mm but can be in the range, for example, from 0.5 mm to 2 mm.

[0190] For a fully shielded module, in some embodiments, the shielding member may be attached to the insulating portion 1528. The shielding member may be electrically connected to the shielding element 1516. FIG. 12A It shows the stage of subsequent manufacturing. FIG. 12B and FIG. 12C An exemplary module 1500 is provided, wherein a conductive portion 1526 is formed around an insulating portion 1528. The conductive portion 1526 can be formed of any suitable conductive material (e.g., metal) and can provide shielding for conductive elements 1525 and 1535 and contact tails 1520 and 1530. In the illustrated embodiment, the conductive element 1526 can be formed as a partition plate that is attached to the insulating portion 1528 using any suitable attachment mechanism such as barbs or latches, or by using an opening in the conductive portion 1526 fitted onto a protrusion of the insulating portion 1528. Alternatively or additionally, the conductive portion 1526 can be formed by coating or covering the insulating portion 1528 with a molded conductive or partially conductive layer.

[0191] In some embodiments, the conductive portion 1526 may be electrically coupled to one or more contact tails. FIG. 13A-13C In one example, the conductive portion 1526 may be integrally connected to the contact tails 1540, 1542, 1544, and 1546 (e.g., by stamping from the same sheet of material). In other embodiments, the contact tails may be formed as separate parts and connected to the conductive portion 1526 in any suitable manner (e.g., by welding).

[0192] In some embodiments, the contact tails 1540, 1542, 1544, and 1546 can be adapted to be inserted into holes of a printed circuit board to make electrical connections with ground traces. In addition, the conductive portion 1526 can be electrically coupled to the shielding member 1516 so that the conductive portion 1526 and the shielding member 1516 can together form a ground conductor. Such a coupling can be provided in any suitable manner such as with a conductive adhesive or filler that contacts the conductive portion 1526 and the shielding member 1516, crimps the shielding member 1516 around the conductive portion 1526, or clamps the conductive element 1526 between the shielding member 1516 and the insulating portion 1528. As another example, the shielding member 1516 can be soldered, welded, or brazed to the conductive portion 1526.

[0193] In some embodiments, the mating contact portions can also be attached to the wafer used to manufacture the wafer module. FIG. 12A-12C is an example module 1500 at a later stage of manufacture according to some embodiments. FIG. 12A-12C is an example module 1500 at a later stage of manufacture according to some embodiments. FIG. 13A-13C shows one end of the example module 1500 (e.g., the module 1500 is adapted to be attached to a printed circuit board at this end), however FIG. 13A shows the opposite end of the example module 1500 (e.g., the module 1500 is adapted to mate with another connector such as a backplane connector at this end). For example, FIG. 12A shows FIG. 13B the opposite end of the conductive elements 1525 and 1535, the cable insulation 1518, and the shielding member 1516. Here, the cable insulation 1518, the shielding member 1516, and any cable jacket or other portion of the cable are shown stripped at the end to expose portions of the conductive elements 1525 and 1535 that can be attached to structures that function as mating contact portions.

[0194] FIG. 13A shows the example module 1500 of FIG. 13C at a later stage of manufacture, where an insulating portion 1658 is formed around the conductive elements 1525 and 1535 that extend from the cable insulation. In some embodiments, the insulating portion 1658 can be formed by molding a non-conductive plastic around the conductive elements 1525 and 1535 so as to maintain a spacing between the conductive elements 1525 and 1535. Such a spacing can be selected to match a spacing between conductive elements of a corresponding connector that is adapted to mate with the module 1500. The spacing of the mating contact portions can be the same as the spacing of the contact tails described above. However, it is not required that the spacing at the mating contact portions and the contact tails be the same, as any suitable spacing between conductive elements can be used at either interface.

[0195] FIG. 13A shows the example module 1500 of FIG. 13Band FIG. 12C An example module 1500 with mating contacts 1665 and 1675 already attached to conductive elements 1525 and 1535, respectively, is shown. Mating contacts 1665 and 1675 can be attached to conductive elements 1525 and 1535 in any suitable manner, such as by soldering, and can be adapted to mate with corresponding mating contacts of another connector.

[0196] In FIG. 12C the example, mating contacts 1665 and 1675 are configured as tubes that are adapted to receive corresponding contacts that are configured as pins or blades. Alternatively, the tubes can be configured to fit within larger tubes or other structures in the corresponding mating interface.

[0197] In some embodiments, the mating contacts can include a flexible member to facilitate electrical contact with a corresponding mating contact of a signal conductor in another connector. In FIG. 13C the example, each of mating contacts 1665 and 1675 has a tab formed thereon, such as tab 1680 formed on mating contact 1675, which can serve as a flexible member. In a configuration in which the tube is to receive a mating contact, tab 1680 can be biased toward the inside of tubular mating contact 1675, such that a spring force can be created that presses tab 1680 against a corresponding mating contact inserted into mating contact 1675. This can facilitate a reliable electrical connection between mating contact 1675 and a corresponding mating contact of another connector. Alternatively, in embodiments in which the tubular mating contact 1675 is to fit within a complementary mating contact structure, the tab can be biased outward. However, the use of a tab for flexibility is not necessary. In some embodiments, for example, flexibility can be achieved through a slit in the tube. The slit can allow a portion of the tube to expand to a larger circumference when receiving a mating member inserted into the tube or to compress to a smaller circumference when inserted into another member.

[0198] In some embodiments, tab 1680 can be partially cut away from mating contact 1675 and can still be integrally connected to mating contact 1675. In alternative embodiments, tab 1680 can be formed as a separate piece and can be attached to mating contact 1675 in some suitable manner, such as by soldering. Further, while a single tab is seen in FIG. 14A-14C , there can be multiple tabs.

[0199] FIG. 13C is an isometric view of the module during further actions performed on the mating contacts shown in FIG. 13A may be added to provide shielding or structural integrity or perform alignment or collection functions during mating of the connectors to form example module 1700, according to some embodiments.

[0200] In some embodiments, the module 1700 can include two conductive elements (not visible) extending from a cable or other insulating housing (not visible). As described above, the conductive elements and the insulating housing can be enclosed by a conductive member 1716, which can be made of any suitable conductive material or materials (e.g., metal) and can provide shielding for the enclosed conductive elements. As in the embodiment shown in FIG. 14A the conductive elements of the module 1700 can be held in place by insulating portions 1758 and can be electrically coupled to mating contact portions 1765 and 1775, respectively.

[0201] In the example shown in FIG. 14B the mating contact portions 1765 and 1775 can be configured as partial tubes (e.g., tubes having slits or cuts in any desired shape and at any desired location) that are adapted to be received or fit within corresponding mating contact portions having any suitable configuration, such as pins, blades, full tubes, partial tubes (having the same or different configuration than the mating contact portions 1765 and 1775), etc.

[0202] In some embodiments, another insulating portion 1770 can be provided at the openings of the mating contact portions 1765 and 1775. The insulating portion 1770 can help maintain a desired spacing between the mating contact portions 1765 and 1775. Such spacing can be selected to match the spacing between mating contact portions of a corresponding connector that is adapted to mate with the module 1700.

[0203] Additionally, the insulating portion 1770 can include one or more features for guiding a corresponding mating contact portion into one of the openings of the mating contact portions 1765 and 1775. For example, a recess 1772 can be provided at the opening 1774 of the mating contact portion 1765. The recess 1772 can be shaped as a truncated cone such that a corresponding mating contact portion (e.g., a pin) can be guided into the opening 1774 during mating, even if the corresponding mating contact portion is initially not perfectly aligned with the opening 1774. This can prevent damage to the corresponding mating contact portion (e.g., a stub) from excessive force applied during mating. It should be understood, however, that aspects of the present disclosure are not limited to the use of any guiding features.

[0204] FIG. 14A An example module 1700 of FIG. 14C is shown in a subsequent manufacturing stage, in which a conductive member 1756 is formed around the insulating portions 1758 and 1770 and the mating contact portions 1765 and 1775. The conductive member 1756 can be formed of any suitable conductive material (e.g., metal) and can provide shielding for the mating contact portions 1765 and 1775.

[0205] In some embodiments, a gap can be provided between the mating contact portions 1765 and 1775 and the inner side of the conductive member 1756. The gap can be of any suitable size (e.g., 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm, 0.1 mm, etc.) and can be occupied by air that is an insulator. The gap can ensure that the flexible members of the mating contact portions move freely. In some embodiments, the size of the air gap can be selected to provide a desired impedance in the mating contact portions. In some embodiments, a lossy material can be included at one or more selected locations within the gap between, for example, the mating contact portions 1765 and 1775 and the conductive member 1756 to reduce undesirable resonances.

[0206] In some embodiments, the conductive member 1756 can include a flexible member that can make electrical contact with a conductive portion that similarly functions as a ground shield in the mating connector. FIG. 14A An exemplary module 1700 is shown in a subsequent stage of manufacture FIG. 14B and FIG. 15 wherein the tabs have been attached to the conductive member 1756. In this example, the tabs function as flexible members and are positioned to make electrical contact with a ground shield in a mating connector. The tabs 1760-1765 can be attached to the conductive member 1756 in any suitable manner, such as by welding. In other embodiments, the tabs 1760-1765 can be integrally connected to the conductive member 1756 (e.g., stamped from the same piece of metal). In the illustrated embodiment, however, the tabs are formed separately and then attached to avoid forming openings in the box-shaped conductive member 1756 where such tabs would be cut away. The tabs can be attached in any suitable manner, such as by welding or brazing, or by snapping a portion of the tab between the conductive member 1756 and another structure in the module, such as the insulating portion 1770.

[0207] In some embodiments, the tabs 1760-1765 can be biased away from the conductive member 1756 so that a spring force can be created that presses the tabs 1760-1765 against a corresponding conductive portion of a connector (e.g., a backplane connector) that is adapted to mate with the module 1700. In this example, the conductive member 1756 is box-shaped to fit within a larger box-shaped mating contact structure in the mating connector. The tabs or other flexible members can facilitate a reliable electrical connection between the conductive member 1756 and the corresponding conductive portion of the mating connector. In some embodiments, the conductive member 1756 and the corresponding conductive portion of the mating connector can be configured as ground conductors (e.g., adapted to be electrically coupled to a ground trace in a printed circuit board). In addition, the conductive member 1756 can be electrically coupled to the shielding member 1716 so that the shielding member 1716 can also be grounded.

[0208] FIG. 15 An example of a mating connector is shown in the image. FIG. 15 This is a partially exploded view of exemplary connectors 1800 and 1850 adapted to mate with each other according to some embodiments. Connector 1800 can be formed in the modules described above. Each module can carry one or more pairs of signal conductors. Alternatively, each module can carry one or more single-ended signal conductors. These modules can be assembled into sheets, and then the sheets are assembled into connectors. Alternatively, the modules can be inserted into or otherwise attached to a support structure to form connector 1800.

[0209] Connector 1850 can similarly be formed from modules, each module having the same number of signal conductors or signal conductor pairs as the corresponding module of connector 1800. Alternatively, connector 1850 can be formed on an integral housing or housing portion, each housing portion being sized to mate with multiple modules in connector 1800.

[0210] In the example shown, connector 1800 can be a daughter card connector, and connector 1850 can be a base plate connector. When connectors 1800 and 1850 mate with each other and with the daughter card and base plate respectively, an electrical connection can be formed between conductive traces in the daughter card and conductive traces in the base plate via conductive elements in connectors 1800 and 1850.

[0211] exist FIG. 14A-14C In the example shown, connector 1800 may include components that can be combined with the same or different modules. FIG. 15 Exemplary module 1700. For example, the modules of connector 1800 may have similar constructions (e.g., the same mating interface and board interface) but different right-angle bend radii, which can be achieved by using cables of different lengths for the mating interfaces or by any other suitable means. Modules can be held together in any suitable manner, for example, by inserting modules into an organizer, or by providing engagement features on the modules, wherein the engagement feature on one module is adapted to engage corresponding engagement features on an adjacent module to hold the adjacent modules together.

[0212] In some implementations, connector 1850 may also include multiple modules. These modules may be identical or may be different from each other. FIG. 15 The exemplary module 1855 shown has a conductive member 1860 configured to receive a connector 1800 from a module 1700. When connectors 1800 and 1850 mate, protrusions 1760 to 1765 (protrusions 1761 and 1762 at...) of connector 1800 can be generated. FIG. 15 (As can be seen in the image) The spring force pressing against the inner wall of the conductive member 1860 of the module 1855 facilitates a reliable electrical connection between the conductive member 1756 and the conductive member 1860.

[0213] In some embodiments, one or more tabs can be provided on one or more interior walls of the conductive member 1860 in addition to or instead of the tabs on the exterior of the conductive member 1756. In FIG. 15 In the example shown, tabs 1861 and 1862 can be attached to opposite interior walls of the conductive member 1860. When the connectors 1800 and 1850 are mated, a spring force can be created that presses the tabs 1861 and 1862 against the exterior of the conductive member 1756. These additional spring forces further facilitate a reliable electrical connection between the conductive member 1756 and the conductive member 1860.

[0214] In some embodiments, having tabs on the ground structures in both mated connectors can improve the electrical performance of the mated connectors. Appropriately placed tabs can reduce the length of any unterminated sections of the ground conductors. While the ground conductors are intended to act as shields that block undesired radiation from reaching the signal conductors, the inventors have recognized and appreciated that, at the operating frequencies of the connector designs shown in FIG. 15 , unterminated sections of the ground conductors can create undesired radiation, thereby degrading the electrical performance of the connectors. In the absence of flexible members such as tabs, to create contact between the mated ground structures, one ground structure or the other can include an unterminated section that is approximately the length of the depth of one connector inserted into the other. The impact of the unterminated section can depend on its length and the frequency of the signals passing through the connector. Thus, in some embodiments, such tabs can be omitted, or, although positioned at a distal portion of the conductive member that can otherwise be unterminated, can be set back from the distal edge such that the unterminated section remains, whereby such unterminated section can be short enough to have a limited impact on the electrical performance of the connector.

[0215] In the example shown, tabs 1861 and 1862 can be located at a distal portion of the conductive member 1860, shown as FIG. 15 the top of the conductive member in. The tabs in this configuration form an electrical connection that ensures that the distal portion of the conductive member 1860 is electrically connected to the conductive member 1756 when the connectors 1800 and 1850 are fully mated to each other. In contrast, the tabs 1760-1765 of the connector 1800 can be located at a distal end of the conductive member 1756 and can form an electrical connection with the conductive member 1860, thereby reducing the length of any unterminated sections of the conductive member 1756.

[0216] While various advantages of the tabs 1760-1765, 1861, and 1862 are discussed above, it should be understood that aspects of the disclosure are not limited to the use of any particular number of tabs on the conductive members 1756 and / or 1860 or any particular configuration of tabs, or to the use of tabs at all. For example, a contact point proximate the distal ends of two mating conductive members serving as a shield can be achieved by providing a flexible portion adjacent to the mating edge of each conductive member as shown, or by providing a flexible member on one of the conductive members having a different inner recess than the mating edge of the conductive member. Further, the particular distribution of flexible members to form a contact point between conductive members serving as a shield is shown by way of example and is not limiting of suitable distributions of flexible members. For example, FIG. 15 Ground conductive members are shown for pairs of signal conductors in modules of a connector 1800 having a flexible member around a pair of signal conductors. In the example shown, the ground conductive members are box-shaped. FIG. 16 In the example of FIG. 18B, the tabs are provided on all four sides of the ground conductive members. As shown, where the box is rectangular, there can be more flexible contact members on the longer sides of the box. FIG. 16 In the example of FIG. 18B, the tabs are provided on all four sides of the ground conductive members. As shown, where the box is rectangular, there can be more flexible contact members on the longer sides of the box.

[0217] In alternative implementations, other mechanisms (e.g., torsion beams) can be used to form an electrical connection between the conductive members 1756 and / or 1860. Additionally, aspects of the disclosure are not limited to the use of multiple contact points to reduce end-to-end shorts, as a single contact point can be suitable in some implementations. Alternatively, there can be additional contact points.

[0218] FIG. 17 are partial exploded and partially cutaway views of example connectors 1900 and 1950 adapted to mate with one another in accordance with some implementations. These connectors can be fabricated as described above with respect to the connectors 1800 and 1850, or in any other suitable manner. In this example, each of the connectors 1900 and 1950 can include 16 modules arranged in a 4x4 grid. For example, the connector 1900 can include modules 1910 configured to mate with modules 1960 of the connector 1950. The modules can be held together in any suitable manner including via support members to which the modules are attached or into which the modules are inserted.

[0219] In some embodiments, the module 1910 can include two conductive elements (not visible) configured as a differential signal pair. Each conductive element can have a contact tail adapted to be inserted into a corresponding hole in a printed circuit board for electrical connection with a corresponding conductive trace in the printed circuit board. The contact tails can be electrically coupled to an elongated middle portion, which can in turn be electrically coupled to mating contact portions adapted to mate with corresponding mating contact portions of a module 1960 of a connector 1950.

[0220] In FIG. 16 the example of the connector 1900, the conductive elements of the module 1910 can extend side-by-side with each other in the y-z plane at the middle portion and can make a right angle turn to couple to the contact tails 1920 and 1930. The conductive element coupled to the contact tail 1920 can be on the outside of the turn and thus can be longer than the conductive element coupled to the contact tail 1930.

[0221] FIG. 16 is an exploded view of example connectors 2000 and 2050 adapted to mate with each other in accordance with some embodiments. Like the example connectors 1900 and 1950, the connectors 2000 and 2050 can each include 16 modules arranged in a 4x4 grid. For example, the connector 2000 can include modules 2010 configured to mate with modules 2060 of the connector 2050.

[0222] Like the connector 1900 in the example of FIG. 17 the connector 2000 can be a right angle connector configured to be inserted into a printed circuit board arranged in an x-y plane. However, the conductive elements of the module 2010 can extend side-by-side with each other in the x-y plane (as opposed to the y-z plane in the example of FIG. 16 the module 2010 can first make a right angle turn in the same x-y plane occupied by the middle portion and then make another right angle turn out of the x-y plane in the positive z direction to couple to the contact tails 2020 and 2030.

[0223] In FIG. 16 embodiments of the connector 2000, the middle portions of each pair of conductive elements are spaced apart from each other in a direction parallel to an edge of the printed circuit board to which the connector 2000 is attached. In FIG. 17 embodiments of the connector 2000, the pair of conductive elements are spaced apart from each other in a direction perpendicular to the surface of the printed circuit board. For each column of a given number of pairs, the difference in orientation can change the aspect ratio of the connector. As can be seen, FIG. 16 the four pairs oriented in FIG. 17 embodiments of the connector 2000 occupy more rows than the same number of pairs in FIG. 17The configuration can be used in electronic systems where, for a wider configuration, there is sufficient space between adjacent daughter cards, but for… FIG. 17 Longer configurations have less space along the edges of the printed circuit board. Conversely, for electronic systems with limited space between adjacent printed circuit boards but more space along the edges, FIG. 16 The configuration may be preferred.

[0224] Alternatively, FIG. 17 The implementation method can be used for wide-side coupling in the middle part, and the middle part can be... FIG. 17 In this implementation, edge coupling is used. For example... FIG. 9C The wide-side coupling of the oriented pair of middle sections shown can introduce less offset in this pair of conductors than edge coupling. In the case of wide-side coupling, the middle sections can turn with the same radius of curvature, making the physical lengths of the middle sections equal. On the other hand, edge coupling facilitates the routing of traces to the contact tail of the connector.

[0225] However, as illustrated, the two configurations can result in a pair of contact tails aligned with each other along the Y-axis corresponding to the column dimensions. In this configuration, since the wide side of the conductive element is parallel to the Y-axis, the contact tails are edge-coupled, meaning the edges of the conductive elements are adjacent. In contrast, when using wide-side coupling, the wide surfaces of the conductive elements are adjacent. Such a configuration can be achieved through… FIG. 16 The transition region is implemented in the embodiment where the conductive element has the combination as described above. FIG. 17 The transitional region described.

[0226] Providing edge coupling at the contact tail can provide a routing path within a printed circuit board to which a connector is attached. As illustrated, in FIG. 18A and FIG. 18B In this implementation, the contact tails in the column are aligned along the Y direction. When vias are formed in the daughter card to receive the contact tails, these vias will similarly be aligned along the Y direction in the column. This direction may correspond to the direction in which traces are routed from the electronics attached to the printed circuit board to the connector at the edge of the circuit board. FIG. 18B Examples of vias (e.g., vias 2105A to 2105C) arranged in columns (e.g., columns 2110 and 2120) of a printed circuit board and routing channels between columns are shown according to some embodiments. FIG. 13A-13C Examples of traces (e.g., traces 2115A to 2115D) extending in these routing channels (e.g., channel 2130) according to some implementations are shown. Having such... FIG. 6AThe routing channels shown in FIG. 21 can allow traces for multiple pairs (e.g., pairs 2115A and 2115B and pairs 2115C and 2115D) to be routed in the same layer of the printed circuit board. As more pairs are routed in the same layer, the number of layers in the printed circuit board can be reduced, which can reduce the overall cost of the electronic assembly.

[0227] While details of specific configurations of conductive elements, housings, and shielding members are described above, it should be understood that such details are provided for illustrative purposes only, as the concepts disclosed herein can be implemented in other ways. In this regard, the various connector designs described herein can be used in any suitable combination, as aspects of the present disclosure are not limited to the particular combinations shown in the drawings. For example, the mating interface features described in connection with FIG. 6B The exemplary mating interface features described can be used with the exemplary connector modules shown in FIG. 12A-12C and FIG. 12A-12C .

[0228] As described above, lossy material can be placed at one or more locations in the connectors in some embodiments, for example, to reduce crosstalk. Any suitable lossy material can be used. Materials that are electrically conductive but have some loss in the frequency range of interest are generally referred to herein as "lossy" materials. The electrically lossy material can be formed of lossy dielectric materials and / or lossy conductive materials. The frequency range of interest depends on the operating parameters of the system in which such connectors are used, but will generally have an upper limit of between about 1 GHz and 25 GHz, although in some applications higher or lower frequencies can be of interest. Some connector designs can have a frequency range of interest that spans only a portion of the range, such as 1 GHz to 10 GHz or 3 GHz to 15 GHz or 3 GHz to 6 GHz.

[0229] The electrically lossy material can be formed of materials that are traditionally considered dielectric materials, such as those that have an electric loss tangent greater than about 0.003 in the frequency range of interest. The "electric loss tangent" is the ratio of the imaginary part to the real part of the complex permittivity of a material. The electrically lossy material can also be formed of materials that are generally considered to be conductors but are relatively poor conductors in the frequency range of interest, including materials that do not provide high electrical conductivity or are otherwise prepared with sufficiently dispersed particles or regions that have properties that result in a relatively weak bulk conductivity in the frequency range of interest. The electrically lossy material generally has an electrical conductivity of about 1 Siemens / meter to about 1 x 10 7The material can have a bulk conductivity of about 10 Siemens / meter to about 100,000 Siemens / meter. As a specific example, a material having a bulk conductivity of about 50 Siemens / meter can be used. However, it will be appreciated that the bulk conductivity of the material can be selected empirically or by electrical simulation using known simulation tools to determine an appropriate bulk conductivity that provides for an appropriate low crosstalk and an appropriate low insertion loss.

[0230] The electrically lossy material can be a partially conductive material such as a material having a surface resistivity between 1 Ω / square and 106Ω / square. In some embodiments, the electrically lossy material has a surface resistivity between 1 Ω / square and 103Ω / square. In some embodiments, the electrically lossy material has a surface resistivity between 10 Ω / square and 100 Ω / square. As a specific example, the material can have a surface resistivity between about 20 Ω / square and 40 Ω / square.

[0231] In some embodiments, the electrically lossy material is formed by adding a filler containing conductive particles to an adhesive. In such embodiments, the lossy member can be formed by molding or otherwise shaping the adhesive into a desired shape. Examples of conductive particles that can be used as a filler to form the electrically lossy material include carbon or graphite formed into fibers, flakes, or other particles. Metals or other particles in the form of powders, flakes, fibers can also be used to provide appropriate electrically lossy properties. Alternatively, a combination of fillers can be used. For example, a metal plated with carbon particles can be used. Silver and nickel are metals that are suitable for fiber plating. The coated particles can be used alone or in combination with other fillers such as carbon flakes. The adhesive or matrix can be any material that will be placed, cured, or can otherwise be used to position the filler material. In some embodiments, the adhesive can be a thermoplastic material, as thermoplastic materials are traditionally used to make electrical connectors as part of the manufacturing of the electrical connector to facilitate molding the electrically lossy material into a desired shape and position. Examples of such materials include LCP and nylon. However, many alternative forms of adhesive materials can be used. Curable materials such as epoxy resins can be used as the adhesive. Alternatively, materials such as thermoset resins or glues can be used.

[0232] Furthermore, while the adhesive materials described above can be used to create the electrically lossy material by forming an adhesive around a conductive particle filler, the present invention is not so limited. For example, the conductive particles can be impregnated into a formed matrix material or can be coated on a formed matrix material, such as by applying a conductive coating to a plastic part or a metal part. As used herein, the term "adhesive" includes encapsulating a filler, impregnating a filler, or otherwise serving as a matrix that holds the filler.

[0233] Preferably, the filler will be present in a sufficient volume percentage to allow the creation of an electrically conductive path from particle to particle. For example, when using metal fibers, the fibers can be present in a volume percentage of about 3% to 40%. The amount of filler will affect the electrical conductivity properties of the material.

[0234] Filled materials can be purchased on the market, such as the materials sold by Ticona under the trade name Techfilm of Billerica, Massachusetts, USA. Such preforms can include epoxy adhesives filled with carbon particles. The adhesive surrounds the carbon particles, which can act as a reinforcing material to the preform. Such preforms can be inserted into the sheet to form all or a portion of the housing. In some embodiments, the preform can be adhered by the adhesive in the preform, which can be cured during the heat treatment process. In some embodiments, the adhesive in the preform can alternatively or additionally be used to secure one or more conductive elements, such as foils, to the lossy material.

[0235] Various forms of reinforcing fibers can be used, in woven or non-woven form, with or without coating. Non-woven carbon fibers are one suitable material. Other suitable materials can be used, such as custom blends sold by RTP Company, as the present invention is not limited in this respect.

[0236] In some embodiments, the lossy member can be manufactured by stamping a sheet of preform or lossy material. For example, the insert can be formed by stamping a preform as described above into an appropriate open pattern. However, other materials can be used in place of or in addition to such preforms. For example, a sheet of ferromagnetic material can be used.

[0237] However, the lossy material can also be formed in other ways. In some embodiments, the lossy member can be formed by interleaving layers of lossy and conductive material, such as metal foil. The layers can be rigidly attached to one another, such as by using an epoxy or other adhesive, or can be held together in any other suitable manner. The layers can be the desired shape before being secured to one another or can be stamped or otherwise shaped after they are held together.

[0238] Thus, with the described embodiments in mind, it should be apparent that various modifications and adaptations can be made by those skilled in the art without departing from the spirit and scope of the present invention. Such modifications and adaptations are intended to fall within the scope of the present invention. Accordingly, the foregoing description and drawings are by way of example only.

[0239] Various modifications can be made to the exemplary structures shown and described herein. For example, examples of techniques for improving signal quality at mating interfaces of electrical interconnect systems are described. These techniques can be used individually or in any suitable combination. Furthermore, the size of the connector can be increased or decreased from the dimensions illustrated. Additionally, it is possible that materials other than those explicitly mentioned can be used to construct the connector. As another example, a connector with four differential signal pairs can be used for illustrative purposes only. Any desired number of signal conductors can be used in the connector.

[0240] Manufacturing techniques can also vary. For example, an embodiment of the daughter card connector 116 is described, which is formed by arranging multiple sheets onto a reinforcing member. It is possible to form an equivalent structure by inserting multiple shielding members and signal jacks into a molded housing.

[0241] As another example, a connector formed by modules is described, each module containing a pair of signal conductors. It is not required that each module contains exactly one pair of signal conductors or that the number of signal pairs is the same in all modules of the connector. For example, modules with two or three pairs can be formed. Furthermore, in some embodiments, core modules with two, three, four, five, six, or more rows in single-ended or differential pair configurations can be formed. Each connector, or each wafer in an embodiment where the connector is wafered, may include such a core module. To create a core module with more rows than the base module includes, additional modules may be coupled to it (e.g., each additional module has a smaller number of pairs, such as one pair per module).

[0242] As another example of a variation, FIG. 16 A module is shown for producing conductive elements connecting contact tails and mating contacts using cables. In such embodiments, the wire is enclosed in an insulator as part of the cable manufacturing process. In other embodiments, the wire can be routed through pathways in a pre-formed insulating housing. In such embodiments, for example, the housing for a sheet or sheet module can be molded or otherwise formed with openings. The wire can then pass through the pathways and, as in the case of a mating assembly... FIG. 17 , ​ and ​ It terminates as shown.

[0243] Furthermore, although many aspects of the invention have been shown and described with reference to a daughterboard connector having a right-angle configuration, it should be understood that the aspects of this disclosure are not limited in this respect, as any inventive concept, whether alone or in combination with one or more other inventive concepts, can be used for other types of electrical connectors, such as backplane connectors, cable connectors, stacked connectors, mezzanine connectors, I / O connectors, chip slots, etc.

[0244] In addition, the present application can also be configured as follows:

[0245] 1. An electrical connector comprising:

[0246] a plurality of modules arranged in a two-dimensional array along a first direction and a second direction orthogonal to the first direction, each module of the plurality of modules comprising an insulating portion and at least one electrically conductive element, wherein:

[0247] at least one module of the plurality of modules comprises at most two electrically conductive elements; and

[0248] an electromagnetic shielding material separating adjacent modules of the plurality of modules, wherein:

[0249] in at least one module of the plurality of modules, the at least one electrically conductive element is separated from the electromagnetic shielding material by the insulating portion.

[0250] 2. The electrical connector of 1, wherein the plurality of modules comprises a plurality of first type modules, a plurality of second type modules, and a plurality of third type modules, and wherein the second type modules are longer than the first type modules and the third type modules are longer than the second type modules.

[0251] 3. The electrical connector of 2, wherein:

[0252] the first type modules are arranged in a first row,

[0253] the second type modules are arranged in a second row, the second row being parallel to and adjacent to the first row, and

[0254] the third type modules are arranged in a third row, the third row being parallel to and adjacent to the second row.

[0255] 4. The electrical connector of 2, wherein:

[0256] the electrical connector comprises a plurality of laminates arranged side-by-side; and

[0257] each laminate of the plurality of laminates comprises the first type modules, the second type modules, and the third type modules.

[0258] 5. The electrical connector of 4, wherein:

[0259] each laminate of the plurality of laminates comprises at least one loss member; and

[0260] the at least one loss member is adjacent to the first type modules, the second type modules, and the third type modules.

[0261] 6. The electrical connector of 5, wherein the first module, the second module, and the third module are adjacent to a plurality of loss members.

[0262] 7. The electrical connector of 1, wherein at least one module of the plurality of modules includes a pair of conductive elements configured to carry a differential signal.

[0263] 8. The electrical connector of 7, wherein a midsection of the pair of conductive elements is broadside coupled, and a contact tail of the pair of conductive elements is edge coupled.

[0264] 9. The electrical connector of 1, wherein the electromagnetic shielding material substantially encloses an insulating portion of each module of the plurality of modules.

[0265] 10. The electrical connector of 1, wherein the electromagnetic shielding material includes a plurality of first type shielding member components having a substantially "U" shaped cross section and a plurality of second type shielding member components having a substantially "U" shaped cross section, wherein:

[0266] each of the first type shielding member components is configured to form an assembly with the second type shielding member components, wherein the assembly generally encloses the insulating portion in at least one module of the plurality of modules.

[0267] 11. The electrical connector of 1, further comprising a loss material in contact with the electromagnetic shielding material, wherein the electromagnetic shielding material includes a metal that surrounds at least one conductive element of the at least one module of the plurality of modules.

[0268] 12. The electrical connector of 1, wherein in at least one module of the plurality of modules:

[0269] the at least one conductive element includes a conductive wire;

[0270] the insulating portion includes a passageway; and

[0271] the wire is routed through the passageway.

[0272] 13. An electrical connector, comprising:

[0273] a plurality of cables, each cable of the plurality of cables including a first conductive wire and a second conductive wire extending from a mounting interface of the electrical connector to a mating interface of the electrical connector; and

[0274] a plurality of termination components manufactured separately from the plurality of cables, wherein:

[0275] The plurality of termination components includes, for each of the plurality of cables, a first termination component and a second termination component attached to the first conductive wire and the second conductive wire, respectively, of the cable at the mounting interface.

[0276] 14. The electrical connector of 13, wherein each of the plurality of cables includes a cable insulator disposed about the first conductive wire and the second conductive wire.

[0277] 15. The electrical connector of 13, wherein,

[0278] the plurality of termination components are arranged in a two-dimensional array, and

[0279] the plurality of termination components are adapted to be attached to a printed circuit board.

[0280] 16. The electrical connector of 13, comprising:

[0281] a plurality of mating contacts manufactured separately from the plurality of cables, wherein:

[0282] the plurality of mating contacts includes, for each of the plurality of cables, a first mating contact and a second mating contact attached to the first conductive wire and the second conductive wire, respectively, of the cable at the mating interface,

[0283] the plurality of mating contacts are arranged in a two-dimensional array, and

[0284] the plurality of mating contacts are adapted to receive respective pin-like contacts of a mating connector.

[0285] 17. The electrical connector of 13, wherein, for at least one of the plurality of cables, the cable insulator includes a first insulating component disposed about the first conductive wire and a second insulating component disposed about the first conductive wire.

[0286] 18. The electrical connector of 13, further comprising, for at least one of the plurality of cables, a ground structure disposed about the cable insulator.

[0287] 19. The electrical connector of 18, wherein the plurality of termination components further includes a termination component electrically connected to the ground structure of the at least one cable.

[0288] 20. The electrical connector of 13, further comprising an organizer disposed at the mounting interface, the organizer including a plurality of openings sized and arranged to receive respective ones of the plurality of termination components.

[0289] 21. The electrical connector of 16, further comprising an insulator at the mating interface, wherein, for at least one cable of the plurality of cables:

[0290] the insulator retains the first mating contact and the second mating contact of the first conductive wire and the second conductive wire, respectively, attached to the at least one cable, thereby maintaining a selected spacing between the first mating contact and the second mating contact.

[0291] 22. The electrical connector of 21, wherein the insulator comprises a recess configured to guide a pin-like contact of a mating connector into an opening of the first mating contact attached to the first conductive wire of the at least one cable.

[0292] 23. A subassembly for an electrical connector, the subassembly comprising:

[0293] a plurality of conductive elements, each conductive element of the plurality of conductive elements comprising a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail, wherein:

[0294] the plurality of conductive elements are arranged in pairs,

[0295] the intermediate portion of each pair of conductive elements is at least partially surrounded by a shielding member of an electromagnetic shielding material, and

[0296] the shielding members of adjacent pairs of conductive elements are electrically coupled within the subassembly.

[0297] 24. The subassembly for an electrical connector of 23, wherein:

[0298] the pairs of conductive elements are arranged in columns, and

[0299] adjacent pairs of conductive elements are spaced apart by the electromagnetic shielding material.

[0300] 25. The subassembly for an electrical connector of 23, wherein:

[0301] the shielding members of the adjacent pairs of conductive elements comprise features that hold the shielding members together and electrically couple the shielding members.

[0302] 26. The subassembly for an electrical connector of 23, wherein:

[0303] the mating contact of each pair of conductive elements is at least partially surrounded by the shielding member.

[0304] 27. The subassembly for an electrical connector of 23, comprising:

[0305] a plurality of contact tails electrically coupled to the shield member, and

[0306] The plurality of contact tails and the contact tails of the pairs of conductive elements form a mounting interface.

[0307] 28. The sub-assembly for an electrical connector of 27, wherein:

[0308] The plurality of contact tails extend from and are offset from edges of the shield member.

[0309] 29. The sub-assembly for an electrical connector of 23, further comprising:

[0310] A lossy material electrically coupling the shield member.

[0311] 30. A connector module, comprising:

[0312] a plurality of conductive elements, each of the plurality of conductive elements including a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail, at least the intermediate portion including broad sides connected by edges, the plurality of conductive elements arranged in pairs such that broad sides align with broad sides; and

[0313] an electromagnetic shielding material at least partially surrounding each pair of conductive elements and spacing adjacent pairs of conductive elements apart, wherein,

[0314] The mating contacts of each pair of conductive elements are aligned in a conductive element pair direction at an angle to a column direction.

[0315] 31. The connector module of 30, wherein:

[0316] The conductive elements of a pair of conductive elements include a transition region between the intermediate portion and the contact tail such that the contact tail edges are coupled.

[0317] 32. The connector module of 31, wherein:

[0318] The transition region includes a convexity toward a broad side of an intermediate portion of another conductive element of the pair of conductive elements.

[0319] 33. The connector module of 31, wherein:

[0320] The transition region includes a convexity away from an edge of an intermediate portion of another conductive element of the pair of conductive elements.

[0321] 34. The connector module of 30, wherein:

[0322] The conductive element of the pair of conductive elements includes a transition region between the intermediate portion and the mating contact portion such that the mating contact portion edge couples.

[0323] 35. The connector module of 34, wherein:

[0324] The transition region of the pair of conductive elements includes a ledge in a first conductive element of the pair of conductive elements toward a wide edge of a second conductive element of the pair of conductive elements.

[0325] 36. The connector module of 35, wherein:

[0326] The transition region of the pair of conductive elements includes a ledge in a first conductive element of the pair of conductive elements away from an edge of an intermediate portion of a second conductive element of the pair of conductive elements.

[0327] 37. A connector module, comprising:

[0328] a pair of conductive elements, each of the pair of conductive elements including a mating contact portion, a contact tail, and an intermediate portion extending between the mating contact portion and the contact tail;

[0329] a first shielding member and a second shielding member at least partially surrounding the pair of conductive elements, the first shielding member and the second shielding member being spaced apart by a gap, and

[0330] a lossy material at least at a portion of the gap and electrically coupling the first shielding member and the second shielding member.

[0331] 38. The connector module of 37, wherein:

[0332] a portion of the gap is adjacent a transition region between an intermediate portion and a contact tail of the pair of conductive elements.

[0333] 39. The connector module of 37, wherein:

[0334] a portion of the gap is adjacent a transition region between an intermediate portion and a mating contact portion of the pair of conductive elements.

[0335] 40. The connector module of 37, wherein:

[0336] the first shielding member and the second shielding member are at least partially covered by the lossy material.

[0337] 41. The connector module of 37, comprising:

[0338] an insulating member that supports the pair of conductive elements and spaces the pair of conductive elements from the first and second shielding members.

[0339] 42. The connector module of 37, wherein:

[0340] the lossy material is at least partially between a portion of the gap.

[0341] 43. A cable assembly comprising:

[0342] a cable including a first end and a second end, the cable including at least one conductive element extending from the first end to the second end;

[0343] an insulating portion; and

[0344] a contact tail extending from the insulating portion and configured to electrically connect with a circuit board, wherein the contact tail is attached to the at least one conductive element at the first end of the cable.

[0345] 44. The cable assembly of 43, wherein the second end of the cable is configured to electrically connect with a mating contact of a complementary connector.

[0346] 45. The cable assembly of 43, wherein the cable of the plurality of modules is a twinaxial cable.

[0347] 46. The cable assembly of 43, wherein the insulating portion is at the first end of the cable.

[0348] 47. The cable assembly of 43, wherein the at least one conductive element is a pair of conductive elements.

[0349] 48. The cable assembly of 47, wherein:

[0350] the contact tails of the pair of conductive elements are positioned for edge coupling.

[0351] 49. The cable assembly of 47, wherein the cable includes a cable insulator disposed about the pair of conductive elements, and a ground structure disposed about the cable insulator.

[0352] 50. The cable assembly of 43, further comprising a conductive structure at the first end of the cable, wherein the conductive structure surrounds at least a portion of the insulating portion, and the conductive structure is configured to electrically connect with the circuit board.

[0353] 51. The cable assembly of 50, wherein:

[0354] The cable includes a cable insulator disposed about the at least one conductive element and a ground structure disposed about the cable insulator; and

[0355] The conductive structure is electrically coupled to the ground structure.

[0356] 52. The cable assembly of 50, further comprising:

[0357] a loss member attached to the conductive structure.

[0358] 53. The cable assembly of 43, wherein the insulating portion is a first insulating portion, and each module of the plurality of modules further comprises a second insulating portion at the second end of the cable.

[0359] 54. The cable assembly of 53, comprising:

[0360] a second insulating portion, and

[0361] a mating contact held in the second insulating portion and attached to the at least one conductive element at the second end of the cable.

[0362] 55. The cable assembly of 54, wherein the mating contact comprises a tubular mating contact.

[0363] 56. The cable assembly of 54, further comprising a conductive structure at the second end of the cable, wherein the conductive structure surrounds at least a portion of the second insulating portion.

[0364] 57. A cable assembly configured for connection to a circuit board, the cable assembly comprising:

[0365] a housing including a surface configured for mounting proximate to the circuit board;

[0366] a plurality of cables, each cable of the plurality of cables including at least one conductive wire; and

[0367] a plurality of termination components attached to the conductive wires of the plurality of cables, wherein the plurality of termination components are configured to make electrical connections with the circuit board.

[0368] 58. The cable assembly of 57, wherein the plurality of termination components extend through the mounting surface and are arranged in a two-dimensional array.

[0369] 59. The cable assembly of 57, wherein the plurality of cables are twinaxial cables.

[0370] 60. The cable assembly of 57, wherein the housing includes a plurality of openings sized and arranged to receive a module including a respective one of the plurality of termination components.

[0371] 61. The cable assembly of 57, wherein the plurality of cables extend from the housing in a direction perpendicular to the surface.

[0372] 62. The cable assembly of 57, wherein:

[0373] the at least one conductive wire is a pair of conductive wires; and

[0374] each cable of the plurality of cables includes a cable insulator disposed about the pair of conductive wires.

[0375] 63. The cable assembly of 62, wherein, for at least one cable of the plurality of cables, the cable insulator includes a first insulator component disposed about the first conductive wire and a second insulator component disposed about the second conductive wire.

[0376] 64. The cable assembly of 62, wherein each cable of the plurality of cables further includes a ground structure disposed about the cable insulator.

[0377] 65. The cable assembly of 57, wherein the plurality of cables are at least partially supported by the housing.

[0378] 66. The cable assembly of 57, wherein:

[0379] the plurality of termination components are attached to first ends of the conductive wires of the plurality of cables,

[0380] the plurality of cables include second ends opposite the first ends, and

[0381] the second ends of the plurality of cables are configured to make electrical connections with signal conductors forming a mating interface of a complementary connector.

[0382] 67. An electrical connector, comprising:

[0383] a plurality of modules arranged in a two-dimensional array along a row direction and a column direction substantially perpendicular to the row direction, each module of the plurality of modules including:

[0384] a pair of conductive elements configured to carry a differential signal, each conductive element of the pair of conductive elements having a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail;

[0385] a shield surrounding the pair of conductive elements; and

[0386] a housing member separating the pair of conductive elements and the shield, wherein:

[0387] for each module in a column, the contact tails of the conductive elements are aligned in the column direction such that a routing channel between contact tails of two adjacent columns allows passage of traces of multiple pairs of conductive elements.

[0388] 68. The electrical connector of 67, wherein:

[0389] for each module in the plurality of modules, the middle portion of the pair of conductive elements is wide-side coupled and the contact tails of the pair of conductive elements are edge coupled.

[0390] 69. The electrical connector of 67, wherein:

[0391] the shield includes at least one contact tail that is offset from the contact tails of the conductive elements in a direction perpendicular to the column direction.

[0392] 70. The electrical connector of 67, comprising:

[0393] at least one flexible member attached to the shield, the at least one flexible member configured to make electrical contact with a shield from a mating electrical connector.

[0394] 71. The electrical connector of 67, wherein the middle portion of each conductive element includes a conductive wire.

[0395] 72. The electrical connector of 67, further comprising a lossy material in contact with the shield.

[0396] 73. The electrical connector of 67, wherein the mating contact portion is at least partially tubular.

[0397] 74. The electrical connector of 73, wherein the mating contact portion is tubular.

[0398] 75. The electrical connector of 67, comprising:

[0399] a mounting interface including the contact tails of the plurality of modules, and

[0400] an organizer disposed at the mounting interface, the organizer including a plurality of openings sized and arranged to receive respective contact tails.

[0401] 76. An electrical assembly comprising:

[0402] a printed circuit board comprising a routing layer and a plurality of traces on the routing layer; and

[0403] an electrical connector mounted to the printed circuit board, the electrical connector comprising a mounting interface facing the printed circuit board, the mounting interface comprising:

[0404] a plurality of pairs of signal contact tails arranged in a plurality of first columns, and

[0405] a plurality of ground contact tails arranged in a plurality of second columns, wherein:

[0406] the first columns are separated by one or more second columns,

[0407] the plurality of traces are between a first column and a second column adjacent to the first column and connected to a respective signal contact tail in the first column, and

[0408] the connector comprises a plurality of modules arranged in a two-dimensional array, each module of the plurality of modules comprising a shield, and the pairs of signal contact tails are within the modules and the plurality of ground contact tails extend from the shields of the plurality of modules.

[0409] 77. The electrical assembly of 76, wherein:

[0410] the electrical connector is mounted at an edge of the printed circuit board; and

[0411] the first plurality of traces extend in a direction corresponding to a direction from the electrical connector to an electronic device attached to the printed circuit board.

[0412] 78. The electrical assembly of 76, wherein:

[0413] the plurality of traces are elongated parallel to the first columns.

[0414] 79. The electrical assembly of 76, wherein:

[0415] the plurality of pairs of signal contact tails comprise differential pairs of signal contact tails.

[0416] 80. The electrical assembly of 79, wherein:

[0417] the plurality of ground contact tails are a first plurality of ground contact tails,

[0418] each first column comprises a second plurality of ground contact tails, and

[0419] The differential pair of signal contact tails is separated from the differential pair of signal conductive elements by the second plurality of ground contact tails.

[0420] 81. The electrical assembly of 76, wherein:

[0421] The differential pair of signal contact tails extends from the differential pair of signal conductive elements; and

[0422] The first plurality of ground contact tails and the second plurality of ground contact tails extend from an electromagnetic shielding material that separates the differential pair of signal conductive elements.

[0423] 82. The electrical assembly of 81, further comprising a lossy material in contact with the electromagnetic shielding material.

[0424] 83. The electrical assembly of 81, wherein:

[0425] The differential pair of signal conductive elements are wide-side coupled.

[0426] 84. The electrical assembly of 81, wherein:

[0427] The differential pair of signal conductive elements are conductive wires.

[0428] 85. The electrical assembly of 76, comprising:

[0429] an organizer arranged at the mounting interface, the organizer comprising a plurality of openings sized and arranged to receive respective contact tails.

[0430] 86. A printed circuit board for mounting a connector, the printed circuit board comprising:

[0431] a plurality of routing layers; and

[0432] a connector package comprising:

[0433] a plurality of first-type via columns, each first-type via column comprising a differential pair of signal vias,

[0434] a plurality of second-type via columns, each second-type via column comprising a plurality of ground vias associated with the differential pair of signal vias,

[0435] a plurality of routing channels between adjacent first-type columns and second-type columns, and

[0436] a plurality of traces from at least two of the differential pairs of signal vias, the plurality of traces routed in one routing channel on one routing layer.

[0437] 87. The printed circuit board of 86, wherein:

[0438] the plurality of ground vias is a first plurality of ground vias, and

[0439] each first-type via column further comprises a second plurality of ground vias; and

[0440] for each first-type via column, each differential pair is separated by a ground via of the second plurality of ground vias.

[0441] 88. The printed circuit board of 86, wherein:

[0442] the plurality of traces are elongated in a direction parallel to the first-type columns.

[0443] 89. An electrical connector, comprising:

[0444] a plurality of laminates, each of the plurality of laminates comprising a column of pairs of conductive elements, and the plurality of laminates being arranged side-by-side so as to form an array of pairs along a first direction and a second direction orthogonal to the first direction, wherein,

[0445] the plurality of laminates comprises an insulating portion and an electromagnetic shielding material, and

[0446] in at least one of the plurality of laminates, the pairs of signal conductors are separated by the insulating portion from the electromagnetic shielding material.

[0447] 90. The electrical connector of 89, wherein, in at least one of the plurality of laminates, the electromagnetic shielding material separates adjacent pairs of conductive elements of the plurality of pairs of conductive elements.

[0448] 91. The electrical connector of 89, wherein, in at least one of the plurality of laminates, each pair of conductive elements of the plurality of pairs of conductive elements is configured to carry a pair of differential signals.

[0449] 92. The electrical connector of 89, wherein, in at least one of the plurality of laminates, a middle portion of the plurality of pairs of conductive elements is wide-side coupled.

[0450] 93. The electrical connector of 89, wherein, a contact tail of the plurality of pairs of conductive elements is edge-coupled.

[0451] 94. The electrical connector of 89, wherein,

[0452] at least one of the plurality of laminates comprises a plurality of modules,

[0453] the plurality of modules comprises a plurality of first-type modules, a plurality of second-type modules, and a plurality of third-type modules, and

[0454] The second type of module is longer than the first type of module, and the third type of module is longer than the second type of module.

[0455] 95. The electrical connector of 89, comprising:

[0456] a mounting interface formed by mounting ends of the array of pairs of electrically conductive elements, the mounting end of each pair of electrically conductive elements aligned on a line arranged at an acute angle relative to the first direction.

[0457] 96. The electrical connector of 89, comprising:

[0458] a mating interface formed by mating ends of the array of pairs of electrically conductive elements, the mating end of each pair of electrically conductive elements aligned on a line arranged at an acute angle relative to the first direction.

[0459] 97. An electrical assembly, comprising:

[0460] a first electrical connector comprising a first mating interface comprising a plurality of first box-shaped first electrically conductive members; and

[0461] a second electrical connector comprising a second mating interface comprising a plurality of box-shaped second electrically conductive members,

[0462] wherein the first box-shaped first electrically conductive members fit within the second electrically conductive members such that the first electrical connector and the second electrical connector mate.

[0463] 98. The electrical assembly of 97, wherein each first electrically conductive member surrounds one or more pairs of mating contacts or one or more single-ended signal mating contacts.

[0464] 99. The electrical assembly of 98, wherein:

[0465] the first electrical connector comprises an insulating portion between the first electrically conductive members and respective mating contacts.

[0466] 100. The electrical assembly of 99, wherein:

[0467] the insulating portion comprises an opening configured to receive a mating contact of the second electrical connector.

[0468] 101. The electrical assembly of 100, wherein:

[0469] the insulating portion comprises a groove configured to guide a mating contact of the second electrical connector.

[0470] 102. The electrical assembly of 97, wherein:

[0471] The first electrical connector includes one or more flexible members coupled to the electrically conductive member.

[0472] 103. The electrical assembly of 102, wherein:

[0473] The one or more flexible members are integrally coupled to the electrically conductive member.

[0474] 104. The electrical assembly of 102, wherein:

[0475] The one or more flexible members are attached to the electrically conductive member.

[0476] 105. The electrical assembly of 102, wherein:

[0477] The one or more flexible members are on an outer surface of the first electrically conductive member.

[0478] 106. The electrical assembly of 97, wherein:

[0479] The electrically conductive member of the first electrical connector includes a flexible portion adjacent a mating edge of the electrically conductive member.

[0480] 107. The electrical assembly of 97, wherein each box-shaped second electrically conductive member surrounds one or more pairs of mating contacts or one or more single-ended signal mating contacts.

[0481] 108. The electrical assembly of 107, wherein:

[0482] The second electrical connector includes one or more flexible members coupled to the electrically conductive member.

[0483] 109. The electrical assembly of 108, wherein:

[0484] The one or more flexible members are on an outer surface of the second electrically conductive member.

[0485] 110. An electrical connector, comprising:

[0486] a plurality of electrically conductive elements, each of the plurality of electrically conductive elements including mating contacts, wherein the mating contacts are arranged to define a mating interface of the electrical connector; and

[0487] a plurality of box-shaped electrically conductive members adjacent the mating interface, wherein each electrically conductive member surrounds one or more pairs of mating contacts or one or more single-ended signal mating contacts.

[0488] 111. The electrical connector of 110, comprising:

[0489] an insulating portion between the electrically conductive portion and a corresponding mating contact portion.

[0490] 112. The electrical connector of 111, wherein:

[0491] the insulating portion comprises an opening configured to receive a mating contact portion of a mating electrical connector.

[0492] 113. The electrical connector of 112, wherein:

[0493] the insulating portion comprises a groove configured to guide a mating contact portion of the mating electrical connector.

[0494] 114. The electrical connector of 110, comprising:

[0495] one or more flexible members coupled to the electrically conductive member.

[0496] 115. The electrical connector of 114, wherein:

[0497] the one or more flexible members are integrally coupled to the electrically conductive member.

[0498] 116. The electrical connector of 114, wherein:

[0499] the one or more flexible members are attached to the electrically conductive member.

[0500] 117. The electrical connector of 114, wherein:

[0501] the one or more flexible members are on an outer surface of the first electrically conductive member.

[0502] 118. The electrical connector of 110, wherein:

[0503] the electrically conductive member comprises a flexible portion adjacent to a mating edge of the electrically conductive member.

Claims

1. A connector module comprising: a plurality of conductive elements, each of the plurality of conductive elements including a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail, at least the intermediate portion including broad sides joined by an edge, the plurality of conductive elements arranged in pairs such that broad side aligns with broad side; and an electromagnetic shielding material at least partially surrounding each pair of conductive elements and separating adjacent pairs of conductive elements, wherein: at least the intermediate portions of the conductive elements in a pair of conductive elements are arranged in a column, each pair of conductive elements includes a transition region between the intermediate portion and the mating contact of the conductive elements in the pair of conductive elements, and the transition region is curved such that the mating contact of each pair of conductive elements aligns in a direction of the pair of conductive elements that is non-orthogonal to the column.

2. The connector module of claim 1, wherein: the contact tail edges of the conductive elements in the pair of conductive elements are edge coupled.

3. The connector module of claim 2, wherein: the transition region is curved toward the broad side of the intermediate portion of the other conductive element in the pair of conductive elements.

4. The connector module of claim 2, wherein: the transition region includes a bend away from the edge of the intermediate portion of the other conductive element in the pair of conductive elements.

5. The connector module of claim 1, wherein: the mating contact edges of the conductive elements in the pair of conductive elements are edge coupled.

6. The connector module of claim 5, wherein: the transition region in the pair of conductive elements includes a bend in a first conductive element in the pair of conductive elements toward the broad side of a second conductive element in the pair of conductive elements.

7. The connector module of claim 6, wherein: the transition region in the pair of conductive elements includes a bend in a first conductive element in the pair of conductive elements away from the edge of the intermediate portion of a second conductive element in the pair of conductive elements.

8. A connector module comprising: a pair of conductive elements, each including a mating contact, a contact tail, and an intermediate portion extending between the mating contact and the contact tail; a first shielding member and a second shielding member at least partially enclosing the pair of conductive elements, the first shielding member and the second shielding member separated by a gap, and a lossy material at least at a portion of the gap and electrically coupling the first shielding member and the second shielding member.

9. The connector module of claim 8, wherein: the portion of the gap is adjacent to a transition region between the intermediate portion and the contact tail of the pair of conductive elements.

10. The connector module of claim 8, wherein: the portion of the gap is adjacent to a transition region between the intermediate portion and the mating contact of the pair of conductive elements.

11. The connector module of claim 8, wherein: the first shielding member and the second shielding member are at least partially covered by the lossy material.

12. The connector module of claim 8, comprising: an insulative member supporting the pair of conductive elements and separating the pair of conductive elements from the first and second shield members.

13. The connector module of claim 8, wherein: the lossy material is at least partially between a portion of the gaps.

14. A cable assembly, comprising: a cable including a first end and a second end, the cable including at least one conductive element extending from the first end to the second end, a first insulative portion at the first end of the cable and a second insulative portion at the second end of the cable; and a contact tail extending from the first insulative portion and configured to electrically connect with a circuit board, wherein the contact tail is attached to the at least one conductive element at the first end of the cable.

15. The cable assembly of claim 14, wherein, the second end of the cable is configured to electrically connect with a mating contact of a complementary connector.

16. The cable assembly of claim 14, wherein, the cable is a twinaxial cable.

17. The cable assembly of claim 14, wherein, the at least one conductive element is a pair of conductive elements.

18. The cable assembly of claim 17, wherein: the contact tails of the pair of conductive elements are positioned for edge coupling.

19. The cable assembly of claim 17, wherein, the cable includes a cable insulator disposed about the pair of conductive elements and a ground structure disposed about the cable insulator.

20. The cable assembly of claim 14, further comprising a conductive structure at the first end of the cable, wherein, the conductive structure surrounds at least a portion of the insulative portion and is configured to electrically connect with the circuit board.

21. The cable assembly of claim 20, wherein: the cable includes a cable insulator disposed about the at least one conductive element and a ground structure disposed about the cable insulator; and the conductive structure is electrically coupled to the ground structure.

22. The cable assembly of claim 20, further comprising: a lossy member attached to the conductive structure.

23. The cable assembly of claim 14, comprising: a mating contact held in the second insulative portion and attached to the at least one conductive element at the second end of the cable.

24. The cable assembly of claim 23, wherein, the mating contact includes a tubular mating contact.

25. The cable assembly of claim 23, further comprising a conductive structure at the second end of the cable, wherein, the conductive structure surrounds at least a portion of the second insulative portion.

26. An electrical assembly, comprising: a printed circuit board including a routing layer and a plurality of traces on the routing layer; and an electrical connector mounted to the printed circuit board, the electrical connector including a mounting interface facing the printed circuit board, the mounting interface including: a plurality of pairs of signal contact tails arranged in a plurality of first columns, and a plurality of ground contact tails arranged in a plurality of second columns, wherein: the first columns are separated by one or more second columns, the plurality of traces are between a first column and a second column adjacent to the first column and connected to a respective signal contact tail in the first column, and the plurality of ground contact tails are connected to the plurality of traces. The electrical connector includes a plurality of modules arranged in a two-dimensional array, each module of the plurality of modules includes a shield, and the pair of signal contact tails are within the module, and the plurality of ground contact tails extend from the shield of the plurality of modules.

27. The electrical assembly of claim 26, wherein: The electrical connector is mounted at an edge of the printed circuit board; and The plurality of traces extend in a direction corresponding to a direction from the electrical connector to an electronic device attached to the printed circuit board.

28. The electrical assembly of claim 26, wherein: The plurality of traces are elongated parallel to the first column.

29. The electrical assembly of claim 26, wherein: The plurality of pairs of signal contact tails includes a differential pair of signal contact tails.

30. The electrical assembly of claim 29, wherein: The plurality of ground contact tails is a first plurality of ground contact tails, Each first column includes a second plurality of ground contact tails, and Each differential pair of signal contact tails is separated by one of the second plurality of ground contact tails.

31. The electrical assembly of claim 30, wherein: The differential pair of signal contact tails extends from a differential pair of signal conductive elements; and The first plurality of ground contact tails and the second plurality of ground contact tails extend from an electromagnetic shielding material that separates the differential pair of signal conductive elements.

32. The electrical assembly of claim 31, further comprising a lossy material in contact with the electromagnetic shielding material.

33. The electrical assembly of claim 31, wherein: The differential pair of signal conductive elements are wide-side coupled.

34. The electrical assembly of claim 31, wherein: The differential pair of signal conductive elements are conductive wires.

35. The electrical assembly of claim 26, comprising: an organizer arranged at the mounting interface, the organizer including a plurality of openings sized and arranged to receive respective contact tails.

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