High density high speed electrical connector

Abstract

The invention relates to a high density high speed electrical connector. A modular high-speed high-density electrical connector may be configured for a variety of configurations, including a direct attachment orthogonal configuration. The connector is assembled with a module that includes a shielded pair of signal conductors, wherein the shielded pair of signal conductors have mating ends that rotate about 45 degrees relative to an intermediate portion of the signal conductors. The connector may have a mating interface with a receptacle in one connector and a pin in a mating connector. The pins may be small in diameter and may be implemented with superelastic wires so as to be resistant to damage despite having a very small effective diameter. The compact mating interface created by the small diameter mating contact may make other portions of the connector include a shield around the signal conductor smaller, which may increase the resonant frequency of the connector and extend its bandwidth.

Description

[0001] This application is a divisional application of the Chinese patent application filed on January 17, 2022, with application number 202080051739.9 and invention name “High-density high-speed electrical connector”. The international filing date of the parent application is May 19, 2020, and the international application number is PCT / US2020 / 033561. Technical Field

[0002] The present patent application relates generally to interconnection systems for interconnecting electronic components, such as interconnection systems including electrical connectors. Background Art

[0003] Electrical connectors are used in many electronic systems. It is often easier and more cost-effective to manufacture the system as separate electronic components such as printed circuit boards ("PCBs") that can be joined together with electrical connectors. A known arrangement for joining several printed circuit boards is to have one printed circuit board used as a backplane. Other printed circuit boards, known as "daughter boards" or "daughter cards," can be connected through the backplane.

[0004] A known backplane is a printed circuit board on which a number of connectors may be mounted. Conductive traces in the backplane may be electrically connected to signal conductors in the connectors so that signals may be routed between the connectors. Daughter cards may also have connectors mounted thereon. The connectors mounted on the daughter cards may be plugged into connectors mounted on the backplane. In this way, signals may be routed between daughter cards through the backplane. The daughter cards may be plugged into the backplane at right angles. Therefore, connectors for these applications may include right angle bends and are often referred to as "right angle connectors."

[0005] Connectors may also be used in other configurations for interconnecting printed circuit boards. Some systems use a midplane configuration. Similar to a backplane, a midplane has connectors mounted on one surface that are interconnected by routing channels within the midplane. The midplane additionally has connectors mounted on a second side so that daughter cards are plugged into both sides of the midplane.

[0006] Daughter cards inserted from opposite sides of the midplane typically have an orthogonal orientation. This orientation positions one edge of each printed circuit board adjacent to the edge of each board inserted into the opposite side of the midplane. Traces within the midplane connecting a board on one side of the midplane to a board on the other side of the midplane can be short to achieve ideal signal integrity characteristics.

[0007] A variation of the midplane configuration is called "direct attach." In this configuration, daughter cards are inserted from opposite sides of the system. The boards are also oriented orthogonally so that the edge of the board inserted from one side of the system is adjacent to the edge of the board inserted from the opposite side of the system. These daughter cards also have connectors. However, instead of plugging into connectors on the midplane, the connectors on each daughter card plug directly into connectors on a printed circuit board that is inserted from the opposite side of the system.

[0008] Connectors of this configuration are sometimes referred to as orthogonal connectors. Examples of orthogonal connectors are shown in U.S. Patents 7,354,274, 7,331,830, 8,678,860, 8,057,267, and 8,251,745. Summary of the invention

[0009] Embodiments of high-density, high-speed electrical connectors and associated modules and assemblies are described. According to some embodiments, the connector module may include a pair of signal conductors, the pair of signal conductors including a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, the pair of mating ends extending in a direction at right angles to the direction in which the pair of contact tails extend, the mating ends of the pair of mating ends being separated in the direction of a first line, the intermediate portions of the pair of intermediate portions being separated in the direction of a second line, and the first line being disposed at an angle greater than 0 degrees and less than 90 degrees relative to the second line.

[0010] According to some embodiments, the wafer may include multiple signal conductor pairs, each signal conductor pair including a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, the paired mating ends of the multiple signal conductor pairs are positioned in columns along a column direction, the intermediate portions of the paired intermediate portions of the multiple signal conductor pairs are aligned in a direction perpendicular to the column direction and are positioned for broadside coupling, and the mating ends of the multiple signal conductor pairs are separated along lines set at an angle greater than 0 degrees and less than 90 degrees relative to the column direction.

[0011] According to some embodiments, a connector may include multiple signal conductor pairs, wherein, for each signal conductor pair of the multiple signal conductor pairs, the signal conductor pair includes a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, the signal conductor pair also includes a transition region between the pair of mating ends and the pair of intermediate portions, the paired mating ends of the multiple signal conductor pairs are arranged in an array including a plurality of rows, the plurality of rows extend along a row direction and are spaced apart from each other in a column direction perpendicular to the row direction, the paired mating ends of the multiple signal conductor pairs are aligned along a first parallel line, the first parallel line is arranged at an angle greater than 0 degrees and less than 90 degrees relative to the row direction, and for each signal conductor pair of the multiple signal conductor pairs, within the transition region, the relative positions of the signal conductors in the signal conductor pair change, so that at a first end of the transition region adjacent to the mating end, the signal conductors are aligned along a line of the first parallel line, and at a second end of the transition region, the signal conductors are aligned in the row direction.

[0012] According to some embodiments, a connector module may include an insulating member and a pair of signal conductors held by the insulating member, each of the pair of signal conductors including a first portion at a first end, a second portion at a second end extending from the insulating portion, and an intermediate portion disposed between the first end and the second end, and the first portion includes a wire having a diameter between 5 mils and 20 mils.

[0013] According to some embodiments, the extender module may include a pair of signal conductors, each of the pair of signal conductors including a first portion at a first end and a second portion at a second end and an electromagnetic shield at least partially surrounding the pair of signal conductors, the first portions of the pair of signal conductors being configured as mating portions and positioned along a first line, and the second portions of the pair of signal conductors being configured to be compressed when inserted into the hole and positioned along a second line parallel to the first line.

[0014] According to some embodiments, a connector may include an insulating portion, a plurality of signal conductors held by the insulating portion, and a plurality of shielding members, the plurality of signal conductors including an elongated mating portion extending from the insulating portion, the plurality of signal conductors including a plurality of pairs of signal conductors arranged in a plurality of rows extending along a row direction, the plurality of shielding members at least partially surrounding the plurality of pairs, and the mating portions of the plurality of pairs being separated along a first parallel line arranged at an angle of 45 degrees relative to the row direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in various figures may be represented by the same reference numeral. For clarity, not every component will be labeled in every figure. In the drawings:

[0016] Figure 1 is a perspective view of a mating direct attach orthogonal connector according to some embodiments;

[0017] Figure 2A yes Figure 1 A perspective view of an electrical connector 102a with an extender module;

[0018] Figure 2B yes Figure 1 A perspective view of the electrical connector 102b;

[0019] Figure 3A is a front view of an electrical connector having an extender module assembly according to an alternative embodiment;

[0020] Figure 3B is configured with Figure 3A A front view of an electrical connector that mates with the connector;

[0021] Figure 3C is a front view of an electrical connector having an extender module assembly according to another alternative embodiment;

[0022] Figure 3D is configured with Figure 3C A front view of an electrical connector that mates with the connector;

[0023] Figure 4 yes Figure 1 A partial exploded view of the electrical connector 102a;

[0024] Figure 5 yes Figure 4 A perspective view of an electrical connector 102a having a single extender module;

[0025] Figure 6 yes Figure 1 An exploded view of the electrical connector 102b;

[0026] Figure 7 is a partially exploded view of an electrical connector with a front housing removed and having a compliant shield member according to some embodiments;

[0027] Figure 8 is a plan view of a portion of a printed circuit board showing routing channels in a footprint for mounting an electrical connector according to some embodiments;

[0028] Fig.9A According to some embodiments Figure 7 A perspective view of the electrical connector 102 with the front housing cut away and having a retaining member;

[0029] Fig. 9B yes Fig.9A A perspective view of a first retaining member 180;

[0030] Fig. 9C yes Fig. 9B An alternative perspective view of the retaining member 180;

[0031] Fig. 10A yes Figure 7 A perspective view of the sheet 130 of the electrical connector 102 is shown;

[0032] Fig. 10B yes Fig. 10A A perspective view of the sheet 130 with the sheet housing member 133b cut away;

[0033] Fig.11 yes Fig. 10A A plan view of a housing member 133a of a sheet 130 and a connector module 200;

[0034] Fig. 12A yes Fig.11 A side view of the connector module 200;

[0035] Fig. 12B yes Fig.11 A perspective view of a connector module 200;

[0036] Fig. 12C yes Fig.11 An alternative perspective view of the connector module 200;

[0037] Fig.13A yes Fig.11 A side view of the connector module 200 with the electromagnetic shielding member 210 cut away;

[0038] Fig. 13B yes Fig.13A A perspective view of a connector module 200;

[0039] Fig. 13C yes Fig.13A An alternative side view of the connector module 200;

[0040] Fig.14A yes Fig.11 A side view of the connector module 200 with the electromagnetic shielding member 210 and the outer insulating members 180a and 180b cut away;

[0041] Fig. 14B yes Fig.14A A perspective view of a connector module 200;

[0042] Fig. 14C yes Fig.14A An alternative side view of the connector module 200;

[0043] Fig.15 yes FIG. 14A to FIG. 14C A perspective view of an inner insulating member 230 of a connector module 200;

[0044] Fig.16A yes FIG. 14A to FIG. 14C A side view of the signal conductors 260a and 260b of the connector module 200;

[0045] Fig. 16B yes Fig.16A A perspective view of signal conductors 260a and 260b;

[0046] Fig. 16C yes Fig.16A An alternative side view of signal conductors 260a and 260b;

[0047] Fig.17A yes Fig.11 has Figure 5 A perspective view of the connector module 200 of the extender module 300;

[0048] Fig. 17B yes Fig.17A A perspective view of the connector module 200 and the extender module 300 with the electromagnetic shielding members 210a and 210b cut away;

[0049] Fig. 17C yes Fig. 17C A perspective view of the extender module and the signal conductor 260 of the connector module 200;

[0050] Fig.18A yes Figure 5 A perspective view of an extender module 300;

[0051] Fig.18B yes Fig.18A A side view of the extender module 300;

[0052] Fig.18C yes Fig.18A An alternative side view of the extender module 300;

[0053] Fig.19A yes Fig.18A 300, wherein the electromagnetic shielding members 310a and 310b are cut away from the extender module;

[0054] Fig.19B yes Fig.19A A side view of an extender module;

[0055] Fig. 20A yes Fig.18A A side view of the signal conductors 302a and 302b of the extender module 300;

[0056] Fig. 20B yes Fig. 20A An alternative side view of signal conductors 302a and 302b;

[0057] Fig.21A is a perspective view of the head connector;

[0058] Fig.21B yes Fig.21A A perspective view of a connector module of a header connector;

[0059] Fig. 22 is a perspective view of an alternative configuration of connectors in which some connector modules are configured for attachment to a printed circuit board and other connector modules are terminated to cables; and

[0060] Fig.23 is a perspective view of a signal conductor of an alternative embodiment of a pair of signal conductors. DETAILED DESCRIPTION

[0061] The inventors have developed techniques for making electrical connectors that are used for high speed signals and have high density and can be manufactured at low cost. These techniques include arrangements of mating interfaces that simply support multiple configurations, including right angle or direct mating orthogonal system configurations or system configurations with cable connections to midplane components. The configurations can also provide signal paths with low mode conversion and reduce other electrical effects that can affect signal integrity.

[0062] The inventors have recognized and appreciated that electrical connectors having angled mating interfaces (e.g., having mating ends of paired signal conductors twisted relative to the middle portions of the signal conductors) provide enhanced flexibility in making connections between connectors having direct-mating orthogonal backplanes or other configurations. Such angled mating interfaces can be formed, for example, in connectors in which signal conductors are wired in pairs, with the mating ends of a pair separated along a first line, and the middle portions of the pair separated along a second line, the second line being at an angle greater than 0 degrees but less than 90 degrees relative to the first line. Two connectors having similar angled interfaces can be used as part of a direct-mating orthogonal connector system. Such connectors can be mated via an easily manufactured extender module having a straight-through signal path. The cost of the interconnect system can be lower due to this use of similar or even identical connectors mated via a simple extender module.

[0063] In some embodiments, the angled interfaces of two mating connectors can be at the same angle relative to the normal of the mating surface of the connector. In some embodiments, the angles of the two mating connectors can have the same size, but can be in opposite directions. The specific angle and direction of each connector can depend on the system configuration. As a specific example, for a connector designed for direct mating orthogonal configuration, the mating connectors can all have a mating interface that is angled at 45 degrees in a clockwise direction. For a parallel plate configuration, the mating connectors can all have a mating interface that is angled at 45 degrees, but in one direction, the angle can be in a clockwise direction, and in other connectors, the mating interface can be angled in a counterclockwise direction. These angles can be described as 45 degrees and 135 degrees, respectively, where the angles of the two connectors are measured in a clockwise direction.

[0064] Since the torsion in the paired signal paths is limited to less than 90 degrees, the mode conversion may be low, so the interconnection system as described herein can provide high signal integrity. The inventors also recognize and understand that the use of a connector with an angled mating interface reduces the angular amount of torsion of the conductors of the signal pairs on the signal paths, which makes the angular torsion rate lower. Reducing the angular torsion rate improves the integrity of the signal carried by the connector system by reducing the offset and / or mode conversion associated with the torsion, even in small connectors. In some embodiments, the angular torsion rate generated in at least one transition region can be about 45 degrees / 1.5 mm or less, which can provide low mode conversion in the transition region. In some embodiments, the angular torsion rate in the transition region between the middle portion of the signal conductor and the mating interface portion of the signal conductor can be, for example, in the range of 45 degrees / mm to 90 degrees / mm or 45 degrees / mm to 80 degrees / mm, and the middle portion of the signal conductor can be aligned broadside to broadside.

[0065] The angled interface may also enable a simple design of an extender module that may be attached to a connector to change the position, orientation, or mating contact type of the mating interface of the connector. Such an extender module design allows a single type of connector to be used on both sides of an interconnect system, with the extender module providing an interface between the connectors. The extender module may have signal conductors that pass through the module without twisting, which enables the extender module to be substantially surrounded by a shield formed by one or a small number of metal sheets that may be cut and folded to partially or completely surround the module.

[0066] These techniques also include using thin signal conductors in portions of the connector, such as in the mating interface and / or mounting interface. Thus, a ground conductor, such as one that can be used to provide shielding around a signal conductor or a pair of signal conductors, can define a small cavity containing the signal conductor or pairs of signal conductors. Due to the small cavity, resonances that may interfere with the high integrity operation of the connector occur at high frequencies that may be outside the desired operating frequency range of the connector. In some embodiments, a ground conductor around a signal pair can define a cavity having a rectangular cross-section, and the longer dimension of the cavity can be reduced to increase the frequency of the lowest frequency resonance supported by the cavity. In some embodiments, a thin signal conductor can be implemented with a superelastic conductive material. At least the mating contact portion of the signal conductor can be formed by a superelastic conductive material, such as a superelastic wire, which can have a small diameter but have suitable mechanical integrity.

[0067] The inventors have recognized and appreciated that the shape and location of features in electromagnetic shields, including near mating ends of signal conductor pairs, can reduce impedance discontinuities associated with variability in spacing between mating connectors. Such features can include inwardly projecting portions of the shield adjacent to the mating end.

[0068] These techniques can be used alone or in any suitable combination. Due to the improved electrical characteristics achieved by these techniques, the electrical connectors described herein can be configured to operate at high bandwidths to obtain high data transfer rates. For example, the electrical connectors described herein can operate at or above 40 GHz and can have a bandwidth of at least 50 GHz, such as up to and including a frequency of 56 GHz and / or a bandwidth in the range of 50 GHz to 60 GHz. For example, such electrical connectors can transfer data at a rate of up to 112 Gb / s.

[0069] Go to the attached picture, Figure 1 and FIG. 2A to FIG. 2B An electrical connector of an electrical interconnect system according to some embodiments is shown. Figure 1 is a perspective view of an electrical interconnect system 100 including first and second mating connectors, which are here configured to directly attach orthogonal connectors 102a and 102b. Figure 2A is a perspective view of the electrical connector 102a, Figure 2B 1 is a perspective view of electrical connector 102b showing the mating interface and mounting interface of those connectors. In the illustrated embodiment, the mating interfaces are complementary such that connector 102a mates with connector 102b. In the illustrated embodiment, the mounting interfaces are similar in that each mounting interface includes an array of press-fit contact tails configured for mounting to a printed circuit board.

[0070] The electrical connectors 102a and 102b may be manufactured using similar techniques and materials. For example, the electrical connectors 102a and 102b may include substantially identical sheets 130. The electrical connectors 102a and 102b having sheets 130 that may be manufactured and / or assembled in the same process may have low manufacturing costs.

[0071] exist Figure 1 In the embodiment shown in FIG. 1 , the first connector 102a includes a first sheet 130a, which includes one or more individual sheets 130 positioned side by side. The sheet 130 is described herein, including reference Fig. 10A The described sheet 130. Further described herein - including reference Fig. 10B It is described that the wafer 130 includes one or more connector modules 200 .

[0072] The wafer 130 also includes a wafer housing 132a that holds the connector module 200. The wafers are held together side by side so that the contact tails extending from the wafer 130 of the first connector 102a form a first contact tail array 136a. The contact tails of the first contact tail array 136a can be configured for mounting to a substrate, such as in combination with Figure 3A For example, the first contact tail array 136 may be configured for press fit insertion, solder mounting, or any other mounting configuration for mounting to a conductor within a printed circuit board or cable.

[0073] In the illustrated embodiment, further described herein - including with reference to Figure 2A The first connector 102a includes an extender housing 120, and the extender module 300 is inside the extender housing 120. In the illustrated embodiment, the first connector 102a includes a signal conductor having a contact tail that forms part of a first contact tail array 136a. The signal conductor has an intermediate portion that engages the contact tail to a mating end. In the illustrated embodiment, the mating end is configured to mate with another signal conductor in the extender module 300. The signal conductor in the extender module 300 also has a mating end that forms a Figure 2A The mating interface of connector 102a is visible in FIG. The ground conductor similarly extends from sheet 130a, through extender module 300, to Figure 2A The mating interface of connector 102a is visible in FIG.

[0074] The second connector 102b includes a second sheet 130b, which includes one or more sheets 130 positioned side by side. The sheets 130 of the second sheet 130b can be configured as described for the first sheet 130a. For example, the sheets 130 of the second sheet 130b have a sheet housing 132b. In addition, the second contact tail array 136b of the second connector 102b is formed by the contact tails of the conductive elements in the second sheet 130b. Like the first contact tail array 136a, the second contact tail array 136b can be configured for press-fit insertion, solder mounting, or any other mounting configuration for mounting to a conductor in a printed circuit board or cable.

[0075] like Figure 1 As shown in , the first contact tail array 136a faces a first direction, and the second contact tail array 136b faces a second direction perpendicular to the first direction. Therefore, when the first contact tail array 136a is mounted to a first substrate (e.g., a printed circuit board) and the second contact tail array 136b is mounted to the substrate 104d, the surface of the first substrate and the surface of the second substrate can be perpendicular to each other. In addition, the first connector 102a and the second connector 102b are mated along a third direction perpendicular to each of the first direction and the second direction. During the process of mating the first connector 102a with the second connector 102b, one or both of the first connector 102a and the second connector 102b move toward the other connector along the third direction.

[0076] It should be understood that although Figure 1 102a and 102b are shown in a directly attached orthogonal configuration, but the connectors described herein may be suitable for other configurations. For example, FIG. 3C to FIG. 3D The connector shown in FIG. 21 has a mating interface that is angled in relative directions and can be used in a coplanar configuration. FIG. 22 shows that the construction technology as described herein can be used in a backplane, midplane, or mezzanine configuration. However, it is not required to use the mating interface in a board-to-board configuration. Fig. 22 It is shown that some or all of the signal conductors within the connector can be terminated to a cable, thereby creating a cable connector or a hybrid cable connector. Other configurations are also possible.

[0077] like Figure 2A As shown in FIG. 1 , the first electrical connector 102a further includes an extender module 300, which provides a mating interface for the first connector 102a. For example, the mating portion of the extender module 300 forms a first mating end array 134a. In addition, as further described herein, including reference Fig.17AAs described herein, the extender module 300 can be mounted to the connector module 200 of the first sheet 130a. The extender housing 120 holds the extender module 300, surrounding at least a portion of the extender module 300. Here, the extender housing 120 surrounds the mating interface and includes a recess 122 for receiving the second connector 102b. As described herein, including reference Figure 4 As depicted, the extender housing 120 also includes a hole through which the extender module 300 extends.

[0078] like Figure 2B As shown in , the second electrical connector 102b has a front housing 110b that is shaped to fit within an opening in the extender housing 120. As further described herein, including with reference to Figure 6 As depicted, the second sheet 130b is attached to the front housing 110b.

[0079] The front housing 110b provides a mating interface for the second connector 102b. For example, the front housing 110b includes a protrusion 112, which is configured to be received in a groove of the extender housing 120. The mating ends of the signal conductors of the sheet 130b are exposed in the holes 114b of the front housing 110b, forming a second mating end array 134b so that the mating ends can engage with the signal conductors of the sheet 130a of the first connector 102a. For example, the extender module 300 extends from the first connector 102a and can be received by the paired signal conductors of the second connector 102b. The grounding conductors of the sheet 130b are similarly exposed in the holes 114b and can similarly mate with the grounding conductors in the extender module 300, which in turn are connected to the grounding conductors in the sheet 130a.

[0080] exist FIG. 2A to FIG. 2B , the first connector 102a is configured to receive the second connector 102b. As shown, the groove 122 of the extender housing 120 is configured to receive the protrusion of the front housing 110b. In addition, the hole 114b is configured to receive the mating portion of the extender module 300.

[0081] It should be understood that in some embodiments, the second sheet 130a of the first connector 102a and the second sheet 130b of the second connector 102b can be substantially identical. For example, the first connector 102a can include a front housing 110a that can receive the sheet from one side and can be configured similarly to the corresponding side of the front housing 110b. The opposite side of the front housing 110a can be configured for attachment to the extender housing 120, such that the front housing 110a is disposed between the first sheet 130a and the extender housing 120. The front housing 110a is further described herein, including reference Figure 4 The front housing 110a is further described.

[0082] The front housing 110b can be configured to mate with the extender housing 120. In some embodiments, the extender housing 120 can be configured so that features that may latch to a feature can slide in and out when inserted into one side of the extender housing 120 to support separable mating when the features that may latch to a feature are inserted into the opposite side of the extender housing 120. In such a configuration, the same component can be used for the front housing 110a or the front housing 110b. The inventors have recognized and appreciated that using an extender module to interface between the same connectors allows for the manufacture of a single type of connector to be used on each side of the electrical interconnect system, thereby reducing the cost of producing the electrical interconnect system. Even though the shapes of the front housing 110a and the front housing 110b are different to support fixed attachment to the extender housing 120 or sliding engagement with the extender housing 120, efficiencies are achieved by using a thin sheet that can be manufactured using the same tooling as both the connector 102a and the connector 102b. For example, if the front housing 110a and the extender housing 120 are made as a single component, similar efficiencies may be achieved in other configurations.

[0083] The electrical connector as described herein may be formed with Figure 2A and Figure 2B Different numbers of signal conductors are shown in FIG. Figure 3A is a front view of a third electrical connector 102c mounted to a substrate 104c and having an extender housing 120c according to an alternative embodiment. Although the third electrical connector 102c is shown as having fewer signal pairs than the first electrical connector 102a, the third electrical connector 102c may be assembled in other ways using components as described with reference to the first electrical connector 102a. For example, the electrical connector 102c may be assembled from an extender housing 120c and a third sheet 130c having a third mating end array 134c and a third contact tail array 136c, and the extender housing 120c, the third sheet 130c, the third mating end array 134c, and the third contact tail array 136c may be configured in the manner described herein with reference to the extender housing 120, the first sheet 130a, the first mating end array 134a, and the first contact tail array 136a.

[0084] exist Figure 3A In the embodiment, the third electrical connector 102c is mounted to the substrate 104c. For example, the third connector 102c can be a right angle connector mounted adjacent to the edge of the substrate 104c. In some embodiments, the substrate 104c can include a printed circuit board. Figure 3AIn the illustrated embodiment, the pairs of contact tails of the third contact tail array 136c are mounted to the substrate 104c. In some embodiments, the contact tails of the third contact tail array 136c are configured to be inserted into holes in the substrate 104c. In some embodiments, the contact tails of the third contact tail array 136c are configured to be mounted to pads on the substrate 104c, such as by surface mount soldering techniques.

[0085] In the illustrated embodiment, pairs of mating ends of the third mating end array 134c are connected along parallel lines 138c and are disposed at a 45 degree angle relative to each of the mating column direction 140c and the mating row direction 142c.

[0086] Figure 3B is configured with Figure 3A 102c is a front view of a fourth electrical connector 102d mated with the third connector 102c shown in FIG. Although the fourth electrical connector 102d is shown as having fewer signal pairs than the second electrical connector 102b, the fourth electrical connector 102d can be configured in other ways in the manner described with reference to the second electrical connector 102d. For example, the electrical connector 102d can be assembled from a front housing 110d and a fourth sheet 130d having a fourth mating end array 134d and a fourth contact tail array 136d. These components can be configured in the manner described herein with reference to the front housing 110b, the second sheet 130b, the second mating end array 134b, and the second contact tail array 136b.

[0087] exist Figure 3B , a fourth electrical connector 102d is mounted to a substrate 104d. In some embodiments, the fourth connector 102d comprises an edge connector mounted adjacent an edge of the substrate 104d. The substrate 104d may comprise a printed circuit board. The contact tails of the fourth contact tail array 136d are mounted to the substrate 104d. In some embodiments, the contact tails of the fourth contact tail array 136d are configured to be inserted into holes in the substrate 104d. In some embodiments, the contact tails of the fourth contact tail array 136d are configured to be mounted to pads on the substrate 104d, such as by solder mounting.

[0088] The front housing 110d includes a hole 114d in which the mating ends of the paired signal conductors of the fourth sheet 130d are positioned so that the signal conductors from the connector 102c can be inserted into the hole 114d to mate with the signal conductors of the fourth sheet 130d. The ground conductors of the fourth sheet 130d are similarly exposed in the hole 114d for mating with the ground conductors from the connector 102c.

[0089] The fourth mating end array 134d includes rows extending along a row direction 142d and spaced apart from each other in a column direction 140d perpendicular to the row direction 142d. The paired mating ends of the fourth mating end array 134d are aligned along parallel lines 138d. In the illustrated embodiment, the parallel lines 138a are arranged at an angle of 45 degrees relative to the row direction 142d.

[0090] In the illustrated embodiment, the mating ends of the signal conductors of the second wafer are connected along parallel lines 138d that are disposed at a 45 degree angle relative to each of the mating column direction 140d and the mating row direction 142d.

[0091] Similar to connectors 102a and 102b, Figure 1 To Figure 2, FIG. 3A to FIG. 3B Connectors 102c and 102d are shown having a direct attach orthogonal configuration. FIG. 3C to FIG. 3D Electrical connectors 102c' and 102d' having a coplanar configuration are shown. When connector 102c' is mated with connector 102d', substrate 104c' and substrate 104d' can be coplanar. Substrates 104c' and 104d' on which connectors 102c' and 102d' are mounted can be aligned in parallel. In this example, connectors 102c' and 102d' differ from connectors 102a, 102b, and 102c and 102d in that the mating interfaces of connectors 102c' and 102d' are angled in relative directions, while the mating interfaces of connectors 102a, 102b, and 102c and 102d are angled in the same direction. Connectors 102c' and 102d' can be constructed in other ways in the manner described for connectors 102a, 102b, and 102c and 102d.

[0092] The mating end arrays 134c' and 134d' can be adapted to be in a coplanar configuration. FIG. 3A to FIG. 3B , the mating ends of the mating end array 134c' are positioned along parallel lines 138c' and the mating ends of the mating end array 134d' are positioned along parallel lines 138d'. FIG. 3C to FIG. 3D In FIG. 1 , parallel lines 138c′ and 138d′ are perpendicular to each other because mating end arrays 134c′ and 134d′ are shown facing in the same direction. FIG. 3A to FIG. 3B The direct attach orthogonal configuration shown in the figure uses the same connector on both sides, but can be FIG. 3C to FIG. 3D A variation of the same connector used in a coplanar configuration is shown.

[0093] In some embodiments, the relative positions of the pairs of mating ends of the mating end array 134c' can be rotated 90 degrees relative to the relative positions of the pairs of mating ends of the mating end array 134d'. In some embodiments, the parallel lines 138c' can be set at an angle of 45 degrees counterclockwise (e.g., +45 degrees) relative to the mating row direction 142c', and the parallel lines 138d' can be set at an angle of 45 degrees clockwise (e.g., -45 degrees or +135 degrees counterclockwise) relative to the mating row direction 142d'. It should be understood that, alternatively, the parallel lines 138d' can be set at an angle of 45 degrees counterclockwise (e.g., +45 degrees) relative to the mating row direction 142d', and the parallel lines 138c' can be set at an angle of 45 degrees clockwise (e.g., -45 degrees or +135 degrees counterclockwise) relative to the mating row direction 142c'.

[0094] Figure 4 yes Figure 1 A partial exploded view of the electrical connector 102a. Figure 4 In this illustrated embodiment, the extender housing 120 is shown removed from the front housing 110 a to illustrate the front housing 110 a and the array of extender modules 300 .

[0095] In the illustrated embodiment, the front housing 110a is attached to the sheet 130. The front housing 110a can be formed, for example, using a dielectric such as plastic in one or more molding processes. As also shown, the front housing 110a includes a protrusion 112a, which is configured here to latch the front housing 110a to the extender housing 120. For example, the protrusion 112a can be received in the opening 124 of the extender housing 120. The extender module 300 is shown as protruding from the front housing 110a. The extender module 300 can be mounted to the signal conductors of the sheet 130 to form a mating array 134a. Engaging the protrusion 112a in the opening 124 can be achieved by applying a force that exceeds the mating force required to press the connectors 102a and 102b together to mate or to separate those connectors when disengaged. Therefore, the extender housing 120 can be fixed to the front housing 110a during operation of the connectors 102a and 102b.

[0096] The hole 126 of the extender housing 120 is sized to allow the mating end of the extender module 300 to extend through the hole 126 of the extender housing 120. The mating ends of the signal conductors and the ground conductors of the extender module 300 can then be exposed within a cavity that serves as a mating interface area defined by the walls of the extender housing 120. The opposite ends of the signal conductors and the ground conductors within the extender module 300 can be electrically coupled to the corresponding signal conductors and the ground conductors within the thin sheet 130a. In this way, the connectors between the signal conductors and the ground conductors within the thin sheet 130a and the connector 102b are inserted into the mating interface area.

[0097] The extender housing 120 may be formed, for example, using a dielectric such as plastic in one or more molding processes. In the illustrated embodiment, the extender housing 120 includes a recess 122. The recess 122 is configured to receive the protrusion 112b ( Figure 6 ). The sliding of the protrusions 112b in the grooves 122 can help align the mating array 134a of the first electrical connector 102a with the mating array 134b of the second electrical connector 102b before sliding the two connectors into a mating configuration.

[0098] Figure 5 yes Figure 1 1 is a perspective view of an electrical connector 102a with a single extender module 300. In the illustrated embodiment, all but one extender module 300 are removed to show the aperture 114a of the front housing 110a through which the extender module 300 extends. For example, the aperture 114a is sized to expose the mating ends of the signal conductors of the wafer 130 and to allow the tail end of the extender module 300 to be inserted into the aperture 114a to engage with the conductive elements within the wafer 130b.

[0099] Figure 6 yes Figure 1 FIG. 1 is a partial exploded view of the second electrical connector 102 b. Here, the front housing 110 b is shown separated from the sheet 130 b. Figure 6 As shown in , the thin slices 130b of the second electrical connector 102b are each formed by a plurality of connector modules 200. In the illustrated embodiment, each thin slice has eight connector modules. The mating ends 202 of the connector modules 200 extend from the thin slice housing 132b to form a mating end array 134b. When the front housing 110b is attached to the thin slice 130b, the mating end array 134b extends into the front housing 110b. The mating ends 202 are accessible through corresponding holes 114b.

[0100] The contact tails 206 extend from the sheet housing 132b in a direction perpendicular to the direction in which the mating ends 202 extend so as to form a contact tail array 136b. The connector module 200 also includes an electromagnetic shield 210 to provide isolation for electrical signals carried by signal pairs adjacent to the connector module 200. In the illustrated embodiment, the shield also has a structure forming the mating contact portion mating end 202 and a structure forming the contact tails within the contact tail array 136b. The electromagnetic shield can be formed of a conductive material such as a metal plate bent and formed into the illustrated shape so as to form a conductive shield.

[0101] Still Figure 6 The sheet 130b and the retaining member 180 are shown in FIG. The retaining member 180 can be stamped from metal or formed from other suitable materials. As further described herein, including reference 9A to 9C As described, the retaining member 180 may be configured to secure the plurality of sheets 130b together.

[0102] A mechanism may be provided to secure the front housing 110b to the sheet 130b. In the illustrated embodiment, the protruding tab 150 is sized and positioned to extend into the opening 116b of the front housing 110b to secure the front housing 110b to the sheet 130b. The force required to insert and remove the protruding tab 150 from the opening 116b may exceed the force of mating and / or disengagement of the connectors 102a and 102b.

[0103] It should be understood that in the above-described embodiment, the first electrical connector 102a and the second electrical connector 102b include portions that may have the same configuration in both connectors. Figures 7 to 9C Portions of the connectors 102a and 102b, which may be identical for both the first electrical connector 102a and the second electrical connector 102b, are shown in greater detail. Figures 7 to 9C The description relates to the universal electrical connector 102, which may be applied to the first electrical connector 102a and the second electrical connector 102b in some embodiments.

[0104] Figure 7 is a partially exploded view of the electrical connector 102 with the compliant shield 170 and without the front housing. The inventors have recognized and appreciated that the pair of contact tails 206 and / or the pair of electromagnetic shield tails 220 passing through the compliant shield 170 can improve signal integrity in the electrical connector 102 .

[0105] The pairs of contact tails 206 of the contact tail array 136 can extend through the compliant shield 170. The compliant shield 170 can include lossy and / or conductive portions and can also include insulating portions. The contact tails 206 can pass through openings or insulating portions of the compliant shield 170 and can be insulated from the lossy or conductive portions. The ground conductors within the connector 102 can be electrically coupled to the lossy or conductive portions, for example, by passing through or pressing against the electromagnetic shield tails 220 of the lossy or conductive portions.

[0106] In some embodiments, the conductive portion may be compliant so that when the connector 102 is mounted to a printed circuit board, the thickness of the conductive portion may be reduced when the conductive portion is pressed between the connector 102 and the printed circuit board. Compliance may result from the material used, and may, for example, be generated by an elastomer filled with conductive particles or conductive foam. When a force is applied to such materials, they may decrease in volume or may be displaced to render them compliant. The conductive and / or lossy portion may be, for example, a conductive elastomer, such as a silicone elastomer filled with conductive particles such as particles of silver, gold, copper, nickel, aluminum, nickel-plated graphite, or combinations thereof or alloys thereof. Alternatively or additionally, such a material may be a conductive open-cell foam, such as a polyethylene foam plated with copper and nickel.

[0107] If present, the insulation may also be compliant.Alternatively or additionally, the compliant material may be thicker than the insulation of compliant shield 170 so that the compliant material may extend from the mounting interface of connector 102 to the surface of a printed circuit board to which connector 102 is mounted.

[0108] The compliant material can be positioned to align with pads on the surface of the printed circuit board to which the pairs of contact tails 206 of the contact tail array 136 are to be attached or inserted through. Those pads can be connected to ground structures within the printed circuit board so that when the electrical connector 102 is attached to the printed circuit board, the compliant material contacts the ground pads on the surface of the printed circuit board.

[0109] The conductive or lossy portions of the compliant shield 170 can be positioned to make electrical connections with the electromagnetic shield 210 of the connector module 200. Such connections can be made, for example, by the electromagnetic shield tails 220 passing through and contacting the lossy or conductive portions. Alternatively or additionally, in embodiments where the lossy or conductive portions are compliant, those portions can be positioned to press against the electromagnetic shield tails 220 or other structures extending from the electromagnetic shield when the electrical connector 102 is attached to a printed circuit board.

[0110] The insulating portions 176 may be organized into rows along the row direction 172 and the column direction 174. When the pairs of contact tails 206 of the contact tail array 136 extend through the insulating portions 176, the row direction 172 of the compliant shield 170 may be substantially aligned with the contact tail row direction 146, and the column direction 174 of the compliant shield 170 may be substantially aligned with the contact tail column direction 144.

[0111] In the illustrated embodiment, the conductive members 178 join the insulating portions 176 and are positioned between the rows of the contact tail array 136. In this location, the shield tails 220 may contact the electromagnetic shield tails 220 either because they press against the tails when compressed or because the shield tails 220 pass through the conductive members 178.

[0112] Figure 8 1 is a plan view of a portion 190 of a substrate 104e showing a portion of a connector footprint to which a connector 102 may be mounted. Here, a 4x4 grid of mounting locations is shown, with mounting locations 194a and 194b being numbered. Each mounting location may accommodate a contact tail from a pair of signal conductors and an electromagnetic shield tail 220 from an electromagnetic shield surrounding the pair. Here, four such electromagnetic shield tails 220 are shown per pair.

[0113] Mounting locations 194a and 194b each include a conductive signal through hole 196 and a conductive ground through hole 198. Conductive signal through holes 196 and conductive ground through holes 198 are configured to receive contact tails and / or electromagnetic shielding tails of an electrical connector. For example, conductive signal through holes 196 and ground through holes 198 can be formed as conductive plated holes into which press-fit tails are inserted. Alternatively, the signal contact tails and / or electromagnetic shielding tails can be soldered to pads on top of conductive signal through holes 196 and / or conductive ground through holes 198.

[0114] In the illustrated embodiment, the substrate 104e is implemented as a multi-layer printed circuit board. Figure 8 A portion of an inner layer of a printed circuit board is shown where traces are visible. Only two traces are shown, but it should be understood that a pair of traces may be connected for each pair of signal conductors. These traces may be on the shown layer of the printed circuit board or on another layer. Other layers may also contain constructive structures that serve as ground planes. Shield tail 220 may be connected to the ground plane.

[0115] Shown in phantom is a ground pad 820, such as may be formed on the surface of a printed circuit board. The ground pad 820 may be connected to one or more of the ground planes within the printed circuit board. In the illustrated embodiment, the ground pad 820 is positioned to align with the conductive member 178 so that when the connector 102 is mounted to the printed circuit board, a conductive path is provided between the electromagnetic shield within the connector 102 and the ground structure within the printed circuit board.

[0116] In the illustrated embodiment, the mounting locations are spaced apart to leave routing channels, of which routing channels 192a and 192b are numbered. Routing channels 192a and 192b house traces that can route signals from vias, which in turn connect to contact tails of the connector, to other locations on the printed circuit board.

[0117] In some embodiments, the conductive signal vias 196 and / or the conductive shielding vias have unplated holes with a diameter less than or equal to 20 mils. In some embodiments, the conductive signal vias 196 and / or the conductive grounding vias 198 have unplated holes with a diameter less than or equal to 10 mils. The mounting positions can then be spaced apart in an array, wherein the center-to-center spacing in the column direction is less than or equal to 2.5 mm and the center-to-center spacing in the row direction is less than or equal to 2.5 mm. Through this spacing, there is space for routing channels between the through holes, including routing channels 192a in the column direction and routing channels 192b in the row direction. It may be advantageous to have routing channels in both the row and column directions because this can reduce the number of layers required to route traces to all signal vias in the connector footprint in the printed circuit board compared to a printed circuit board where the routing channels are available only in one direction. Since cost, size, and weight all increase with the increase in the number of layers, reducing the number of layers provides many advantages.

[0118] In some embodiments, the conductive signal vias 196 adjacent to the mounting locations 194a and 194b are configured to receive adjacent pairs of contact tails spaced a distance less than or equal to 5 mm along the line 146e. In some embodiments, the conductive signal vias 196 adjacent to the mounting locations 194a and 194b are configured to receive adjacent pairs of contact tails of electrical connectors, sheets, and / or connector modules spaced a distance less than or equal to 4 mm from center to center along the line 146e. In some embodiments, the conductive signal vias 196 adjacent to the mounting locations 194a and 194b are configured to receive adjacent pairs of contact tails of electrical connectors, sheets, and / or connector modules spaced a distance less than or equal to 2.4 mm along the line 146e. In some embodiments, in the vertical direction, adjacent mounting locations can be spaced less than 8 mm, less than 5 mm, less than 4 mm, or less than or equal to 2.4 mm from center to center along the line 144e.

[0119] Despite the compact array of mounting locations, routing channels in both the row and column directions can be achieved by implementing each of the mounting locations in a relatively compact area. The compactness of each mounting location can depend on the spacing between a pair of signal conductors within the connector module 300 and the spacing between the signal conductors and the electromagnetic shielding surrounding them.

[0120] The inventors have recognized and appreciated that these dimensions can be made smaller by including superelastic materials in electrical connectors. Superelastic materials are characterized by the amount of strain required for those materials to yield, wherein superelastic materials can withstand higher strains before yielding. In addition, the shape of the stress-strain curve of a superelastic material includes a "superelastic" region.

[0121] Superelastic materials may include shape memory materials that undergo a reversible martensitic phase transformation when a suitable mechanical driving force is applied. The phase transformation may be a diffusionless solid-solid phase transformation with an associated shape change; the shape change allows the superelastic material to adapt to relatively large strains compared to conventional (i.e., non-superelastic) materials, so superelastic materials typically exhibit a much larger elastic limit than conventional materials. The elastic limit is defined herein as the maximum strain to which a material can be reversibly deformed without yielding. Conventional conductors typically exhibit an elastic limit of up to 1%, while superelastic conductive materials may have an elastic limit of up to 7% or 8%. Therefore, superelastic conductive materials can be made smaller without sacrificing the ability to withstand considerable strain. In addition, some superelastic conductive materials can also return to their original form when exposed to a transformation temperature specific to the material, even when the strain exceeds its elastic limit. In contrast, conventional conductors are typically permanently deformed once the strain exceeds their elastic limit.

[0122] Such materials can enable small signal conductors, but provide a sturdy structure. Such materials facilitate reducing the width of the electrical conductors of the electrical connector, which can result in reduced spacing between the electrical conductors and the electromagnetic shields of the electrical connectors in the connector module 300. For example, in some embodiments, the superelastic member can have a diameter between 20 mils, such as between 8 mils and 14 mils (or an effective diameter resulting from a cross-sectional area having an area of ​​a circle equal to the diameter), or in some embodiments, the superelastic member can have a diameter between 5 mils and 8 mils, or the superelastic member can have a diameter within any sub-range of the range between 5 mils and 14 mils.

[0123] In addition to enabling wiring channels in the row and column directions, more compact connector modules may have undesirable resonant modes at high frequencies, which may exceed the desired operating frequency range of the electrical connector. Undesirable resonant frequency modes within the operating frequency range of the electrical connector may be reduced accordingly, which provides increased signal integrity for signals carried by the connector module.

[0124] In some embodiments, the contact tails of the contact tail array 136 and / or the mating ends of the mating end array 134 may include a superelastic (or pseudo-elastic) material. Depending on the particular embodiment, the superelastic material may have a suitable inherent conductivity or may be made suitable for conductivity by coating or attaching to a conductive material. For example, a suitable conductivity may be in the range of about 1.5 μΩcm to about 200 μΩcm. Examples of superelastic materials that may have a suitable inherent conductivity include, but are not limited to, metal alloys such as copper-aluminum-nickel, copper-aluminum-zinc, copper-aluminum-manganese-nickel, nickel-titanium (e.g., nitinol), and nickel-titanium-copper. Additional examples of potentially suitable metal alloys include Ag-Cd (approximately 44-49 at% Cd), Au-Cd (approximately 46.5-50 at% Cd), Cu-Al-Ni (approximately 14-14.5 wt%, approximately 3-4.5 wt% Ni), Cu-Au-Zn (approximately 23-28 at% Au, approximately 45-47 at% Zn), Cu-Sn (approximately 15 at% Sn), Cu-Zn (approximately 38.5-41.5 wt% Zn), Cu-Zn-X (X = Si, Sn, Al, Ga, approximately 1-5 at% X), Ni-Al (approximately 36-38 at% Al), Ti-Ni (approximately 49-51 at% Ni), Fe-Pt (approximately 25 at% Pt), and Fe-Pd (approximately 30 at% Pd).

[0125] In some embodiments, a particular superelastic material may be selected for its mechanical response rather than its electronic properties, and a particular superelastic material may not have suitable inherent conductivity. In such embodiments, the superelastic material may be coated with a more conductive metal such as silver to improve conductivity. For example, the coating may be applied using a chemical vapor deposition (CVD) process, a physical vapor deposition (PVD) process, or any other suitable coating process, as the present disclosure is not limited in this regard. The coated superelastic material may also be particularly beneficial in high frequency applications where a large portion of the electrical conduction occurs near the surface of the conductor.

[0126] In some embodiments, a connector element including a superelastic material can be formed by attaching the superelastic material to a conventional material, which can have a higher conductivity than the superelastic material. For example, the superelastic material can be employed only in portions of the connector element that may be subject to large deformations, while other portions of the connector that do not deform significantly during operation of the connector can be made of conventional (highly conductive) materials.

[0127] The inventors have recognized and appreciated that using superelastic conductive materials to implement portions of an electrical connector enables smaller structures that are still strong enough to withstand the operational requirements of the electrical connector, and thus can facilitate higher signal conductor density within the portion made of superelastic material. This tighter spacing can be achieved by the interconnect system. For example, as described above with reference to Figure 8 As described, the mounting footprint for receiving the electrical connector 102 on the substrate may be adapted to receive a high density contact tail array 136 .

[0128] The spacing between the conductive signal vias 196 and / or the conductive ground vias 198 on the substrate 104e can be adapted to match the spacing of the pairs of contact tails 206 and / or the pairs of electromagnetic shielding tails 220 of the contact tail array 136 of the electrical connector 102. Therefore, tighter spacing between signal conductors and / or smaller spacing between signal conductors and ground conductors will produce a more compact footprint. Alternatively or additionally, more space will be available for routing channels.

[0129] In some embodiments, the contact tails of the electrical connector 102 can be implemented with ultra-elastic materials, which can enable smaller vias and tighter spacing between adjacent pairs than conventional contact tails. In some embodiments, the conductive signal vias 196 adjacent to the mounting locations 194a and 194b can be spaced on a 2.4 mm x 2.4 mm grid.

[0130] This close spacing can be achieved by fine contact tails, such as can be achieved with, for example, a superelastic wire having a diameter less than 10 mils. In some embodiments, the contact tails of the connector described herein can be configured to be inserted into a plated hole formed with an unplated diameter less than or equal to 20 mils. In some embodiments, the contact tails can be configured to be inserted into a through hole drilled with an unplated diameter less than or equal to 10 mils. In some embodiments, the contact tails can each have a width between 6 mils and 20 mils. In some embodiments, the contact tails can each have a width between 6 mils and 10 mils, or in other embodiments, the contact tails can each have a width between 8 mils and 10 mils.

[0131] 9A to 16C Additional details of the components of connector 102 are provided. Fig.9A A sheet 130 is shown, FIG. 9B to FIG. 9C The retaining member 180 of the electrical connector 102 is shown. Fig.9A In the illustrated embodiment, the sheets 130 are positioned along the contact trailing direction 146, and the retaining tabs 152 of the sheet housing 132 engage with the retaining member 180. The retaining member 180 is configured to secure the sheets 130 to each other. FIG. 9B to FIG. 9C 1 , the retaining member 180 includes a slot 182 for receiving the retaining tab 152 of the wafer 130. The retaining member 180 may be stamped from metal, but may alternatively be formed from a dielectric material such as plastic.

[0132] Fig. 10A is a perspective view of the wafer 130 of the electrical connector 102. In the illustrated embodiment, the wafer housing 132 is formed of two housing members 133a and 133b. Fig. 10B 1 is a perspective view of the sheet 130 with the sheet housing member 133a cut away. Fig. 10A and Fig. 10B As shown in FIG. 1 , the wafer 130 includes a connector module 200 between two wafer housing members 133a and 133b. In the illustrated embodiment, the wafer housing members 133a and 133b hold the connector module 200 in the wafer 130.

[0133] The wafer shell members 133a and 133b include a protrusion 154 and a hole 156 configured to receive the protrusion 154 so as to hold the wafer shell members 133a and 133b together. In some embodiments, the wafer shell members 133a and 133b can be formed of or include a lossy conductive material such as a conductive plated plastic or an insulating material. The inventors have recognized and appreciated that the use of lossy conductive materials to implement the wafer shell members 133a and 133b provides damping for undesirable resonant modes in and between the connector modules 200, thereby improving the signal integrity of the signals carried by the electrical connector 102.

[0134] Any suitable lossy material can be used for these structures and other structures that are "lossy". Materials that conduct but have some loss or absorb electromagnetic energy in the frequency range of interest through another physical mechanism are generally referred to as "lossy" materials in this article. Electrically lossy materials can be formed of lossy dielectric materials and / or poorly conductive materials and / or lossy magnetic materials. Magnetic lossy materials can be formed, for example, of materials that are traditionally regarded as ferromagnetic materials, such as those materials that have a magnetic loss tangent greater than about 0.05 in the frequency range of interest. "Magnetic loss tangent" is the ratio of the imaginary part to the real part of the complex electromagnetic permeability of the material. Actual lossy magnetic materials or mixtures containing lossy magnetic materials can also exhibit useful amounts of dielectric loss or conductive loss effects over a portion of the frequency range of interest. Electrically lossy materials can be formed of materials that are traditionally regarded as dielectric materials, such as those materials that have an electric loss tangent greater than about 0.05 in the frequency range of interest. "Electric loss tangent" is the ratio of the imaginary part to the real part of the complex dielectric constant of the material. Electrically lossy materials may also be formed from materials that are generally considered to be conductors but are relatively poor conductors in the frequency range of interest, the materials containing conductive particles or conductive regions that are sufficiently dispersed that they do not provide high electrical conductivity or are otherwise prepared to have properties that result in relatively poor bulk conductivity compared to a good conductor, such as copper, in the frequency range of interest.

[0135] Electrically lossy materials typically have a bulk conductivity of about 1 Siemens / meter to about 10,000 Siemens / meter and preferably about 1 Siemens / meter to about 5,000 Siemens / meter. In some embodiments, materials with a bulk conductivity between about 10 Siemens / meter and about 200 Siemens / meter can be used. As a specific example, a material with a conductivity of about 50 Siemens / meter can be used. However, it should be understood that the conductivity of the material can be selected empirically or through electrical simulation using known simulation tools to determine a suitable conductivity that provides suitable low crosstalk and suitable low signal path attenuation or insertion loss.

[0136] An electrically lossy material may be a partially conductive material, such as a material having a surface resistivity between 1 Ω / square and 100,000 Ω / square. In some embodiments, the electrically lossy material has a surface resistivity between 10 Ω / square and 1000 Ω / square. As a specific example, the material may have a surface resistivity between approximately 20 Ω / square and 80 Ω / square.

[0137] In some embodiments, an electrically lossy material is formed by adding a filler containing conductive particles to an adhesive. In such embodiments, a lossy member can be formed by molding or otherwise forming an adhesive with a filler into a desired form. Examples of conductive particles that can be used as fillers to form electrically lossy materials include carbon or graphite or other types of particles formed into fibers, flakes, nanoparticles. 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, metal-plated carbon particles can be used. Silver and nickel are metal coatings suitable for fibers. 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 solidify, cure, or can be used to position the filler material in other ways. In some embodiments, the adhesive can be a thermoplastic material that is traditionally used to make electrical connectors to facilitate molding the electrically lossy material into a desired shape and position as part of the manufacture of the electrical connector. Examples of such materials include liquid crystal polymers (LCP) and nylon. However, many alternative forms of adhesive materials can be used. A curable material such as epoxy resin may be used as the adhesive. Alternatively, a material such as a thermosetting resin or adhesive may be used.

[0138] Furthermore, while the above-described binder materials can be used to create an electrically lossy material by forming a binder around a conductive particulate filler, the invention is not limited thereto. For example, the conductive particles can be impregnated into a formed matrix material or can be coated onto a formed matrix material, such as by applying a conductive coating to a plastic part or a metal part. As used herein, the term "binder" includes a material that encapsulates a filler, is impregnated with a filler, or otherwise serves as a base for holding a filler.

[0139] Preferably, the filler will be present in a sufficient volume percentage to allow for the creation of a conductive path from particle to particle. For example, when metal fibers are used, the fibers may be present in an amount of about 3% to 40% by volume. The amount of filler may affect the conductive properties of the material.

[0140] Filling materials are available commercially, such as from Celanese Corporation under the trade name Materials sold, which can be filled with carbon fiber or stainless steel wire. Lossy materials, such as lossy conductive carbon-filled adhesive preforms, such as those sold by Techfilm of Billerica, Massachusetts, USA, can also be used. Such preforms can include epoxy resin adhesives filled with carbon fiber and / or other carbon particles. The adhesive surrounds the carbon particles, which can be used as reinforcing materials for the preforms. Such preforms can be inserted into connector sheets to form all or part of the housing. In some embodiments, the preforms can be adhered by adhesives in the preforms, and the adhesives can be cured during the heat treatment process. In some embodiments, the adhesive can take the form of a separate conductive or non-conductive adhesive layer. In some embodiments, the adhesive in the preform can be alternatively or additionally used to fix one or more conductive elements such as foil strips to lossy materials.

[0141] Various forms of reinforcing fibers, in woven or nonwoven form, coated or uncoated, may be used. Nonwoven carbon fibers are a suitable material. Other suitable materials such as customized blends sold by RTP Company may be used, as the present invention is not limited in this respect.

[0142] In some embodiments, the lossy portion can be manufactured by stamping a preform or sheet of lossy material. For example, the lossy portion can be formed by stamping a preform as described above with an appropriate opening pattern. However, other materials can be used instead of or in addition to such a preform. For example, a sheet of ferromagnetic material can be used.

[0143] However, the lossy portion may be formed in other ways. In some embodiments, the lossy portion may be formed by interleaving layers of lossy and conductive material, such as metal foil. The layers may be rigidly attached to each other, such as by using an epoxy or other adhesive, or may be held together in any other suitable manner. The layers may have the desired shape before being secured to each other, or may be stamped or otherwise formed after they are held together. As another alternative, the lossy portion may be formed by plating a plastic or other insulating material with a lossy coating, such as a diffused metal coating.

[0144] like Fig. 10B As shown in , the connector module 200 is aligned along the mating column direction 140. Fig. 10B As shown in FIG. 1 , the connector module 200 includes a mating end 202 and a mounting end where the contact tails 206 of the signal conductors in the module are exposed. The mating end and the mounting end of the module 200 are connected by an intermediate portion 204. The connector module 200 also includes an electromagnetic shield 210 having an electromagnetic shield tail 212 and an electromagnetic shield mating end 212 at the mounting end and the mating end of the module, respectively.

[0145] In the illustrated embodiment, the mating ends of the signal conductors of each connector module are separated at the mating end 202 along parallel lines 138 that are at a 45 degree angle relative to the mating column direction 140 .

[0146] In the illustrated embodiment, the contact tails 206 of the signal conductors within the connector module are positioned in columns along the contact tail column direction 144, and the pairs of contact tails 206 are also separated along the contact tail column direction 144. As shown, the contact tail column direction 144 is perpendicular to the mating column direction 140. However, it should be understood that the mating end and the mounting end can have any desired relative orientation. According to various embodiments, the contact tails 206 can be edge-coupled or broadside-coupled.

[0147] Fig.11 FIG. 1 is a plan view of the housing member 133 b of the sheet 130 and a connector module 200. Fig.11 As shown in FIG. 1 , the wafer housing member 133b includes a groove 160 shaped to receive the connector module 200. The housing member 133a may similarly include a groove that cooperates with the groove 160 to form a channel in which the connector module 200 is disposed.

[0148] Groove 160 includes first notch 162 and second notch 164, each notch shaped to receive a protrusion from connector module 200, such as protrusion 232. Such notches and protrusions can provide mechanical integrity to sheet 130 so that module 200 does not rotate when connector 102 is pressed against, for example, a printed circuit board.

[0149] FIG. 12A to FIG. 12C A side view, a perspective view, and an alternative perspective view of a representative connector module 200 are shown, respectively. Fig. 10B As shown in , the sheet can include a column of connector modules 200. Each of the connector modules can be in a separate row at the mating interface and the mounting interface of the connector. In a right-angle connector, the modules in each row can have a middle portion 204 of different lengths. In some embodiments, the mating end and the mounting end can be the same.

[0150] like FIG. 12A to FIG. 12C As shown in FIG. 1 , the electromagnetic shield members 210a and 210b are disposed around the inner insulating member 230. The first and second holding members 222 of the electromagnetic shield members 210a and 210b hold the first shield member 210a to the second shield member 210b surrounding the inner insulating member 230.

[0151] In the illustrated embodiment, the electromagnetic shield member 210 completely covers the connector module 200 on two sides, with gaps 218 on the remaining two sides so that only partial coverage is provided on those sides. The inner insulating member 230 is exposed through the gaps 218. However, in some embodiments, the electromagnetic shield member 210 can completely cover the insulating member 230 on 4 sides. The gaps 218 can be relatively narrow so as not to allow any significant amount of electromagnetic energy to pass through the gaps. The gaps can, for example, be less than half the wavelength of the highest frequency in the intended operating range of the connector, or in some embodiments, the gaps can, for example, be less than one-quarter the wavelength of the highest frequency in the intended operating range of the connector. The signal conductors within the connector module 200 are described herein, including with reference to FIG. 16A to FIG. 16C The signal conductors in the connector module 200 are shown. The electromagnetic shielding member 210 may be a conductive shielding member. For example, the electromagnetic shielding member 210 may be stamped from a metal sheet.

[0152] FIG. 12A to FIG. 12C 2 and 3. The first transition region 208a and the second transition region 208b of the connector module 200 are shown. In the first transition region 208a, the mating end 202 is connected to the intermediate portion 204. In the second transition region 208b, the intermediate portion 204 is connected to the contact tail 206.

[0153] The electromagnetic shield members 210a and 210b include an electromagnetic shield tail 220 and an electromagnetic shield mating end 212 at the mating end 202, the electromagnetic shield tail 220 extending from the module 200 parallel to and along the sides of the contact tail 206 of the signal conductor within the module 200. The electromagnetic shield mating end 212 surrounds the mating end of the signal conductor.

[0154] The electromagnetic shield mating end 212 is stamped with an outward protrusion 214 in the first transition region 208a and an inward protrusion 216 at the mating end 202. Therefore, the outward protrusion 214 is disposed between the intermediate portion 204 and the inward protrusion 216. The electromagnetic shield mating end 212 stamped with the outward protrusion 214 counteracts the change in impedance along the length of the connector module 200 associated with the shape change of the connector module 200 in the transition region. For example, at frequencies between 45 GHz and 50 GHz, the impedance along the signal path through the connector module 200 can be between 90 ohms and 100 ohms.

[0155] The electromagnetic shield mating end 212 embossed with the inward projection 216 provides a more constant impedance between a first operating state in which the connector module 200 is firmly pressed against a mating connector and a second operating state in which the connector module 200 is partially disengaged such that there is a gap between the connector module 200 and the mating connector, but the connectors are close enough to mate the signal conductors in those connectors. In some embodiments, the impedance change between the fully mated configuration and the partially disengaged configuration of the mating end 202 is less than 5 ohms at the operating frequency of the connector, for example, in the range of 45 GHz to 50 GHz.

[0156] FIG. 13A to FIG. 13C 2 are a side view, a perspective view, and an alternative side view of the connector module 200 with the electromagnetic shielding members 210a and 210b cut away, respectively. FIG. 13A to FIG. 13C As shown in , outer insulating members 280a and 280b are disposed on opposite sides of the inner insulating member 230. The outer insulating members 280a and 280b can be formed using a dielectric material such as plastic. The protrusion 232 of the inner insulating member 230 is disposed closer to the contact tail 206 than the mating end 202 and extends in a direction opposite to the direction along which the contact tail 206 extends.

[0157] The mating end 202 of the signal conductor within the connector module 200 includes compliant receptacles 270a and 270b, each having mating arms 272a and 272b. In the illustrated embodiment, the compliant receptacles 270a and 270b are configured to receive and contact the mating portion of the signal conductor of the mating connector between the mating arms 272a and 272b.

[0158] Also like FIG. 13A to FIG. 13CAs shown in, the insulating parts of the connector module 200 can insulate the sockets 270a and 270b from each other. These insulating parts can also position the sockets 270a and 270b and provide holes, and the mating parts of the mating connector can enter the sockets 270a and 270b through the holes. These insulating parts can be formed as a part of the insulating member 230. In the embodiment shown, the inner insulating member 230 has an extension 234, and the extension 234 includes arms 236a and 236b and holes 238a and 238b. The extension 234 extends beyond the compliant sockets 270a and 270b in the direction of its elongation at the mating end 202. The arms 236a and 236b are spaced farther apart than the mating end 202. Holes 238a and 238b can be configured to receive wires passing therethrough so that the wires extend into the compliant sockets 270a and 270b. For example, the gap between arms 272a and 272b of compliant sockets 270a and 270b aligns with holes 238a and 238b.

[0159] FIG. 14A to FIG. 14C 2 are a side view, a perspective view, and an alternative side view of the connector module 200 with the electromagnetic shielding members 210a and 210b and the outer insulating members 280a and 280b cut away, respectively. FIG. 14A to FIG. 14C As shown in , the connector module 200 includes a signal conductor 260, which is shown here as a signal conductor 260a and 260b implemented as a differential pair. When the connector module 200 is assembled, the signal conductor 260a can be disposed between the outer insulating member 280a and the inner insulating member 230, and the signal conductor 260b can be disposed between the outer insulating member 280b and the inner insulating member 230.

[0160] The inner insulating member 230 and one or more of the outer insulating members 280a and 280b may include features that hold the insulating components together, thereby securely positioning the signal conductor 260 within the insulating structure. In the illustrated embodiment, the first retaining member 240 and the second retaining member 242 of the inner insulating member 230 may extend into openings in the outer insulating members 280a and 280b. In the illustrated embodiment, the first retaining member 240 is disposed adjacent to the mating end 202 and extends in a direction perpendicular to the direction along which the mating end 202 extends. The second retaining member 242 is disposed adjacent to the contact tail 206 and extends in a direction perpendicular to the direction along which the contact tail 206 extends.

[0161] The middle portions of the signal conductors 260a and 260b are on opposite sides of the inner insulating member 230. In the illustrated embodiment, the signal conductors 260a and 260b are each stamped from a sheet of metal and then bent into a desired shape. The middle portion is flat, and the thickness of the middle portion is equal to the thickness of the sheet of metal. Therefore, the middle portion has opposite broadsides that are joined together by edges that are thinner than the broadsides. In this embodiment, the middle portions are aligned broadside to broadside to provide broadside coupling within the module 200.

[0162] exist FIG. 14A to FIG. 14C , signal conductor 260 includes mating end 262, intermediate portion 264, contact tail 266 at mating end 202, intermediate portion 204, and contact tail 206 of connector module 200. As shown, mating end 262 includes compliant receptacles 270a and 270b, and contact tail 266 includes eye-of-needle press fit tail.

[0163] In the illustrated embodiment, the mating ends 262 and contact tails 266 of a pair of signal conductors 260 are not aligned broadside to broadside as with the intermediate portion 264. Thus, the relative positions of the pair of signal conductors 260a and 260b change between the intermediate portion 264 and each of the mating ends 262 and contact tails 266. The relative positions change in the transition regions 268a and 268b.

[0164] The first transition region 268a of the signal conductor 260 connects the mating end 262 to the intermediate portion 264. The second transition region 268b connects the contact tail 266 of the signal conductor 260 to the intermediate portion 264. In each of these transition regions 268a and 268b, the angular position around an axis parallel to the longitudinal dimension of the pair of signal conductors 260a and 260b changes. The angular distance between the signal conductors 260a and 260b can remain the same, for example at 180 degrees. In the illustrated embodiment, the angular position of the signal conductors 260a and 260b changes by 45 degrees within the transition region 268a and by 90 degrees within the transition region 268b, so that there is an angular twist in the pair considering crossing the transition regions 268a and 268b.

[0165] The inner insulating member 230 can be shaped to accommodate a pair of signal conductors having such transition regions. In the illustrated embodiment, the signal conductors 260 are disposed in the grooves 250 on opposite sides of the inner insulating member 230. The transition regions 268a and 268b of the signal conductors 260 are disposed within the transition guides 252a and 252b of the grooves 250. The grooves 250 of the inner insulating member 230 are described herein, including with reference to Fig.15 The groove 250 of the inner insulating member 230 is depicted.

[0166] It should be understood that some embodiments do not include the second transition region 268b, such as in embodiments where the contact tails are shown aligned broadside to broadside. Fig.23 middle.

[0167] Fig.15 2 is a perspective view of the inner insulating member 230 of the connector module 200. Fig.15 As shown in , the inner insulating member 230 includes a main body 244 and an extension 234 joined together by a connecting portion 246. The inner insulating member 230 can be formed using a dielectric material such as plastic and can be formed by, for example, molding. The opposite side of the main body 244 includes a groove 250. The groove 250 is formed to receive the signal conductor 260 of the connector module 200. In the illustrated embodiment, the groove 250 includes a first transition guide 252a and a second transition guide 252b configured to conform to the signal conductor in the transition area 268a and 268b. For example, the transition guides 252a and 252b can be formed to accommodate the transition of the signal conductor 260. The connecting portion 246 is disposed between the extension 234 and the main body 244.

[0168] FIG. 16A to FIG. 16C yes FIG. 14A to FIG. 14C 260a and 260b of the connector module 200. FIG. 16A to FIG. 16C , the mating ends 262a and 262b extend in a first direction, and the contact tails 266a and 266b extend in a second direction at right angles to the first direction. In the illustrated embodiment, the contact tails 266a and 266b are configured as press-fit ends. Therefore, the contact tails 266a and 266b can be configured to compress when inserted into a hole, such as in a printed circuit board.

[0169] Here, each signal conductor 260a and 260b is configured to carry a component of a differential signal. Signal conductors 260a and 260b can each be formed as a single, integral conductive element, which can be stamped from a metal sheet. However, in some embodiments, signal conductors 260a and 260b can each be formed by a plurality of conductive elements that are fused, welded, soldered or otherwise joined together. For example, portions of signal conductors 260a and 260b, such as contact tails 266a and 266b and mating ends 262a and 262b, can be formed using a superelastic conductive material.

[0170] Due to the transition region 268a, the mating ends 262a and 262b are separated from each other along the line 138, while the intermediate portions 264a and 264b adjacent to the mating ends 262a and 262b are separated along the mating row direction 142. As shown, for example, in Figure 7, the connector 102 may be configured such that all modules 200 are positioned in a row extending along the row direction 142. All modules may include similarly oriented mating ends such that for each module, the mating ends of the signal conductors will be separated from each other along a line parallel to the line 138.

[0171] The relative positions of the signal conductors 260a and 260b change along the first transition region 268a such that at a first end of the first transition region 268a adjacent to the mating ends 262a and 262b, the signal conductors 260a and 260b are aligned along the first parallel line 138, and at a second end of the first transition region 268a adjacent to the intermediate portions 264a and 264b, the signal conductors 260a and 260b are aligned along the mating row direction 142. In the example shown, the first transition region 268a provides a 45 degree twist between the line 138 and the mating row direction 142. Within the first transition region 268a, the signal conductor 260a extends away from the contact tail column direction 144, and the signal conductor 260b extends toward the contact tail column direction 144.

[0172] Although the relative positions of the signal conductors 260a and 260b vary over the transition region, the inventors have recognized and appreciated that the signal integrity of a pair of signal conductors can be enhanced by configuring the module 200 to maintain each of the signal conductors 260a and 260b adjacent to the same corresponding shielding member 210a or 210b over the entire transition region. Alternatively or in addition, the spacing between the signal conductors 260a and 260b and the corresponding shielding member 210a or 210b can be relatively constant over the transition region. For example, in some embodiments, the spacing between the signal conductors and the shielding member can vary by no more than 30%, 20%, or 10%.

[0173] Module 200 may include one or more features that provide for such relative positioning and spacing of signal conductors and shielding members. Fig. 12A … Fig. 12C and Fig.16A … Fig. 16C As can be seen from the comparison of the shield members 210a and 210b, the shield members 210a and 210b have a generally planar shape in the middle portion 204, which is parallel to the middle portion 264 of the corresponding signal conductor 260a or 260b. The shield mating end 212 can be formed from the same metal sheet as the middle portion, wherein the shield mating end 212 is twisted relative to the middle portion 204. The twisting of the shield member can have the same angle and / or the same angular twist rate as the signal conductor, ensuring that each signal conductor, ensuring that the same shield member is adjacent to the same signal conductor over the entire transition area.

[0174] In addition, as in FIG. 16A to FIG. 16CAs can be seen in FIG. 1 , the mating ends 262a and 262b are formed by rolling a conductive material of a metal sheet from which the signal conductor 260 is formed into a generally tubular configuration. The material is rolled toward a centerline between the mating ends 262a and 262b. Such a configuration allows the flat surface of the signal conductor to face outward toward the shield member, which may help maintain a constant spacing between the signal conductor and the shield member, even in a torsion region.

[0175] It should be understood that the spacing between the signal conductors 260a and 260b can be substantially constant in units of distance. Alternatively, the spacing can provide a substantially constant impedance. In this case, for example, where the signal conductor is wider, such as due to being rolled into a tube, the spacing relative to the shield can be adjusted to ensure that the impedance of the signal conductor is substantially constant.

[0176] like FIG. 16A to FIG. 16C 268b, contact tails 266a and 266b are separated along the contact tail column direction 144, and the intermediate parts 264a and 264b adjacent to contact tails 266a and 266b are separated along the contact tail row direction 146. Therefore, contact tails 266a and 266b are separated along a first direction, and the intermediate parts 264a and 264b adjacent to contact tails 266a and 266b are separated along a second direction perpendicular to the first direction. This difference in the direction of the separation of the sections of the same conductor is the result of the second transition region 268b. In the illustrated embodiment, the signal conductor is twisted 90 degrees in the second transition region 268b so that there is a 90 degree difference between the contact tail column direction 144 and the second contact tail row direction 146. The relative positions of the signal conductors 260a and 260b change along the second transition region 268b so that at a first end of the second transition region 268b adjacent to the contact tails 266a and 266b, the signal conductors 260a and 260b are aligned along the contact tail column direction 144, and at a second end of the second transition region 268b adjacent to the middle portions 264a and 264b, the signal conductors 260a and 260b are aligned along the contact tail row direction 146.

[0177] As described above, the extender module 300 enables the mating interface of the electrical connector 102 to be adapted. Figure 1As shown in , connectors such as connector 102 can be mated with each other by attaching an extender module to one of the connectors. Extender module 300 can be mounted on connector module 200 to provide a modified mating interface for electrical connector 102. Thus, extender module 300 can be configured at one end for attachment to the mating interface of connector 102, and extender module 300 can be configured at the other end for mating with connector 102. In such a configuration, there can be one extender module attached to each connector module 200.

[0178] Fig.17A is a perspective view of the connector module 200 with the extender module 300 attached. Fig. 17B is a perspective view of the connector module 200 and the extender module 300 with the electromagnetic shield members 210 a and 210 b cut away. Fig. 17C yes Fig. 17C 200 and a perspective view of the extender module and the signal conductors 260 of the connector module 200.

[0179] The extender module 300 includes mating portions 304a and 304b at the ends of the extender module 300. The mating portions 304a and 304b extend away from the connector module 200. Here, the mating portions 304a and 304b are configured to fit into round conductors in a socket of a mating connector. In an embodiment where the mating connector has a socket such as sockets 270a and 270b, the dimensions of the mating arms 272a and 272b will be determined to deflect when the mating portions 304a and 304b are inserted, and a contact force is generated. In some embodiments, the contact force can be between 25gm and 45gm. In some embodiments, the contact force can be between 30gm and 40gm.

[0180] exist FIG. 17A to FIG. 17C , the extender module 300 is attached to the connector module 200. The attachment between the extender module 300 and the connector module 200 can be detachable, so that the extender module 300 can be removed from the connector module 200 and reattached multiple times. However, in the illustrated embodiment, the extender module 300 is configured to make a connection with the connector module 200 that is maintained throughout the useful life of the connector resulting from the combination. Portions 306a and 306b of the signal conductors 302 of the extender module 300 extend toward the connector module 200 and are configured to make such a connection.

[0181] In the illustrated embodiment, the mating portions 304a and 304b of the signal conductor 302 of the extender module 300 are located at the mating interface 314 of the extender module 300. The second portions 306a and 306b of the signal conductor 302 of the extender module 300 are located at the mounting interface 316 of the extender module 300. The mating portions 304a and 304b and each of the second portions 306a and 306b extend in a direction parallel to the direction in which the extender module 300 is elongated. The second portions 306a and 306b include contact tails that are configured to extend through the holes 238a and 238b of the extension portion 234 of the inner insulating member 230. When mounted to the connector module 200, the second portions 306a and 306b are positioned between the mating arms 272a and 272b of each of the compliant receptacles 270a and 270b. In the illustrated embodiment, the second portions 306a and 306b are terminated with press-fit ends that are configured to be inserted between the mating arms 272a and 272b. Mounting the second portions 306a and 306b of the signal conductor 302 of the extender module 300 to the mating ends 262 of the signal conductor 260 of the connector module 200 may require a force of at least 60N.

[0182] In some embodiments, the mating parts 304a and 304b and / or the second parts 306a and 306b can be formed by superelastic conductive materials. The use of superelastic materials can enable those parts to have a small width while providing sufficient robustness. For example, the mating parts 304a and 304b can have an effective diameter between 5 mils and 20 mils. The signal conductor with the superelastic mating part can be formed completely by superelastic materials. Alternatively, the conductor can be partially formed by conventional metals such as phosphor bronze, with superelastic components attached thereto. For example, the superelastic wire can be attached or brazed to a conventional metal member by forming a mechanically connected tab. In some embodiments, the mating parts 304a and 304b and / or the second parts 306a and 306b can include superelastic wires with a width between 5 mils and 20 mils. In some embodiments, the mating parts 304a and 304b and / or the second parts 306a and 306b can include superelastic wires with a width less than 12 mils.

[0183] The mating portions 304a and 304b of the signal conductor 302 of the extender module 300 can be configured to mate with the mating ends 262a and 262b of the signal conductor 260 of the connector module 200. In the illustrated embodiment, the mating portions 304a and 304b are terminated with pins configured to extend through the holes 238a and 238b of the extension 234 and are sized to fit between the arms 272a and 272b of the compliant receptacles 270a and 270b. When formed using a superelastic material, the spacing distance of the mating portions 304a and 304b can be less than the spacing distance of the holes of the extension 234, so that the mating portions 304a and 304b deform when they extend through the holes and / or enter the mating ends 262a and 262b, and reshape when removed from the holes and / or mating ends 262a and 262b.

[0184] The use of small diameter wires can also support tighter spacing between signal pairs within the connector, and also support shielding around each pair having a relatively small cross-sectional area, including at the mating interface of the connector, where the electromagnetic shield may have its largest cross-sectional area. The effective diameter of the signal conductor at the mating interface is set by the outer dimensions of the arms 272a and 272b of the compliant sockets 270a and 270b when deflected as a result of inserting the mating portions 304a and 304b. The smaller diameter mating portions 304a and 304b allow the outer dimensions of the arms 272a and 272b to be smaller as when deflected. The smaller size of the signal conductors, in turn, results in smaller spacing between components at the mating interface, including the signal conductors and the grounded electromagnetic shield surrounding the signal conductors to provide the desired impedance to the signal conductors.

[0185] The cross-sectional area of ​​the largest part of the electromagnetic shielding element can be, for example, 3 mm 2 Up to 5mm 2 The maximum dimension is less than 4 mm, such as 3.8 mm or less, or in some embodiments, less than 3.5 mm or 3 mm. Such a small size can establish a frequency of the lowest frequency resonant mode supported by the housing formed by the electromagnetic shield, which is outside the expected operating range of the connector. The resonant frequency outside the operating range improves the integrity of the signal passing through the connection system.

[0186] Another advantage of the connectors described herein is the consistency of the mating interfaces provided. Regardless of whether the connector is mated directly with another connector or with one or more extender modules forming a mating interface therebetween, each mating interface can provide desired impedance characteristics. For example, the mating portions 304a and 304b of the signal conductor 302 of the extender module 300 can provide the same benefit of impedance uniformity associated with the mating portions of the mating connector, even if the mating portions 304a and 304b are not completely located within the mating ends of the mating connector, such as the compliant receptacles 270a and 270b of the connector module 200. In some embodiments, the impedance variation between the mating configuration and the disengagement configuration of the mating end 202 can be less than 5 ohms at the operating frequency of the connector, such as in the range of 45 GHz to 50 GHz.

[0187] 18A to 18C 3 are perspective views, side views, and alternate side views of the extender module 300. 18A to 18C As shown in , the extender module 300 includes an insulating member 330 , electromagnetic shielding members 310 a and 310 b , and a pair of signal conductors, each signal conductor having a mating portion and a portion for attaching to a signal conductor within a connector extending from the insulating member 330 .

[0188] In the illustrated embodiment, the extender module 300 is elongated in a straight line from the mating portions 304a and 304b at the mating interface 314 to the second portions 306 and 306b at the mounting interface 316. The mating portions 304a and 304b of the signal conductor 302 are separated from each other along a first line 320. The second portions 306a and 306b of the signal conductor 302 are similarly separated from each other along a line, here a second line 322 that is parallel to the first line 320.

[0189] Additional details of the second sections 306a and 306b are provided in 18A to 18C As shown, these portions are press-fit tails having a shape that will compress when inserted into the opening to apply a force to the sides of the opening. The press-fit tails are shown as having an "S" shape or serpentine cross-section. Other shapes of press fits such as eye-of-the-needle press fits used to attach signal conductors to printed circuit boards may alternatively be used on some or all connector modules.

[0190] The insulating member 330 can be formed using a dielectric material such as plastic, which can be insert molded or otherwise formed around the signal conductor of the extender module. The insulating member can be formed with structural features. For example, the insulating member 330 can include features that facilitate attachment to or mating with the signal module. The protrusions 332a and 332b and the protrusions 334a and 334b ​​can be formed to be assembled between the protrusions 216 at the mating end 202 of the connector module 200. Alternatively or additionally, the insulating member 330 can include features that facilitate engagement with the front housing 110 and / or the extender housing 120 or positioning relative to the front housing 110 and / or the extender housing 120. Wings 336a and 336b can provide this function. Wings 336a and 336b are arranged between the mating interface 314 and the mounting interface 316, and extend in relative directions parallel to lines 320 and 322. Each of the wings 336a and 336b has a concave portion 338a or 338b that is indented in a direction opposite to the direction in which the corresponding wing 336a or 336b extends.

[0191] Electromagnetic shielding members 310a and 310b can be attached on opposite sides of the extender module 300. Electromagnetic shielding members 310a and 310b can include conductive shielding members. For example, electromagnetic shielding members 310a and 310b can be stamped from metal sheets. Electromagnetic shielding member 310a includes a first attachment member 312a, and electromagnetic shielding member 310b includes a second attachment member 312b for engaging with the first attachment member 312a to attach electromagnetic shielding members 310a and 310b to each other. In the illustrated embodiment, the first attachment member 312a includes a hook-shaped tab, and the second attachment member 312b includes an opening for receiving the tab, so that the hook of the tab is latched in the opening. The first attachment member 312a and the second attachment member 312b engage each other at the concave portions 338a and 338b of the wings 336a and 336b.

[0192] Electromagnetic shielding members 310a and 310b may also include features for mating with electromagnetic shielding members within a connector module with which extender module 300 mates or is attached. 18A to 18CIn the example of, the mating contact surface is formed on the part of the electromagnetic shielding members 310a and 310b. The mating contact parts 350a, 350b, 352a and 352b are formed at each distal end of the shielding members 310a and 310b, adjacent to the mating interface or the mounting interface. The mating contact parts 350a, 350b, 352a and 352b are shown here as convex surfaces formed in the electromagnetic shielding members 310a and 310b. The convex surface can be plated with gold or other anti-oxidation materials to enhance electrical contact. In addition, the most distal parts of the electromagnetic shielding members 310a and 310b beyond the mating contact parts can be embedded in the part of the insulating member 330 or protected by the part of the insulating member 330 to prevent the electromagnetic shielding members 310a and 310b from being tripped or hooked on the structure with the connector module 200 when the mating end 262 of the signal conductor 260 of the connector module 200 is inserted.

[0193] FIG. 19A to FIG. 19B 3 are a side view and an alternative side view of the extender module 300 with the electromagnetic shielding members 310 a and 310 b cut away from the extender module to better illustrate the insulating member 330 .

[0194] FIG. 20A to FIG. 20B are side and alternative side views of signal conductors 302a and 302b of extender module 300.

[0195] Signal conductors 302a and 302b can be stamped out of sheet metal. Alternatively, signal conductors 302a and 302b can be formed using a plurality of conductive elements that are fused, welded, brazed or otherwise coupled together. For example, the matching portions 304a and 304b and / or second portions 306a and 306b of signal conductors 302a and 302b can be formed separately and then attached to each other. This method can make matching portions 304a and 304b easily be formed with smooth surfaces and / or different material properties. In some embodiments, matching portions 304a and 304b can be formed by superelastic conductive materials. In some embodiments, matching portions 304a and 304b include superelastic wires with a diameter between 5 mils and 20 mils.

[0196] The construction techniques employed in manufacturing the extender module 300 may also be used to form modules of other configurations. Fig.21AShown is a header connector 2120 that can be mounted to a printed circuit board formed with a module 2130, for example, which can be formed using the construction technology described above in conjunction with the extender module 300. In this example, the header connector 2120 has a mating interface identical to the mating interface of the connector 102a. In the illustrated embodiment, both have mating ends of paired signal conductors aligned along parallel lines at 45 degree angles relative to the column direction and / or row direction of the mating interface. Therefore, the header connector 2120 can be mated with a connector in the form of a connector 102b. However, compared with the mounting interface of the connector 102a, the mounting interface 2124 of the header connector 2120 is in a different orientation relative to the mating interface. Specifically, the mounting interface 2124 is parallel to the mating interface 2122 rather than perpendicular to the mating interface 2122. The header connector 2120 can be suitable for use in a backplane, a midplane, a mezzanine, and other such configurations. For example, the header connector 2120 can be mounted to a backplane, a midplane, or other substrates, which are perpendicular to a daughter card or other printed circuit board to which a right-angle connector such as connector 102b is attached. Alternatively, the header connector 2120 can accommodate a mezzanine connector having the same mating interface as connector 102b. The mating end of the mezzanine connector can face a first direction, and the contact tail of the mezzanine connector can face a direction opposite to the first direction. For example, the mezzanine connector can be mounted to a printed circuit board that is parallel to the substrate on which the header connector 2120 is mounted.

[0197] exist Fig.21A In the embodiment shown in FIG. 2 , the header connector 2120 has a housing 2126 that can be formed of an insulating material such as molded plastic. However, some or all of the housing 2126 can be formed of a lossy or conductive material. The bottom plate of the housing 2126 through which the connector module passes can, for example, be formed of or include a lossy material that is coupled to an electromagnetic shield of the connector module 2130. As another example, the housing 2126 can be a die-cast metal or a metal-plated plastic.

[0198] The housing 2126 may have features that enable mating with the connector. In the illustrated embodiment, the housing 2126 has features that enable mating with the connector 102b, similar to the housing 120. Thus, the portion of the housing 2126 that provides the mating interface is as described above in conjunction with the housing 120 and the connector 102b. Figure 2A The mounting interface 2124 of the housing 2126 is suitable for mounting to a printed circuit board.

[0199] Such a connector can be formed by inserting connector modules 2130 in rows and columns into housing 2126. Each module can have mating contact portions 2132a and 2132b, which can be shaped similarly to mating portions 304a and 304b, respectively. Mating contact portions 2132a and 2132b can be similarly made of small diameter superelastic wire.

[0200] Fig.21B An exemplary connector module 2130 is shown in more detail. As with the extender module 300, portions of a pair of conductive elements may be held within an insulating portion (not numbered). Mating contact portions 2132a and 2132b, which may be integrated with the portions of the conductive elements within the housing or formed separately and attached to those portions, extend from the mating interface portion of the connector module 2130.

[0201] The contact tails 2134a and 2134b can extend from the mounting interface portion of the connector module 2130. The contact tails 2134a and 2134b can be integrated with portions of the conductive elements within the housing, and the contact tails 2134a and 2134b can be similar to the contact tails 206a and 206b ( Fig. 17C ) and formed.

[0202] The connector module 2130 may also have an electromagnetic shielding member similar to the electromagnetic shielding members 310a and 310b on the opposite side. Fig.21B A complementary shield member (not visible) may be attached to an opposite side of the connector module 2130. The mating end of the shield member 2140a may be shaped similarly to the mating ends of the shield members 310a and 310b. For example, the shield member 2140a includes a mating contact portion 2144a that may be shaped similarly to the mating contact portion 350a.

[0203] The mounting end of the connector module 2130 can be shaped similarly to the mounting end of the connector module 200. Thus, the electromagnetic shield member can include contact tails 2142a and 2142b that are shaped and positioned relative to the contact tails 2134a and 2134b in the same manner that the electromagnetic shield tail 220 is shaped and positioned relative to the contact tails 206a and 206b.

[0204] exist Fig.21AIn the embodiment shown in FIG. 1 , the paired mating contact portions 2132a and 2132b are separated from each other along parallel lines that are at an angle of about 45 degrees relative to the row direction and / or the column direction. This configuration can be achieved by passing the conductive elements directly through the connector module 2130 so that the contact tails 2134a and 2134b are in the same plane as the mating contact portions 2132a and 2132b. In this configuration, the module 2130 will be installed in the housing 2126 with the side at Fig.21B It is visible at a 45 degree angle relative to the row and column directions.

[0205] By rotating the connector module 2130 45 degrees relative to the row or column direction, the Figure 8 However, each of the mounting locations, such as mounting locations 194a and 194b, will similarly be rotated 45 degrees relative to the row and column directions. In such a configuration, routing channels can be created in the row direction, such as Figure 8 As shown in . The routing channels can extend at a 45 degree angle relative to the row direction, rather than the routing channels in the column direction.

[0206] Alternatively, the connector module 2130 can be configured to provide Figure 8 For example, the mounting interface 2124 may be Figure 7 21. Such a mounting interface may be achieved by a 45 degree twist in the conductive element passing through the connector module 2130. In such an embodiment, the conductive element may be shaped by such a twist and inserted into a portion of the housing having a similarly shaped recess to provide such a twist.

[0207] The modularity of the components as described herein can support other connector configurations using the same or similar components. Those connectors can be easily configured to mate with the connectors as described herein. For example, Fig. 22 A modular connector is shown in which some of the connector modules are configured for terminating cables, such as twin-axial cables, rather than having contact tails configured for mating with a printed circuit board. Fig. 22 In the example of , the connector has a wafer assembly 2204, a cable wafer 2206, and a housing 2202. In this example, the cable wafer 2206 can be positioned side by side with the wafer in the wafer assembly 2204 and inserted into the housing 2202 in the same manner as the wafer is inserted into the housing 110 or 120 to provide a mating interface with a socket or pin, respectively. In an alternative embodiment, Fig. 22 The connector may be just a cable connector, for example by having only a cable sheet 2206, or Fig. 22The connector can be a hybrid cable connector as shown, having a side-by-side wafer assembly 2204 and a cable wafer 2206, or in some embodiments, having some modules in the wafer configured for attachment to a tail of a printed circuit board and other modules configured for terminating a tail of a cable.

[0208] Through the cable configuration, signals passing through the mating interface of the connector can be coupled to other components in the electronic system that includes the connector 2200. Such an electronic system may include a printed circuit board to which the connector 2200 is mounted. Signals passing through the mating interface in the module mounted to the printed circuit board can be transferred to other components also mounted to the printed circuit board via traces in the printed circuit board. Other signals passing through the mating interface in the cable modules can be routed to other components in the system via cables terminated to those modules. In some systems, the other ends of those cables may be connected to components on other printed circuit boards that cannot be reached via traces in the printed circuit board.

[0209] In other systems, those cables can be connected to components on the same printed circuit board on which other connector modules are installed. Such a configuration may be useful because the connectors described herein support signals with frequencies that can reliably pass through the printed circuit board only on relatively short traces. High-frequency signals, such as signals transmitting 56Gbps or 112Gbps, are significantly attenuated in traces on the order of 6 inches long or longer. Therefore, the following system can be implemented, in which the connector mounted to the printed circuit board has a cable connector module for such high-frequency signals, wherein the cables terminated to those cable connector modules are also connected at the mid-board of the printed circuit board, such as 6 inches or more inches from the edge or other position on the printed circuit board where the connector is installed.

[0210] exist Fig. 22 In the example of , the pairs at the mating interface do not rotate relative to the row direction or the column direction. However, a connector with one or more cable sheets can be achieved by rotating the mating interface as described above. For example, the mating ends of paired signal conductors can be arranged at a 45 degree angle relative to the mating row direction and / or the mating column direction. The mating column direction for the connector can be a direction perpendicular to the board mounting interface, and the mating row direction can be a direction parallel to the board mounting interface.

[0211] Furthermore, it should be understood that although Fig. 22The cable connector modules are shown to be in only one slice and all slices have only one type of connector module, but neither is a limitation of the modular technology described herein. For example, the connector modules of the top row or the connector modules of the row can be cable connector modules, while the remaining rows can have connector modules configured for mounting to a printed circuit board.

[0212] Additional exemplary implementations of the techniques described herein are described further below.

[0213] In a first example, a connector module includes a pair of signal conductors, wherein the pair of signal conductors include a pair of mating ends, a pair of contact tails, and a pair of middle portions connecting the pair of mating ends to the pair of contact tails, the pair of mating ends extend in a direction at right angles to a direction in which the pair of contact tails extend, the mating ends of the pair of mating ends are separated in the direction of a first line, the middle portions of the pair of middle portions are separated in the direction of a second line, and the first line is set at an angle greater than 0 degrees and less than 90 degrees relative to the second line.

[0214] In a first example, the first line is disposed at an angle greater than 30 degrees and less than 60 degrees relative to the second line.

[0215] In a first example, the first line is disposed at an angle of 45 degrees relative to the second line.

[0216] In a first example, the pair of signal conductors further include a transition region connecting the pair of intermediate portions and the pair of mating ends, wherein at the transition region, a first signal conductor of the pair of signal conductors extends toward a third line, the pair of contact tails are separated along the third line, and a second signal conductor of the pair of signal conductors extends away from the third line.

[0217] In a first example, the connector module further includes an electromagnetic shield at least partially surrounding the mating ends of the pair of signal conductors, and the electromagnetic shield defines a perimeter of the mating ends that is less than 4.5 mm. 2 area.

[0218] In a first example, the electromagnetic shield is embossed with an outward protrusion adjacent the transition region to counteract a change in impedance along the length of the pair of signal conductors associated with a change in shape along the length of the pair of signal conductors.

[0219] In a first example, the electromagnetic shield is further embossed with inward protrusions adjacent the pair of mating ends so as to reduce a difference between a mating impedance and a partially unmated impedance of the connector module.

[0220] In a first example, the electromagnetic shielding member includes a pair of conductive shielding members, each of the conductive shielding members includes a middle portion, a mating portion integral with the middle portion, and a transition portion between the mating portion and the middle portion, and the transition portion provides a twist in the shielding member at an angle of the first line relative to the second line.

[0221] In a first example, the connector module also includes a first insulating member supporting the pair of signal conductors, each of the pair of mating ends of the pair of signal conductors includes a pair of mating arms separated by a gap, and the first insulating member includes a portion extending beyond the pair of mating ends and including a pair of holes aligned with the gap.

[0222] In a first example, the pair of mating ends are configured to receive a wire through the pair of holes and retain the wire between the pair of mating arms.

[0223] In a first example, the contact tails are configured for insertion into holes in a substrate.

[0224] In a first example, the contact tail is configured for insertion into a hole having a diameter less than or equal to 20 mils.

[0225] In a first example, the contact tails each have a width between 6 mils and 20 mils.

[0226] In a first example, the contact tail is configured for insertion into a hole having a diameter less than or equal to 10 mils.

[0227] In a first example, the contact tails each have a width between 6 mils and 10 mils.

[0228] In a modification of the first example, the contact tail is configured to make an electrical connection to a pad of a substrate.

[0229] In a first example, the transition region includes a 45 degree transition of the pair of signal conductors over a length of between 1.4 mm and 2 mm.

[0230] In a first example, the connector module also includes an insulating portion, the insulating portion includes a first side and a second side, the first side includes a first groove, the second side includes a second groove, the first middle portion of the pair of middle portions is arranged in the first groove, and the second middle portion of the pair of middle portions is arranged in the second groove.

[0231] In a second example, a thin sheet includes a plurality of signal conductor pairs, each signal conductor pair including a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, the paired mating ends of the plurality of signal conductor pairs are positioned in columns along a column direction, the intermediate portions of the paired intermediate portions of the plurality of signal conductor pairs are aligned in a direction perpendicular to the column direction and positioned for broadside coupling, and the mating ends of the plurality of signal conductor pairs are separated along lines set at an angle greater than 0 degrees and less than 90 degrees relative to the column direction.

[0232] In a second example, the lines are disposed at an angle greater than 30 degrees and less than 60 degrees relative to the column direction.

[0233] In a second example, the lines are arranged at an angle of 45 degrees relative to the column direction.

[0234] In a second example, the wafer further includes a housing supporting the plurality of signal conductor pairs.

[0235] In a second example, each of the multiple signal conductor pairs includes multiple connector modules, and each of the multiple connector modules also includes an electromagnetic shielding member arranged around the signal conductor pair, wherein a portion of the electromagnetic shielding member at least partially surrounds the mating ends of the signal conductors in the signal conductor pair, and the portion of the electromagnetic shielding member is a rectangle with a width less than 2 mm and a length less than 3.8 mm.

[0236] In a second example, the housing includes a first housing member including a plurality of grooves, and a connector module of the plurality of connector modules is disposed within a groove of the plurality of grooves.

[0237] In a second example, the housing is formed of a lossy conductive material.

[0238] In a second example, the column direction is a mating interface column direction, the paired contact tails of the plurality of signal conductor pairs are positioned in columns along the mounting interface column direction; and the contact tails in the paired contact tails are separated in a mounting interface row direction perpendicular to the mounting interface column direction.

[0239] In a second example, the mating interface column direction is orthogonal to the mounting interface column direction.

[0240] In a second example, the pair of contact tails are configured to be inserted into a hole having a diameter less than or equal to 20 mils.

[0241] In a second example, each contact tail in the pair of contact tails has a width between 6 mils and 20 mils.

[0242] In a second example, the pair of contact tails are configured to be inserted into a hole having a diameter less than or equal to 10 mils.

[0243] In a second example, each contact tail in the pair of contact tails has a width between 6 mils and 10 mils.

[0244] In a second example, a center-to-center spacing between adjacent pairs of contact tails in the mounting interface column direction is less than or equal to 5 mm.

[0245] In a second example, a center-to-center spacing between adjacent pairs of contact tails in the mounting interface column direction is less than or equal to 2.4 mm.

[0246] In a second example, the mounting interface row direction is orthogonal to the mounting interface column direction.

[0247] In a third example, a connector includes a plurality of signal conductor pairs. For each of the plurality of signal conductor pairs, the signal conductor pair includes a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, the signal conductor pair also includes a transition region between the pair of mating ends and the pair of intermediate portions, the paired mating ends of the plurality of signal conductor pairs are arranged in an array including a plurality of rows, the plurality of rows extend along a row direction and are spaced apart from each other in a column direction perpendicular to the row direction, the paired mating ends of the plurality of signal conductor pairs are aligned along a first parallel line, the first parallel line is arranged at an angle greater than 0 degrees and less than 90 degrees relative to the row direction, and for each of the plurality of signal conductor pairs, within the transition region, the relative positions of the signal conductors in the signal conductor pair change, so that at a first end of the transition region adjacent to the mating end, the signal conductors are aligned along a line of the first parallel line, and at a second end of the transition region, the signal conductors are aligned in the row direction.

[0248] In a third example, the first parallel lines are disposed at an angle greater than 30 degrees and less than 60 degrees relative to the row direction.

[0249] In a third example, the first parallel lines are disposed at an angle of 45 degrees relative to the row direction.

[0250] In a third example, each pair of intermediate portions is broadside coupled, and wherein each pair of contact tails is broadside coupled.

[0251] In a third example, the pairs of contact tails of the plurality of signal conductor pairs are arranged in a second array, and the second array includes columns of pairs of contact tails extending along a third direction.

[0252] In a third example, the third direction is orthogonal to the row direction.

[0253] In a third example, the third direction is perpendicular to both the column direction and the row direction.

[0254] In a third example, each of the plurality of signal conductor pairs further comprises a second transition region, within which the relative positions of the signal conductors in the signal conductor pair change such that at a first end of the second transition region adjacent to the contact tail, the pair of signal conductors are aligned along a second parallel line parallel to the third direction, and at a second end of the transition region adjacent to the middle portion, the pair of signal conductors are aligned along a third parallel line set at an angle greater than 45 degrees and less than 135 degrees relative to the third direction.

[0255] In a third example, the second parallel lines are disposed at an angle greater than 80 degrees and less than 100 degrees with respect to the third direction.

[0256] In a third example, the second parallel lines are perpendicular to the third direction.

[0257] In a third example, the second parallel lines are parallel to the row direction.

[0258] In a third example, an electronic component includes a connector in combination with: a first printed circuit board including a first edge, wherein the connector is a first connector and contact tails of the first connector are mounted to the first printed circuit board adjacent to the first edge; a second printed circuit board; and a second connector, the second connector being mounted to the second printed circuit board and configured to mate with the first connector.

[0259] In a third example, the contact tails of the first connector are inserted into holes of the first printed circuit board.

[0260] In a modification of the third example, the contact tails of the first connector are mounted to pads on the surface of the first printed circuit board.

[0261] In a third example, the contact tails of the first connector are pressed into unplated holes of the first printed circuit board having a diameter less than or equal to 20 mils.

[0262] In a third example, the width of the contact tails of the first connector is between 6 mils and 20 mils.

[0263] In a third example, the contact tails of the first connector are pressed into unplated holes of the first printed circuit board having a diameter between 6 mils and 12 mils.

[0264] In a third example, the width of the contact tails of the first connector is between 6 mils and 12 mils.

[0265] In a third example, the first printed circuit board includes a first layer and a second layer, a trace manufactured on the first layer and extending in a first direction is connected to a first contact tail of a pair of contact tails of the first connector, and a trace manufactured on the second layer and extending in a second direction perpendicular to the first direction is connected to a second contact tail of the pair of contact tails of the first connector.

[0266] In a third example, the second array includes pairs of contact tails of the first connector, the pairs of contact tails being arranged in a repeating pattern, wherein a center-to-center spacing between adjacent pairs of contact tails in the third direction is less than or equal to 5 mm, and a center-to-center spacing between adjacent pairs of contact tails in a direction perpendicular to the third direction is less than or equal to 5 mm.

[0267] In a third example, the second array includes pairs of contact tails of the first connector, the pairs of contact tails being arranged in a repeating pattern, wherein a center-to-center spacing between adjacent pairs of contact tails in the third direction is less than or equal to 2.4 mm, and a center-to-center spacing between adjacent pairs of contact tails in a direction perpendicular to the third direction is less than or equal to 2.4 mm.

[0268] In a third example, the first printed circuit board is perpendicular to the second printed circuit board.

[0269] In a third example, a surface of the second printed circuit board faces a mating end of the first connector.

[0270] In a third example, the mating end of the first connector extends in a first direction, the contact tails of the first connector extend in a second direction, and a surface of the second printed circuit board faces a direction perpendicular to the first direction and the second direction.

[0271] In a third example, the second connector also includes a plurality of signal conductor pairs, each of the plurality of signal conductor pairs including a pair of mating ends, a pair of contact tails, a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, and a transition region between the pair of mating ends and the pair of intermediate portions, the mating ends of the plurality of signal conductor pairs being arranged in a first array including a plurality of rows, the plurality of rows extending along the row direction and spaced apart from each other in a column direction perpendicular to the row direction, the signal conductors in the signal conductor pairs being aligned along first parallel lines, the first parallel lines being arranged at an angle greater than 0 degrees and less than 90 degrees relative to the row direction, and within the transition region, the relative positions of the signal conductors in the signal conductor pairs are changed, so that at a first end of the transition region adjacent to the mating end, the signal conductors are aligned along the first parallel lines, and at one end of the transition region, the signal conductors are aligned in the row direction.

[0272] In a third example, the second connector further comprises a plurality of extender modules, each of the plurality of extender modules comprising a pair of signal conductors, each signal conductor having a first portion and a second portion, the second portions of the plurality of extender modules being mounted to the mating ends of the plurality of signal conductors of the second connector, the first portions of the plurality of extender modules being configured to be received in the mating ends of the first connector, and the paired signal conductors of the plurality of extender modules each extending in a straight line from the first portion to the second portion.

[0273] In a third example, the electronic assembly is further configured to transmit data from the first connector to the second connector at a rate of approximately 112 Gb / s.

[0274] In a third example, the electronic assembly is further configured to operate at a bandwidth of approximately 50 GHz to 60 GHz.

[0275] In a fourth example, a connector module includes an insulating member and a pair of signal conductors held by the insulating member, wherein each signal conductor of the pair of signal conductors includes a first portion at a first end, a second portion at a second end extending from the insulating portion, and an intermediate portion disposed between the first end and the second end, and the first portion includes a wire having a diameter between 5 mils and 20 mils.

[0276] In a fourth example, the wire is a superelastic wire.

[0277] In a fourth example, the superelastic wire of each of the pair of signal conductors is soldered to a middle portion of the signal conductor.

[0278] In a fourth example, the connector module further includes an electromagnetic shield at least partially surrounding the middle portion of the pair of signal conductors, and the electromagnetic shield defines a perimeter of the first portion that is less than 4.5 mm. 2 area.

[0279] In a fourth example, the electromagnetic shield is embossed with an outward protrusion adjacent the first end to counteract variations in impedance along the length of the pair of signal conductors associated with variations in shape along the length of the pair of signal conductors.

[0280] In a fourth example, the electromagnetic shielding member is further embossed with an inward protrusion adjacent to a distal end of the first portion so as to reduce a difference between a fully mated impedance and a partially unmated impedance of the connector module.

[0281] In a fourth example, the electromagnetic shield member includes a conductive shield.

[0282] In a fourth example, the second portion includes a superelastic wire having a width between 5 mils and 20 mils.

[0283] In a fourth example, the superelastic wire has a diameter less than 12 mils.

[0284] In a fourth example, the superelastic wire is configured for insertion into a hole having a diameter less than or equal to 10 mils.

[0285] In a fourth example, the mating force of the superelastic wire is between 25 gm and 45 gm.

[0286] In a modification of the fourth example, the mating force of the superelastic wire is between 30 gm and 40 gm.

[0287] In a fourth example, the second portion includes a press-fit member.

[0288] In a fourth example, a cross-section of the press-fit member has a serpentine shape.

[0289] In a fourth example, an electrical connector includes a plurality of connector modules arranged in a plurality of parallel rows extending along a row direction.

[0290] In a fourth example, a change in impedance between a fully mated configuration and a partially disengaged configuration of the first portion is less than 5 ohms at 20 GHz.

[0291] In a fourth example, a second portion of a connector module in the plurality of connector modules includes contact tails, and pairs of contact tails are arranged in a repeating pattern in a second plurality of rows extending along a first direction and are positioned along a second direction perpendicular to the first direction, wherein a center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.5 mm, and a center-to-center spacing between adjacent pairs of contact tails in the second direction perpendicular to the first direction is less than or equal to 2.5 mm.

[0292] In a fourth example, a second portion of the plurality of connector modules includes contact tails, and pairs of contact tails are arranged in a repeating pattern in a second plurality of rows extending along a first direction and are positioned along a second direction perpendicular to the first direction, wherein a center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.4 mm, and a center-to-center spacing between adjacent pairs of contact tails in the second direction perpendicular to the first direction is less than or equal to 2.4 mm.

[0293] In a fourth example, the first portion of each signal conductor pair of the plurality of connector modules is aligned along a first parallel line disposed at a 45 degree angle relative to the row direction.

[0294] In a fourth example, in the range of 45 GHz to 50 GHz, the total impedance of each connector module is between 90 ohms and 100 ohms.

[0295] In a fifth example, an extender module includes: a pair of signal conductors, each of the pair of signal conductors including a first portion at a first end and a second portion at a second end; and an electromagnetic shield at least partially surrounding the pair of signal conductors, the first portions of the pair of signal conductors being configured as mating portions and positioned along a first line, and the second portions of the pair of signal conductors being configured to be compressed when inserted into a hole and positioned along a second line parallel to the first line.

[0296] In a fifth example, the electromagnetic shield includes a conductive shield.

[0297] In a fifth example, a cross section of the second portion is “S” shaped.

[0298] In a fifth example, the second portion is configured for insertion into an interface hole having a diameter less than or equal to 20 mils.

[0299] In a fifth example, the width of the second portion is between 6 mils and 20 mils.

[0300] In a fifth example, the second portion is configured for insertion into an interface hole having a diameter less than or equal to 10 mils.

[0301] In a fifth example, the width of the second portion is between 6 mils and 10 mils.

[0302] In a fifth example, a connector includes: an insulating portion and a plurality of signal conductors supported by the insulating portion, each of the plurality of signal conductors having a mating portion defining an interface hole; and a plurality of extender modules, second portions of the signal conductors of the extender modules being inserted into the interface holes.

[0303] In a fifth example, the plurality of extender modules further include a plurality of signal conductor pairs having paired second portions each aligned along a first parallel line, the plurality of signal conductors further include a plurality of signal conductor pairs having paired middle portions and paired mating portions connected by a transition region, the signal conductors in each signal conductor pair being aligned along the first parallel line at a first portion of the transition region adjacent to the pair of mating portions, and the signal conductors being aligned along a second parallel line at a second portion of the transition region adjacent to the pair of middle portions, the second parallel line being arranged at an angle of 45 degrees relative to the first parallel line.

[0304] In a sixth example, a connector includes: an insulating portion; a plurality of signal conductors held by the insulating portion; and a plurality of shielding members, the plurality of signal conductors including an elongated mating portion extending from the insulating portion, the plurality of signal conductors including a plurality of paired signal conductors, the plurality of paired signal conductors being arranged in a plurality of rows extending along a row direction, the plurality of shielding members at least partially surrounding the plurality of pairs, and the mating portions of the plurality of pairs being separated along a first parallel line arranged at an angle of 45 degrees relative to the row direction.

[0305] In a sixth example, the plurality of shield members include conductive shields.

[0306] In a sixth example, the insulating portion includes a planar portion having a first surface and a second surface opposite to the first surface, the mating portion extends in a direction perpendicular to the first surface, and the signal conductor further includes a tail extending through the second surface.

[0307] In a sixth example, the contact tails are arranged in a repeating pattern in a second plurality of rows extending along a first direction and are positioned along a second direction perpendicular to the first direction, wherein a center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 5 mm, and a center-to-center spacing between adjacent pairs of contact tails in the second direction perpendicular to the first direction is less than or equal to 5 mm.

[0308] In a sixth example, the contact tails are arranged in a repeating pattern in a second plurality of rows extending along a first direction and are positioned along a second direction perpendicular to the first direction, wherein a center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.4 mm, and a center-to-center spacing between adjacent pairs of contact tails in the second direction perpendicular to the first direction is less than or equal to 2.4 mm.

[0309] In a sixth example, the contact tail is configured for insertion into a hole having a diameter less than or equal to 20 mils.

[0310] In a sixth example, the width of the contact tail is between 6 mils and 20 mils.

[0311] In a sixth example, the contact tail is configured for insertion into a hole having a diameter less than or equal to 10 mils.

[0312] In a sixth example, the width of the contact tail is between 6 mils and 10 mils.

[0313] In a sixth example, the plurality of paired signal conductors further include a middle portion connected to the mating portion through a transition region, the signal conductors in each pair of signal conductors are separated along the first parallel lines at a first portion of the transition region adjacent to the mating portion, and the signal conductors are separated along second parallel lines parallel to the row direction at a second portion of the transition region adjacent to the middle portion.

[0314] It should be appreciated that aspects of each of the examples described above may be combined in a single embodiment.

[0315] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art.

[0316] For example, Fig.23 A pair of signal conductors 260' is shown having an angled mating interface, as described above in connection with signal conductor 260. Similar to signal conductor 260, signal conductor 260' has broadside coupled intermediate portions 264a' and 264b'. Unlike signal conductor 260, signal conductor 260' has broadside coupled contact tails 266a' and 266b' separated along lines 144' that are parallel to the row direction of the board mounting interface of the connector including signal conductor 260'. Fig.23 The signal conductors shown in can be combined with connectors using the techniques described herein.

[0317] For example, signal conductors 260a and 260b are described as being configured to carry differential signals. In other embodiments, module 200 may include conductors configured to carry single-ended electrical signals. For example, one signal conductor may carry a signal while another signal conductor may be grounded. Alternatively, in some embodiments, a single signal conductor may be used in place of a pair of signal conductors 260a and 260b in some embodiments, where the ground reference is carried by the electromagnetic shield.

[0318] As another example, the use of a press fit connection to attach the extender module 300 to the connector module is described. Other forms of attachment may be used, including identical separable contacts at both ends of the extender module or other forms of fixed attachment such as welding or soldering.

[0319] In addition, the electrical connectors 102a to 102d described herein can be adapted for use in any suitable configuration, such as a backplane or midplane. For example, in a backplane configuration, the first connector 102a and the second connector 102b can be mated in the same direction in which one of the first contact tail array 136a and the second contact tail array 136b faces and the other contact tail array faces oppositely. Alternatively, the surface of the substrate 104c on which the first contact tail array 136a is mounted and the surface of the substrate 104d on which the second contact tail array 136b is mounted can be parallel to each other. In another configuration, the first contact tail array 136a and the second contact tail array 136b can face a first direction, wherein the first connector 102a and the second connector 102b are configured to mate in a direction perpendicular to the first direction.

[0320] It should be understood that in some embodiments, the connector module 200 may include a single insulating member rather than having separate outer insulating members 280a and 280b and inner insulating member 230. In some embodiments, the connector module 200 includes one insulating member instead of the outer insulating members 280a and 280b, and also includes the inner insulating member 230. In some embodiments, the dielectric constant of the outer insulating members 280a and 280b may be different from the dielectric constant of the inner insulating member 230. Alternatively, the outer insulating members 280a and 280b and the inner insulating member 230 have substantially the same dielectric constant.

[0321] It should be understood that the mating end 262 may include alternative mating components such as pins, compliant beams or wires instead of compliant sockets 270a and 270b. Likewise, the contact tails 266a and 266b may alternatively be configured to be mounted to conductive pads on a surface of, for example, a printed circuit board in a manner other than press-fit.

[0322] As yet another example, a transition region is described in which there is a 45 degree or 90 degree twist. Other amounts of twist are possible in the transition region. In some embodiments, the parallel lines 138 are disposed at an angle greater than 0 degrees and less than 90 degrees relative to the mating row direction 142 or the mating column direction 140. In some embodiments, the parallel lines 138 are disposed at an angle greater than 30 degrees and less than 60 degrees relative to the mating row direction 142 or the mating row direction 140. In some embodiments, the parallel lines 138 are parallel to the mating column direction 140 or the mating row direction 142.

[0323] Likewise, in some embodiments, the contact tail row direction 146 can be disposed at an angle greater than 45 degrees and less than 135 degrees relative to the contact tail column direction 144. In some embodiments, the contact tail row direction 146 can be disposed at an angle greater than 80 degrees and less than 100 degrees relative to the contact tail column direction 144. In the illustrated embodiment, the contact tail row direction 146 is perpendicular to the contact tail column direction 144. However, in some embodiments, the contact tail row direction 146 is parallel to the contact tail column direction 144.

[0324] Furthermore, the twist in each of the two mating connectors may be the same or may be different in angular amount. Furthermore, the twist in each of the two mating connectors may be in the same direction or in opposite directions. For example, in Fig.16A In the illustrated embodiment, the contact tails 266a and 266b are twisted in a clockwise direction to the intermediate portions 264a and 264b. The intermediate portions 264a and 264b are twisted in a clockwise direction to the mating ends 262a and 262b again. One or both of such twistings can be in a counterclockwise direction, and the direction of the twisting in each transition region 268a and / or 268b can be the same or different in the mating connector. For example, the twisting in the transition region 268a from the intermediate portions 264a and 264b to the mating ends 262a and 262b can be opposite in each mating connector in the two mating connectors to support the parallel plate connector configuration.

[0325] As another example of variation, paired signal conductors can be configured without any twist in the pair. The mating interface of each pair can be at an angle of, for example, 45 degrees relative to the mating interface row direction. The tail of each pair can be at the same angle relative to the mounting interface row direction. Such a configuration can be used for mezzanine connectors or other suitable types of connectors, and can cause the footprint of the connector to occupy a relatively small surface area of ​​the printed circuit board to which the connector is mounted.

[0326] It should be understood that in some embodiments, the contact tails of the third contact tail array 136c are configured to be inserted into a hole having a diameter less than or equal to 20 mils. In some embodiments, the contact tails of the third contact tail array 136c are configured to be inserted into a hole having a diameter less than or equal to 10 mils. In some embodiments, the contact tails of the third contact tail array 136c each have a width between 6 mils and 20 mils. In some embodiments, the contact tails of the third contact tail array 136c each have a width between 6 mils and 10 mils.

[0327] As another example of possible variations, the extender module 300 is shown with two electromagnetic shielding members covering two opposing sides of the module. Alternatively, the electromagnetic shielding can be implemented with shielding members that cover or partially cover 3 sides or all 4 sides of the module. In some embodiments, the electromagnetic shielding members partially cover some or all sides with gaps on the partially covered sides. Such a shielding configuration can be implemented with one or more shielding members.

[0328] As another possible variation, it should be understood that while some embodiments described herein include second portions 306a and 306b of extender module 300 implemented by contact tails, in some embodiments, second portions 306a and 306b may be shaped like mating portions 304a and 304b. The mating portions may include pins configured to extend through holes in extension portion 234, and the mating portions may be sized to fit between arms 272a and 272b of compliant receptacles 270a and 270b such that the pins may be removed from compliant receptacles 270a and 270b without damaging either connector.

[0329] Such changes, modifications and improvements are intended to be part of this disclosure and are intended to fall within the spirit and scope of the present invention. In addition, although the advantages of the present invention are pointed out, it should be understood that not every embodiment of the present invention will include each described advantage. Some embodiments may not implement and may not implement any feature described as advantageous in this article in some cases. Therefore, the above description and accompanying drawings are only examples.

[0330] The various aspects of the present invention may be used alone, in combination, or in a variety of arrangements not specifically discussed in the previously described embodiments, and therefore the various aspects of the present invention are not limited in their application to the details and arrangements of the components set forth in the previous description or shown in the accompanying drawings. For example, the various aspects described in one embodiment may be combined in any manner with the various aspects described in other embodiments.

[0331] In addition, the present invention can be implemented as a method that provides an example. The actions performed as part of the method can be ordered in any suitable manner. Therefore, the following embodiments can be constructed, in which the actions are performed in an order different from the order shown, even if shown as sequential actions in illustrative embodiments, the embodiments can still include performing some actions simultaneously.

[0332] Regarding the implementation methods including the above embodiments, the following technical solutions are also disclosed:

[0333] Solution 1. A connector module, comprising:

[0334] A pair of signal conductors, where:

[0335] The pair of signal conductors includes a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails;

[0336] The pair of mating ends extend in a direction that is at right angles to the direction in which the pair of contact tails extend; and

[0337] The mating ends of the pair of mating ends are separated in the direction of the first line;

[0338] The middle portions of the pair of middle portions are separated in the direction of the second line;

[0339] The first line is disposed at an angle greater than 0 degrees and less than 90 degrees with respect to the second line.

[0340] Solution 2. The connector module according to Solution 1, wherein:

[0341] The first line is disposed at an angle greater than 30 degrees and less than 60 degrees relative to the second line.

[0342] Solution 3. The connector module according to Solution 2, wherein:

[0343] The first line is disposed at an angle of 45 degrees relative to the second line.

[0344] Solution 4. The connector module according to Solution 3, wherein:

[0345] The pair of signal conductors further includes a transition region connecting the pair of intermediate portions and the pair of mating ends, wherein a first signal conductor of the pair of signal conductors extends toward a third line at the transition region and the pair of contact tails are separated along the third line, and

[0346] A second signal conductor of the pair of signal conductors extends away from the third line.

[0347] Solution 5. The connector module according to Solution 3 further comprises an electromagnetic shield at least partially surrounding the mating ends of the pair of signal conductors, and wherein the electromagnetic shield defines an area less than 4.5 mm around the mating ends. 2 area.

[0348] Option 6. A connector module according to Option 5, wherein the electromagnetic shield is embossed with an outward protrusion adjacent to the transition region to offset changes in impedance along the length of the pair of signal conductors associated with changes in the shape of the pair of signal conductors along the length.

[0349] Solution 7. The connector module according to Solution 6, wherein the electromagnetic shielding member is further embossed with an inward protrusion adjacent to the pair of mating ends so as to reduce the difference between the mating impedance and the partial disengagement impedance of the connector module.

[0350] Solution 8. The connector module according to Solution 7, wherein:

[0351] The electromagnetic shield includes a pair of conductive shielding members;

[0352] Each of the conductive shield members includes a middle portion, a mating portion integral with the middle portion, and a transition portion between the mating portion and the middle portion; and

[0353] The transition portion provides a twist in the shield member at an angle of the first line relative to the second line.

[0354] Aspect 9. The connector module according to aspect 3 further comprises a first insulating member supporting the pair of signal conductors, and wherein:

[0355] Each of the pair of mating ends of the pair of signal conductors includes a pair of mating arms separated by a gap; and

[0356] The first insulating member includes a portion extending beyond the pair of mating ends and including a pair of holes aligned with the gap.

[0357] Solution 10. The connector module according to Solution 9, wherein:

[0358] The pair of mating ends are configured to receive a wire through the pair of holes and retain the wire between the pair of mating arms.

[0359] Embodiment 11. The connector module of embodiment 3, wherein the contact tail is configured to be inserted into a hole in a substrate.

[0360] Embodiment 12. The connector module of embodiment 11, wherein the contact tail is configured to be inserted into a hole having a diameter less than or equal to 20 mils.

[0361] Embodiment 13. The connector module of embodiment 12, wherein the contact tails each have a width between 6 mils and 20 mils.

[0362] Embodiment 14. The connector module of embodiment 11, wherein the contact tail is configured to be inserted into a hole having a diameter less than or equal to 10 mils.

[0363] Embodiment 15. The connector module of embodiment 14, wherein the contact tails each have a width between 6 mils and 10 mils.

[0364] Embodiment 16. The connector module according to Embodiment 3, wherein the contact tail is configured to make an electrical connection with a pad of a substrate.

[0365] Embodiment 17. A connector module according to Embodiment 4, wherein the transition region includes a 45 degree transition of the pair of signal conductors over a length between 1.4 mm and 2 mm.

[0366] Solution 18. The connector module according to Solution 1, further comprising:

[0367] An insulating portion includes a first side and a second side, wherein the first side includes a first groove, the second side includes a second groove, and a first middle portion of the pair of middle portions is disposed in the first groove, and a second middle portion of the pair of middle portions is disposed in the second groove.

[0368] Solution 19. A sheet comprising:

[0369] a plurality of signal conductor pairs, each signal conductor pair comprising a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails,

[0370] in:

[0371] The paired mating ends of the plurality of signal conductor pairs are positioned in columns along a column direction;

[0372] intermediate portions of the paired intermediate portions of the plurality of signal conductor pairs are aligned in a direction perpendicular to the column direction and positioned for broadside coupling; and

[0373] The mating ends of the plurality of signal conductor pairs are separated along lines disposed at an angle greater than 0 degrees and less than 90 degrees relative to the column direction.

[0374] Embodiment 20. The sheet according to embodiment 19, wherein:

[0375] The lines are disposed at an angle greater than 30 degrees and less than 60 degrees relative to the column direction.

[0376] Embodiment 21. A sheet according to Embodiment 19, wherein the lines are arranged at an angle of 45 degrees relative to the column direction.

[0377] Option 22. The sheet according to Option 21 further includes a shell supporting the plurality of signal conductor pairs.

[0378] Embodiment 23. The wafer according to embodiment 21, wherein each of the plurality of signal conductor pairs comprises a plurality of connector modules, each of the plurality of connector modules further comprising:

[0379] An electromagnetic shield is disposed around the pair of signal conductors, wherein a portion of the electromagnetic shield at least partially surrounds the mating ends of the signal conductors of the pair of signal conductors and is rectangular with a width less than 2 mm and a length less than 3.8 mm.

[0380] Embodiment 24. The sheet according to embodiment 23, wherein:

[0381] The housing includes a first housing member including a plurality of grooves; and

[0382] A connector module of the plurality of connector modules is disposed within a recess of the plurality of recesses.

[0383] Option 25. A sheet according to Option 24, wherein the shell is formed of a lossy conductive material.

[0384] Embodiment 26. The sheet according to embodiment 21, wherein:

[0385] The column direction is the mating interface column direction;

[0386] The pairs of contact tails of the plurality of signal conductor pairs are positioned in a column along a mounting interface column direction; and

[0387] The contact tails in the pair of contact tails are separated in a mounting interface row direction perpendicular to the mounting interface column direction.

[0388] Option 27. A thin sheet according to Option 26, wherein the direction of the mating interface column is orthogonal to the direction of the mounting interface column.

[0389] Embodiment 28. A wafer according to embodiment 21, wherein the pair of contact tails are configured to be inserted into a hole having a diameter less than or equal to 20 mils.

[0390] Embodiment 29. A wafer according to embodiment 28, wherein the width of each contact tail in the pair of contact tails is between 6 mils and 20 mils.

[0391] Embodiment 30. A wafer according to embodiment 21, wherein the pair of contact tails are configured to be inserted into a hole having a diameter less than or equal to 10 mils.

[0392] Embodiment 31. A wafer according to embodiment 30, wherein the width of each contact tail in the pair of contact tails is between 6 mils and 10 mils.

[0393] Embodiment 32. A thin sheet according to Embodiment 26, wherein the center-to-center spacing between adjacent pairs of contact tails in the direction of the mounting interface column is less than or equal to 5 mm.

[0394] Embodiment 33. A wafer according to Embodiment 26, wherein the center-to-center spacing between adjacent pairs of contact tails in the direction of the mounting interface column is less than or equal to 2.4 mm.

[0395] Option 34. An electrical connector according to Option 26, wherein the row direction of the mounting interface is orthogonal to the column direction of the mounting interface.

[0396] Solution 35. A connector, comprising:

[0397] a plurality of signal conductor pairs, wherein for each signal conductor pair in the plurality of signal conductor pairs:

[0398] The signal conductor pair includes a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails.

[0399] The signal conductor pair also includes a pair of mating ends and a pair of intermediate portions.

[0400] The transitional region between

[0401] The paired mating ends of the plurality of signal conductor pairs are arranged in an array comprising a plurality of rows extending along a row direction and spaced apart from each other in a column direction perpendicular to the row direction;

[0402] The paired mating ends of the plurality of signal conductor pairs are aligned along first parallel lines, the first parallel lines being disposed at an angle greater than 0 degrees and less than 90 degrees relative to the row direction; and

[0403] For each signal conductor pair of the plurality of signal conductor pairs, within the transition region, the relative positions of the signal conductors of the signal conductor pair vary such that at a first end of the transition region adjacent to the mating end, the signal conductors are aligned along a line of the first parallel lines, and at a second end of the transition region, the signal conductors are aligned in the row direction.

[0404] Embodiment 36. A connector according to Embodiment 35, wherein the first parallel lines are arranged at an angle greater than 30 degrees and less than 60 degrees relative to the row direction.

[0405] Embodiment 37. A connector according to Embodiment 35, wherein the first parallel lines are arranged at an angle of 45 degrees relative to the row direction.

[0406] Embodiment 38. A connector according to Embodiment 35, wherein each pair of intermediate portions is broadside coupled, and wherein each pair of contact tails is broadside coupled.

[0407] Embodiment 39. The connector according to embodiment 35, wherein:

[0408] The pairs of contact tails of the plurality of signal conductor pairs are arranged in a second array;

[0409] The second array includes columns of the pairs of contact tails extending along a third direction.

[0410] Embodiment 40. A connector according to Embodiment 39, wherein the third direction is orthogonal to the row direction.

[0411] Embodiment 41. A connector according to Embodiment 40, wherein the third direction is perpendicular to both the column direction and the row direction.

[0412] Embodiment 42. The connector according to embodiment 40, wherein:

[0413] Each signal conductor pair of the plurality of signal conductor pairs further includes a second transition region;

[0414] Within the second transition region, the relative positions of the signal conductors of the signal conductor pair change such that at a first end of the second transition region adjacent to the contact tail, the pair of signal conductors are aligned along a second parallel line parallel to the third direction, and at a second end of the transition region adjacent to the middle portion, the pair of signal conductors are aligned along a third parallel line disposed at an angle greater than 45 degrees and less than 135 degrees relative to the third direction.

[0415] Embodiment 43. A connector according to Embodiment 42, wherein the second parallel line is arranged at an angle greater than 80 degrees and less than 100 degrees relative to the third direction.

[0416] Embodiment 44. A connector according to Embodiment 42, wherein the second parallel line is perpendicular to the third direction.

[0417] Embodiment 45. A connector according to Embodiment 42, wherein the second parallel lines are parallel to the row direction.

[0418] Solution 46. An electronic component, comprising the connector according to Solution 40, wherein the electronic component is combined with:

[0419] a first printed circuit board including a first edge, wherein the connector is a first connector and contact tails of the first connector are mounted to the first printed circuit board adjacent the first edge;

[0420] a second printed circuit board;

[0421] A second connector is mounted to the second printed circuit board and is configured to mate with the first connector.

[0422] Embodiment 47. An electronic assembly according to Embodiment 46, wherein the contact tail of the first connector is inserted into the hole of the first printed circuit board.

[0423] Embodiment 48. An electronic assembly according to Embodiment 46, wherein the contact tails of the first connector are mounted to pads on the surface of the first printed circuit board.

[0424] Embodiment 49. An electronic assembly according to Embodiment 47, wherein the contact tails of the first connector are pressed into holes of the first printed circuit board having an unplated diameter less than or equal to 20 mils.

[0425] Embodiment 50. The electronic assembly of embodiment 49, wherein the width of the contact tail of the first connector is between 6 mils and 20 mils.

[0426] Embodiment 51. The electronic assembly of embodiment 47, wherein the contact tails of the first connector are pressed into unplated holes of the first printed circuit board having a diameter between 6 mils and 12 mils.

[0427] Embodiment 52. The electronic assembly of embodiment 51, wherein the width of the contact tail of the first connector is between 6 mils and 12 mils.

[0428] Embodiment 53. The electronic assembly according to embodiment 46, wherein:

[0429] The first printed circuit board comprises a first layer and a second layer;

[0430] a trace fabricated on the first layer and extending in a first direction connected to a first contact tail of the pair of contact tails of the first connector; and

[0431] A trace fabricated on the second layer and extending in a second direction perpendicular to the first direction is connected to a second contact tail of the pair of contact tails of the first connector.

[0432] Embodiment 54. The electronic assembly of embodiment 46, wherein the second array comprises pairs of contact tails of the first connector, the pairs of contact tails being arranged in a repeating pattern, wherein:

[0433] The center-to-center spacing between adjacent pairs of contact tails in the third direction is less than or equal to 5 mm; and

[0434] A center-to-center spacing between adjacent pairs of contact tails in a direction perpendicular to the third direction is less than or equal to 5 mm.

[0435] Embodiment 55. The electronic assembly of embodiment 46, wherein the second array comprises pairs of contact tails of the first connector, the pairs of contact tails being arranged in a repeating pattern, wherein:

[0436] A center-to-center spacing between adjacent pairs of contact tails in the third direction is less than or equal to 2.4 mm; and

[0437] A center-to-center spacing between adjacent pairs of contact tails in a direction perpendicular to the third direction is less than or equal to 2.4 mm.

[0438] Embodiment 56. An electronic component according to Embodiment 46, wherein the first printed circuit board is perpendicular to the second printed circuit board.

[0439] Embodiment 57. An electronic component according to Embodiment 46, wherein a surface of the second printed circuit board faces the mating end of the first connector.

[0440] Embodiment 58. The electronic assembly according to embodiment 46, wherein:

[0441] The mating end of the first connector extends in a first direction;

[0442] The contact tails of the first connector extend in a second direction; and

[0443] A surface of the second printed circuit board faces a direction perpendicular to the first direction and the second direction.

[0444] Embodiment 59. The electronic assembly according to embodiment 46, wherein the second connector further comprises:

[0445] A plurality of signal conductor pairs, each of the plurality of signal conductor pairs comprising a pair of mating ends, a pair of contact tails, a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails, and a transition region between the pair of mating ends and the pair of intermediate portions, wherein:

[0446] The mating ends of the plurality of signal conductor pairs are arranged in a first array comprising a plurality of rows extending along the row direction and spaced apart from each other in a column direction perpendicular to the row direction; and

[0447] The signal conductors of the signal conductor pairs are aligned along first parallel lines, the first parallel lines being arranged at an angle greater than 0 degrees and less than 90 degrees relative to the row direction;

[0448] Within the transition region, the relative positions of the signal conductors of the signal conductor pair change so that at a first end of the transition region adjacent to the mating end, the signal conductors are aligned along the first parallel lines, and at one end of the transition region, the signal conductors are aligned in the row direction.

[0449] Embodiment 60. The electronic assembly according to embodiment 46, wherein the second connector further comprises a plurality of extender modules, each of the plurality of extender modules comprising:

[0450] a pair of signal conductors, each signal conductor having a first portion and a second portion; and

[0451] in:

[0452] The second portions of the plurality of extender modules are mounted to the mating ends of the plurality of signal conductors of the second connector;

[0453] A first portion of the plurality of extender modules is configured to be received in a mating end of the first connector; and

[0454] The pairs of signal conductors of the plurality of extender modules each extend in a straight line from the first portion to the second portion.

[0455] Embodiment 61. The electronic assembly of Embodiment 46 is further configured to transmit data from the first connector to the second connector at a rate of approximately 112 Gb / s.

[0456] Embodiment 62. The connector according to Embodiment 35 is also configured to operate at a bandwidth of approximately 50 GHz to 60 GHz.

[0457] Solution 63. A connector module comprising:

[0458] insulating member; and

[0459] A pair of signal conductors held by the insulating member, wherein each of the pair of signal conductors includes a first portion at a first end, a second portion at a second end extending from the insulating portion, and an intermediate portion disposed between the first end and the second end, and the first portion includes a wire having a diameter between 5 mils and 20 mils.

[0460] Embodiment 64. A connector module according to Embodiment 63, wherein the wire is a superelastic wire.

[0461] Embodiment 65. A connector module according to Embodiment 64, wherein the superelastic wire of each signal conductor in the pair of signal conductors is soldered to a middle portion of the signal conductor.

[0462] Embodiment 66. The connector module according to embodiment 63, wherein:

[0463] The connector module further includes an electromagnetic shield at least partially surrounding a middle portion of the pair of signal conductors; and

[0464] The electromagnetic shielding element defines a periphery of the first portion that is less than 4.5 mm 2 area.

[0465] Option 67. A connector module according to Option 66, wherein the electromagnetic shield is embossed with an outward protrusion adjacent to the first end so as to offset the change in impedance along the length of the pair of signal conductors associated with the change in shape of the pair of signal conductors along the length of the pair of signal conductors.

[0466] Embodiment 68. A connector module according to Embodiment 67, wherein the electromagnetic shielding member is further embossed with an inward protrusion adjacent to the distal end of the first portion so as to reduce the difference between the fully mated impedance and the partially disengaged impedance of the connector module.

[0467] Embodiment 69. The connector module according to Embodiment 68, wherein the electromagnetic shielding member comprises a conductive shielding member.

[0468] Embodiment 70. A connector module according to Embodiment 63, wherein the second portion comprises a superelastic wire having a width between 5 mils and 20 mils.

[0469] Embodiment 71. An electrical connector according to Embodiment 70, wherein the diameter of the superelastic wire is less than 12 mils.

[0470] Embodiment 72. An electrical connector according to Embodiment 71, wherein the superelastic wire is configured to be inserted into a hole having a diameter less than or equal to 10 mils.

[0471] Embodiment 73. An electrical connector according to Embodiment 70, wherein the mating force of the superelastic wire is between 25 gm and 45 gm.

[0472] Embodiment 74. An electrical connector according to Embodiment 70, wherein the mating force of the superelastic wire is between 30 gm and 40 gm.

[0473] Embodiment 75. A connector module according to Embodiment 63, wherein the second portion includes a press-fit member.

[0474] Embodiment 76. A connector module according to Embodiment 75, wherein the cross-section of the press-fit member has a serpentine shape.

[0475] Embodiment 77. An electrical connector comprises a plurality of connector modules according to Embodiment 68, wherein the plurality of connector modules are arranged in a plurality of parallel rows extending along a row direction.

[0476] Embodiment 78. An electrical connector according to Embodiment 77, wherein the impedance change between the fully mated configuration and the partially disengaged configuration of the first part is less than 5 ohms at 20 GHz.

[0477] Embodiment 79. The electrical connector of embodiment 77, wherein the second portion of the connector module of the plurality of connector modules comprises contact tails, and pairs of contact tails are arranged in a second plurality of rows extending along the first direction in a repeating pattern and are positioned along a second direction perpendicular to the first direction, wherein:

[0478] The center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.5 mm; and

[0479] A center-to-center spacing between adjacent pairs of contact tails in a second direction perpendicular to the first direction is less than or equal to 2.5 mm.

[0480] Embodiment 80. The electrical connector according to embodiment 77, wherein the second portions of the plurality of connector modules include contact tails, pairs of contact tails are arranged in a second plurality of rows extending along the first direction in a repeating pattern and are positioned along a second direction perpendicular to the first direction, wherein:

[0481] The center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.4 mm; and

[0482] A center-to-center spacing between adjacent pairs of contact tails in a second direction perpendicular to the first direction is less than or equal to 2.4 mm.

[0483] Embodiment 81. An electrical connector according to Embodiment 77, wherein the first portion of each signal conductor pair of the plurality of connector modules is aligned along a first parallel line disposed at an angle of 45 degrees relative to the row direction.

[0484] Embodiment 82. An electrical connector according to Embodiment 77, wherein, in the range of 45 GHz to 50 GHz, the total impedance of each connector module is between 90 ohms and 100 ohms.

[0485] Embodiment 83. An extender module comprising:

[0486] a pair of signal conductors, each signal conductor of the pair of signal conductors comprising a first portion at a first end and a second portion at a second end; and

[0487] an electromagnetic shield at least partially surrounding the pair of signal conductors,

[0488] in:

[0489] The first portions of the pair of signal conductors are configured as mating portions and are positioned along a first line;

[0490] The second portions of the pair of signal conductors are configured to compress when inserted into the hole and to be positioned along a second line parallel to the first line.

[0491] Embodiment 84. An extender module according to Embodiment 83, wherein the electromagnetic shielding member includes a conductive shielding member.

[0492] Option 85. An extender module according to Option 83, wherein the cross-section of the second portion is "S" shaped.

[0493] Embodiment 86. An extender module according to Embodiment 83, wherein the second portion is configured to be inserted into an interface hole having a diameter less than or equal to 20 mils.

[0494] Embodiment 87. An extender module according to Embodiment 86, wherein the width of the second portion is between 6 mils and 20 mils.

[0495] Embodiment 88. An extender module according to Embodiment 83, wherein the second portion is configured to be inserted into an interface hole having a diameter less than or equal to 10 mils.

[0496] Embodiment 89. An extender module according to Embodiment 87, wherein the width of the second portion is between 6 mils and 10 mils.

[0497] Solution 90. A connector, comprising:

[0498] an insulating portion and a plurality of signal conductors supported by the insulating portion, each of the plurality of signal conductors having a mating portion defining an interface cavity; and

[0499] A plurality of extender modules according to Option 83, wherein a second portion of the signal conductor of the extender module is inserted into the interface hole.

[0500] Embodiment 91. The connector according to embodiment 89, wherein:

[0501] A plurality of said extender modules further comprising a plurality of signal conductor pairs, said plurality of signal conductor pairs having paired second portions each aligned along a first parallel line;

[0502] The plurality of signal conductors further comprises a plurality of signal conductor pairs having a pair of intermediate portions and a pair of mating portions connected by a transition region;

[0503] The signal conductors of each signal conductor pair are aligned along the first parallel lines at a first portion of the transition region adjacent to the pair of mating portions; and

[0504] The signal conductor is aligned along a second parallel line at a second portion of the transition region adjacent the pair of intermediate portions, the second parallel line being disposed at a 45 degree angle relative to the first parallel line.

[0505] Solution 92. A connector, comprising:

[0506] Insulation part;

[0507] a plurality of signal conductors held by the insulating portion;

[0508] a plurality of shielding members; and

[0509] in:

[0510] The plurality of signal conductors include an elongated mating portion extending from the insulating portion;

[0511] The plurality of signal conductors include a plurality of paired signal conductors, the plurality of paired signal conductors being arranged in a plurality of rows extending along a row direction;

[0512] The plurality of shield members at least partially surround the plurality of pairs; and

[0513] The mating portions of the plurality of pairs are separated along first parallel lines disposed at an angle of 45 degrees relative to the row direction.

[0514] Embodiment 93. A connector according to Embodiment 92, wherein the plurality of shielding members include conductive shielding members.

[0515] Embodiment 94. The connector according to embodiment 92, wherein:

[0516] The insulating portion includes a planar portion having a first surface and a second surface opposite to the first surface;

[0517] The matching portion extends in a direction perpendicular to the first surface;

[0518] The signal conductor also includes a tail extending through the second surface.

[0519] Embodiment 95. The connector of embodiment 94, wherein the contact tails are arranged in a second plurality of rows extending along the first direction in a repeating pattern and are positioned along a second direction perpendicular to the first direction, wherein:

[0520] The center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 5 mm; and

[0521] A center-to-center spacing between adjacent pairs of contact tails in a second direction perpendicular to the first direction is less than or equal to 5 mm.

[0522] Embodiment 96. The connector of embodiment 94, wherein the contact tails are arranged in a second plurality of rows extending along the first direction in a repeating pattern and are positioned along a second direction perpendicular to the first direction, wherein:

[0523] The center-to-center spacing between adjacent pairs of contact tails in the first direction is less than or equal to 2.4 mm; and

[0524] A center-to-center spacing between adjacent pairs of contact tails in a second direction perpendicular to the first direction is less than or equal to 2.4 mm.

[0525] Embodiment 97. A connector according to Embodiment 94, wherein the contact tail is configured to be inserted into a hole having a diameter less than or equal to 20 mils.

[0526] Embodiment 98. A connector according to Embodiment 97, wherein the width of the contact tail is between 6 mils and 20 mils.

[0527] Embodiment 99. A connector according to Embodiment 94, wherein the contact tail is configured to be inserted into a hole having a diameter less than or equal to 10 mils.

[0528] Embodiment 100. A connector according to Embodiment 97, wherein the width of the contact tail is between 6 mils and 10 mils.

[0529] Embodiment 101. A connector according to embodiment 92, wherein:

[0530] The plurality of paired signal conductors also include an intermediate portion connected to the mating portion through a transition region;

[0531] The signal conductors in each pair of signal conductors are separated along the first parallel lines at a first portion of the transition region adjacent the mating portion; and

[0532] The signal conductors are separated along second parallel lines parallel to the row direction at a second portion of the transition region adjacent to the middle portion.

[0533] The use of ordinal terms such as "first", "second", "third", etc. in the claims to modify claim elements does not itself mean any priority, precedence or order of one claim element relative to another claim element or the temporal order of the actions of performing the method, but is merely used as a mark to distinguish one claim element with a certain name from another element with the same name (but using ordinal terms), thereby distinguishing the elements of the claim.

[0534] As defined and used herein, all definitions should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0535] Unless explicitly indicated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one".

[0536] As used herein in the specification and claims, the phrase "at least one" when referring to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but not necessarily including each and every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements other than the elements specifically identified in the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those elements specifically identified.

[0537] As used herein in the specification and claims, the phrase "and / or" should be understood to mean "either or both" of the elements so combined, i.e., elements that exist in combination in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same way, i.e., "one or more" of the elements so combined. In addition to the elements explicitly identified by the "and / or" clause, other elements may optionally be present, regardless of whether they are related or unrelated to those elements explicitly identified. Thus, as a non-limiting example, when used with an open-ended term such as "including", a reference to "A and / or B" may refer to only A (optionally including elements other than B) in one embodiment; to only B (optionally including elements other than A) in another embodiment; to both A and B (optionally including other elements) in yet another embodiment; and so on.

[0538] As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be understood to be inclusive, i.e., including at least one of a plurality of elements or lists of elements, but also including more than one of a plurality of elements or lists of elements, and optionally including other unlisted items. Only explicitly indicating the opposite terms such as "only one of ... " or "just one of ... " or when used in the claims, "consisting of ... " will refer to including exactly one element in a plurality of elements or lists of elements. In general, the term "or" as used herein should only be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") before exclusive terms such as "any one", "one of ... ", "only one of ... " or "just one of ... ". When used in the claims, "consisting essentially of ... " should have its ordinary meaning used in the field of patent law.

[0539] In addition, the words and terms used herein are for descriptive purposes and should not be considered as limiting. The use of "includes," "comprising," or "having," "containing," "involving," and variations thereof herein is intended to encompass the items listed thereafter and their equivalents and additional items.

Claims

1. A connector module, comprising: A pair of signal conductors, where: The pair of signal conductors includes a pair of mating ends, a pair of contact tails, and a pair of intermediate portions connecting the pair of mating ends to the pair of contact tails; The pair of mating ends extend in a direction that is at right angles to the direction in which the pair of contact tails extend; and The mating ends of the pair of mating ends are separated in the direction of the first line; The middle portions of the pair of middle portions are separated in the direction of the second line; The first line is disposed at an angle greater than 0 degrees and less than 90 degrees with respect to the second line.

2. The connector module according to claim 1, wherein: The first line is disposed at an angle greater than 30 degrees and less than 60 degrees relative to the second line.

3. The connector module according to claim 2, wherein: The first line is disposed at an angle of 45 degrees relative to the second line.

4. The connector module according to claim 3, wherein: The pair of signal conductors further includes a transition region connecting the pair of intermediate portions and the pair of mating ends, wherein a first signal conductor of the pair of signal conductors extends toward a third line at the transition region and the pair of contact tails are separated along the third line, and A second signal conductor of the pair of signal conductors extends away from the third line.

5. The connector module of claim 3, further comprising an electromagnetic shield at least partially surrounding the mating ends of the pair of signal conductors, and wherein: The electromagnetic shielding member defines a perimeter of the mating end that is less than 4.5 mm 2 area.

6. The connector module according to claim 5, wherein: The electromagnetic shield is embossed with an outward protrusion adjacent the transition region to counteract variations in impedance along the length of the pair of signal conductors associated with variations in shape of the pair of signal conductors along the length.

7. The connector module according to claim 6, wherein: The electromagnetic shield is also embossed with inward projections adjacent the pair of mating ends to reduce a difference between mating impedance and partial unmating impedance of the connector module.

8. The connector module according to claim 7, wherein: The electromagnetic shield includes a pair of conductive shielding members; Each of the conductive shield members includes a middle portion, a mating portion integral with the middle portion, and a transition portion between the mating portion and the middle portion; and The transition portion provides a twist in the shield member at an angle of the first line relative to the second line.

9. The connector module of claim 3, further comprising a first insulating member supporting the pair of signal conductors, and wherein: Each of the pair of mating ends of the pair of signal conductors includes a pair of mating arms separated by a gap; and The first insulating member includes a portion extending beyond the pair of mating ends and including a pair of holes aligned with the gap.

10. The connector module according to claim 9, wherein: The pair of mating ends are configured to receive a wire through the pair of holes and retain the wire between the pair of mating arms.

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