Cable apparatus and method

Abstract

A cable apparatus and method. A board connector and method. The cable assembly may include a cable. The cable assembly and / or the board connector may include one or more connectors and / or one or more conductors. The cable assembly may be a waveguide. The cable assembly, the board connector, or portions thereof may be made by 3D printing or additive manufacturing, including multi-material 3D printing or additive manufacturing. The multiple materials may include two or more of a non-conductive or insulating material, a conductive material, an electrical loss material, and a magnetic absorbing material.

Description

[0001] CROSS REFERENCE TO PRIOR APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 359,397, filed on July 8, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present embodiments relate generally to cable apparatus / assemblies with specific embodiments for use with waveguides being shown. Background Art

[0004] Typical waveguides are extruded thermoplastics and wrapped with metal tape. However, this practice often has limited cross-sectional shapes (e.g., oval, circular), is prone to kinking / collapse, dents, has thick walls, poor signal quality, and is difficult to metalize (e.g., wrapped with metal tape and / or requires adhesive to wrap the metal tape). Therefore, there is a need for improved customizability of cable assemblies, such as, but not limited to, waveguide structure (e.g., perimeter, diameter, wall thickness, wall support, flexibility, etc.), metallization, mechanical support, manufacturing, and / or signal performance.

[0005] The present invention aims to overcome or at least improve upon the disadvantages of the prior art. Summary of the invention

[0006] In some embodiments of the present invention, for example, a cable assembly may include a cable and at least one first connector integrally attached to a first end of the cable, wherein both the cable and the connector are printed using a 3D printer.

[0007] In addition, in some embodiments, the cable assembly may include at least one second connector integrally attached to the second end of the cable, wherein the second end of the cable is opposite to the first end of the cable. In various embodiments, the cable may be a hollow waveguide. In some embodiments, the cable may include at least one cable conductor. In some embodiments, the cable may include at least two cable conductors. In various embodiments, at least one first connector may include a first vacuum port. In some embodiments, at least one second first connector may include a second vacuum port. In various embodiments, the cable may not be extruded. In some embodiments, at least one first connector may not include a stamped electrical connector conductor. In various embodiments, the cable assembly may be printed within an area of ​​approximately 50 cubic mm.

[0008] In some embodiments, a cable assembly may include a cable having opposing ends, wherein at least a portion of the cable is printed using a 3D printer.

[0009] In addition, in various embodiments, the cable assembly may include one or more connectors, wherein at least one connector may be attached to at least one of the opposite ends. In some embodiments, the cable may include a non-conductive material and a conductive material surrounding at least a portion of the non-conductive material. In various embodiments, the cable may include one or more walls having one or more surface increasing structures. In some embodiments, the one or more surface increasing structures may be a corrugated portion. In various embodiments, the cable may include one or more support structures. In some embodiments, the one or more support structures may define one or more channels within the cable. In various embodiments, the cable may include a single channel therein. In some embodiments, at least one of the cable and / or the at least one connector may include one or more vacuum ports. In various embodiments, the cable assembly may include one or more lenses. In some embodiments, the cable assembly may include at least one electrical conductor. In various embodiments, the cable assembly may include at least two electrical conductors. In some embodiments, at least a portion of at least one connector may be printed. In various embodiments, the cable and the at least one connector are printed together. In some embodiments, at least one of the conductive material and the non-conductive material may be printed. In various embodiments, a cross-section of at least a portion of the cable may not be symmetrical. In various embodiments, the cable may be flexible between a first orientation and a second orientation different from the first orientation, and wherein the cable may be printed in the first orientation. In some embodiments, the cable may be a waveguide. In various embodiments, the cable may not be extruded.In various embodiments, the cable may include at least one connector on each of opposite ends of the cable.

[0010] In some embodiments, a method of 3D printing at least a portion of a cable assembly.

[0011] In some embodiments, a method of manufacturing a cable assembly includes the steps of simultaneously 3D printing the entire cable assembly during a single preprogrammed complete printing cycle or process.

[0012] In various embodiments, a method of manufacturing a cable assembly includes the steps of attaching a conductive contact or conductive conductor to a corresponding flexible cable conductor without one or more of solder, IDC, and / or friction connection. In some embodiments, the method may include electroplating the conductive contact or conductive conductor.

[0013] In some embodiments, a 3D printed cable assembly.

[0014] In various embodiments, the dielectric waveguide is composed of a photosensitive polymer.

[0015] In some embodiments, the dielectric waveguide may include a waveguide body defining an outer surface, wherein (i) the outer surface further includes a first surface and a second surface intersecting the first portion, (ii) the first surface is approximately linear, and (iii) the second surface is approximately non-linear. In various embodiments, the second surface may have a greater total surface area than the first surface. In some embodiments, the second surface may define a repeating or recurring surface pattern. In various embodiments, the waveguide body may be hollow or at least partially hollow along a longitudinal length of at least a portion of the waveguide body.

[0016] In some embodiments, the dielectric waveguide may include a waveguide body defining an outer surface, wherein the outer surface has at least one second surface that is in the form of any one or more of sinusoidal, wavy, textured, rough, uneven, and / or non-smooth.

[0017] Furthermore, in various embodiments, the cross-section of the waveguide body can be solid along at least a portion of the longitudinal length of the waveguide body. In some embodiments, the waveguide body can be hollow or at least partially hollow along at least a portion of the longitudinal length of the waveguide body.

[0018] In some embodiments, the article may include a first portion and a second portion, the second portion being physically connected to the first portion, electrically connected to the first portion, or physically connected to the first portion and electrically connected to the first portion, wherein both the first portion and the second portion are printed using a 3D printer.

[0019] In addition, in some embodiments, the first portion and the second portion can be visually and structurally different from each other. In various embodiments, the first portion can include a non-flexible dielectric housing. In some embodiments, the second portion can be flexible, plastic, or one or more of capable of bending. In various embodiments, the first portion can include at least one electrical contact or at least one electrical conductor. In some embodiments, the second portion can include at least one waveguide, at least one conductive cable conductor, or both.

[0020] In some embodiments, a 3D printed electrical connector includes a 3D printed non-conductive housing and at least one 3D printed electrical contact or conductor.

[0021] In some embodiments, a 3D printed cable assembly includes a 3D printed non-conductive housing and at least one 3D printed flexible cable, wherein the at least one 3D printed flexible cable is physically carried by the non-conductive housing and electrically connected to at least one electrical contact carried by the 3D printed non-conductive housing, or is physically carried by the non-conductive housing and electrically connected to at least one electrical contact carried by the 3D printed non-conductive housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the drawings, like reference numerals generally refer to like parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

[0023] Figure 1 is a perspective view of one embodiment of a cable assembly illustrating one embodiment of a cable.

[0024] Figure 2 yes Figure 1 0014] Figure 2 is a perspective view of a cable assembly showing an embodiment of one or more connectors connected to the cable.

[0025] Figure 3 yes Figure 2 A top view of the cable assembly.

[0026] Figure 4 It is along Figure 1 and Figure 2 A cross-sectional view taken along line 4-4 shows the hollow cable.

[0027] Figure 5 yes Figure 2 A perspective view of another embodiment of a cable and connector with portions removed showing a support structure defining a channel therein.

[0028] Figure 6 It is along Figure 5 A cross-sectional view taken along line 6-6 of FIG. 6 illustrates a support structure defining a channel therein.

[0029] Figure 7 is in another / different orientation / configuration Figure 2 A perspective view of a cable assembly.

[0030] Figure 8 yes Figure 2 An enlarged perspective view of the connector.

[0031] Fig. 9 is a perspective view of another embodiment of a cable assembly showing one of two opposing ends of a coaxial cable assembly.

[0032] Fig.10 is a perspective view of another embodiment of a cable assembly showing one of two opposing ends of a twin-axial cable assembly.

[0033] Fig.11 is a perspective view of another embodiment of a cable assembly showing a non-waveguide cable assembly.

[0034] Fig.12 A perspective side view of a GC6 brand cable assembly, board connector, and printed circuit board.

[0035] Fig.13 yes Fig.12 A perspective top view of a CG6 brand cable assembly is shown in FIG. 1 with the connector housing removed for clarity.

[0036] Fig.14 is a top view of a differential signal pair with no cable attachment mechanical or electrical interruptions and with skew and / or impedance tuning. DETAILED DESCRIPTION

[0037] The embodiments may be further understood with reference to the various drawings. Referring to the drawings, the embodiments provide one or more cable assemblies 20 (eg, waveguide 21, coaxial 22, twinaxial 23, non-waveguide 24). Figures 1 to 8 As shown in the embodiment of FIG. 1 , an example of a cable assembly 20 may be one or more waveguides 21 for conducting electricity. The cable assembly 20 may include a body or housing defined by one or more components. Figure 1 As shown, the cable assembly 20 and / or waveguide 21 may include a cable 30. One or more cables 30 may include an elongated body 31 having opposite ends (a first end 30a and a second end 30b). The cables 30 may be of various shapes, lengths, cross-sections, sizes, and configurations and still be within the scope of the present invention. Figure 2 , Figure 3 , Figure 5 , Figure 7 and Figure 8 In some of the illustrated embodiments, the cable assembly 20 and / or the cable 30 may include one or more connectors 40 (e.g., a first connector 40a, a second connector 40b). The one or more connectors 40 (if used) may be adjacent to or connected / attached to one or more ends (e.g., the first end 30a and / or the second end 30b). The one or more connectors 40 may be of various shapes, sizes, quantities, and configurations and still be within the scope of the present invention. For example, although the connectors 40 (if used) on the opposite ends of the cable 30 shown in this one embodiment are the same, in some embodiments, the connectors may be different. The one or more cable assemblies 20 or portions thereof may electrically / physically connect two or more devices / structures (e.g., cable assemblies, modules, optical generators, etc.).

[0038] The one or more cable assemblies 20 (eg, 21 - 24 ) or portions thereof may be used in various applications or devices. For example, the one or more applications / devices may include, but are not limited to, one or more module interconnects, optical generators, and the like.

[0039] In some embodiments, the cable assembly 20 (e.g., 21-24), waveguide 21, and / or cable 30 may include an elongated body 31. The body 31 may have an outer perimeter 32 and an inner perimeter 33. Although other cross-sectional shapes are contemplated, the outer perimeter 32 and the inner perimeter 33 may be generally rectangular in shape, such as Figure 4 and Figure 6 As shown in this embodiment of the present invention. One or more walls 31a-31d may define an outer periphery 32 and / or an inner periphery 33. The walls may be different and / or the same in shape from each other, as shown in this embodiment. In the embodiment shown, the body 31 may include a pair of first opposing walls 31a and 31b, which interconnect a pair of second opposing walls 31c and 31d. In some embodiments, the first opposing walls 31a, 31b may be the same. In some embodiments, the second opposing walls 31c, 31d may be the same. As shown in this embodiment, the first opposing wall may be different from the second opposing wall. The first opposing walls 31a, 31b (e.g., short axis / short length) or the outer periphery 32 or a portion thereof may define the current side. The second opposing walls 31c, 31d (e.g., long axis / long length) or the outer periphery or a portion thereof may define the electric field.

[0040] In some embodiments, the cable and / or one or more walls / surfaces defining the inner perimeter 33 and / or the outer perimeter 32 (e.g., first opposing walls 31a and 31b) may include a surface or surface area increasing structure 50. The outer surface or perimeter may include a first linear surface and a second non-linear surface. The second surface may have a greater total surface area than the first surface. The second surface may include a repeating or recurring surface pattern. As shown in this embodiment of the drawings, the outer perimeter 32 and / or walls (e.g., first opposing walls 31a, 31b, short axis / short length) may include the one or more surface increasing structures 50. One embodiment of the surface increasing structure 50 (e.g., second surface), if used, may include at least one wall / surface (e.g., outer perimeter) of the first opposing walls 31a, 31b having one or more waves / corrugations / ribs / fins 52 and / or sinusoidal / textured / rough / uneven / unsmooth (e.g., defining a channel 53 therebetween). In addition, one or more walls and / or first opposing walls 31a, 31b may have an increased cross-sectional area compared to one or more walls and / or second opposing walls 31c, 31d. The surface increasing structure 50 and / or the increased cross-sectional area can increase conductivity, increase heat dissipation and / or allow for a higher current density to be achieved for a given amount of resistance and / or heat rise. In the one embodiment shown in the drawings, the inner periphery 33, surface or wall (e.g., first opposing wall, second opposing wall) or portion thereof can be substantially planar, as shown in this one embodiment. Although not shown, the inner periphery or portion thereof can include one or more surface increasing structures.

[0041] In some embodiments, the cable assembly 20 (e.g., 21-24) or portions thereof (e.g., body, connector, cable) can be defined by one or more components. As shown in this embodiment of the drawings, the cable assembly 20, the cable 30, and / or the body 31 can include a single component. Figure 1 The cable 30 or body 31 is shown as a single member in FIG. 1 , but it should be understood that in some embodiments, the cable can be multiple members defining one or more lengths / circumferences.

[0042] The inner perimeter and / or outer perimeter can be of various shapes, sizes, quantities, and configurations and still be within the scope of the invention. For example, the cross-section of the body is shown as being the same for the entire length of the cable, however the cross-section (e.g., inner perimeter, outer perimeter, wall and / or surface added structure) can change / vary along the length. As shown in this one embodiment, the cable and / or body can be asymmetrical, however it should be understood that in some embodiments the cable / body can be symmetrical.

[0043] In some embodiments, the cable assembly 20 (e.g., 21-24), waveguide 21, cable 30, and / or body 31 may include / define one or more support structures / grids / webs 60. The one or more support structures 60 (if used) may be one or more members 62 that provide mechanical support or reinforcement to the cable or body. In some embodiments, the support structure may reduce collapse / kinking of the cable. Figure 5 and Figure 6 As shown in this embodiment of the present invention, a support structure 60 or member 62 can be positioned within the inner perimeter 33 or body 31 of the cable 30. The support structure 60 can connect one or more walls / surfaces 31a-31d of the inner perimeter 33. The support structure / member can define one or more elongated channels 63 within the inner perimeter, cable and / or body. The support structure (if used) can extend one or more lengths or portions of the cable or body. The support structures and / or channels can be of various shapes, sizes, quantities, locations and configurations and still be within the scope of the present invention.

[0044] In some embodiments, the cable assembly 20, waveguide 21, cable 30, and / or body 31 may include / define a hollow interior and / or be devoid of support structures 60 (eg, protrusions, members). Figures 1 to 4 and Figures 7 and 8As shown in this embodiment of FIG, the waveguide 21, cable 30 and / or body 31 are hollow and / or include a single passage 64 therethrough. The inner perimeter, wall or surface (e.g., planar, curved) may not define one or more support structures and / or provide a hollow portion or single passage for one or more lengths of the cable or body.

[0045] In some embodiments, the cable assembly 20 (e.g., 21-24), waveguide 21, cable 30, and / or body 31 may include the one or more connectors 40. The one or more connectors 40 may include / attach to one or more ends 30a, 30b of the cable / body. The connector 40 (if used) may electrically / physically connect the cable / body or a portion thereof to one or more devices. Figure 2 , Figure 3 , Figure 5 and Figures 9 to 11 In the illustrated embodiment, the one or more connectors 40 may include one or more contacts or electrical conductors 42 and / or mechanical fasteners 44. The mechanical fasteners 44, if used, may be flanges having one or more mounting holes, such as Figure 2 , Figure 3 , Figure 5 , Figure 7 and Figure 8 The contacts or electrical conductors 42 may be positioned on one or more surfaces (e.g., flanges, mechanical fasteners) of the one or more connectors 40. In some embodiments, the connector 40 may not include stamped electrical connector conductors or contacts. Alternatively, in various embodiments, the contacts may be stamped. In Figure 2 , Figure 3 , Figure 5 , Figure 7 and Figure 8 In some embodiments shown, the one or more connectors 40 or portions thereof may be integrally or monolithically formed with the cable and / or the body (e.g., integrally or monolithically printed). Alternatively, in some embodiments, the one or more connectors 40 may be manufactured separately (e.g., printed, molded, etc.) and subsequently assembled to the cable 30 and / or the body 31.

[0046] In some embodiments, the cable assembly 20 (e.g., 21-24), waveguide 21, cable 30, body 31 and / or connector 40 or portions thereof may include one or more conductive materials 70 and / or non-conductive materials 72. As shown in this embodiment, the cable 30 and / or connector 40 may include one or more conductive materials 70 and non-conductive materials 72. The one or more conductive materials 70 may include one or more first conductive materials 70a and / or second conductive materials 70b. The one or more non-conductive materials 72 may include one or more first non-conductive materials 72a and / or second non-conductive materials 72b. Figure 4 and Figure 6 In some embodiments more clearly shown in FIG. 1 , the one or more first conductive materials 70a (if used) may surround / cover or be disposed on the first non-conductive material 72a of the cable 30 (e.g., the outer perimeter or circumference (e.g., 360 degrees)) and / or extend the length of the cable or a portion thereof. In some embodiments, the one or more second conductive materials 70b (if used) may surround / cover or be disposed on the one or more second non-conductive materials 72b (e.g., the outer perimeter) of the connector 40. The first conductive material 70a and the second conductive material 70b may be electrically / physically connected to each other. The first non-conductive material 72a and the second non-conductive material 72b may be physically connected to each other. The first conductive material 70a and the second conductive material 70b may be electrically connected to the one or more contacts or electrical conductors 42 of the one or more connectors 40. In some embodiments, the first conductive material 70a and the second conductive material 70b may be integrally formed (e.g., printed) with each other or separately formed. In some embodiments, the first conductive material 70a and the second conductive material 70b may be integrally formed (e.g., printed) with the contacts or electrical conductors 42 or separately formed. In some embodiments, the first non-conductive material 72a and the second non-conductive material 72b may be made integrally with each other (eg, printed) or separately.

[0047] In some embodiments, the cable assembly 20, waveguide 21, cable 30 and / or connector 40 may include one or more vacuum ports 80. The vacuum port 80 (if used) may be in fluid communication with one or more external vacuum sources (not shown). In the illustrated embodiment, each of the opposite ends 30a, 30b of the cable 30 / assembly 20 and / or connector 40 includes a vacuum port 80. It should be understood that in some embodiments, only one end may include a vacuum port. For example, when two or more cables or cable assemblies are connected in series with each other. In the illustrated embodiment, the wall or second opposing wall 31c, 31d may include the one or more vacuum ports 80. The one or more vacuum ports 80 may be in fluid communication with each other through one or more channels 63, 64 defined by the inner periphery 33 of the cable 30 / connector 40 and / or the support structure 60. The vacuum source / port may provide a vacuum through the cable / assembly / connector (e.g., channel) to reduce the overall dielectric constant of the structure.

[0048] In some embodiments, Figure 2 As shown in this embodiment of FIG, the cable assembly 20, waveguide 21, cable 30 and / or connector 40 can include one or more lenses 84 and / or adjustment mechanisms 86. The adjustment mechanism 86 (if used) can adjust the optical properties and / or light properties of the lens 84 (if used).

[0049] In some embodiments, the cable assembly 20 (e.g., 21-24), waveguide 21, cable 30, non-conductive material 72 and / or conductive material or conductors 70, 42 or portions thereof can be made by additive manufacturing. For example, in some embodiments, the cable 30 (e.g., body), connector 40, non-conductive material 72 and / or the one or more conductive materials 70 or portions thereof can be printed (e.g., 3D printed) with one or more materials. One such process can be, but is not limited to, photopolymerization technology, material jetting and / or binder jetting. Figures 2 to 11 In one embodiment shown in , both the cable 30 and the connector 40 (e.g., the one or more conductive materials or conductors 70a, 70b and / or 42 and the non-conductive materials 72a, 72b) can be printed together. For example, the non-conductive / dielectric material 72 (e.g., resin, glass-infused 3D printed material) and / or the conductive material 70 (e.g., metal) can be printed together to form a cable assembly (e.g., a connector and a cable). Figures 1 to 11In another embodiment shown, the cable 30 or a portion thereof (e.g., the one or more conductive materials 70a and / or the non-conductive material 72a) may be printed (e.g., 3D printed). For example, the non-conductive / dielectric material 72 (e.g., resin) and / or the conductive material 70 (e.g., metal) may be printed together to form a cable assembly (e.g., a cable). In another embodiment, a first printed structure (e.g., a cable having both a non-conductive material and one or more conductive materials) may be printed and assembled / attached with at least one second printed structure (e.g., one or more connectors having both a non-conductive material and one or more conductive materials), which is printed separately from the first printed structure. In various embodiments, the non-conductive material 72a, 72b of both the cable and / or the connector may be printed in a first print, and the one or more conductive materials 70a, 70b may be printed in a second print, either continuously or after the first print. For example, the non-conductive material of a cable with or without a connector may be printed (e.g., a first print), and then the conductive material may be printed directly (e.g., a second print) on the printed cable / connector first print. Additionally, in some embodiments, either the cable or the connector may be printed with a non-conductive material with or without a conductive material, and the other of the cable or the connector may not be printed. For example, a cable may be printed with both a conductive material and a non-conductive material, and then one or more connectors (e.g., not printed) may be attached to the cable.

[0050] In some embodiments, it should be understood that the conductive contacts or conductors 42 (if used) may or may not be printed with the connector / cable in the examples described herein. If the conductive plate is not printed with the connector / cable, the conductive plate can be attached to the connector later (e.g., printed and attached, printed on a portion of the connector, stamped).

[0051] In some embodiments, the non-conductive material of the cable assembly (e.g., 21-24) or a portion thereof (e.g., a cable and / or a connector) is printed and then metalized / plated with one or more coatings / layers (e.g., conductive materials). For example, the non-conductive material 30 of the cable and / or connector 40 can be printed and subsequently plated with one or more layers, such as, but not limited to, a non-plated layer, and then plated with one or more materials (e.g., metals and / or alloys). The conductive contacts or conductive conductors can be attached to the non-conductive material or flexible cable 30 without one or more of solder, IDC, and / or friction connection. If the non-conductive material of the connector and cable is printed separately, the connector and cable can be coated with conductive material separately and then combined, or combined first and then coated with conductive material. The low surface roughness of the plated and / or printed conductive material can allow for improved mechanical and / or signal performance compared to metal strips.

[0052] A variety of printers may be used and still be within the scope of the invention. In some applications, the cable and / or connector or portions thereof may be printed using one or more of a high-resolution digital light projection (DLP) photopolymer printer (such as a Boston Microfabrication (BMF) S230 brand printer with a 2 μm resolution), an inkjet printer (such as a NANODIMENSION DRAGONFLY brand printer commercially available from NANODIMENSION, Ness Ziona, Israel), an aerosol jet printer, an atomic layer deposition (ALD) printer, a fused deposition (FDM) printer, a fused filament fabrication printer, and a syringe / slurry dispenser or printer. An example of a printer that combines multiple printing technologies is the NSCRYPT 3DN-300 brand printer, commercially available from NSCRYPT, Orlando, Florida.

[0053] In some embodiments, the cable assembly 20 (e.g., 21-24), the cable 30, the connector 40, or portions thereof, may be made of various materials. The cable and / or connector, or portions thereof, may be made of one or more materials (e.g., non-conductive, conductive, metal (e.g., conductive or metallic), thermally conductive, non-thermally conductive, printed, non-printed, electrically lossy, magnetically absorptive, electrically lossy material tuned to a resonant frequency within 5 GHz, magnetically absorptive material tuned to a resonant frequency of 5 GHz, etc.). Conductive materials may include (but are not limited to): conductive polymers, superconducting materials or superconducting materials, niobium, niobium titanium, yttrium barium copper oxide, indium tin oxide, silver, copper, nickel, metal oxides, metal inks, etc., which may be used in some applications of the conductive material 70. The electrical conductivity of the electrically lossy material is typically about 1 Siemens / meter to about 6.1×10 7 Siemens / meter, preferably about 1 Siemens / meter to about 1×10 7Siemens / meter, most preferably about 1 Siemens / meter to about 30,000 Siemens / meter. The electrically lossy material can be a partially conductive material, such as a material having 1Ω / square and 10 6 Ω / square. In some embodiments, the electrically lossy material has a surface resistivity between 1 Ω / square and 10 3 In some embodiments, the electrically lossy material has a surface resistivity between 10 Ω / square and 100 Ω / square. As a specific example, the material may have a surface resistivity between approximately 20 Ω / square and 40 Ω / square.

[0054] The non-conductive or dielectric material 72 or portions thereof may be ceramic or plastic or polymer-based materials / resins (e.g., thermosets, LOCTITE 406, UV curable thermoplastics, photopolymers, thermopolymers) used in some applications of the assembly. In some embodiments, the one or more cable assemblies 20 (e.g., 21-24), cables 30, and / or connectors 40 may be printed in various orientations / positions / configurations within various build volumes. The assembly may be printed in various configurations such as Figures 1 to 3 Print in the first orientation / position / configuration shown. Figure 1 , Figure 2 and Figure 5 As shown in this embodiment of the present invention, an elongated structure of a component 20 (e.g., a cable and / or connector) or a portion thereof can be printed within a current DLP printer volume, such as a 50 mm by 50 mm by 50 mm XYZ build volume (e.g., 50 cubic mm). Because the cross-section of the component (e.g., a cable) can be reduced and / or flexible, the cable 30 can be coiled / spiraled / overlapped within the build volume (e.g., a first orientation). The connector (if used / printed with a cable) can be positioned relative to the spiral position of the cable (e.g., inside and / or outside (shown)). In some embodiments, the connector or other portion can be non-flexible. For one or more applications, the component or portion thereof (e.g., a cable) can subsequently be bent or reconfigured to at least another or second orientation / position / configuration (e.g., different from the first orientation that was printed), such as Figure 7 In some embodiments, components or portions thereof can be printed and used in the same orientation. For example, in some embodiments, Figure 7 The orientation of the assembly 20 in may be both the first orientation and the second orientation. In some embodiments, the connector may be visually and structurally distinct from the cable.

[0055] In some embodiments, the cable assembly 20 may be a device other than the waveguide 21. For example, the non-waveguide cable assembly 20 may be a coaxial cable assembly 22 or a twinaxial cable assembly 23. Fig. 9As shown, the coaxial cable assembly 22 may include at least one cable conductor 90, a cable 30, and / or a connector 40. For example, the coaxial cable assembly 22 may include at least one cable conductor 90 extending through the cable 30 and the connector 40 at opposite ends 30a, 30b. In addition, for example, the twinaxial cable assembly 23 may include at least two cable conductors 90. Fig.10 As shown, the twinaxial cable assembly 23 may include at least two cable conductors 90, a cable 30 and / or a connector 40. The coaxial or twinaxial cable assembly 22, 23 (e.g., shield, cable conductor 90, connector contact, jacket, dielectric material, conductive material, etc.) or a portion thereof may be printed in a printing process (e.g., 3D printing), which includes a coaxial or twinaxial cable, an electrical connector conductor, etc. In some embodiments, the coaxial or twinaxial or waveguide or flexible circuit cable assembly 22, 23 may include a printed portion and a non-printed portion thereof. 3D printing a complete cable assembly (e.g., a coaxial cable assembly, a twinaxial cable assembly, a non-waveguide assembly, a waveguide assembly, a flexible circuit cable assembly) may not include the following steps: stamping and forming electrical connector contacts; overmolding electrical connector contacts; extruding coaxial or twinaxial cable conductors with a polymer; wrapping the cable with a shield; and / or terminating the cable conductors to electrical connector contacts, etc.

[0056] Another embodiment of the non-waveguide component 24 of the cable assembly 20 is Fig.11 . One or more portions of the assembly 24 may be printed. For example, a printer (e.g., a 3D printer) may print the metal and / or dielectric material (e.g., two ends, one end) of the cable 30 and / or connector 40, and then the mating end of the cable conductor 90 or the contact or electrical conductor 42 may be plated in a separate step. Alternatively, in some embodiments, the contact or electrical conductor 42 may be printed with the remainder of the assembly.

[0057] A method may include the steps of providing any one of a visual depiction, an image, a model, an engineering model, a solid model, a 3D model, an encrypted model, a SOLIDWORKS model, etc. representing any one of a group selected from a three-dimensional multi-material electrical connector or a three-dimensional multi-material cable assembly. Another step may include tuning or improving single-ended or differential impedance by eliminating solder or welding or insulation displacement or epoxy or conductive epoxy or crimp attachment between one or more of the cables or waveguides and one or more corresponding electrical conductors, electrical pads or electrical traces in the visual depiction, the image, the model, the engineering model, the solid model, the 3D model, the encrypted model, the SOLIDWORKS model, etc. Another step may include printing a three-dimensional multi-material electrical connector or a three-dimensional multi-material cable assembly according to or appearing like the visual depiction, the image, the model, the engineering model, the solid model, the 3D model, the encrypted model, the SOLIDWORKS model, etc. during a single printing process or a single printing cycle or a single printing operation. Another step may include electroplating portions of the three-dimensional multi-material electrical connector or the three-dimensional multi-material cable assembly after the step of printing the three-dimensional multi-material electrical connector or the three-dimensional multi-material cable assembly during a single printing process or a single printing cycle or a single printing operation.

[0058] The multi-material may include at least two different materials, such as a conductive material for some parts and a non-conductive material for other parts, a thermally conductive material for some parts and a thermally insulating material for other parts, etc., or any possible combination of the above materials. A single printing process or cycle or operation may represent a time period from when a printer starts printing a multi-material object to a future time when the multi-material object is fully printed. A single printing process or cycle or operation may represent a time period from when a printer or a group of printers creates an object that substantially includes all features of an underlying model. A single printing process or cycle or operation may represent a time period that starts when a printer is instructed to print and ends when the instructed print job is completed. A single printing process / cycle / operation may be completed with a single printer. A single printing process / cycle / operation may be completed with a single printer having at least two different print heads, each of which is respectively connected to two separate storage containers, each storage container containing materials that are different from each other in terms of electrical conductivity, thermal conductivity, dielectric constant, etc. A single printing process / cycle / operation may be completed with a single print head attached to two separate material storage containers, each of which contains materials that are different from each other in terms of electrical conductivity, thermal conductivity, dielectric constant, etc. A single printing process or cycle or operation can be completed with a device for delivering two materials, wherein the two materials are different from each other. A single printing process / cycle / operation can be completed with two different printers, which work to create a common three-dimensional printed object. A single printing process or cycle or operation does not have to be continuous. Intervals can be made within a single printing process or cycle or operation to solidify materials, switch or replace or position print heads, replenish material storage containers, move objects from one printer to another, etc.

[0059] A method may include the steps of creating or printing a three-dimensional electrical interconnect having an electrical conductor and an insulating housing during a single printing process or a single printing cycle or a single printing operation. Another method may include the steps of creating or printing a finished three-dimensional electrical interconnect having an electrical conductor, an insulating housing, and an electrical conductor plating during a single printing process or a single printing cycle or a single printing operation. For example, one or more printers may manufacture or replicate a three-dimensional electrical conductor made of a conductive metal (such as copper, silver, aluminum, etc.) or a conductive alloy, and then deposit a precious metal on the conductor (e.g., on one or more of the mating, mounting, and intermediate portions of the conductor).

[0060] A device may include the cable assembly 20, 21 shown above, including Figures 9 to 11 As a non-limiting example, Fig.11A cable assembly 24 is shown which may include a dielectric or electrically insulating housing 45, contacts or electrical conductors 42, and at least one of a coaxial or twinaxial or waveguide or flexible cable 30. The electrically insulating housing 45 and the contacts or electrical conductors 42 together may form an electrical connector. The contacts or electrical conductors 42 may include plating, shielding, or both. Plating such as at one or more of the mating end, mounting end, and / or intermediate portion of the contacts or electrical conductors 42 or on electrical pads may be printed in situ with the remainder of the cable assembly 20, the contacts or electrical contacts 42, and the cables 30. The cables 30 may each include at least one cable conductor, at least two cable conductors, at least three cable conductors, or three or more cable conductors 90 ( Fig. 9 and Fig.10 Cable conductor 90 ( Fig. 9 and Fig.10 ) can be a flexible cable conductor. Fig. 9 and Fig.11 As shown, the cable conductor 90 may form part of an RF or coaxial transmission line. Fig.10 and Fig.11 As shown, the physically adjacent cable conductors 90 may form part of a twinaxial transmission line.

[0061] The cable assemblies 22, 23, 24 may each include a dielectric or electrically insulating housing, such as Fig.11 The electrical insulating housing 45 is shown. A plurality of traces or pads or contacts or electrical conductors 42 may be carried by the electrical insulating housing 45, or by a printed circuit board carried by the electrical insulating housing 45. A plurality of cable conductors 90 ( Fig. 9 and Fig.10 ) can each be electrically connected to a corresponding one of the plurality of traces or pads or contacts or conductors 42. The cable conductor 90 ( Fig. 9 and Fig.10 ) may not be mechanically attached to corresponding traces or pads or contacts or electrical conductors 42 ( Fig.11 ).

[0062] The applicant helps solve the first long-term need in the industry, that is, to reduce the number of steps or manufacturing time or cost required to manufacture complex multi-component objects (such as cable assemblies) without reducing or eliminating the electrical performance of the object. As an example, the present invention reduces the number of processing steps to no more than one, no more than two, or no more than three printing cycles or printing operations or printing cycles. The entire cable assembly or board connector can be printed in situ using no more than one or two printers. Conductor stamping, shell molding, cable extrusion and winding, cable attachment, and even contact or electrical conductor plating can be completed with one or two multi-material three-dimensional printers. As another example of solving a long-term need, soldered joints or soldered cable attachments that are prone to rupture, short circuits, and electrical open circuits can be eliminated in cable assemblies.

[0063] An unexpected result of the present invention is that 3D printing reduces electrical interruptions along the entire or entire electrical length, physical length, or both of a single-ended transmission line carried by a cable assembly. An unexpected result of the present invention is that 3D printing reduces electrical interruptions along the entire or entire electrical length, physical length, or both of a differential signal transmission line carried by a cable assembly. Without being bound by theory, by eliminating the need for mechanical component attachment, such as soldering two components together, fastening two components together, welding two components together, gluing or epoxying two components together, etc., single-ended or differential impedance can be tightly controlled, insertion loss can be reduced, undesirable resonances can be mitigated, and undesirable crosstalk can be reduced.

[0064] By comparing the present disclosure of the applicant to a random cable assembly commercially available from SAMTEC Corporation, the reduction in the number of steps required to manufacture a complex multi-component object or the reduction in manufacturing time or cost can be illustrated from a high level. A randomly selected finished cable assembly sold by the applicant in 2023 currently requires more than ten discrete manufacturing steps, more than three discrete component transport processes for intermediate step processing, and more than four independent manufacturing equipment to produce a finished cable assembly. In contrast, the embodiments disclosed herein reduce the discrete manufacturing steps to one print cycle or one print operation or one print cycle, without discrete component transport processes for intermediate step processing, and no more than one or two 3D or additive manufacturing printers.

[0065] Can be helped by Fig.12 and Fig.13 Examples are shown that reduce or eliminate soldered joints or soldered cable attachments. Fig.12A GC6 series cable assembly 29P and a corresponding mating board connector 65P are shown, both of which are commercially available from Samtec in 2023. The electrically insulating housing 45P of the cable assembly 29P is formed into two parts held together by three fasteners. The single-ended or coaxial or RF cable 46P each carries a corresponding single-ended or coaxial or RF cable conductor 47P. The twin-axial cable 49P each carries at least one or two twin-axial cable conductors 48P. Each GC6 series cable assembly 29P may also include a two-part electrically insulating housing 45P, three fasteners and a latch. The electrically insulating board connector housing 51P carries at least eighty-four stamped, formed and gold-plated circuit board conductors 54P. A shield 57P is shown. Stamping, forming and plating require at least three manufacturing or processing steps. Using the disclosure provided in this patent application, at least the stamping step can be eliminated, which results in a 33% percentage reduction and a 40% percentage difference.

[0066] Back to Fig.13 In the illustrated GC6 series cable assembly 29P, each corresponding single-ended or coaxial or RF cable conductor 47P can be soldered to a corresponding corresponding first printed circuit board mounting pad 52P carried by a printed circuit board 58P. The twin-axial cables 49P each carry at least one or a pair of corresponding twin-axial cable conductors 48P, which are soldered to a corresponding corresponding second PCB mounting pad 55P carried by the printed circuit board 58P. The printed circuit board mating pads 59P are gold plated and each is electrically connected to a corresponding first printed circuit board mounting pad 52P or a corresponding second printed circuit board mounting pad 55P. The cable ground shields (such as the exposed cable ground shield 61P) are each soldered to a corresponding printed circuit board ground pad 56P.

[0067] therefore, Fig.12 and Fig.13 The construction of the GC6 series cable assembly 29P shown in FIG. 2 requires many brazed joints and more than, more than three, more than four, and more than five separate brazing process steps. For example, Fig.13 As shown, there are up to 22 discrete single-ended or coaxial or RF cable solder joints, there are up to 36 discrete twinaxial or differential solder joints, and there are up to 18 solder joints between the corresponding cable ground shield of each twinaxial cable 49P and the corresponding printed circuit board ground pad 56P. Conservatively speaking, Fig.12 and Fig.13There are fifty to seventy-six separate solder joints in the GC6 series cable assembly 30P shown in the patent application. Using the disclosure provided in the present patent application, all discrete solder joints except one discrete solder joint, or all discrete solder joints except two discrete solder joints, or all discrete solder joints except three discrete solder joints, or all discrete solder joints except four discrete solder joints can be eliminated, thereby meeting the long-standing demand for reducing solder joints. Historically, solder joints alone or in any combination increase solder joint costs, solder joint failures, solder joint ruptures, electrical short circuits between two adjacent solder joints, electrical open circuits between cable conductors and corresponding mounting pads, and more manufacturing steps and manufacturing time required for manufacturing cable assemblies or board connectors. Reducing from seventy-six mechanical solder joints to zero represents a 100% reduction. The percentage difference between seventy-six and one (dividing by zero is impossible) is about 195%.

[0068] According to the disclosure provided in this specific embodiment, Fig.12 and Fig.13 The GC6 series cable assembly 29P shown in can be manufactured using a single multi-material printer in no more than one printing operation or no more than two printing operations. The GC6 series board connector 65P can be manufactured using a single multi-material printer in no more than one printing operation or cycle or no more than two printing cycles or operations or cycles. A method may include the following steps, which reduce the number of processing steps required to create a finished cable assembly by at least 10%, at least 20%, at least 30%, at least 33%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90% and at least 95% compared to soldering or otherwise discretely attaching each individual cable conductor to a corresponding discrete printed circuit board mounting pad or a corresponding discrete contact or conductor mounting end. A method may include the following steps, which reduce the number of processing steps required to create a finished board connector by at least 10%, at least 20%, at least 30%, at least 33%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90% and at least 95% compared to separately stamping, forming and plating circuit board conductors.

[0069] A method for reducing the manufacturing steps required to create a multi-material circuit board connector or a multi-material cable assembly by at least 30%, or at least 31%, or at least 32%, or at least 33%, or at least 34%, or at least 35%, or at least 36%, or at least 37%, or at least 38%, or at least 38%, or at least 39%, or at least 40%, or at least 41%, or at least 42%, or at least 43%, or at least 44%, or at least 45%, or at least 46%, or at least 47%, or at least 48%, or at least 49%, or at least 50%, the method comprising the steps of printing the circuit board connector or cable assembly during a single printing cycle or printing operation or printing cycle.

[0070] In addition to reducing the number of manufacturing steps and the total number of undesirable brazed joints, this article is about Figures 1 to 11 and Fig.14 An unexpected benefit of the described embodiments is that the impedance of a single-ended or differential signal of a cable assembly or waveguide can be tightly controlled over the entire transmission path that follows or over the entire physical length of a circuit board connector or cable assembly or over the entire electrical length of a circuit board connector or cable assembly. Due to manufacturing tolerances and varying manufacturing processes, the present invention provides repeatability and signal integrity performance that is not currently achievable by printing or molding or stamping components of a cable assembly and then assembling the individual components. In other words, the benefit of 3D printing the entire cable assembly is localized and / or tuned and / or tightly controlled impedance control at each point along the waveguide or single-ended or differential signal transmission line.

[0071] Any cable assembly 20, 21, 22, 23, 24 described herein may be free of any one, any two, any three, any four, or any five of the following: a mechanical crimp between a cable conductor and an associated lead frame conductor; a soldered connection between a cable conductor and an associated lead frame conductor; an insulation displacement connection between a cable conductor and an associated lead frame conductor; a weld or ultrasonic weld between a cable connector and an associated lead frame conductor; a conductive polymer or epoxy between a cable connector and an associated lead frame conductor; and a laser attachment between a cable conductor and an associated lead frame conductor. The cable assembly may be free of mechanically stamped or pressed cable conductors.

[0072] Fig.14Two contacts or electrical conductors 42 of a differential signal pair are shown. Of course, in single-ended applications, one contact or electrical conductor 42 can be a signal conductor and the remaining contact or electrical conductor 42 can be a ground conductor. As shown, the twinaxial cable conductor 48 and the associated contacts or electrical conductors 42 of the twinaxial cable 49 can form a single or unitary electrical conductor that is physically seamless or physically continuous or electrically seamless or physically seamless. In other words, the device can include a cable assembly 20, 21, 22, 23, 24 or cable 30 without an attached transition portion between the twinaxial cable conductor 48 and the associated contacts or electrical conductors 42 shown or between the radio frequency (RF) cable conductors and the associated contacts or electrical conductors 42. In other words, an interconnect such as the cable assembly 20, 21, 22, 23, 24 can include contacts or electrical conductors 42, such as signal or single-ended or differential signal conductors, and associated cable conductors, such as the twinaxial cable conductor 48 or the cable conductor 90 ( Fig. 9 and Fig.10 The cable conductors (such as the twin-axial cable conductors 48) may be physically attached, electrically attached, or physically and electrically attached to the contacts or electrical conductors 42, and the contacts or electrical conductors 42 may be connected to the associated shielded cable conductors (such as the twin-axial cable conductors 48 or the cable conductors 90). Fig. 9 and Fig.10 )) There is no visible attachment area or no mechanical attachment between the PCB traces or PCB pads or contacts or electrical conductors 42 and the cable conductors (such as the RF cable conductors 47 or twinax cable conductors 48 shown) can be integral or can be printed as one continuous electrical path, one continuous electrical conductor, or one continuous electrical transmission line. There can be a seamless physical transition, a seamless electrical transition, or both between the twinax cable conductors 48 and the contacts or traces or electrical conductors 42.

[0073] Applicants' embodiments can prevent electrical interruptions, such as when twinax cable conductor 48P ( Fig.13 ) soldered to the second PCB mounting pad 55P ( Fig.13), eliminating electrical discontinuities by 3D printing, multi-material printing, or both can improve insertion loss. Eliminating electrical discontinuities can improve impedance matching and can improve impedance tuning to a desired impedance. The present invention allows for local, tuned, and / or more precise impedance control over every linear millimeter or the entire length of a single-ended or differential signal transmission path throughout a cable assembly or board connector, thereby producing 100±10 ohms, 100±1 ohms, 100±0.5 ohms, 100±0.1 ohms, 85±5 ohms, 85±1 ohms at every point along the entire physical length, electrical length, or both of an interconnect (such as a circuit board connector or cable assembly). , 85±0.5 ohm, 85±0.1 ohm, 77±5 ohm, 77±1 ohm, 77±0.5 ohm, 77±0.1 ohm, 75±5 ohm, 75±1 ohm, 75±0.5 ohm, 75±0.1 ohm, 60±5 ohm, 60±1 ohm, 60±0.5 ohm, 60±0.1 ohm, 50±5 ohm, 50±1 ohm, 50±0.5 ohm, 50±0.1 ohm, etc. Precisely tuned and optimized impedance.

[0074] like Fig.14 As shown, skew correction, impedance correction, or both can be printed directly into a cable assembly or board connector or flexible cable or printed circuit board. Air or other dielectric gaps 81 can be formed around or adjacent to one or more contacts or conductors 42 that form a differential signal pair. The conductors 42 can be printed with jogs 82 that are designed to equalize skew by leveling the electrical length of the two contacts or conductors of the differential signal pair. Skew correction, impedance correction, or both can be performed at the interconnect, at the cable, at the waveguide, and / or at the host PCB level to tune the entire transmission channel from one chip or ASIC to another chip or ASIC.

[0075] The embodiments described herein may also have positive and expected environmental impacts. Waste may be reduced. Interconnects, such as cable assemblies or board connectors, may be designed in one country and then printed in the same country or even in a different country, thereby offsetting the cost of shipping the finished product. A method of manufacturing an object such as an interconnect or an electrical interconnect may include the step of creating a model of a multi-material interconnect or the step of opening a mold of the multi-material interconnect. Another step may include printing the multi-material interconnect at a location at least 5 km away from the location where the model was created or from the location of the printing function or printing process or a single printing cycle or a single printing operation. Other steps may include executing a print command and then printing the multi-material interconnect on a printer at a location at least 5 km away from where the print command was executed. All that is needed at the target printing location is a suitable printer, such as a three-dimensional multi-material printer. Alternatively, a model representing an interconnect (such as a cable assembly or board connector) may be transported within 5 km of a printer that prints the interconnect according to the model alone or in combination with another printer. In partial overview, a method of reducing the number of steps required to create a multi-material cable assembly by at least 33% compared to mechanically attached stamped conductors and wires may include the step of printing a multi-material cable assembly 20, 21, 22, 23, 24 as a single piece using a three-dimensional multi-material printer. The 3D multi-material printed cable assembly 22, 23, 24 may include an electrically insulating housing; an electrical conductor or electrical contact or electrical trace or electrical pad carried by the electrically insulating housing; and at least one cable that is electromagnetically and geometrically continuous with respect to a respective one of the electrical conductor or electrical contact or electrical trace or electrical pad. The impedance of the 3D multi-material printed cable assembly 22, 23, 24 may be 100±0.5 ohms or 85±0.5 ohms or 75±0.5 ohms or 60±0.5 ohms or 50±0.5 ohms. The 3D printed cable assembly 22, 23, 24 may include an electrically insulating housing and an electrical conductor or electrical contact or electrical trace or electrical pad carried by the electrically insulating housing. At least one cable may be electromagnetically and geometrically continuous with the electrical conductor or electrical contact or electrical trace or electrical pad without any mechanical attachment between the electrical conductor or electrical contact or electrical trace or electrical pad and the at least one cable. The impedance of the 3D printed cable assembly may be selected from the group consisting of 100±0.5 ohms or 85±0.5 ohms or 75±0.5 ohms or 60±0.5 ohms or 50±0.5 ohms.

[0076] The 3D printed multi-material cable assembly may include a conductive material and a non-conductive material. Both the conductive material and the non-conductive material are printed during a single printing cycle or a single printing cycle or a single printing operation.

[0077] In some embodiments, a method of printing an interconnect includes the steps of printing an electrical interconnect including an electrical conductor and an insulating housing during a single printing process or a single printing cycle or a single printing operation.

[0078] In some embodiments, a method of printing an interconnect includes the steps of printing a finished electrical interconnect including an electrical conductor, an insulating housing, and an electrical conductor plating during a single printing process or a single printing cycle or a single printing operation.

[0079] In some embodiments, the cable assembly includes an electrically insulating housing. In various embodiments, the assembly may include an electrical conductor carried by the electrically insulating housing. In some embodiments, the assembly may include a coaxial or twinaxial or flexible circuit cable, each of which includes one or two cable conductors, wherein the finished cable assembly is free of: a mechanically stamped or pressed cable conductor; a mechanical crimp between the cable conductor and the associated lead frame conductor or the associated printed circuit board pad; a soldered connection between the cable conductor and the associated lead frame conductor or the associated printed circuit board pad; an insulation displacement connection between the cable conductor and the associated lead frame conductor or the associated printed circuit board pad; a weld or ultrasonic weld or ultrasonic bond between the cable connector and the associated lead frame conductor or the associated printed circuit board pad; a conductive polymer or conductive epoxy between the cable connector and the associated lead frame conductor or the associated printed circuit board pad; and a laser attachment between the cable conductor and the associated lead frame conductor or the associated printed circuit board pad.

[0080] Additionally, in some embodiments, the assembly can include a precious metal plating carried by one or more electrical conductors. In various embodiments, the assembly can include a signal conductor attached to an associated shielded cable conductor, wherein there is no visible attachment area or no mechanical attachment between the signal conductor and the associated cable conductor of the shielded cable.

[0081] In some embodiments, a method of reducing the number of steps required to create a multi-material cable assembly by at least 33% compared to mechanically attached stamped conductors and wires includes the step of printing the multi-material cable as a single piece using a three-dimensional multi-material printer.

[0082] In some embodiments, the 3D printed cable assembly may include an electrically insulating housing. In various embodiments, the assembly may include an electrical conductor or an electrical contact or an electrical trace or an electrical pad carried by the electrically insulating housing. In some embodiments, the assembly may include at least one cable that is electromagnetically and geometrically continuous with the electrical conductor or the electrical contact or the electrical trace or the electrical pad, without any mechanical attachment between the electrical conductor or the electrical contact or the electrical trace or the electrical pad and the at least one cable, wherein the impedance of the 3D printed cable assembly is selected from the group consisting of: 100±0.5 ohms or 85±0.5 ohms or 75±0.5 ohms or 60±0.5 ohms or 50±0.5 ohms.

[0083] In some embodiments, a 3D printed cable assembly may include a conductive material and a non-conductive material, wherein both the conductive material and the non-conductive material are printed during a single printing cycle or a single printing cycle or a single printing operation.

[0084] In some embodiments, the cable assembly may include an electrically insulating housing. In various embodiments, the assembly may include a plurality of electrical conductors or electrical contacts or electrical traces or electrical pads carried by the electrically insulating housing, or a printed circuit board carried by the electrically insulating housing. In some embodiments, the assembly may include a plurality of cable conductors, each cable conductor electrically connected to a corresponding one of the plurality of electrical conductors or electrical contacts or electrical traces or electrical pads, wherein at least 25% of the cable conductors are not mechanically attached to the corresponding electrical conductors or electrical contacts or electrical traces or electrical pads of the cable conductors.

[0085] Furthermore, in some embodiments, at least 50% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads. In various embodiments, at least 75% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads. In some embodiments, 100% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads. In various embodiments, the method or cable assembly or waveguide according to the present invention may include electrically lossy material, magnetically absorptive material, or both.

[0086] Although several embodiments have been described and shown herein, a person of ordinary skill in the art will readily conceive of various other means and / or structures for performing functions and / or obtaining results and / or one or more advantages described herein, and each of these variations and / or modifications is considered to fall within the scope of the embodiments described herein. More generally, it will be readily understood by those skilled in the art that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and that actual parameters, dimensions, materials, and / or configurations will depend on one or more specific applications for which this teaching is used. Using no more than routine experiments, those skilled in the art will recognize or be able to find many equivalents of the specific embodiments described herein. Therefore, it should be understood that the foregoing embodiments are presented only by way of example, and within the scope of the appended claims and their equivalents, embodiments may be practiced in a manner different from that specifically described and claimed. The embodiments of the present disclosure relate to each individual feature, system, article, material, and / or method described herein. In addition, if such features, systems, articles, materials, and / or methods are not mutually inconsistent, any combination of two or more such features, systems, articles, materials, and / or methods is included within the scope of the present disclosure.

[0087] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0088] Unless clearly 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".

[0089] The phrase "and / or" used herein in the specification and claims should be understood to mean "either one 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 manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and / or" clause, other elements may optionally exist, whether related or unrelated to those specifically identified elements. Therefore, as a non-limiting example, when used in conjunction with an open language such as "including", a reference to "A and / or B" may refer to only A (optionally including elements other than B) in one embodiment; only B (optionally including elements other than A) in another embodiment; in yet another embodiment, both A and B (optionally including other elements); and so on.

[0090] As used herein in the specification and claims, "or" shall 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" shall be interpreted as inclusive, i.e., including at least one element in a plurality of elements or a list of elements, but also including more than one element in a plurality of elements or a list of elements, and optionally, including additional unlisted items. Only terms that clearly indicate the opposite, such as "only one" or "exactly one", or when used in the claims, "consisting of..." will refer to including exactly one element in a plurality of elements or a list of elements. Typically, when preceded by an exclusive term, such as "either", "one", "only one" or "exactly one", the term "or" as used herein will only be interpreted as indicating an exclusive alternative element (i.e., "one or the other, but not two"). When used in the claims, "consisting essentially of..." should have its ordinary meaning used in the field of patent law.

[0091] As used herein in the specification and claims, the phrase "at least one" with respect 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 at least one of each element specifically listed within the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements may optionally be present other than those specifically identified within the list of elements to which the phrase "at least one" refers, whether related or unrelated to those specifically identified elements. Thus, as a non-limiting example, “at least one of A and B” (or equivalently, “at least one of A or B”, or equivalently, “at least one of A and / or B”) may refer in one embodiment to at least one A, optionally including more than one A, wherein B is not present (and optionally including elements other than B); in another embodiment, may refer to at least one B, optionally including more than one B, wherein A is not present (and optionally including elements other than A); in yet another embodiment, may refer to at least one A, optionally including more than one A, and at least one B, optionally including more than one B (and optionally including other elements); and so on.

[0092] It should also be understood that in any method claimed herein that includes more than one step or action, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are recited unless clearly indicated to the contrary.

[0093] In the claims, as well as in the foregoing description, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "maintaining," "consisting of," etc. shall be construed as open-ended, i.e., meaning including, but not limited to. Only transitional phrases such as "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as described in Section 2111.03 of the U.S. Patent Office Manual of Patent Examining Procedures.

[0094] It should be understood that the embodiments are not limited in their application to the details of the construction and arrangement of the components set forth in the specification or shown in the drawings. The present invention can have other embodiments and can be practiced or implemented in various ways. Unless otherwise limited, the terms "connect", "couple", "communicate with..." and "install" and their variations are used broadly herein and cover direct and indirect connections, couplings and installations. In addition, the terms "connect" and "couple" and their variations are not limited to physical or mechanical connections or couplings.

[0095] The foregoing description of several embodiments of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and / or forms disclosed, and obviously many modifications and variations are possible in light of the above teachings.

Claims

1. A cable assembly comprising a cable and at least one first connector, wherein the at least one first connector is integrally attached to a first end of the cable, wherein: Both the cable and the connector are printed using a 3D printer.

2. The cable assembly of claim 1, further comprising at least one second connector integrally attached to the second end of the cable, wherein: The second end of the cable is opposite to the first end of the cable.

3. The cable assembly according to any one of claims 1 and 2, wherein: The cable is a hollow waveguide.

4. The cable assembly according to any one of claims 1 and 2, wherein: The cable comprises at least one cable conductor.

5. The cable assembly according to any one of claims 1 and 2, wherein: The cable comprises at least two cable conductors.

6. The cable assembly according to any one of claims 1 to 2, wherein: The at least one first connector includes a first vacuum port.

7. The cable assembly according to any one of claims 1 to 3 and 6, wherein: The at least one second first connector includes a second vacuum port.

8. The cable assembly according to any one of claims 1 to 7, wherein: The cables are not extruded.

9. The cable assembly according to any one of claims 1 to 8, wherein: The at least one first connector does not include stamped electrical connector conductors.

10. The cable assembly according to any one of claims 1-3 and 6-9, wherein: The cable assembly is printed within an area of ​​approximately 50 mm3.

11. A cable assembly, comprising: A cable having opposite ends, wherein at least a portion of the cable is printed using a 3D printer.

12. The cable assembly of claim 11, further comprising one or more connectors, wherein: At least one connector is attached to at least one of the opposing ends.

13. The cable assembly according to any one of claims 11 to 12, wherein: The cable includes a non-conductive material and a conductive material, the conductive material surrounding at least a portion of the non-conductive material.

14. The cable assembly according to any one of claims 11 to 13, wherein: The cable also includes one or more walls having one or more surface increasing structures.

15. The cable assembly according to claim 14, wherein: The one or more surface increasing structures are undulations.

16. The cable assembly according to any one of claims 11 to 15, wherein: The cable also includes one or more support structures.

17. The cable assembly according to claim 16, wherein: The one or more support structures define one or more channels within the cable.

18. The cable assembly according to any one of claims 11 to 15, wherein: The cable includes a single channel therein.

19. The cable assembly according to any one of claims 12 to 18, wherein: At least one of the cable and the at least one connector includes one or more vacuum ports.

20. The cable assembly of any one of claims 11-19, further comprising one or more lenses.

21. The cable assembly of claims 11-12, further comprising at least one electrical conductor.

22. The cable assembly of claims 11-12, further comprising at least two electrical conductors.

23. The cable assembly according to any one of claims 12 to 22, wherein: At least a portion of the at least one connector is printed.

24. The cable assembly according to any one of claims 12 to 23, wherein: The cable and the at least one connector are printed together.

25. The cable assembly according to any one of claims 11, 12, and 14-24, wherein: At least one of the conductive material and the non-conductive material is printed.

26. The cable assembly according to any one of claims 11 to 25, wherein: At least a portion of the cable has an asymmetric cross-section.

27. The cable assembly according to any one of claims 11 to 26, wherein: The cable is flexible between a first orientation and a second orientation different from the first orientation, and wherein the cable is printed in the first orientation.

28. The cable assembly according to any one of claims 11-20 and 23-27, wherein: The cable is a waveguide.

29. The cable assembly according to any one of claims 11 to 28, wherein: The cables are not extruded.

30. The cable assembly according to any one of claims 12-28, wherein: The cable includes the at least one connector on each of the opposing ends of the cable.

31. A method of 3D printing at least a portion of a cable assembly according to claims 11-30.

32. A method of manufacturing a cable assembly comprising the step of simultaneously 3D printing the entire cable assembly during a single pre-programmed complete printing cycle or process.

33. A method of manufacturing a cable assembly comprising the step of attaching an electrically conductive contact or electrically conductive conductor to a corresponding flexible cable conductor without one or more of solder, IDC and / or friction connection.

34. The method of claim 33, further comprising the step of electroplating the conductive contacts or conductors.

35. A 3D printed cable assembly.

36. A dielectric waveguide composed of a photosensitive polymer.

37. A dielectric waveguide comprising a waveguide body defining an outer surface, wherein: (i) the outer surface further includes a first surface and a second surface intersecting the first portion, (ii) the first surface is approximately linear, and (iii) the second surface is approximately non-linear.

38. The dielectric waveguide of claim 37, wherein The second surface has a greater total surface area than the first surface.

39. The dielectric waveguide according to any one of claims 37-38, wherein The second surface defines a repeating or recurring surface pattern.

40. The dielectric waveguide according to any one of claims 37 to 39, wherein The waveguide body is hollow or at least partially hollow along at least a portion of the longitudinal length of the waveguide body.

41. A dielectric waveguide comprising a waveguide body defining an outer surface, wherein: The outer surface has at least one second surface that takes any one or more of the form of sinusoidal, wavy, textured, rough, uneven, and / or non-smooth.

42. The dielectric waveguide of claim 41, wherein The waveguide body is solid in cross-section along at least a portion of a longitudinal length of the waveguide body.

43. The dielectric waveguide of claim 41, wherein The waveguide body is hollow or at least partially hollow along at least a portion of the longitudinal length of the waveguide body.

44. An article comprising a first portion and a second portion, the second portion being physically connected to the first portion, electrically connected to the first portion, or physically connected to the first portion and electrically connected to the first portion, wherein: Both the first part and the second part are printed using a 3D printer.

45. The article of claim 44, wherein: The first portion and the second portion are visually and structurally distinct from each other.

46. ​​The article according to any one of claims 44 and 45, wherein The first portion includes a non-flexible dielectric housing.

47. The article of any one of claims 44-46, wherein The second portion is one or more of flexible, pliable or able to yield.

48. The article of any one of claims 44-47, wherein The first part comprises at least one electrical contact or at least one electrical conductor.

49. The article of any one of claims 44-48, wherein The second portion includes at least one waveguide, at least one electrically conductive cable conductor, or both.

50. A 3D printed electrical connector comprising a 3D printed non-conductive housing and at least one 3D printed electrical contact or conductor.

51. A 3D printed cable assembly comprising a 3D printed non-conductive housing and at least one 3D printed flexible cable, wherein the at least one 3D printed flexible cable is physically carried by the non-conductive housing and electrically connected to at least one electrical contact carried by the 3D printed non-conductive housing, or is physically carried by the non-conductive housing and electrically connected to the at least one electrical contact carried by the 3D printed non-conductive housing.

52. A method of printing an interconnect comprising the steps of printing an electrical interconnect comprising an electrical conductor and an insulating housing during a single printing process or a single printing cycle or a single printing operation.

53. A method of printing an interconnect comprising the steps of printing a finished electrical interconnect comprising an electrical conductor, an insulating housing and an electrical conductor plating during a single printing process or a single printing cycle or a single printing operation.

54. A cable assembly comprising: Electrically insulating housing; an electrical conductor carried by the electrically insulating housing; as well as a coaxial or twinaxial or flexible circuit cable, each of which comprises one or two cable conductors, respectively, Among them, the finished cable assembly does not have: mechanically stamped or pressed cable conductors; mechanical crimping portions between cable conductors and associated lead frame conductors or associated printed circuit board pads; soldered connections between cable conductors and associated lead frame conductors or associated printed circuit board pads; insulation displacement connections between cable conductors and associated lead frame conductors or associated printed circuit board pads; welds or ultrasonic welds or ultrasonic joints between cable connectors and associated lead frame conductors or associated printed circuit board pads; conductive polymers or conductive epoxies between cable connectors and associated lead frame conductors or associated printed circuit board pads; and laser attachment portions between cable conductors and associated lead frame conductors or associated printed circuit board pads.

55. The cable assembly of claim 54, further comprising a precious metal plating carried by one or more of the electrical conductors.

56. An electrical cable assembly comprising a signal conductor attached to an associated shielded cable conductor, wherein: There is no visible attachment area or mechanical attachment between the signal conductor and the associated cable conductor of the shielded cable.

57. A method of reducing the number of steps required to create a multi-material cable assembly by at least 33% compared to mechanically attached stamped conductors and wires, comprising the step of printing the multi-material cable as a single piece using a three-dimensional multi-material printer.

58. A 3D printed cable assembly, comprising: Electrically insulating housing; an electrical conductor or electrical contact or electrical trace or electrical pad carried by the electrically insulating housing; At least one cable, the at least one cable is electromagnetically and geometrically continuous with the electrical conductor or electrical contact or electrical trace or electrical pad, without any mechanical attachment between the electrical conductor or electrical contact or electrical trace or electrical pad and the at least one cable, wherein the impedance of the 3D printed cable assembly is selected from the group consisting of: 100±0.5 ohms or 85±0.5 ohms or 75±0.5 ohms or 60±0.5 ohms or 50±0.5 ohms.

59. A 3D printed cable assembly, comprising a conductive material and a non-conductive material, wherein: Both the conductive material and the non-conductive material are printed during a single printing cycle or a single printing cycle or a single printing operation.

60. A cable assembly comprising Electrically insulating housing; a plurality of electrical conductors or electrical contacts or electrical traces or electrical pads carried by the electrically insulating housing, or a printed circuit board carried by the electrically insulating housing; as well as A plurality of cable conductors, each of the plurality of cable conductors being electrically connected to a corresponding one of the plurality of electrical conductors or electrical contacts or electrical traces or electrical pads, wherein at least 25% of the cable conductors are not mechanically attached to the corresponding electrical conductors or electrical contacts or electrical traces or electrical pads of the cable conductors.

61. The cable assembly of claim 60, wherein: At least 50% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads.

62. The cable assembly of claim 60, wherein: At least 75% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads.

63. The cable assembly of claim 60, wherein: 100% of the cable conductors are not mechanically attached to corresponding electrical conductors or electrical contacts or electrical traces or electrical pads.

64. The method or cable assembly or waveguide of any one of claims 1-63, further comprising an electrically lossy material, a magnetically absorptive material, or both.

Images