Lossy materials for improved signal integrity

Abstract

An electrical contact of an electrical connector includes a contact body and a lossy material on the contact body. An electrical connector includes a contact having a lossy material on a contact body. A method of applying a lossy material to a contact of an electrical connector includes providing a contact and applying a lossy material to the contact.

Description

[0001] This application is a divisional application of the invention patent application with the application date of July 12, 2019, application number 201980056648.1 (international application number PCT / US2019 / 041576), and invention name “Lossful Materials for Improving Signal Integrity”.

[0002] This application claims priority to U.S. patent application serial number 62 / 697,022 filed on July 12, 2018, U.S. patent application serial number 62 / 724,347 filed on August 29, 2018, and U.S. patent application serial number 62 / 839,130 ​​filed on April 26, 2019, the disclosures of each of which are hereby incorporated by reference as if fully set forth herein. background 1. Field of the Invention

[0004] The present invention relates to connectors, connector assemblies, and cable assemblies. More particularly, the present invention relates to controlling the resonant characteristics of connectors and connector assemblies.

[0005] 2. Description of Related Fields

[0006] An electrical connector typically includes an electrically insulating connector housing and a plurality of electrical contacts supported by the connector housing. The electrical contacts typically define a mounting end and a docking end opposite the mounting end. The mounting end is typically configured to be mounted to a first complementary electrical device such as a printed circuit board (PCB) or a cable. The docking end can be configured to dock with a second complementary electrical device, such as a complementary electrical connector. Typically, the docking end defines an interface that is separable from the complementary electrical contacts of the complementary electrical connector. In some configurations, the electrical contacts can be configured as power contacts that are configured to transmit power between the first electrical device and the second electrical device. In other configurations, some electrical contacts can be pre-assigned as electrical contacts, while other electrical contacts can be pre-assigned as ground contacts. Thus, during operation, the electrical connector can transmit electrical signals along the electrical signal contacts between the first complementary electrical device and the second complementary electrical device.

[0007] When designing an electrical connector, an important consideration is the ability of the electrical connector to transmit signals at the desired operating frequency while maintaining the integrity of the electrical signal, which can degrade during operation. In some applications, the operating frequency is desired to be as high as possible while mitigating the signal degradation that tends to be exacerbated at high operating frequencies. In other applications, the desired operating frequency is within a range that has speeds appropriate for the application and is intended to minimize signal degradation. Degradation of electrical signals is known to manifest in a variety of ways, including: crosstalk, such as near-end crosstalk (NEXT), far-end crosstalk (FEXT), insertion loss, skew, common mode issues, stubs on connector contacts and in PCBs, half-wavelength horizontal propagation or resonance, and quarter-wavelength horizontal propagation or resonance; cavity resonance between ground planes on two PCBs, and impedance mismatches within the electrical connector, between the electrical connector and the PCB, and in breakout regions near the connector.

[0008] Figure 1 shows the relationship between insertion loss and operating frequency for a conventional connector. Connector insertion loss increases with the connector's resonant frequency. This is a typical resonant characteristic of certain connectors. Insertion loss resonances can have many causes, including impedance mismatches within the connector, between the connector and the printed circuit board (PCB), and in the shunt area near the connector; offset / common-mode issues; stubs on the connector contacts and in the PCB; crosstalk; half-wavelength and quarter-wavelength horizontal propagation or resonance; and cavity resonance between the ground planes on two PCBs. The pursuit of electrical connector design is a never-ending process.

[0009] US Patent No. 8,083,553 describes an electrically lossy insert disposed in a wafer for an electrical connector and located near a mating interface of the electrical connector. The electrically lossy insert is electrically connected to a shield in the wafer. The lossy insert is not connected to an electrical contact of the electrical connector.

[0010] US Patent No. 8,007,316 describes a contact assembly that uses a dielectric material between an electrical conductor and a conductive layer such that the dielectric material, the electrical conductor, and the conductive layer form a capacitive element. US Patent No. 8,007,316 does not disclose lossy materials in the contact assembly.

[0011] It is also known to incorporate ceramic ferrites in electrical connectors to control unwanted electromagnetic interference (EMI) and unwanted resonance. However, ceramic ferrites are difficult to machine and have imprecise mechanical tolerances, so their use in connectors and cable assemblies is generally immature. Summary of the Invention

[0012] To overcome the above problems, preferred embodiments of the present invention use lossy materials to alter the resonant characteristics of an electrical connector, connector assembly, or cable assembly.

[0013] In one example, an electrical contact for an electrical connector may include a contact body and a lossy material on the contact body.

[0014] The lossy material can be conductive or non-conductive. In one example, the lossy material is non-conductive. Additionally, the lossy material can be magnetically absorptive. In one example, the lossy material can include a carbon microcoil. In one example, the lossy material can be configured to absorb electromagnetic interference substantially within ±5 GHz of a first predetermined operating frequency. The lossy material can be electrically lossy or magnetically lossy. The lossy material can be disposed on a tip of the contact body. Alternatively or additionally, the lossy material can be disposed on a base of the contact body. The base can extend from a first end of a middle portion of the contact body toward a mounting end of the electrical contact. In some examples, the base can be at least partially defined by the mounting end or completely defined by the mounting end. The tip can be disposed such that the middle portion is disposed between the tip and the mounting end. The butt end can extend from a second end of the middle portion, opposite the first end, and the tip can define a distal end of the electrical contact. In some examples, the tip can be at least partially defined by the butt end or completely defined by the butt end. The electrical contact can be configured as an electrical ground contact, which can be configured to connect to ground, a reference, or a power source. Alternatively, the electrical contact can be configured as a signal contact for transmitting an electrical signal. The lossy material can be tuned to reduce electrical interference at a predetermined operating frequency. In some examples, the lossy material can be located only on one side of the contact body.

[0015] Thus, an electrical connector may include electrical contacts according to the examples described herein.

[0016] For example, a first electrical contact of an electrical connector may include a lossy material that is substantially tuned to a first frequency, and a second electrical contact of the electrical connector may include a lossy material that is substantially tuned to a second frequency different from the first frequency. In one example, the lossy material may be included at the mating ends of each of the first and second electrical contacts. The lossy material may be disposed on the tip of the contact body. Alternatively or additionally, the lossy material may be disposed on the base of the contact body. In one example, the first and second electrical contacts may be configured as electrical signal contacts. In this regard, in one example, the lossy material may be disposed only on the electrical signal contacts of the electrical connector. Alternatively, the first and second electrical contacts may be configured as electrical ground contacts. In this regard, in one example, the lossy material may be disposed only on the ground contacts of the electrical connector. In other examples, the electrical contacts may not be designated as signal contacts or ground contacts.

[0017] In other examples, an electrical contact roll may include electrical contacts according to various examples disclosed herein.

[0018] According to a preferred embodiment of the present invention, a method of applying a lossy material to a contact of an electrical connector includes providing a contact and applying the lossy material to the contact.

[0019] The lossy material can be conductive or non-conductive. The lossy material can be non-conductive and can be substantially magnetically absorptive at a first frequency of ±5 GHz. The lossy material can include a carbon microcoil. The lossy material can be electrically lossy or magnetically lossy. The lossy material can be applied to the tip of the electrical contact. Alternatively, the lossy material can be applied to the base of the electrical contact. In one example, the lossy material is applied to only one side of the contact, such as the side opposite the wiped surface of the electrical contact at the butt end of the electrical contact.

[0020] Providing the electrical contacts may include the step of stamping the electrical contacts from a sheet of metal. The contacts may be included in a roll of contacts. The contacts may be connected to ground or may transmit electrical signals. Applying the lossy material may include cutting a sheet of lossy material and moving the electrical contact into physical contact with the cut sheet, thereby causing the lossy material to adhere to the electrical contact. The lossy material may be applied to the electrical contacts at the butt ends of the electrical contacts. The lossy material may be substantially tuned to a particular frequency. The lossy material applied to the first electrical contact may be substantially tuned to a first frequency, and the lossy material applied to the second electrical contact may be substantially tuned to a second frequency different from the first frequency. In one example, the lossy material may be applied only to electrical contacts that transmit electrical signals. Alternatively, the lossy material may be applied only to electrical ground contacts that are connected to ground or are configured to be connected to ground.

[0021] According to a preferred embodiment of the present invention, an electrical connector includes a connector housing and electrical contacts. In one example, the electrical contacts may be directly supported by the connector housing. In another example, the electrical contacts may be indirectly supported by the connector housing. For example, the electrical contacts may be supported by corresponding lead frame housings, which in turn are supported by the connector housing. In one example, the connector housing may include a lossy material adjacent to at least one electrical contact.

[0022] The lossy material may be located at or near the tip of at least one electrical contact. In one example, the lossy material may be located at the tip of at least one electrical contact. Alternatively or additionally, the lossy material may be located on the base of at least one electrical contact. The lossy material may be conductive or non-conductive. In one example, the lossy material may be non-conductive. Furthermore, the lossy material may be configured to be magnetically absorptive substantially at a first frequency ±5 GHz. In one example, the lossy material may include a carbon microcoil. The lossy material may be electrically lossy or magnetically lossy. The lossy material may be tuned to reduce signal degradation when transmitting electrical signals substantially at a specific predetermined operating frequency ±5 GHz. For example, when transmitting electrical signals substantially at a specific predetermined operating frequency ±5 GHz, the lossy material may be tuned to reduce a maximum amount of signal degradation. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The foregoing summary of illustrative embodiments of the present application and the following detailed description will be better understood when read in conjunction with the accompanying drawings. For the purpose of example of the present disclosure, illustrative embodiments are shown in the accompanying drawings. However, it should be understood that the application is not limited to the precise arrangements and instrumentalities shown.

[0025] In the attached figure:

[0026] FIG1 is a graph plotting the insertion loss of a conventional electrical connector as a function of operating frequency;

[0027] Figure 2 is a graph plotting the dielectric constant and permeability of an electrical connector including a lossy material as a function of operating frequency;

[0028] Figure 3 is a graph plotting insertion loss as a function of operating frequency with and without a lossy material according to the present disclosure;

[0029] Figure 4 is a graph plotting insertion loss as a function of operating frequency with and without a lossy material according to another aspect of the present disclosure;

[0030] Figure 5 is a cross-sectional view of an electrical connector with lossy material oriented vertically in one example;

[0031] Figure 6 yes Figure 5 A cross-sectional view of the electrical connector shown in , but showing the lossy material oriented horizontally in another example;

[0032] Figure 7is a perspective view of an electrical connector in one example, the electrical connector including a lossy material disposed along a mounting interface of a connector housing of the electrical connector;

[0033] Figure 8A is a side cross-sectional view of an electrical connector including lossy material according to another example;

[0034] Figure 8B is a perspective view of a data communications assembly including a portion removed Figure 8A , and showing the electrical connector mounted to a first electrical device and docked with a second electrical device;

[0035] Figure 8C yes Figure 8B Another perspective view of a portion of the data communications assembly shown in;

[0036] Figure 9A yes Figure 8A A perspective view of a lead frame assembly of an electrical connector shown in FIG;

[0037] Figure 9B yes Figure 9A a perspective view of a leadframe housing of a leadframe assembly in FIG. 1 , the leadframe housing defining a void configured to receive a lossy material;

[0038] Figure 9C yes Figure 9A A side cross-sectional view of the lead frame assembly shown in FIG. Figure 9B Lossy material in the void shown in ;

[0039] Figure 9D yes Figure 9A Another perspective view of the lead frame assembly shown in;

[0040] Figure 9E yes Figure 9A A top view of the electrical connector shown in ;

[0041] Figure 9F yes Figure 9A A side view of the electrical connector shown in FIG, wherein the electrical contact is shown in a relaxed position and, when mated with a complementary electrical contact, in a deflected position;

[0042] Figure 10 is a perspective view of an electrical connector housing in one example, the electrical connector housing including a housing body and a lossy material disposed on the housing body;

[0043] Figure 11Ashowing first and second electrical contacts of respective first and second electrical connectors aligned for inter-mateability, wherein the electrical contacts include lossy material disposed on respective tips of the electrical contacts according to one example;

[0044] Figure 11B Shown Figure 11A , wherein the first electrical contact and the second electrical contact are connected to each other;

[0045] Figure 12A is a perspective view of a leadframe assembly including a leadframe housing and electrical contacts supported by the leadframe housing, wherein the leadframe assembly is free of lossy material;

[0046] Figure 12B yes Figure 12A A perspective view of a lead frame assembly as shown in FIG, but including lossy material according to one example;

[0047] Figure 13A is a perspective view of a plurality of lead frame assemblies of an electrical connector, which in one example include lossy material;

[0048] Figure 13B yes Figure 13A an end view of a lead frame assembly shown in ;

[0049] Figure 14A An edge card connector in one example includes a connector housing and a plurality of electrical contacts supported by the connector housing, and a lossy material disposed on the ground contacts;

[0050] Figure 14B yes Figure 14A a perspective view of a lead frame assembly of an edge card connector shown in;

[0051] Figure 14C yes Figure 14B Another perspective view of the lead frame assembly shown in;

[0052] Figure 14D yes Figure 16A A perspective view of the ground contact shown in FIG;

[0053] Figure 15 is a perspective view of an edge card connector in another example in which lossy material is disposed on the connector housing;

[0054] Figure 16A yes Figure 15 A perspective view of a portion of an edge card connector as shown in , but with lossy material disposed elsewhere;

[0055] Figure 16B yes Figure 16AAnother perspective view of the edge card connector shown in ;

[0056] Figure 16C yes Figure 16A a perspective view of a selected portion of an edge card connector shown in ;

[0057] Figure 17 is a perspective view of a portion of a data communications assembly showing a cable termination with lossy material according to one example;

[0058] Figure 18 yes Figure 17 A perspective view of a portion of the data communications assembly shown in , but showing a cable termination with lossy material according to another example;

[0059] Figure 19A is a perspective view of a cable connector including a lossy material that provides strain relief according to one example;

[0060] Figure 19B is included Figure 19A A top view of a data communications assembly of a cable connector shown in FIG, showing a cable mounted to a substrate;

[0061] Figure 20A is an end view of a cable connector according to one example, the cable connector including a cover enclosing a cable, the housing including a lossy material;

[0062] Figure 20B yes Figure 20A A perspective view of the cover shown in ;

[0063] Figure 21A is a perspective view of an electrical connector assembly including a first electrical connector and a second electrical connector mated with each other and mounted to a cable and a substrate, respectively, the first electrical connector and the second electrical connector including a first electrical shield and a second electrical shield, respectively;

[0064] Figure 21B yes Figure 21A An exploded perspective view of the electrical connector assembly shown in ;

[0065] Figure 22 yes Figure 21A A perspective view of the first electrical connector shown in ;

[0066] Figure 23A yes Figure 21A a side cross-sectional view of the electrical connector assembly shown in ;

[0067] Figure 23B yes Figure 21A a side cross-sectional view of a first electrical shield shown in ;

[0068] Figure 23C yes Figure 21A a side cross-sectional view of a second electrical shield shown in ;

[0069] Figure 24 yes Figure 21A a schematic side cross-sectional view of the electrical connector assembly shown in , but constructed according to another example; and

[0070] Figure 25 is a perspective view of a conductive cage having a lossy material disposed around an opening to an interior of the cage according to one example.

[0071] Specific description

[0072] Lossy materials can be used to alter the resonant characteristics of connectors, connector assemblies, cable assemblies, or data communication components that include any one or more of these. Generally speaking, the electrical and magnetic properties of a material can be defined by its dielectric constant, ε, and magnetic permeability, μ, which are both frequency-dependent. The dielectric constant, ε, and magnetic permeability, μ, are complex numbers:

[0073] ε=ε'-ε”

[0074] μ=μ'-μ"

[0075] Where the real part (') is related to energy storage and the imaginary part (") is related to energy loss. The lossy material can be selected to have a specific dielectric constant ε and magnetic permeability μ. Dopants can be added to the base material to change the dielectric constant ε and magnetic permeability μ. The dopants can change the magnitude of the dielectric constant ε and magnetic permeability μ of the lossy material, and thus can selectively increase or decrease the damping effect of the lossy material at a given operating frequency of the electrical signal. Therefore, the dopants can change the frequency dependence of the lossy material and can shift or tune the frequency at which the lossy material is configured to provide electrical shielding. For example, the lossy material can be configured to absorb electromagnetic interference (EMI) during operation of the electrical connector. By tuning the frequency dependence of the lossy material, the lossy material can best function to provide electrical shielding or absorption at a predetermined specific frequency or frequency range, while allowing energy of different frequencies to pass through.

[0076] The lossy material can be electrically lossy. Alternatively or additionally, the lossy material can be magnetically lossy. Electrically lossy materials can have good broadband performance over a wide frequency range, are typically electrically conductive (e.g., can be made of carbon), can be easily simulated, and can be used as readily moldable materials that can be used for electrostatic control and electroplating. Magnetic lossy materials can have tunable frequency performance. Furthermore, magnetic lossy materials can have higher volumetric efficiency than electrical lossy materials. Thus, a reduced amount of magnetic lossy material can provide similar effects as electrical lossy materials compared to electrical lossy materials. Furthermore, magnetic lossy materials can be conductive or non-conductive. Conventional magnetic lossy materials can be used as crude molded parts and are more complex to simulate. Figure 2 is a graph that plots the dielectric constant and permeability of a typical lossy material as a function of frequency. Of course, different lossy materials will have different graphs.

[0077] The lossy material can be obtained in a variety of forms. The lossy material can be injection molded. For example, the lossy material can be included in an injection moldable resin that acts as a binder for the lossy material. The resin with the lossy material can then be injection molded. The lossy material can also be dispensable, such as epoxy resins and urethanes. If the lossy material is dispensable, the lossy material can be applied to the connector after the connector housing is formed, which is typically formed by injection molding. The lossy material can be applied while the injection molded housing is drying, which is typically during a period of time when additional manufacturing steps cannot be performed until the housing reaches a certain degree of dryness. Ultraviolet (UV) light or heat can be used to dry the connector housing. A two-stage injection molding process can also be used, in which the first stage uses an injection molding material without the lossy material and the second stage uses an injection molding material with the lossy material. For example, the first stage can use a material without the lossy material to form the housing by injection molding, and in the second stage, a material with the lossy material can be injection molded into the housing.

[0078] As an example, the lossy material may include a carbon microcoil (CMC). The CMC may include a variety of sizes and shapes, and different types of CMC may be used together. For example, the CMC may include a spiral shape in which the coil diameter is in the micron range, the fiber diameter is from about 0.01 μm to about 1.0 μm, the coil spacing is from about 0.1 μm to about 5.0 μm, and the total length is from about 10 μm to about 10 mm. The spiral may be left-handed and / or right-handed. The CMC may have a single helical structure or a double helical structure. The fibers of the coil may have a flat shape or a round shape. The coils of the CMC may be three-dimensional. Alternatively, the coils of the CMC may be two-dimensional and therefore confined within a single plane. The CMC may be made by any suitable method, including using different catalyst particles to grow the coils.

[0079] In some examples, the lossy material may include a CMC embedded in a dielectric material. For example, the CMC may be included in a silicone rubber structure. The silicone rubber structure may be configured as a sheet. However, it should be understood that other dielectric materials, such as LCP (liquid crystal polymer) or glass-reinforced LCP, may be used. When mixed with the dielectric material, the CMC may form an LCR circuit network, where "L" represents an inductor, "C" represents a capacitor, and "R" represents a resistor. The CMC and the dielectric material may be used to absorb a portion of the magnetic field generated during operation of the electrical connector. Characteristics of the CMC in the dielectric material, such as at least one or more, up to all, of the concentration, size, shape, and geometry of the CMC in the dielectric material, may be varied to adjust the magnetic absorption characteristics of the lossy material, including the wavelength (frequency) at which the lossy material is configured to absorb magnetic fields. For example, varying the coil diameter or coil length may tune the frequency at which the lossy material absorbs magnetic fields. Alternatively or additionally, varying the dielectric constant (Dk) of the dielectric material of the lossy material may change the frequency at which the lossy material absorbs magnetic fields.

[0080] Some electrical connectors include conductive shields to provide electrical shielding between adjacent signal contacts or between differential signal pairs. However, such conductive shields typically work by containing electric fields and directing currents. Therefore, such conductive shields are generally ineffective against magnetic fields, can become a source of resonance at some frequencies, and generally work best when grounded. Lossy materials can be conductive or non-conductive. Furthermore, lossy materials work by containing or absorbing fields and by internally reflecting and / or dissipating energy. Thus, lossy materials can provide shielding against magnetic fields. For example, lossy materials can be configured to absorb magnetic fields. Furthermore, in some examples, lossy materials can be grounded. In other examples, lossy materials can be ungrounded.

[0081] Lossy materials can be applied to different parts or locations of an electrical connector to change the resonant characteristics of the electrical connector. For example, adding lossy materials can change the resonant frequency and / or can reduce the resonant peak, such as Figure 3 and Figure 4 As shown in . Figure 3 In the case of a hot melt with a narrow bandwidth, a lossy material is used (in Figure 3 Identified as “Materials” in Figure 4 In the case of a wideband rubber sheet, a lossy material is used (in Figure 4 Lossy materials can shift the resonant frequency to frequencies outside the desired operating frequency range of the electrical connector.

[0082] In some examples, and in all examples described herein, the lossy material can be an epoxy. For example, the epoxy can be a conductive epoxy. Furthermore, the lossy material can be applied to different locations of the electrical connector. In some examples, the lossy material can be dispensed using computer numerical control (CNC). Thus, the application of the lossy material can be easily and quickly customized, such that the epoxy is applied at predetermined locations of the electrical connector or at predetermined locations of a component configured to be included in the electrical connector, the component including one or more of the connector housing, one or more electrical contacts, and the lead frame housing.

[0083] Now refer to Figure 5 The electrical connector 20 may include an electrically insulating connector housing 22 and a plurality of electrical contacts 24 supported by the connector housing 22. In one example, the electrical contacts 24 may be press-fit or otherwise mechanically attached to the connector housing 22. Alternatively, the electrical contacts 24 may be insert-molded into the connector housing 22. Each electrical contact 24 may include a contact body defining a mating end 26 and a mounting end 28 opposite the mating end 26. Each contact body may also include an intermediate portion 27 extending from the mating end 26 to the mounting end 28, and thus the electrical contacts 24 may also include an intermediate portion 27 extending from the mating end 26 to the mounting end 28. Thus, the mounting end 28 may extend from a first end of the intermediate portion 27, and the mating end 26 may extend from a second end of the intermediate portion 27, opposite the first end. The contact body may further define a tip 29, and thus the electrical contacts 24 may further define a tip 29, which defines a distal end of the contact body. The tip 29 can extend outward from the butt end 26 so that the butt end 26 is disposed between the middle portion of the contact and the tip 29. The mounting end 28 can be configured to be mounted to a first electrical device, which can be configured as a substrate. In some examples, the substrate can be configured as a printed circuit board. Thus, the connector housing 22 can define a mounting interface 23 that is configured to face the underlying substrate when the electrical connector 20 is mounted to the underlying substrate.

[0084] When the electrical connector 20 is docked with the second electrical connector, the docking end 26 can be configured to dock with a corresponding electrical contact of the second electrical connector. Specifically, the electrical connector 20 can dock with the second electrical connector along a docking direction. The docking end 26 can define a detachable interface with the corresponding electrical contact of the second electrical connector. Thus, the electrical connector 20 can undock from the second electrical connector along an undocking direction opposite to the docking direction. Both the docking direction and the undocking direction can be oriented along the longitudinal direction L.

[0085] The electrical contacts 24 can be arranged along rows 32, which can be oriented along a lateral direction A that is perpendicular to the longitudinal direction L. The connector housing 22 can include a partition wall 30 disposed between the mating ends 26 of adjacent pairs of electrical contacts 24. In one example, the pairs of electrical contacts 24 can define differential signal pairs. Alternatively, the electrical signal contacts can be single-ended. In this regard, the partition wall 30 can be disposed between adjacent electrical contacts 24 as desired, or between any number of adjacent electrical contacts 24. Therefore, it can be said that the partition wall 30 can be disposed between at least the first and second electrical contacts 24 of the electrical connector 20. The electrical contacts 24 can be configured as signal contacts. Alternatively, one or more electrical contacts 24 can be configured as ground contacts. Alternatively, the electrical connector 20 can have no ground contacts. The connector housing 22 can further extend along a lateral direction T that is perpendicular to each of the longitudinal direction and the lateral direction A. In some examples, the electrical contacts 24 can be arranged in a plurality of rows 32 that are spaced apart from one another along a transverse direction T that is perpendicular with respect to each of the longitudinal direction and the lateral direction A.

[0086] The connector housing 22 can define a docking interface 25 that, when the electrical connector 20 is docked with a second electrical connector, is typically received within the second electrical connector or by a complementary docking interface of the second electrical connector. In this regard, the electrical connector assembly can include the electrical connector 20 and the second electrical connector, and the electrical connector 20 can be referred to as the first electrical connector. The electrical connector 20 can be mounted to an underlying substrate to define a data communications assembly. When the electrical connector is mounted to the underlying substrate and docked with the second electrical connector, the electrical connector 20 can establish data communication between the substrate and the second electrical connector. Thus, the electrical contacts 24 can transmit signals between the substrate and the second electrical connector at an operating frequency.

[0087] The butt end 26 and the mounting end 28 can be disposed opposite each other and oriented along the longitudinal direction L. Thus, the electrical contact 24 can be referred to as a vertical contact, and the electrical connector 20 can be referred to as a vertical electrical connector. Alternatively, the butt end 26 and the mounting end 28 can be oriented perpendicular to each other such that the electrical contact 24 defines a right-angle contact, and the electrical connector 20 can be referred to as a right-angle electrical connector, as described below with respect to Figures 8A to 9F Described in more detail.

[0088] like Figure 5 As shown in , the electrical connector 20 may include a lossy material 64 that is tuned to substantially absorb magnetic fields at the operating frequency of the electrical connector 20. The term "substantially" with respect to frequency includes the stated frequency and frequencies within plus or minus five GHz of the stated frequency (+ / - 5 GHz). In one example, the connector housing 22 may include the lossy material 64. Specifically, the connector housing 22 may include a housing body 31 and the lossy material 64 carried by the housing body 31. Specifically, the lossy material 64 may be embedded in the housing body 31. Alternatively or additionally, the lossy material 64 may be disposed on an outer surface of the housing body 31. The lossy material 64 may be magnetically absorbent. In one example, the lossy material 64 may be conductive. For example, the lossy material 64 may have a conductivity greater than 1 Siemens per meter up to a conductivity of approximately 6.1×10^7 Siemens per meter. Alternatively, the lossy material 64 may be non-conductive. For example, the lossy material 64 may have a conductivity of from 1 Siemens per meter to about 1×10 −17 Siemens per meter.

[0089] The housing body 31 of the connector 22 can be electrically insulating, can support the electrical contacts 24, and can define the mounting interface 23 and the docking interface 25. The housing body 31 can directly support the electrical contacts, and thus the connector housing 22 can directly support the electrical contacts. Alternatively, as will be described in more detail below, the housing body 31 can indirectly support the electrical contacts, and thus the connector housing 22 can indirectly support the electrical contacts. For example, the housing body 31 can support at least one lead frame assembly, which in turn includes at least some or all of the electrical contacts 24.

[0090] For example, Figure 5As shown in , the lossy material 64 can be disposed on at least one partition wall, including a plurality or all of the partition walls 30. In one example, the lossy material 64 can be embedded in at least one partition wall 30. Thus, the lossy material 64 can be disposed between adjacent pairs of electrical contacts 24 in the manner described above. In one example, the lossy material 64 can be configured as an insert or coating. Alternatively, the lossy material 64 can be insert-molded into the partition wall 30. The lossy material 64 can be oriented along a longitudinal direction L and a transverse direction T. The lossy material 64 can have its largest dimension in the longitudinal direction L. The longitudinal direction L can be oriented perpendicular to the mounting interface 23 of the connector housing 22. Of course, it should be understood that the lossy material 64 can be sized and shaped in any suitable alternative manner as desired. Alternatively, the connector housing 22 can have at least one void defined therein, and the lossy material 64 can be inserted into the at least one void. The at least one void can be a single void or multiple voids as desired. Alternatively or additionally, the lossy material 64 may be applied to one or both outer surfaces of the partition wall 30 that face the respective electrical contacts 24 .

[0091] The lossy material 64 can be aligned with at least a portion of the electrical contact 24 along the lateral direction A. Thus, a straight line passing through at least a portion of the electrical contact 24 also passes through the lossy material 64. The at least a portion of the electrical contact 24 can include the butt end 26. Alternatively or additionally, the at least a portion of the electrical contact 24 can include a tip 29. Thus, the lossy material 64 can be disposed at the tip 29. In one example, the lossy material 64 can be disposed only at the tip 29. Alternatively or additionally, the at least a portion of the electrical contact 24 can include at least a portion of the intermediate portion 27, such as the entire intermediate portion 27. The lossy material 64 can be disposed at the tip of a signal contact. Alternatively or additionally, the lossy material 64 can be disposed at the tip of a ground contact. The lossy material can span a majority of the height of the partition wall 30 along the longitudinal direction L. The lossy materials at each partition wall 30 can be aligned with each other along the lateral direction A.

[0092] Now refer to Figure 6Alternatively or additionally, the lossy material 64 may be applied to the connector housing 22 at other locations within the connector housing. For example, the lossy material 64 may be disposed on one or both of the mounting interface 23 and the docking interface 25. Specifically, the lossy material 64 may have a longest dimension parallel to the mounting interface 23. Thus, when the electrical connector 20 is mounted to an underlying substrate, the lossy material 64 may have a longest dimension parallel to the underlying substrate, the mounting interface 23. The lossy material 64 may be configured as a plate oriented along the lateral direction A and the transverse direction T. In one example, the lossy material 64 may be embedded within one or both of the mounting interface 23 and the docking interface 25. For example, the lossy material 64 may be insert molded into one or both of the mounting interface 23 and the docking interface 25. Alternatively, the lossy material 64 may be molded to define the connector housing 22. Thus, the entirety of the connector housing 22 may include the lossy material 64. Alternatively, the lossy material 64 may be applied to the exterior surface of one or both of the mounting interface 23 and the docking interface 25.

[0093] For example, now refer to Figure 7 , the lossy material 64 can be disposed on the mounting interface 23 of the connector housing 22. Specifically, the lossy material 64 can be applied to the outer surface of the connector housing 22 at the mounting interface 23. Thus, the lossy material 64 can be on a surface of the connector housing 22 that is configured to face the underlying substrate when the electrical connector 20 is mounted to the underlying substrate. Thus, when the electrical connector 20 is mounted to the substrate, the lossy material 64 can face the substrate. For example, as described above, the electrical contacts 24 can be arranged in first and second rows 32, each oriented in a lateral direction A and spaced apart from one another in a transverse direction T. The lossy material 64 can be disposed on the outer surface of the connector housing at a location between the rows 32. In one example, the lossy material 64 can be disposed equidistantly between the rows 32. Furthermore, the lossy material 64 can be disposed equidistantly between the mounting ends 28 of the electrical contacts 24.

[0094] Now the overall reference Figures 8A to 9F The electrical connector 20 can be configured as a right-angle connector. Specifically, the butt end 26 and the mounting end 28 can be oriented substantially perpendicular to each other. In one example, the butt end 26 can be oriented along a longitudinal direction L, and the mounting end 28 can be oriented along a transverse direction T. For example, the butt end 26 can extend outward from the connector housing 22 along the longitudinal direction L, and the mounting end 28 can extend outward from the connector housing 22 along the transverse direction T.

[0095] The electrical contacts 24 can be indirectly supported by the connector housing 22. Specifically, the electrical connector 20 can include at least one leadframe assembly 50, the leadframe assembly 50 including a leadframe housing 52 and a corresponding plurality of electrical contacts 24 supported by the leadframe housing 52. At least one leadframe housing 52 can be supported by the connector housing 22, and thus at least one leadframe assembly 50 can be supported by the connector housing 22. In one example, the electrical connector 20 can include a first leadframe assembly 50a and a second leadframe assembly 50b. Each of the first leadframe assembly 50a and the second leadframe assembly 50b can include a corresponding first and second plurality of electrical contacts 24 supported by the corresponding leadframe housing 52. The electrical contacts 24 of each leadframe assembly 50 can be aligned along a corresponding row 32, which is oriented in the lateral direction A as described above.

[0096] The lead frame assembly 50a and the lead frame assembly 50b can be spaced apart from each other along the transverse direction T. Therefore, the first lead frame housing and the second lead frame housing 52 of the first lead frame assembly 50a and the second lead frame assembly 50b can be spaced apart from each other along the transverse direction T, respectively. Each lead frame housing 52 can define an inner surface 53 and an outer surface 55 opposite to the inner surface 53 along the transverse direction T, and the inner surface 53 faces the other lead frame housing. In addition, the rows 32 can be spaced apart from each other along the transverse direction T. In one example, the electrical contacts 24 can be insert molded into the corresponding lead frame housing 52. Alternatively, the electrical contacts 24 can be inserted into the corresponding lead frame housing. Although the electrical connector 20 is shown as including a first lead frame assembly 50a and a second lead frame assembly 50b, it should be understood that the electrical connector can include any number of lead frame assemblies as desired.

[0097] The electrical contacts 24 may include a plurality of electrical signal contacts 54 and a plurality of ground contacts 56. For example, adjacent electrical signal contacts 54 along a row 32 may define a differential signal pair. The electrical contacts 24 may further include a plurality of electrical ground contacts 56. The electrical ground contacts 56 may be disposed between adjacent differential signal pairs along a row 32. Thus, in one example, each lead frame assembly 50 may include a plurality of signal contacts 54 and a plurality of ground contacts 56. It should be understood that the electrical signal contacts 54 may alternatively be single-ended. Furthermore, the electrical ground contacts 56 may be disposed in any alternative suitable location as desired.

[0098] Now also refer to Figures 8B to 8C, the rows 32 can be arranged so that the mounting ends 28 of the electrical contacts 52 are configured to be mounted to a first electrical device 58. The first electrical device 58 can be a first substrate 60, which can be configured as a first printed circuit board. When the first substrate 60 is received between the docking ends of each row 32, the docking ends 26 can establish an electrical connection with the opposing surface of the first substrate 60. The first substrate 60 can be an electrical connector, such as a QSFP connector in one example. Therefore, the first electrical device 58 can be configured as a QSFP connector. Of course, it should be understood that the first electrical device 58 can be configured in any suitable manner as desired.

[0099] Now also refer to Figures 8B to 8C , the rows 32 can be arranged such that the mounting ends 28 of the electrical contacts 52 are configured to be mounted to a first electrical device 58. The first electrical device 58 can be a first substrate 60, which can be configured as a first printed circuit board. Thus, the mounting ends 28 are configured to establish an electrical connection with the first substrate 60. The first substrate 60 can be an electrical connector, such as a QSFP connector in one example. Thus, the first electrical device 58 can be configured as a QSFP connector. Of course, it should be understood that the first electrical device 58 can alternatively be configured in any suitable manner as desired.

[0100] Now also refer to Figures 8B to 8C , the rows 32 can be arranged so that the butt ends 26 of the electrical contacts 52 of the rows 32 are spaced apart from each other to receive a second electrical device 62. The second electrical device 62 can be a second substrate 63, which can be configured as a second printed circuit board. When the second substrate 63 is received between the butt ends 26 of each row 32, the butt ends 26 can establish an electrical connection with the opposite surface of the second substrate 63. The second substrate 63 can be an electrical connector, such as a QSFP connector in one example. Therefore, the second electrical device 62 can be configured as a QSFP connector. Of course, it should be understood that the second electrical device 62 can be configured in any suitable manner as needed.

[0101] The data communication assembly 66 may include the electrical connector 20 as described above, and the first and second electrical devices 58, 62. Thus, when the electrical connector is mounted to the first electrical device 58 and docked to the second electrical device 62, the first and second electrical devices 58 may be in electrical communication with each other.

[0102] In one example, Figures 8A to 8C The electrical connector 20 shown in FIG may be configured as a UEC5-2 electrical connector commercially available from Samtec, having a place of business in New Albany, Indiana, USA However, the electrical connector 20 may further include a lossy material 64, as will now be described.

[0103] Now refer to Figures 9A to 9E One or both, or even all, of the leadframe housings 52 of the electrical connector can include lossy material 64. For example, one or both of the leadframe housings 52 can define at least one void 68 configured to receive lossy material 64. The at least one void 68 can define a single void or multiple voids as desired. Void 68 can extend into any suitable surface of the leadframe housing 52 as desired.

[0104] For example, the void 68 can extend into the outer surface 55 toward the inner surface 53. In one example, the void 68 can terminate in the lead frame housing 52 without extending through the inner surface 53 in a lateral direction. In addition, the void 68 can terminate in the lateral direction A without extending through one of the lateral sidewalls of the lead frame housing 52, the lateral sidewalls opposing each other along the lateral direction A. Thus, in one example, the void can be configured as a recess. For example, in one example, the recess can be open only to the outer surface 55. Alternatively, the void 68 can extend through the inner surface 53 in the lateral direction T. Thus, it should be understood that the void 68 can alternatively define a through hole that is open to more than one different surface of the lead frame housing 52. For example, the through hole can be open to both the inner surface 53 and the outer surface 55 of the lead frame housing 52. Alternatively or additionally, the void 68 can extend through one or both lateral sidewalls of the lead frame housing 52. Still alternatively, the gap 68 may terminate without extending through the front or rear walls of the leadframe housing 52 , where the front or rear walls are opposite each other along the longitudinal direction L. Alternatively, the gap 68 may extend through one or both of the front and rear walls of the leadframe housing 52 .

[0105] The lossy material 64 can be disposed in the void 68. Thus, the lossy material 64 can be disposed between the butting end 26 and the mounting end 28 relative to the longitudinal direction L. The void 68 can be defined by a base 70, which is defined by the leadframe housing 52. The base 70 can define a plurality of raised areas 72. In one example, the electrical contacts 52 can extend through the raised areas. The lossy material can be substantially flush with at least one surface of the leadframe housing 52 that defines the opening to the void 68. For example, in one example, the lossy material can be substantially flush with the outer surface 55 of the leadframe housing 52. When used to describe a size, shape, spatial relationship, distance, direction, or other similar parameter, the term "substantially" and its derivatives and words of similar meaning include the parameter and within plus or minus 10%, including plus or minus 5%, including plus or minus 3%, including plus or minus 1% of the parameter. However, with respect to the term "substantially" in relation to the stated frequencies, the term "substantially" and its derivatives and words of similar meaning include the stated frequencies and frequencies within a range of plus or minus 5 GHz of the stated frequencies.

[0106] Continue to refer Figures 8A to 9F , the lead frame housing 52 may include an insert 57 that protrudes forward in the mating direction and is configured to be disposed between the electrical signal conductors of each differential pair. Specifically, the insert 57 may contact each electrical signal contact at a location adjacent to the recess and protrusion of the electrical contact. In one example, the insert 57 may include a web extending forward and a button at the distal end of the web. The button and the web may be disposed between adjacent electrical contacts 24, and the button may be adjacent to the adjacent electrical contacts 24. Since the insert may be part of the lead frame housing 52, the insert may be an electrically insulating material that is integrally insert-molded with the rest of the lead frame housing 52. The insert 57 may control the impedance of the differential signal pair based on its dielectric constant. Therefore, the dielectric constant of the lead frame housing 52 may be selected to provide a desired impedance, and the dielectric constant of the insert 57 may be selected to provide a desired impedance. In one example, the insert 57 may further include a lossy material disposed on the insert or in a gap within the insert. As Figure 9F As shown in FIG, the electrical contacts 24 can be deflected when mated with a complementary electrical connector. The insert 57 can be held between each adjacent electrical contact 24 and abut each adjacent electrical contact 24 as the electrical contacts 24 deflect.

[0107] like Figure 10 , it will be appreciated that, instead of or in addition to providing lossy material to one or more portions of the electrical connector 20, the connector housing 22 can be made of a lossy material 64. Thus, the entirety of the connector housing 22 can include the lossy material 64. Although certain examples of electrical connectors including the lossy material 64 have been described, it will be appreciated that any suitable alternative electrical connector may be used.

[0108] Although the lossy material 64 may be disposed on the housing body 31 as described above, it should be understood that the electrical connector may include the lossy material 64 at other locations. For example, referring now to Figures 11A to 11B, at least one electrical contact 24 of the electrical connector may include a lossy material 64 disposed on the contact body. For example, multiple electrical contacts 24 of the electrical connector up to all electrical contacts 24 may include lossy material. In one example, the at least one electrical contact 24 may be configured as a ground contact of the electrical connector. Therefore, the at least one electrical contact 24 may include multiple ground contacts of the electrical connector up to all ground contacts. Alternatively or additionally, the at least one electrical contact 24 may be configured as a signal contact of the electrical connector. Therefore, the at least one electrical contact 24 may include multiple signal contacts of the electrical connector up to all signal contacts. In one example, the lossy material 64 may be disposed on the mating end 26 of the contact body. Alternatively or additionally, the lossy material 64 may be disposed on the tip 29 of the contact body. As Figures 11A to 11B As shown in FIG, lossy material 64 can be disposed on a corresponding tip 29 of at least one electrical contact 24 of the electrical connector and on a corresponding tip 29 of a complementary electrical contact 24' of the complementary electrical connector. When the first and second electrical connectors mate with each other at their respective mating ends 26, the electrical contact 24 can mate with the complementary electrical contact 24'.

[0109] Specifically, the mating ends 26 of the electrical contact 24 and the complementary electrical contact 24' can define respective wiping surfaces 34 that are configured to wipe each other when the electrical contacts 24 and 24' are mated with each other. Figure 11A As shown in FIG, when the respective electrical connectors are aligned to mate with each other along the mating direction, the wiping surfaces 34 can be aligned with each other along the longitudinal direction L. Next, as shown in FIG. Figure 11B As shown in , the electrical contacts 24 and 24' can be directed toward each other in their respective mating directions, so that the wiping surfaces 34 ride along each other while abutting each other. The wiping surfaces 34 ride along each other until the electrical contacts 24 and 24' are in abutment with each other. The abutting ends of the electrical contacts 24 and 24' can deviate from each other when they are abutted. Specifically, the electrical contacts 24 and 24' are resiliently resilient. Therefore, when the curved wiping surfaces 34 ride along each other, the abutment of the wiping surfaces 34 can cause the abutting ends 26 of the electrical contacts 24 and 24' to deviate from each other in the transverse direction T.

[0110] Tips 29 can be configured to flare outward from wiping surface 34 as they extend in a direction away from their respective midsections 27. For example, tips 29 can extend away from the respective portions of electrical contact 24 that define wiping surface 34. Thus, when electrical contact 24 and electrical contact 24' are aligned for mating with each other, tips 29 of electrical contacts 24 and 24' can be offset from each other along transverse direction T. Consequently, tips 29 of electrical contacts 24 and 24' can move past each other without contacting each other. Lossy material 64 can be disposed on first surface 36 of each of electrical contacts 24 and 24', the first surface 36 being opposite wiping surface 34. Specifically, lossy material 64 can be disposed on first surface 36 at mating end 26. Furthermore, lossy material 64 can be disposed on first surface 36 at mating end 26 rather than on second surface 38. Similarly, lossy material 64 can be disposed on first surface 36 at tip 29. In one example, the lossy material 64 may be disposed on the first surface 36 at the tip 29 rather than on the second surface 38. Alternatively, as described below with respect to Figure 14D In more detail, lossy material 64 can be disposed on first surface 36 and second surface 38 at tip 29. Furthermore, lossy material can be disposed on edge 42 extending between first surface 36 and second surface 38, which can define broadside 40 of electrical contact 24. In one example, first surface 36 and second surface 38 can be opposed to each other along transverse direction T. Broadside 40 of electrical contact 24 extends between and to edges 42 along a plane perpendicular to the orientation of the electrical contact. Alternatively, the plane can be said to extend along transverse direction T and lateral direction A. Edges 42 can be opposed to each other along lateral direction A. Broadside 40 can define a length within the plane that is greater than the length of edges 42. In another example, broadside 40 can be opposed to each other along lateral direction A, and edges 42 can be opposed to each other along transverse direction T.

[0111] Continue to refer Figures 11A to 11BThe first surface 36 may define a recessed portion 44, and the second surface 38 may define a raised portion 46 that is opposite and aligned with the recessed portion 44. When the electrical connector 24 and the electrical connector 24' are mated with each other, the raised portions 46 of the electrical contacts 24 and 24' may travel along each other. Thus, at least a portion of the raised portion 46 of each electrical contact may define at least a portion of the wiping surface 36. The recessed portion 44 and raised portion 46 of each electrical contact may oppose each other along the direction in which the first and second contacts 36 and 38 oppose each other. Thus, when the first and second surfaces 36 and 38 oppose each other along the transverse direction T, the recessed portion 44 and raised portion 46 may oppose each other and align with each other along the transverse direction T. When the first and second surfaces 36 and 38 oppose each other along the lateral direction A, the recessed portion 44 and raised portion 46 may oppose each other and align with each other along the lateral direction A. In one example, the lossy material 64 may extend along the first surface 36 between the recessed portion 44 and the distal-most end 48 of the electrical contact. Additionally, lossy material 64 may extend along a portion of recess 44 that is smaller than the entire recess 44, as shown at electrical contact 24. Alternatively, lossy material 64 may be provided only at the distal end of recess 44, as shown at electrical contact 24'.

[0112] It has been discovered that the lossy material 64 disposed at the tip 29 of the electrical contact can reduce a phenomenon known as the stump effect. Specifically, the tip 29 can act as a quarter-wave resonator during operation. The lossy material 64 disposed at the tip 29 can absorb at least a portion of the resulting magnetic field emitted from the tip 29. Figure 5 As shown in FIG, the convex portions 46 of adjacent electrical contacts 24 defining a differential signal pair can face each other. Thus, the concave portions 44 of the electrical contacts 24 of adjacent differential pairs can face each other. Thus, because the lossy material 64 is disposed on the concave portions 44, the lossy material 64 can be disposed between adjacent differential signal pairs.

[0113] It should be understood that, in one example, the lossy material 64 can be disposed only at the tip 29. Alternatively, the lossy material 64 can be disposed at other locations on the first surface 36 of the electrical contact. For example, the lossy material 64 can alternatively or additionally be disposed at the butt end 26 as described above. Alternatively or additionally, the lossy material 64 can also be disposed at the base 35 of the electrical contact 24, as described below with reference to FIG. 14A to 14D As stated.

[0114] Now roughly refer to Figures 5 to 11B, the lossy material can be tuned to attenuate the resonant frequency of the tip 29 or any other suitable frequency. The lossy material 64 of the electrical contacts of the differential signal pair can be tuned to absorb magnetic fields at first and second different frequencies. Specifically, first and second different types of lossy materials tuned to absorb magnetic fields at first and second different frequencies, respectively, can be disposed at the first signal contact and the second signal contact, respectively, or at the differential signal pair. For example, a first type of lossy material configured to absorb frequencies of approximately 10 GHz can be disposed on the first electrical contact 24 of the differential signal pair. A second type of lossy material capable of absorbing frequencies of approximately 15 GHz can be disposed on the second electrical contact 24 of the differential signal pair. Although in one example the first frequency can be 10 GHz and the second frequency can be 15 GHz, it should be recognized that the first and second frequencies can be selected as needed to reduce unwanted resonant frequencies.

[0115] The lossy material 64 can define any suitable volume, size, and shape as desired. In addition, the lossy material 64 can be disposed at any suitable location on the electrical contact 24. The volume, size, shape, and location of the lossy material 64 can be determined by testing or computer simulation. In some cases, the volume, size, shape, and location can result in manufacturing tradeoffs. Contact with the lossy material can be included in any suitable electrical connector. The lossy material can be applied to signal contacts of the electrical connector that transmit electrical signals, i.e., signal contacts that send and / or receive electrical signals. In some electrical connectors, the lossy material can be applied only to the signal contacts.

[0116] In one example, the lossy material 64 can be a dispensed material, such as epoxy. Alternatively, the lossy material 64 can be a stamped material. With a dispensed material, the lossy material can be applied after the electrical contact 24 or housing body 31 is formed by stamping the metal sheet. For example, a thin sheet of uncured epoxy can be die-cut and applied to the contact by pick and place or other automated process, and then cured after initial attachment to the electrical contact 24 or housing 31. When attaching the lossy material 64 to the electrical contact 24, the lossy material 64 can be applied to the contact reel and the electrical contact 24 in the reel-to-reel stage. Of course, it should be understood that any suitable alternative manufacturing method can be used to manufacture the lossy material 64.

[0117] Thus, it will be appreciated that the lossy material 64 can be disposed on or within the housing body 31, can be defined by the connector housing 22, can be included in the lead frame assembly, can be carried by the electrical contacts, or a combination of one or more of the foregoing. Furthermore, while the lead frame assembly can define differential signal pairs along corresponding rows as described above, it will be further appreciated that the lead frame assembly can define differential signal pairs along columns oriented perpendicular to the rows.

[0118] For example, reference FIG. 12A to FIG. 12B , the electrical connector may include a connector housing that supports a plurality of lead frame assemblies 74 constructed according to another example. For example, the lead frame assembly may include a lead frame housing 76 and a corresponding plurality of electrical contacts 24 supported by the lead frame housing 76. The electrical contacts 24 may be right-angle contacts, such that the butt ends 26 are oriented in the longitudinal direction L and the mounting ends 28 are oriented in the transverse direction T. The butt ends 26 of the electrical contacts 24 of each lead frame assembly 74 may be aligned along corresponding columns, and thus the butt ends 26 are perpendicular to the rows, wherein the corresponding columns are oriented in the transverse direction T. The mounting ends 28 of the electrical contacts of each lead frame assembly 74 may be aligned in the longitudinal direction L or the butt direction. Adjacent signal contacts of each lead frame assembly 74 define corresponding differential signal pairs. The lead frame assembly 74 may further include a plurality of ground contacts, such that at least one ground contact is disposed between adjacent differential signal pairs. Alternatively, the lead frame assembly 74 may be free of ground contacts. A plurality of lead frame assemblies 74 may be supported by the connector housing such that the lead frame assemblies 74 are arranged in rows, where the rows are oriented in the lateral direction A. As shown in FIG.

[0119] Each lead frame housing 76 may define opposing side surfaces 73 and 75 that are opposite to each other along a lateral direction A. FIG. 12A to FIG. 12B As shown in , the lead frame assembly 74 may include a plurality of voids 78 configured to receive the lossy material 64. For example, the voids 78 may extend in at least one or both of the side surface 73 and the side surface 75. The voids 78 may terminate in the lead frame housing 76 without extending to the electrical contacts 24 supported by the lead frame housing 76. Thus, the voids 78 may be configured as pockets. In addition, at least a portion of the voids 78 may be aligned with corresponding electrical contacts 24 supported by the lead frame housing 76. For example, the voids 78 may define a plurality of front voids 78a that are aligned in a lateral direction with a portion of at least some of the electrical contacts oriented in the longitudinal direction L. Thus, the front plurality of voids 78a may be elongated in the longitudinal direction L and aligned with corresponding electrical contacts 52 supported by the lead frame housing 76. The front voids 78a may also be aligned with each other in a transverse direction T. As shown Figure 12B As shown in FIG, the lossy material 64 may be disposed in the front void 78a and thus aligned in the lateral direction A with the corresponding electrical contact.

[0120] The gaps 78 may also include rear gaps 78b. Respective portions of the rear gaps 78b may be aligned along the lateral direction A with the curved portions of at least some of the corresponding electrical contacts 24, which bend as the corresponding electrical contacts 24 extend between the mating end 26 and the mounting end 28. The gaps 78b are oriented along the longitudinal direction L. Thus, the rear gaps 78b may be elongated along the longitudinal direction L. The rear gaps 78b may further be aligned with one another along the transverse direction T. Some rear gaps 78b may have different lengths along the longitudinal direction L, and in some examples, the lengths may differ from those of other rear gaps 78b.

[0121] As described above, the gap 78 can be configured to receive Figure 12B . Specifically, as with the other voids described herein, void 78 can be substantially filled with lossy material 64. Furthermore, lossy material 64 can be substantially flush with at least one of side surfaces 73 and side surfaces 75 of leadframe housing 76 that define an opening to the void. In this regard, it should be understood that lossy material 64 can be disposed between columns of electrical contacts along a row, whereby the electrical contacts define differential signal pairs along a direction perpendicular to the row. It will be appreciated that lossy material 64 disposed in front void 78a can be tuned to substantially attenuate a first frequency, and lossy material 64 in rear void 78b can be configured to substantially attenuate a second frequency different from the first frequency. The first frequency can be higher than the second frequency. Alternatively, the second frequency can be higher than the first frequency. Alternatively, the first frequency and the second frequency can be substantially equal to each other.

[0122] Now refer to 13A to 13B , the first lead frame assembly 74a and the second lead frame assembly 74b can be positioned adjacent to each other in the connector housing. FIG. 12A to FIG. 12B In terms of the gap, 13A to 13B The middle gap 78 is positioned at different locations to illustrate that the gap 78 can be positioned at any suitable location as desired. For example, the lead frame housing 76 may include a lower gap 78c that is positioned proximate the mounting interface, while the front gap 78a can be positioned proximate the docking interface. Therefore, the lower gap 78c can be elongated along the lateral direction T. In addition, the lower gap 78c can be aligned along the lateral direction A with a portion of a corresponding electrical contact 24 supported by the lead frame housing 76, which portion is oriented along the lateral direction T. The first side surface 73 of the lead frame housing 76 of the first lead frame assembly 74a can face the second side surface 75 of the lead frame housing 76 of the second lead frame assembly 74b along the lateral direction A.

[0123] In one example, the void 78 in the first side surface 73 of the first leadframe assembly 74a can be aligned with the void 78 in the second side surface 75 of the second leadframe assembly 74b along the lateral direction A. Thus, when the lossy material 64 is disposed in the void 78, the lossy material 64 carried by the leadframe housing 76 of the first leadframe assembly 74a can face the lossy material 64 carried by the leadframe housing 76 of the second leadframe assembly 74b. In some examples, the lossy material 64 carried by the leadframe housing 76 of the first leadframe assembly 74a can be generally aligned with the lossy material 64 carried by the leadframe housing 76 of the second leadframe assembly 74b. For example, the lossy material 64 carried by the leadframe housing 76 of the first leadframe assembly 74a can abut the lossy material 64 carried by the leadframe housing 76 of the second leadframe assembly 74b. Alternatively, the lossy material 64 carried by the leadframe housing 76 of the first leadframe assembly 74a may be spaced apart in the lateral direction A from the lossy material 64 carried by the leadframe housing 76 of the second leadframe assembly 74b.

[0124] Now roughly refer to 14A to 16C In another example, the electrical connector can be configured as an edge card connector 80. In this regard, it should be understood that any appropriately configured electrical connector can include the lossy material 64 in any manner described herein. Furthermore, unless otherwise indicated, the placement of the lossy material 80 described in accordance with any example herein can be incorporated into any other example.

[0125] Now refer to 14A to 14D Specifically, edge card connector 80 may include an electrically insulating connector housing 82, and therefore a connector housing 82, comprising a housing body 83 and a plurality of electrical contacts 84 supported by housing body 83. Electrical contacts 84 may include electrical signal contacts 86. Electrical contacts 84 may further include electrical ground contacts 88. In one example, edge card connector 80 may include multiple leadframe assemblies 112, each leadframe assembly 112 comprising a leadframe housing 114 and a corresponding electrical contact 84 supported by leadframe housing 114. Thus, electrical contacts 84 may be supported by a corresponding leadframe housing 114, which in turn is supported by housing body 83 and, therefore, connector housing 82. In this regard, it can be said that electrical contacts 84 are indirectly supported by housing body 83 and, therefore, by connector housing 82. Alternatively, edge card connector 80 may lack leadframe assembly 112, such that electrical contacts 84 may be directly supported by connector housing 82.

[0126] The electrical contacts 84 can define respective mounting ends 28 configured to be mounted to a first complementary electrical component in the manner described above. The electrical contacts 84 can also include docking ends 26 configured to dock with a second complementary electrical device in the manner described above. The connector housing can define a mounting interface 100 and a docking interface 102 of the type described above. The edge card connector 80 can be configured as a vertical connector, whereby the mounting end 28 and the docking end are oriented substantially parallel to one another. Alternatively, the edge card connector 80 can be configured as a right-angle connector, whereby the mounting end 28 and the docking end are oriented substantially perpendicular to one another. As described above with respect to the electrical contacts 24 of the electrical connector 20, the electrical contacts 84 can each define a wiping surface 34, defining a first surface 36 and a second surface 38 of a wide side 40, and the electrical contacts 84 can define respective edges 42, recesses 44, protrusions 46, and tips 29.

[0127] In one example, the electrical contacts 84 can be spaced apart from one another along at least one row 97, which can be oriented along the longitudinal direction L. The mounting end 28 and the mating end can be opposite one another along the longitudinal direction L. Although the edge card connector 80 is shown as including a single row of electrical contacts 84, it should be understood that the edge card connector 80 can include multiple rows of electrical contacts spaced apart from one another along the transverse direction T.

[0128] The mounting end 28 can be configured to be mounted to a first electrical device, such as the first substrate described above. The docking end 26 can be configured to dock with a second electrical device, such as a card that can be received by the docking end 26, so that the edge card connector 80 is in electrical communication with the second electrical device. Thus, the edge card connector 80 can place the first electrical device and the second electrical device in electrical communication with each other in the manner described above. Although 14A to 16C An example of an edge card connector 80 and portions thereof is shown, but it will be appreciated that any suitable electrical connector may be used.

[0129] In one example, the housing body 83, and thus the connector housing 82, can include a base 104 and walls 106 extending outward from the base 104 in a longitudinal direction L. The walls 106 can define the docking interface 102 of the edge card connector 80. The housing body 83 can also include a plurality of partition walls 108 defining corresponding cavities 110. The cavities 110, in turn, can receive the docking ends 26 of at least one electrical contact 84. The partition walls 108 can be spaced apart from each other in a lateral direction A and can extend from the walls 106 in a transverse direction T. The walls 106, and thus the connector housing 82, can further include laterally outer sidewalls 109 that oppose each other and can cooperate with the laterally outermost partition walls 108 to define a laterally outermost cavity 110. The cavity 110 can include a ground cavity and a signal cavity. The ground cavity can receive at least one ground contact 88. In one example, the laterally outermost cavity can be the ground cavity. The signal cavity can receive at least one signal contact 86. For example, the signal cavities can receive pairs of signal contacts 86 defining differential signal pairs. Ground cavities can be disposed between adjacent signal cavities such that the ground contacts 88 received therein can be disposed between adjacent differential signal pairs along a row. As described above, the signal contacts 86 and the ground contacts 88 can be aligned with each other along the lateral direction A.

[0130] The electrical connector can include at least one leadframe assembly 112 supported by the connector housing 82. For example, the at least one leadframe assembly 112 can be supported by the base 104. In one example, the edge card connector 80 includes a first leadframe assembly and a second leadframe assembly 112, but it should be understood that the electrical connector 80 can include any number of leadframe assemblies as desired. Each leadframe assembly 112 can include a leadframe housing 114 and a corresponding electrical contact 84 from a plurality of electrical contacts 84 supported by the leadframe housing 114 in the manner described above. The electrical contacts 84 can be insert molded into the leadframe housing 114 or can be inserted into the leadframe housing 114 as desired. When the leadframe assemblies 112 are supported by the connector housing 80, the corresponding electrical contacts 84 can be spaced apart and aligned with each other along the lateral direction A. Furthermore, the leadframe assemblies 112 can be positioned adjacent to each other along the lateral direction A. Thus, the electrical contacts 84 of the first leadframe assembly 112 may be aligned along the lateral direction A with the electrical contacts 84 of the second leadframe assembly 112 .

[0131] Each lead frame assembly 112 may include at least one pair of signal contacts 86 positioned adjacent to each other. Adjacent signal contacts 86 may define differential signal pairs. Alternatively, the signal contacts 86 may be single-ended. Each lead frame assembly 112 may further include at least one ground contact 88 positioned adjacent to the differential signal pairs. For example, each lead frame assembly 112 may include a pair of ground contacts 88 that are positioned such that the differential signal pairs are disposed between the ground contacts 88 in a lateral direction. Thus, when the lead frame assemblies 112 are positioned adjacent to each other, the card edge connector 80 may include a pair of ground contacts (SSGGSS, where "G" represents a ground contact and S represents a ground contact) disposed between adjacent differential signal pairs in a lateral direction. It should be understood that the electrical contacts of all electrical connectors described herein may define a contact pattern as described or any alternative contact pattern. For example, the contact pattern may include GSGS or SSGSS. Alternatively, if desired, the edge card connector 80 may be free of ground contacts. The edge card connector 80 may include the contact patterns described above with respect to Figures 8A to 9F An insert 57 of the type described.

[0132] Now refer to 14A to 16C To illustrate, the edge card connector 80 can include lossy material 64 in one or more of several suitable locations. For example, as with the electrical connector 20 described above, the lossy material 64 can be carried by at least one, or more, or all of the housing body, one or more signal contacts, one or more ground contacts, and the leadframe housing. In one example, the lossy material 84 can be magnetically absorptive and non-conductive in the manner described above.

[0133] Now refer to 14A to 14DSpecifically, the lossy material 64 can be disposed on the tip 29 of at least one of the electrical contacts 84. For example, the lossy material 64 can be configured as a cap 113 disposed on the corresponding tip 29 of at least one of the electrical contacts 84. In one example, the lossy material 64 can be molded onto the electrical contact. Alternatively, the tip 29 can be press-fit into an opening of a cap defined by the lossy material. Alternatively, the lossy material 64 can be adhesively attached to the electrical contact 24. Alternatively, the lossy material 64 can be sprayed onto the electrical contact 24. Alternatively, the electrical contact 24 can be immersed in a liquid bath of the lossy material 64. The lossy material 64 can be disposed on a first surface 36 opposite the wiping surface 34. The lossy material 64 can further be disposed on a second surface 38 defining the wiping surface 34. Specifically, the lossy material 64 can be disposed distal to the wiping surface 34. Thus, the lossy material can be disposed on the broadside 40 of the at least one electrical contact 84. Alternatively or additionally, the lossy material 64 can further be disposed on one or both edges 42. In one example, the lossy material 64 can be disposed on the outermost surface of the at least one electrical contact 84.

[0134] The lossy material 64 can surround at least a portion of the tip 29 along a plane that is perpendicular to the tip orientation and extends along at least three sides of the tip. The plane can alternatively be oriented along the lateral direction A and the transverse direction T. The three sides can be bounded by one or both of the broadsides 40 and the edge 38. The broadsides 40 and the edge 38 can similarly be bounded along a plane that is oriented along the lateral direction A and the transverse direction T. Alternatively, the lossy material 64 can surround all four sides of the at least one electrical contact 84, including two broadsides 40 and two edges 38. However, other arrangements are also possible. For example, the lossy material 64 can be positioned along one side, two sides, three sides, or four sides of the at least one electrical contact 84. In addition, the lossy material 64 can encapsulate the tip 29 in that it can be disposed over the entirety of the farthest surface of the contact 84. By placing the lossy material 64 at the tip 29 distal to the wiping surface 34 of the at least one electrical contact 84, in addition to reducing the stub effect discussed above, the lossy material 64 does not mechanically interfere with the docking of the at least one electrical contact 84 to a complementary electrical contact.

[0135] Alternatively or additionally, the lossy material 64 may be disposed on the base 35 of at least one electrical contact 84. The base 35 of the electrical contact may be supported by, aligned with, or disposed within the leadframe housing 114. The base 35 may be included in a central portion of the electrical contact. The mounting end 28 may extend from the base 35 in a lateral direction toward the complementary first electrical device. In one example, the lossy material 64 may extend along at least a portion of both the broadside 40 and the edge 42 of the base 35. In this regard, the lossy material 64 is configured as a collar 115 that may at least partially or completely surround the electrical contact at the base 35 or any suitable alternative location. Thus, the lossy material 64 may surround the base 35 in a plane oriented perpendicular to the base 35. The lossy material 64 disposed on the base 35 may be confined to the base 35 and, therefore, may not extend in a lateral direction to locations not disposed within the leadframe housing 114. Alternatively, the lossy material 64 disposed on the base 35 may extend further outside the leadframe housing 114. However, it should be understood that the lossy material 64 may be disposed at any suitable location on the at least one electrical contact 84, up to the entirety of the at least one electrical contact 84, as desired. When the electrical contact 24 is directly supported by the connector housing, the lossy material 64 at the base 35 may be localized and, therefore, not extend to a location outside the connector housing. Alternatively, the lossy material 64 disposed on the base 35 may extend further outside the connector housing.

[0136] In one example, at least one electrical contact 84 including lossy material 64 can be bounded by at least one ground contact 88. For example, at least one electrical contact 84 can be bounded by a plurality of ground contacts 88. Specifically, at least one electrical contact 84 can be bounded by all of the ground contacts 88. By placing the lossy material 64 on the ground contacts 84 rather than on the signal contacts 86, desired signal frequencies are less attenuated. Alternatively or additionally, at least one electrical contact 84 can be bounded by at least one signal contact 86. For example, at least one electrical contact 84 can be bounded by a plurality of signal contacts 86. Specifically, the electrical contact 84 can be bounded by all of the signal contacts 86. Placing the lossy material at the base 35 of the ground or signal contacts can help absorb unwanted frequencies near the mounting interface 100, recognizing that the substrate footprint can be electrically noisy.

[0137] The lossy material 64 can have attenuation characteristics that can be tuned in the manner described above to attenuate frequencies within a range of plus or minus 5 GHz of a selected frequency. For example, the lossy material 64 can be configured to attenuate the resonant frequency of the electrical connector and all connectors disclosed herein without attenuating frequencies substantially outside the resonant frequency (e.g., frequencies outside of plus or minus 5 GHz of the resonant frequency). Of course, it should be understood that the lossy material 64 can be configured to attenuate other frequencies as needed. The lossy material 64 can be further tuned to attenuate frequency bands wider than 10 GHz. The wider frequency band range can be up to about 50 GHz, such as about 40 GHz, for example, about 30 GHz, and in one example about 20 GHz. In addition, the lossy material 64 can be provided at different locations of the electrical connector and all connectors disclosed herein, for example 14A to 16C Thus, the lossy material can be tuned to attenuate different frequencies at different locations of the electrical connector and all electrical connectors disclosed herein. The different attenuation frequencies can be any frequency disclosed herein.

[0138] Now refer to Figure 15 , the connector housing 82 may include the lossy material 64. For example, the connector housing 82 may define at least one void 68 that extends at least into or through the housing body 83, the at least one void 68 containing the lossy material 64. The at least one void 68 may include a plurality of voids 68. Alternatively or additionally, the lossy material 64 may be disposed on an outer surface of the housing body 83. The void 68 may be aligned with the tip 29 of the ground contact 88 along the lateral direction A. In this regard, it should be understood that the tip 29 of the signal contact 86 may be offset relative to the tip 29 of the ground contact 88 along the mating direction. Thus, the void 68 and the lossy material 64 may be offset longitudinally from the tip 29 of the signal contact 86. Therefore, a straight line oriented along the lateral direction A that passes through the void 68, and therefore through the lossy material 64, may also pass through the tip 29 of the ground contact 88, but not through the tip 29 of the signal contact 86. Alternatively, the tips 29 of the signal contacts 86 may be aligned with the tips 29 of the ground contacts 88 in the lateral direction A. The gap 68 may extend through at least one or more, and up to all, of the partition walls 108 and the outer sidewalls 109 .

[0139] Now refer to 16A to 16CThe electrical connector can include an attenuating wall 116 that can be made of the lossy material 64, or can define a recess that includes the lossy material 64. The attenuating wall 116 can be aligned with the tip 29 of one or both of the electrical signal contact 86 and the electrical ground contact 88 along the lateral direction T. For example, the attenuating wall 116 can face the first surface 36 of the ground contact 88 that is opposite the wiping surface 34 of the ground contact 88. Because the butt ends of some signal contacts 86 can be mirror images of other signal contacts 86, the attenuating wall 116 can face the first surface 36 of some signal contacts 86 and the second surface 38 of other signal contacts 86. In one example, the attenuating wall 116 can be partial, and thus, in this example, the attenuating wall 116 does not extend past the recess 44 and the protrusion 46 of the electrical contact 84 toward the mounting end 28. The attenuating walls 116 may include the rear wall 107, as well as dividing walls 108 and lateral outer walls 109 of the type described above with respect to the connector housing 82, extending from the rear wall 107 to define corresponding cavities 110. At least one or more, up to all, of the dividing walls 108 and lateral outer walls 109 may be aligned with the tips 29 of the signal contacts 86 and the tips 29 of the ground contacts 88 in the lateral direction A. Thus, a portion of the attenuating walls 116 may further be aligned with the tips 29 of the signal contacts 86 and the tips 29 of the ground contacts 88 in the lateral direction A. The attenuating walls 116 may be separate from the housing body 83 or may be supported by the housing body 83 as desired.

[0140] Now refer to Figures 17 and 18 In one example, the data communication assembly can be configured as a cable assembly 120. The cable assembly 120 can include at least one cable 122, such as a plurality of cables 122, and a complementary electrical device 124. The cable 122 can be mounted to corresponding electrical contacts, which can be configured as electrical contact pads of the electrical device 124. In one example, the electrical device 124 can be defined by a substrate 125, which can be configured as a printed circuit board. However, as will be understood from the following description, the electrical device 124 can alternatively be configured as any suitable electrical device. For example, the electrical device can be configured as an electrical connector.

[0141] The electrical cable 122 can be a twinaxial cable comprising a first and a second electrical signal conductor 128 surrounded by a common outer electrically insulating jacket 130. The first and second electrical signal conductors 128 can be disposed within respective inner electrical insulators and thereby electrically insulated from one another within the outer electrically insulating jacket 130. Furthermore, in one example, the first and second electrical signal conductors 128 can define a differential signal pair. The twinaxial cable can further define an electrical shield 129 disposed between the inner electrical insulator 127 and the outer electrically insulating jacket 130. Alternatively, the electrical cable 122 can be configured as a coaxial cable comprising a single electrical conductor surrounded by an outer electrically insulating jacket. Exposed portions of the electrical shield 129 can extend outwardly from the outer electrically insulating jacket 130 in a longitudinal direction L and can terminate at respective ground contact pads 131 of the substrate 125. The exposed portions of the electrical signal conductors 128 can extend outwardly in the longitudinal direction L relative to the electrical shield 129 and can be mounted to corresponding electrical contact pads 133 of the substrate 125. The exposed signal conductors 128 can be aligned with each other in the lateral direction A.

[0142] The cable assembly 120 may include a lossy material 64. For example, Figure 17 As shown in FIG, the non-conductive lossy material 64 can cover one or more, up to all, exposed portions of the electrical signal conductors 128. Thus, the non-conductive lossy material 64 can be disposed on the substrate 125 and can cover at least a portion of, up to substantially all, the exposed portions of the electrical contact pads 93 and corresponding electrical signal conductors 128. Alternatively or additionally, the lossy material 64 can be disposed between adjacent pairs of first and second electrical signal conductors. The lossy material 64 can be separated from the exposed portions of the electrical signal conductors 128 and the corresponding contact pads 123 and, thus, can be conductive or non-conductive. Alternatively, the lossy material 64 can contact one or more exposed portions of the electrical conductors 88 and / or electrical contact pads 123, in which case it may be desirable for the lossy material 64 to be non-conductive. In one example, the lossy material 64 can be arranged in a stripe disposed between each pair of first and second electrical signal conductors 128 along a lateral direction A. Furthermore, the stripe can be aligned laterally with the exposed portions of the electrical signal conductors 128.

[0143] The cable 122 can be configured as at least one cable strap 89 mounted on at least one surface of the substrate 125. Specifically, the substrate 125 can define a first opposing surface 134a and a second opposing surface 134b that are opposite to each other along the transverse direction T. A first cable strap 129 can be mounted to the first surface 134a, and a second cable strap 129 can be mounted to the second surface 134a. Figure 18As shown in , the lossy material 64 can alternatively or additionally be disposed on one or both of the first surface 134a and the second surface 134b so as to be positioned between the substrate 125 and the cable ribbon 129 mounted to the respective first surface 134a and the second surface 134b. For example, the lossy material 64 can be elongated along the lateral direction A and can span at least a portion of up to the entire width of the respective at least one cable ribbon 129 along the lateral direction A. Without being bound by theory, it is believed that Figures 17 and 18 The lossy material shown in can reduce crosstalk during operation of the cable assembly 120.

[0144] Now refer to Figures 19A to 20B , and as described above, in one example, the cable assembly 120 can include at least one cable 122, such as a plurality of cables 122, and a complementary electrical device 124. The complementary electrical device 124 can be configured as an electrical connector 140, which can also be referred to as a cable connector.

[0145] The electrical connector 140 can include an electrically insulating connector housing 142 and a plurality of electrical contacts 144 supported by the connector housing 142. In one example, the electrical contacts 144 can be press-fit or otherwise mechanically attached to the connector housing 142. Alternatively, the electrical contacts 144 can be insert molded into the connector housing 142. Still alternatively, the electrical contacts 144 can be supported by at least one lead frame housing of a corresponding lead frame assembly, which in turn is supported by the connector housing 142 in the manner described above. Each electrical contact 144 can define a mating end 146 and a mounting end 148 opposite the mating end 146. The mounting end 148 can be configured to be mounted to a first electrical device, which can be configured as at least one cable, such as the plurality of cables 122.

[0146] The electrical contacts 144 can include electrical signal contacts 167 and ground contacts 168. Adjacent electrical signal contacts 167 along corresponding rows 152 can define differential signal pairs. The electrical contacts 144 can include at least one or more ground contacts 168 between the differential signal pairs along the rows 152. When the electrical connector 140 is mated with a second electrical connector, the mating ends 146 of the electrical contacts 144 can be configured to mate with corresponding electrical contacts of the second electrical connector.

[0147] When the electrical connector 140 is docked with the second electrical connector, the docking end 146 can be configured to dock with the corresponding electrical contact of the second electrical connector. Specifically, the electrical connector 140 can dock with the second electrical connector along a docking direction. The docking end 146 can define an interface that is separable from the corresponding electrical contact of the second electrical connector. Therefore, the electrical connector 140 can be undocked from the second electrical connector along an undocking direction opposite to the docking direction. Both the docking direction and the undocking direction can be oriented along the longitudinal direction L. The mounting end 148 can be configured to be mounted to a first electrical device, and the first electrical device can be configured as at least one cable 122, such as a plurality of cables 122.

[0148] The cable 122 can be mounted to the electrical connector 140 at a cable termination interface. In one example, the mounting ends 148 of the signal contacts 167 can be configured to be mounted to the respective first and second signal conductors 128 of the cable 122. The mounting ends 148 of the ground contacts 168 can be configured to be mounted to the respective electrical shields of the cable 122, or to a drain wire, if present. In one example, the lossy material 64 can be positioned adjacent to the cable termination interface. Figures 9A to 9B In the example shown, the lossy material 64 can be configured as a strain relief configured to provide strain relief to the signal conductors 128 of the cable 122. The lossy material 64 can cover at least a portion of the total length of the exposed portion of the electrical shield 129 and at least a portion of the ground contact 168 to which the exposed portion of the electrical shield is mounted. In this regard, the lossy material can secure the outer insulating jacket 130 to the connector housing. Thus, the lossy material can provide strain relief for at least one electrical contact. Therefore, if a tensile force is applied to one or more cables 122, the tensile force will be absorbed by the lossy material 64 rather than by the connection between the electrical signal conductors 128 and the electrical signal contacts 167. In one example, the lossy material 64 can be molded onto the exposed portion of the electrical shield 129 and at least a portion of the ground contact 168 to which the exposed portion of the electrical shield is mounted. If desired, the lossy material 64 may alternatively or additionally be as described above with respect to Figures 17 and 18 Configured as described.

[0149] Now refer to FIG. 20A to FIG. 20BThe lossy material 64 can surround one or both of the outer insulating jacket 130, the exposed portion of the electrical shield, and the exposed portion of the electrical signal conductor 128, as desired. Specifically, the lossy material 64 can be configured as a protective cover 154 that is configured to be mounted to the electrical connector. The protective cover 154 can have an upper wall 155 and a pair of opposing side walls 156 that extend downwardly from the upper wall 155 toward the electrical connector 140 when the cover 154 is mounted to the electrical connector 140. The side walls 156 can be opposed to each other along the lateral direction A. The cover 154 can further include a divider wall 157 that extends downwardly from the upper wall 155 between the side walls 156. For example, the divider wall 157 can be equidistantly spaced from the side walls 156 relative to the lateral direction A. The divider wall 157 can extend along a portion of the total length of the cover 154, up to the entirety of the cover 154, along the longitudinal direction L. The cover 154 may define at least one pair of cavities 158 extending from the partition wall 177 to the opposing side walls 156 , respectively.

[0150] During operation, the electrical connector 140 can include a cover 154 mounted thereon such that the cover 154 cooperates with a portion of the electrical connector to surround one or more of, up to all of, the following: a portion of the outer electrically insulating jacket 130, an exposed portion of the electrical shield, and at least a portion of, up to all of, the exposed portions of the electrical signal conductors 128 of one or more electrical cables 122. For example, one or more of, up to all of, the following can be disposed within the first cavity 158: a portion of the outer electrically insulating jacket 130, an exposed portion of the electrical shield, and at least a portion of, up to all of, the exposed portions of the electrical signal conductors 128 of the first cable 122; and one or more of, up to all of, the following can be disposed within the second cavity 158: a portion of the outer electrically insulating jacket 130, an exposed portion of the electrical shield, and at least a portion of, up to all of, the exposed portions of the electrical signal conductors 128 of the second cable 122. A partition wall 177 can be disposed between adjacent cables 122 mounted to the electrical connector. The cover 154 may be mechanically rigid and, thus, configured to provide a mechanical barrier protecting the cable termination interface.

[0151] Now the overall reference Figures 21A to 24It has been further recognized that near-end crosstalk (NEXT) can be reduced by applying a lossy material to one or more surfaces of an ungrounded conductive substrate of an electrical shield disposed between adjacent rows of signal contacts. For example, the lossy material can be configured to absorb electromagnetic interference generated during operation of the electrical connector. It has been discovered that NEXT can be reduced when the conductive substrate is ungrounded, and therefore when the electrical shield is ungrounded (meaning that no portion of the electrical shield, including the conductive substrate, is in contact with any electrical ground of the electrical connector, or with any grounded conductive structure mated to or mounted to the electrical connector). Additionally, it has been discovered that NEXT can be reduced when the conductive substrate is not mechanically connected to any other conductive structure of the electrical connector, and therefore when the electrical shield is not mechanically connected to any other conductive structure of the electrical connector. Of course, it will be understood that the conductive substrate can alternatively be grounded, if desired. However, the ability to reduce NEXT with an ungrounded electrical shield is a surprising result, as ungrounded electrical shields in electrical connectors typically act as antennas, which tend to degrade signal integrity, including crosstalk, at data frequencies greater than 5 GHz.

[0152] Now refer to Figures 21A to 21B The electrical connector assembly 220 may include a first electrical connector 222 and a second electrical connector 224. The second electrical connector 224 is configured to mate with the first electrical connector 222 along a longitudinal direction L, where the longitudinal direction L may define a mating direction. The first electrical connector 222 and the second electrical connector 224 may each be configured to be mounted to a corresponding first electrical device and a corresponding second electrical device. For example, the first electrical connector 222 may be mounted to at least one cable 226 so that the first electrical connector 222 and the at least one cable 226 are in electrical communication. In this regard, the first electrical connector 222 may be referred to as a cable connector. The second electrical connector 224 may be configured to be mounted to a lower substrate 228, which may be configured as a printed circuit board (PCB). When the first electrical connector 222 and the second electrical connector 224 are respectively mounted to the at least one cable 226 and the substrate 228, the first electrical connector 222 and the second electrical connector 224 place the at least one cable 226 and the substrate 228 in electrical communication with each other. Therefore, the electrical connector assembly 220 may further include at least one cable 226 and a substrate 228.

[0153] Also refer to Figure 22, the first electrical connector 222 can include a first electrically insulating connector housing 230 and a plurality of first electrical contacts 232 supported by the connector housing 230. The electrical contacts 32 can be arranged in a first plurality of rows 234. The rows 234 can be oriented along a lateral direction A that is perpendicular to the longitudinal direction L and can also be referred to as a row direction. In addition, adjacent rows 234 can be spaced apart from each other along a lateral direction T that is perpendicular to the lateral direction A and the longitudinal direction L.

[0154] Each electrical contact 232 may define a docking end 236 and a mounting end 238 opposite the docking end. The mounting end 238 may be configured to be mounted to a first electrical device. When the first electrical connector 222 and the second electrical connector 224 are docked with each other, the docking end 236 may be configured to dock with a corresponding electrical contact 240 of the second electrical connector 224. The docking end 236 and the mounting end 238 may be arranged relative to each other along the longitudinal direction L and oriented along the longitudinal direction L. Therefore, the electrical contact 232 may be referred to as a vertical contact, and the first electrical connector 222 may be referred to as a vertical electrical connector. Alternatively, the docking end 236 and the mounting end 238 may be oriented perpendicularly to each other so that the electrical contact 232 defines a right-angle contact, and the first electrical connector 222 may be referred to as a right-angle electrical connector.

[0155] As described above, the first electrical connector 222 can be mounted to multiple cables 226 to define a cable connector. Each cable 226 can include at least one electrical signal conductor 242 and an electrical insulator 244 surrounding the signal conductor 242. Each cable 226 can further include an electrical ground. In one example, the electrical ground can be configured as an electrical shield that at least partially or completely surrounds the electrical insulator 244 and, therefore, at least partially or completely surrounds the at least one signal conductor 242. Thus, it can be said that the at least one signal conductor 242 can be electrically shielded, and thus the cables 226 can be electrically shielded. In one example, the cables 226 can be configured as twinaxial cables, each including a pair of signal conductors 242 surrounded by an electrical insulator 244. The pair of signal conductors 242 of each cable 226 can be arranged along a common row 234, or along a lateral direction A. Alternatively, the cables 226 can be configured as coaxial cables, whereby the at least one electrical signal conductor 242 defines only a single electrical signal conductor. Adjacent electrical signal conductors 242 along a corresponding row 234 can define a differential signal pair. Alternatively, the electrical signal conductors 242 can be single-ended. Multiple cables can be placed adjacent to each other along each row 234 as desired.

[0156] The electrical contacts 232 may include electrical signal contacts 247 and electrical ground contacts 248. Alternatively, the electrical contacts 232 may define an open pin area and not be assigned as ground contacts or signal contacts before use. The mounting ends 238 of the electrical ground contacts 248 may be configured to individually contact the electrical grounding members of the cable 226. In addition, the electrical ground contacts 248 may be electrically shared with each other. That is, the electrical ground contacts 248 may all be electrically connected to each other. In one example, each row of electrical ground contacts 248 may be defined by a single integral conductive structure. The conductive structure may be metallic. The mounting ends 238 of the electrical signal contacts 247 may be configured to contact corresponding electrical signal conductors 242 of the cable 226. The docking ends 236 of the electrical ground contacts 248 may be disposed between adjacent docking ends 236 of the electrical signal contacts 247. For example, at least one butt end 236 of the electrical ground contact 248 can be positioned between adjacent pairs of butt ends 236 of the electrical signal contacts 247 along each corresponding row 234. In one example, a pair of butt ends 236 of the electrical ground contact 248 can be positioned between adjacent pairs of butt ends 236 of the electrical signal contacts 247 along each corresponding row 234. Thus, the electrical contacts 232 can be arranged in a repeating SSGG configuration along the corresponding rows, where "S" represents one or more of the butt ends 236, mounting ends 238, and bodies of the electrical signal contacts 247, and "G" represents one or more of the butt ends 236, mounting ends 238, and bodies of the electrical ground contacts 248. The bodies of the electrical signal contacts 247 and the electrical ground contacts 248 can each extend from their respective butt ends 236 to their respective mounting ends 238. Alternatively, the electrical contacts 232 can be arranged in a repeating SSG configuration along the corresponding rows. In this regard, it should be understood that the electrical contacts 232 can be arranged in any suitable alternative configuration of signal contacts and ground contacts as desired. In addition, the butt ends 236 of the electrical ground contacts 248 can be aligned with the butt ends 236 of the electrical signal contacts 247 along the corresponding rows 234. Similarly, the mounting ends 238 of the electrical ground contacts 248 can be aligned with the mounting ends of the electrical signal contacts 247 along the corresponding rows 234.

[0157] The second electrical connector 224 includes a second electrically insulating connector housing 250 and a plurality of second electrical contacts 240 supported by the second connector housing 250. The electrical contacts 232 of the first electrical connector 222 can be insert-molded into the first connector housing 230. Alternatively, the electrical contacts 232 of the first electrical connector 222 can be inserted into the first connector housing 230. Similarly, the electrical contacts 240 of the second electrical connector 224 can be insert-molded into the second connector housing 250. Alternatively, the electrical contacts 240 of the second electrical connector 224 can be inserted into the second connector housing 250.

[0158] The electrical contacts 240 can be arranged in a second plurality of rows 252. The rows 252 can be oriented along a lateral direction A. Furthermore, adjacent rows 252 can be spaced apart from one another along a transverse direction T. Thus, the rows 234 and 252 can be oriented parallel to one another.

[0159] Each electrical contact 240 of the second electrical connector 224 can define a docking end 254 and a mounting end 256 opposite the docking end. The mounting end 256 can be configured to be mounted to the substrate 228, thereby placing the second electrical connector 224 in electrical communication with the substrate 228. When the first and second electrical connectors 222, 224 are docked with each other, the docking end 254 can be configured to dock with the docking end 236 of the corresponding electrical contact 232 of the first electrical connector 222. The docking end 254 and the mounting end 256 can be disposed relative to each other and oriented along the longitudinal direction L. Therefore, the electrical contacts 240 can be referred to as vertical contacts, and the second electrical connector 224 can be referred to as a vertical electrical connector. Alternatively, the docking end 254 and the mounting end 256 can be oriented perpendicularly to each other, such that the electrical contacts 240 define right-angle contacts, and the second electrical connector 224 can be referred to as a right-angle electrical connector.

[0160] Now refer to Figures 21A to 23C The first electrical connector 222 may include at least one first electrical shield 258 configured to reduce near-end crosstalk in the first electrical connector 222. Furthermore, the electrical shield 258 may be configured to reduce near-end crosstalk in the first electrical connector assembly 220. Similarly, the second electrical connector may include at least one first electrical shield 258 configured to reduce near-end crosstalk in the second electrical connector 224. Furthermore, the second electrical shield 260 may be configured to reduce near-end crosstalk in the electrical connector assembly 220. The first electrical shield 258 will now be described, followed by the second electrical shield 260.

[0161] The first electrical shield 258 can include a conductive substrate 262 supported by the connector housing 230. In one example, the conductive substrate 262 can be configured as a plate. In another example, the conductive substrate 262 can define a mesh. For example, the conductive substrate 262 can include a plurality of conductive fibers. The fibers can be woven to define a mesh. It will be appreciated that the mesh can define a plurality of openings. The openings can be defined by gaps between the fibers. Alternatively, it will be appreciated that the openings can alternatively be defined to extend through the substrate 262. For example, the plurality of openings can be defined in a non-woven substrate or plate. In one example, the conductive substrate 262 can be metallic. Thus, the plate or fibers can be metallic. For example, the conductive substrate 262 can be made of copper, which can be pure copper or a copper alloy. Of course, it will be appreciated that the conductive substrate 262 can be made of and include any suitable alternative material as desired. The electrical shield 260 can be disposed between the first and second signal contacts 247 to provide electrical shielding therebetween, and thus the conductive substrate 262 can be disposed between the first and second signal contacts 247 to provide electrical shielding therebetween. For example, the electrical shield 260 , and thus the conductive substrate 262 , may be disposed between adjacent first and second rows of the plurality of rows 234 of electrical contacts and provide electrical shielding between the signal contacts 247 in the first row and the signal contacts 247 in the second row.

[0162] In one example, the conductive substrate 262, and therefore the electrical shield 258, may not be grounded. Thus, the electrical shield 258, and therefore the conductive substrate 262, do not contact any conductive structure that, in turn, contacts any ground contact 248. Furthermore, in one example, the electrical connector 222 can be configured such that no portion of the electrical shield 258, and therefore the conductive substrate 262, contacts any grounded conductive structure of the electrical connector 222 or any conductive structure mated to or mounted to the electrical connector 222. Alternatively, in some examples, the conductive substrate 262 can be in electrical communication with the electrical ground contact 248, if desired. The conductive substrate 262 can be flat along a plane defined by the longitudinal direction L and the lateral direction A. Furthermore, the conductive substrate 262 can be positioned equidistantly between the first and second rows 234 relative to the transverse direction T. Of course, it should be understood that the conductive substrate can define any suitable shape as desired. Although the electrical shield 258 is depicted between the first and second rows, it should be appreciated that the electrical connector 222 may include multiple electrical shields disposed between various adjacent rows in the plurality of rows 234 .

[0163] The electrical shield 258 may also include a lossy material 64 disposed on at least a portion, up to the entirety, of the conductive substrate 262. For example, as described in more detail below, the lossy material 64 may be disposed on a majority of the conductive substrate 262. In one example, the lossy material 64 may be disposed on the entire conductive substrate 262. In one example, the lossy material 64 may be conductive. In another example, the lossy material 64 may be non-conductive. In one example, the lossy material 64 may be disposed on a portion of the conductive substrate 262. For example, the lossy material 64 may be GDS. Alternatively, the lossy material 64 may be LS-30. In another example, the lossy material can be HM2000, commercially available from Arc Technologies, Inc., with a place of business in Massachusetts. In one example, the lossy material 64 can be a broadband lossy material. Thus, the lossy material 64 of the first electrical connector 222 of the electrical connector assembly 220 can be free of a CMC that can be configured to tune the absorption frequency of the lossy material 64 as described above.

[0164] The conductive substrate 262 can define a first side 263a and a second side 263b opposite the first side 263a along a transverse direction T. The first side 263a can face the first row 234, and the second side 263b can face the second row 234. The conductive substrate 262 can further define at least one edge extending from the first side 263a to the second side 263b. For example, the conductive substrate 262 can define a first edge 265a and a second edge 265b opposite the first edge 265a along a longitudinal direction L. For example, the first edge 265a can be spaced apart from the second edge 265b in the mating direction. Thus, the first edge 265a can be positioned adjacent to the mating interface of the first electrical connector 222. Furthermore, the first edge 265a can face the second electrical connector 224. The second edge 265b can be positioned adjacent to the mounting interface of the first electrical connector 222. When the first electrical connector is configured as a vertical connector, the mounting interface of the first electrical connector 222 can face away from the second electrical connector. The conductive substrate 262 may define side edges 265 c that are opposite to each other along the lateral direction A and extend from the first edge 265 a to the second edge 265 b and from the first side 263 a to the second side 263 b .

[0165] In one example, the lossy material 64 may be disposed on at least one of the first side 263a, the second side 263b, and at least one edge of the conductive substrate 262. For example, the lossy material 64 may be disposed on at least one of the first side 263a and the second side 263b. For example, the lossy material 64 may be disposed on the entirety of at least one of the first side 263a and the second side 263b. In one example, the lossy material 64 may be disposed on each of the first side 263a and the second side 263b. The lossy material 64 may extend from the first edge 265a to the second edge 265b and between the opposing side edges 265c. Alternatively or additionally, the lossy material 64 may be impregnated into the conductive substrate 262 in the manner described above.

[0166] Thus, the lossy material 64 can extend continuously between the plurality of electrical contacts 232 in the first row and the plurality of electrical contacts 232 in the second row. In one example, the lossy material 64 can extend continuously between all of the signal contacts 247 in the first row 234 and all of the signal contacts 247 in the second row 234. For example, the lossy material 64 can extend continuously between all of the electrical contacts 232 in the first row 234 and all of the electrical contacts 232 in the second row 234. Thus, it will be understood that the electrical shield 258, including the substrate 262 and the lossy material 64, can extend to a position that is aligned with the mounting ends 238 of the electrical signal contacts 247 in each of the first and second rows along the lateral direction T. The mounting position can be referred to as a position where the mounting ends 238 of the signal contacts 247 contact or mount to the signal conductors 242 of the cable 226. Additionally, the electrical shield 258, including the substrate 262 and the lossy material 64, can extend to a position that aligns with the mating positions of the electrical signal contacts 247 in each of the first and second rows along the lateral direction T. The mating position can be referred to as a position where the mating ends 236 of the signal contacts 247 in the first electrical connector 222 contact or mate with the signal contacts of the second electrical connector 224.

[0167] The conductive substrate 262 may have a thickness along the transverse direction T from the first side 263a to the second side 263b. The lossy material 64 disposed on the first side 263a may also have a thickness along the transverse direction. The thickness of the lossy material 64 disposed on the first side 263a may be greater than, less than, or substantially equal to the thickness of the conductive substrate 262. In one example, the thickness of the lossy material 64 disposed on the first side 263a may be substantially within 50% of the thickness of the conductive substrate 262. Similarly, the lossy material 64 disposed on the second side 263b may also have a thickness along the transverse direction. The thickness of the lossy material 64 disposed on the second side 263b may be greater than, less than, or substantially equal to the thickness of the conductive substrate 262. In one example, the thickness of the lossy material 64 disposed on the second side 263b may be substantially within 50% of the thickness of the conductive substrate 262.

[0168] In one example, the thickness of the electrical shield 258 can be in a range of about 5 microns to about 1000 microns, such as from about 5 microns to about 500 microns. For example, the thickness of the electrical shield 258 can be in a range of about 10 microns to about 500 microns, such as from about 50 microns to about 300 microns. The thickness of the conductive substrate 262 can be in a range of about 5 microns to about 1000 microns, such as from about 5 microns to about 500 microns. For example, the thickness of the substrate 262 can be in a range of about 10 microns to about 500 microns, such as from about 50 microns to about 300 microns. Of course, it should be understood that the thickness of the conductive substrate 262 and the thickness of the lossy material disposed on each of the first side 263a and the second side 263b can vary as desired.

[0169] In some examples, lossy material 64 can be disposed on one or both of edge 265a and edge 265b. Alternatively or additionally, lossy material 64 can be disposed on one or both of side edges 265c. Thus, it will be appreciated that conductive substrate 262 can be encapsulated by lossy material 64 as desired.

[0170] It should be understood that a method can include the step of supporting the electrical shield 258 by the first connector housing 230. For example, in one example, the lossy material 64 can be applied to the conductive substrate 262 in any suitable manner as desired. For example, the lossy material 64 can be applied to the conductive substrate in any manner described above with respect to the electrical contacts, connector housing, and leadframe housing. Thus, the lossy material can define a coating on the outer surface of the substrate 262. Alternatively, for example, the first substrate 262 can define a plurality of openings therethrough, such as when the first substrate 262 is a mesh, and the first substrate 262 can be impregnated with the lossy material 64. Thus, the thickness of the electrical shield 258 can be less than the sum of the thickness of the lossy material alone and the thickness of the substrate 26 alone. Next, the electrical shield 258 can be insert molded into the first connector housing 230. Alternatively, the electrical shield 258 can be secured to the connector housing 230 in any manner as desired. Alternatively, the conductive substrate 262 can be initially supported by the first connector housing 230. For example, the conductive substrate 262 can be insert molded into the first connector housing. Alternatively, the conductive substrate 262 may be secured to the connector housing 230 in any manner as desired. Next, the lossy material 64 may be applied to the exposed portion of the conductive substrate 262, as described above.

[0171] A portion of the electrical shield 258 can be cantilevered in the mating direction. For example, the connector housing 230 can define a cantilevered portion 231, and a portion of the electrical shield 258 can be supported by the cantilevered portion. For example, a first portion of the cantilevered portion 231 can contact the lossy material 64 disposed on the first side 263a of the conductive substrate 262, and a second portion of the cantilevered portion 231 can contact the lossy material 64 disposed on the second side 263b of the conductive substrate 262. The cantilevered portion 231 can define a plug that is received in a corresponding receptacle 251 defined by the second connector housing 250 of the second electrical connector 224, so that the first and second electrical connectors 222, 224 mate with each other. Alternatively, the second electrical connector 224 can define the plug, and the first electrical connector 222 can define the receptacle.

[0172] Continue to refer Figures 21A to 23CThe second electrical shield 260 may include a second conductive substrate 266 supported by the second connector housing 250. Therefore, the conductive substrate 262 may be referred to as a first conductive substrate. The second conductive substrate 266 may be configured as described above with respect to the conductive substrate 262. Thus, for example, the substrate 266 may be configured as a plate. Alternatively, the substrate 266 may have openings. For example, the substrate 266 may be configured as a mesh. The electrical shield 260, and therefore the conductive substrate 266, may be disposed between the first and second electrical contacts 240 to provide electrical shielding therebetween. For example, the second electrical shield 260, and therefore the conductive substrate 266, may be disposed between adjacent rows of the plurality of second rows 252 of electrical contacts 240. The electrical contacts 240 may include electrical signal contacts 268 and electrical ground contacts 270. The mating ends 254 of the electrical signal contacts 268 may be configured to mate with corresponding mating ends 236 of the electrical signal contacts 247 of the first electrical connector 222. The mounting end 256 of the electrical ground contact 270 can be mounted to the substrate 228. Similarly, the mating end 254 of the electrical ground contact 270 can be configured to mate with the corresponding mating end 236 of the electrical ground contact 270 of the first electrical connector 222. The mounting end 256 of the electrical ground contact 270 can be mounted to the substrate 228.

[0173] The second electrical shield 260 can provide electrical shielding between the first row of signal contacts 268 and the second row of signal contacts 268. In one example, the conductive substrate 266 is metal. For example, the conductive substrate 266 can be made of copper, which can be pure copper or a copper alloy. Of course, it should be understood that the conductive substrate 266 can be made of any suitable alternative material as desired.

[0174] In one example, the second conductive base plate 266, and therefore the second electrical shield 260, may not be grounded. Therefore, the second electrical shield 260, and therefore the conductive base plate 266, does not contact any conductive structure that, in turn, contacts any ground contacts 270. Furthermore, in one example, the electrical connector 224 can be configured such that no portion of the second electrical shield 260, and therefore the conductive base plate 266, contacts any grounded conductive structure of the electrical connector 224 or any grounded conductive structure that mates with or is mounted to the electrical connector 224. Alternatively, in some examples, the conductive base plate 266 can be in electrical communication with the electrical ground contacts 270, if desired. The conductive base plate 266 can be flat along a plane defined by the longitudinal direction L and the lateral direction A. Furthermore, the conductive base plates 266 can be positioned equidistantly between the first and second rows 252 relative to the transverse direction T. Of course, it should be understood that the conductive base plate 266 can define any suitable shape as desired. Although the second electrical shield 260 is described as being disposed between the first and second rows 252 , it should be appreciated that the electrical connector 222 may include multiple electrical shields disposed between corresponding different adjacent rows of the plurality of rows 252 .

[0175] The second electrical shield 260 can further include a lossy material 272 disposed on at least a portion of the conductive substrate 266. The lossy material 272 can be as described above with respect to the lossy material 64. Thus, the lossy material 272 can be referred to as a second lossy material given that it is included in the second electrical shield 260, but the lossy material 272 can be the same as the lossy material 64, which can be referred to as a first lossy material given that it is included in the first electrical shield 258. The lossy material 272 can be disposed on a majority of the conductive substrate 266, for example, as described in more detail below. In one example, the lossy material 272 can be disposed on the entire conductive substrate 266. In one example, the lossy material 272 can be conductive. In another example, the lossy material 272 can be non-conductive. In one example, the lossy material 272 can be provided by a company having a place of business in Houston, Texas. In this regard, the lossy material 272 may be the same material as the lossy material 64 of the first electrical shield 258 .

[0176] The second conductive substrate 266 can define a first side 267a and a second side 267b opposite the first side 267a along a transverse direction T. The first side 267a can face the first row 252, and the second side 267b can face the second row 252. The second conductive substrate 266 can further define at least one edge extending from the first side 267a to the second side 267b. For example, the conductive substrate 266 can define a first edge 269a and a second edge 269b opposite the first edge 269a along a longitudinal direction L. For example, the first edge 269a can be spaced apart from the second edge 269b in the mating direction. Thus, the first edge 269a can be positioned adjacent to the mating interface of the first electrical connector 222. Furthermore, the first edge 269a can face the first electrical connector 222. The second edge 269b can be positioned adjacent to the mounting interface of the second electrical connector 224. Thus, the second edge 269b can face the substrate 228. The second conductive substrate 266 may define side edges that are opposite to each other along the lateral direction A and extend from the first edge 269a to the second edge 269b and from the first side 267a to the second side 267b.

[0177] In one example, the lossy material 272 may be disposed on at least one of the first side 267a, the second side 267b, and at least one edge of the conductive substrate 266. For example, the lossy material 272 may be disposed on at least one of the first side 267a and the second side 267b. For example, the lossy material 272 may be disposed on the entirety of at least one of the first side 267a and the second side 267b. In one example, the lossy material 272 may be disposed on each of the first side 267a and the second side 267b. The lossy material 272 may extend from the first edge 269a to the second edge 269b and between opposing side edges. Alternatively or additionally, the lossy material 272 may be impregnated into the second conductive substrate 266 in the manner described above.

[0178] Thus, the lossy material 272 can extend continuously between the plurality of electrical contacts 240 in the first row 252 and the plurality of electrical contacts 240 in the second row 252. In one example, the lossy material 272 can extend continuously between all signal contacts 268 in the first row 262 and all signal contacts 268 in the second row 262. For example, the lossy material 272 can extend continuously between all electrical contacts 240 in the first row 262 and all electrical contacts 240 in the second row 252. Thus, it can be appreciated that the second electrical shield 260, including the substrate 266 and the lossy material 272, can extend to a position that is aligned along the lateral direction T with the mounting ends 256 of the electrical signal contacts 268 in each of the first and second rows 252. The mounting position can be referred to as a position where the mounting ends 256 of the signal contacts 268 contact or mount to a solder ball, which in turn is mounted to the substrate 228. The second electrical shield 260 can extend outward from the mounting end of the connector housing 250 toward the substrate 228 to a position spaced apart from the substrate 228 along the longitudinal direction L, thereby defining a gap extending from the second electrical shield 260 to the substrate 228. For example, the gap can extend from the second edge 269b to the substrate 28. In one example, the gap can be less than approximately 0.5 mm. For example, the gap can be less than approximately 0.3 mm. In one example, the gap can be approximately 0.1 mm. When the second electrical connector 224 is mounted to the substrate 228, the mounting end of the connector housing 250 can face the substrate 228. It may be desirable to minimize this gap, as well as all gaps disclosed herein, to enhance the effective shielding of the electrical shields 258 and 260. It may further be desirable to eliminate this gap.

[0179] Additionally, the second electrical shield 260 , including the substrate 266 and the lossy material 272 , can extend to a position that aligns with the mating positions of the electrical signal contacts 268 in each of the first and second rows along the lateral direction T. The mating position can be referred to as a position where the mating ends 254 of the signal contacts 268 in the second electrical connector 24 contact or mate with the signal contacts 247 of the first electrical connector 222 .

[0180] The conductive substrate 266 may have a thickness along the transverse direction T from the first side 267a to the second side 267b. The lossy material 272 disposed on the first side 267a may also have a thickness along the transverse direction. The thickness of the lossy material 272 disposed on the first side 267a may be greater than, less than, or substantially equal to the thickness of the conductive substrate 266. In one example, the thickness of the lossy material 272 disposed on the first side 267a may be substantially within 50% of the thickness of the conductive substrate 266. Similarly, the lossy material 272 disposed on the second side 267b may also have a thickness along the transverse direction. The thickness of the lossy material 272 disposed on the second side 267b may be greater than, less than, or substantially equal to the thickness of the conductive substrate 266. In one example, the thickness of the lossy material 272 disposed on the second side 267b may be substantially within 50% of the thickness of the conductive substrate 266.

[0181] In one example, the thickness of the second electrical shield 260 can be in a range of approximately 5 microns to approximately 1000 microns, such as from approximately 5 microns to approximately 500 microns. For example, the thickness of the second electrical shield 260 can be in a range of approximately 10 microns to approximately 500 microns, such as from approximately 50 microns to approximately 300 microns. Therefore, it should be understood that the second electrical shield 260 can have the same thickness as the first electrical shield 258. Furthermore, the lossy material 272 can have the same thickness as the lossy material 64. The thickness of the second conductive substrate 266 can be in a range of approximately 5 microns to approximately 1000 microns, such as from approximately 5 microns to approximately 500 microns. For example, the thickness of the substrate 266 can be in a range of approximately 10 microns to approximately 500 microns, such as from approximately 50 microns to approximately 300 microns. Of course, it should be understood that the thickness of the conductive substrate 266 and the thickness of the lossy material 272 disposed on each of the first side 267a and the second side 267b can vary as desired.

[0182] In some examples, lossy material 272 can be disposed on one or both of edge 267a and edge 267b. Alternatively or additionally, lossy material 272 can be disposed on one or both side edges. Thus, it will be appreciated that conductive substrate 262 can be encapsulated with lossy material 272 as desired.

[0183] It should be understood that a method may include the step of supporting the second electrical shield 260 by the second connector housing 250. For example, in one example, the lossy material 272 may be applied to the conductive substrate 266 as described above with respect to applying the lossy material 64 to the conductive substrate 262. Next, the second electrical shield 260 may be insert molded into the second connector housing 250. Alternatively, the second electrical shield 260 may be secured to the connector housing 250 in any manner as desired. Alternatively, the conductive substrate 266 may be initially supported by the second connector housing 250. For example, the conductive substrate 266 may be insert molded into the second connector housing 250. Alternatively, the conductive substrate 266 may be secured to the connector housing 250 in any manner as desired. Next, the lossy material 272 may be applied to the exposed portion of the conductive substrate 266 as described above.

[0184] Now refer to Figure 21B and Figures 23A to 23C As described above, the first electrical connector 222 and the second electrical connector 224 are configured to mate with each other. Furthermore, in one example, the first electrical shield 258 and the second electrical shield 260 can be aligned with each other along the longitudinal direction L. Furthermore, the electrical connector assembly 220 can define a space extending from the first electrical shield 258 to the second electrical shield 260 along the longitudinal direction L. Specifically, the first electrical shield 258 can extend along the longitudinal direction L to the mounting end of the connector housing 230. When the first electrical connector 222 and the second electrical connector 224 are mated with each other, the mounting end of the connector housing 230 can face the second electrical connector 224. Alternatively, the first electrical shield 258 can be recessed inwardly relative to the mounting end of the connector housing 30 along the longitudinal direction L. The mounting end of the connector housing 230 can be aligned with the first electrical shield 258, particularly with the first edge 265a, along the longitudinal direction L. Furthermore, the second electrical shield 260 can extend to the mating end of the second connector housing 250, particularly to a region of the mating end aligned with the second electrical shield 260 along the longitudinal direction L.

[0185] When the first electrical connector 222 and the second electrical connector 224 are mated with each other, the mating ends of the corresponding first connector housing 230 and second connector housing 250 can abut each other. Because the first electrical shield 258 can be recessed from the mating end of the first housing 30 and the second electrical shield 260 extends to the mating end of the second housing 250, the electrical connector assembly 220 can define a gap extending longitudinally from the first electrical shield 258 to the second electrical shield 258. Alternatively, the first electrical shield 258 can extend to the mating end of the first housing 230 and the second electrical shield 260 can be recessed from the mating end of the second housing 250. Alternatively, each of the first electrical shield 258 and the second electrical shield 260 can be recessed from the mating end of the first housing 230 and the mating end of the second housing 250, respectively. In one example, the gap can be less than approximately 0.5 mm. For example, the gap can be less than approximately 0.3 mm.

[0186] In one example, each of the first electrical connector 222 and the second electrical connector 224 can be configured to transmit signals along the corresponding electrical signal contacts at a data transmission speed of 256 gigabits per second, wherein worst-case asynchronous multi-source crosstalk does not exceed 4% at a rise time of approximately 5 picoseconds to approximately 240 picoseconds. For example, each of the first electrical connector 222 and the second electrical connector 224 can be configured to transmit signals along the corresponding electrical signal contacts at a data transmission speed of 256 gigabits per second, wherein worst-case asynchronous multi-source crosstalk does not exceed 5% at a rise time of approximately 5 picoseconds to approximately 240 picoseconds. In another example, each of the first electrical connector 222 and the second electrical connector 224 can be configured to transmit signals along the corresponding electrical signal contacts at a data transmission speed of 256 gigabits per second, wherein worst-case asynchronous multi-source crosstalk does not exceed 5% at a rise time of approximately 5 picoseconds to approximately 240 picoseconds.

[0187] In one example, the first electrical shield 258 and the second electrical shield 260 can be aligned with each other along the longitudinal direction. For example, the first electrical shield 258 and the second electrical shield 260 can be coplanar with each other along a plane defined by the longitudinal direction L and the lateral direction A. Therefore, the first conductive substrate 262 and the second conductive substrate 266 can be aligned with each other along the longitudinal direction L. Furthermore, the first electrical shield 258 and the second electrical shield 260 can be coplanar with each other along a plane defined by the longitudinal direction L and the lateral direction A. Furthermore, the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 can be aligned with the lossy material 272 disposed on the first side 267a of the second conductive substrate 266. For example, the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 can be coplanar with the lossy material 272 disposed on the first side 267a of the second conductive substrate 266 along the plane defined by the longitudinal direction L and the lateral direction A. Furthermore, the lossy material 64 disposed on the second side 263b of the first conductive substrate 262 can be aligned with the lossy material 272 disposed on the second side 267b of the second conductive substrate 266. For example, the lossy material 64 disposed on the second side 263b of the first conductive substrate 262 can be coplanar with the lossy material 272 disposed on the second side 267b along a plane defined by the longitudinal direction L and the lateral direction A.

[0188] Now refer to Figure 24 In another example, at least corresponding portions of the first shield 258 and the second shield 260 can overlap each other along the transverse direction T. Specifically, the first conductive substrate 262 and the second conductive substrate 266 can be offset relative to each other along the transverse direction T. In addition, the first conductive substrate 262 can extend outward from the connector housing 230 toward the second electrical connector 224. In addition, a portion of the first substrate 262 can be received by the second connector housing 250. Alternatively or additionally, the second conductive substrate 266 can extend outward from the connector housing 250 toward the first electrical connector 222. In addition, a portion of the second substrate 266 can be received by the first connector housing 220.

[0189] Thus, a portion of the first substrate 262 can overlap a portion of the second substrate 266 such that a straight line oriented along the transverse direction T can pass through each of the first and second substrates 262, 266. In one example, a portion of the first side 263a of the first substrate 262 and a portion of the second side 267b of the second substrate 266 can face each other along the transverse direction T. The first and second substrates 262, 266 can overlap each other along the longitudinal direction L by any suitable distance as desired. For example, in one example, the first and second substrates 262, 266 can overlap each other along the longitudinal direction L by up to approximately 2.5 mm. For example, the first and second substrates 262, 266 can overlap each other along the longitudinal direction L by up to approximately 1 mm. In another example, the first and second substrates 262, 266 can overlap each other along the longitudinal direction L by approximately 0.5 mm.

[0190] Furthermore, the first conductive substrate 262 can overlap with the lossy material 272, which is disposed at a first overlap region on one or both of the first side 267a and the second side 267b of the second conductive substrate 266. Furthermore, the first side 263a of the first conductive substrate 262 can abut the lossy material 272 disposed on the second side 267b of the second conductive substrate 266. Thus, the lossy material disposed on the second side 267b of the second conductive substrate 266 can be disposed between the first conductive substrate 262 and the second conductive substrate 266 at the first overlap region.

[0191] Similarly, the second conductive substrate 266 may overlap the lossy material 64, which is disposed on one or both of the first side 263a and the second side 263b of the first conductive substrate 262 at a second overlap region. Furthermore, the second side 267b of the second conductive substrate 266 may abut the lossy material 64 disposed on the first side 263a of the first conductive substrate 262. Thus, the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 may be disposed between the first conductive substrate 262 and the second conductive substrate 266 at the second overlap region. In one example, the first overlap region and the second overlap region may have a substantially equal distance along the longitudinal direction L. This distance may range from greater than 0 mm to approximately 1.5 mm. For example, this distance may range from greater than 0 mm to approximately 1 mm. Specifically, this distance may range from greater than 0 mm to approximately 0.5 mm. In a specific example, this distance may be approximately 0.25 mm.

[0192] Furthermore, the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 can be aligned with the lossy material 272 disposed on the second side 267b of the second conductive substrate 266 along the longitudinal direction L. Furthermore, the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 can abut the lossy material 272 disposed on the second side 267b of the second conductive substrate 266. Alternatively, the gap can extend along the longitudinal direction L from the lossy material 64 disposed on the first side 263a of the first conductive substrate 262 to the lossy material 272 disposed on the second side 267b of the second conductive substrate 266. Unless otherwise specified, the lossy material 64 disposed on the side 263a of the first substrate 262 and the lossy material 272 disposed on the side 267b of the second substrate 266, respectively, are aligned with each other along the mating direction, with the side 263a and the side 267b facing each other.

[0193] Alternatively, the electrical shield of one of the first electrical connector and the second electrical connector can extend outwardly a sufficient distance from the butt end of the corresponding electrical contact so that the electrical shield is disposed between the first electrical contact and the second electrical contact of the other of the first electrical connector and the second electrical connector. The first electrical contact and the second electrical contact can be configured as signal contacts. In one example, the electrical shield of one of the first electrical connector and the second electrical connector can extend outwardly a sufficient distance from the butt end of the corresponding electrical contact so that the electrical shield is the only electrical shield disposed between the first electrical contact and the second electrical contact of the other of the first electrical connector and the second electrical connector. For example, the electrical shield of one of the first electrical connector and the second electrical connector can extend outwardly a sufficient distance from the butt end of the corresponding electrical contact so that the electrical shield is disposed between the first row of electrical contacts and the second row of electrical contacts of the other of the first electrical connector and the second electrical connector. In one example, the electrical shield of one of the first electrical connector and the second electrical connector can extend outwardly a sufficient distance from the mating end of the corresponding electrical contact so that the electrical shield is the only electrical shield disposed between the first row of electrical contacts and the second row of electrical contacts of the other of the first electrical connector and the second electrical connector.

[0194] While the lossy material 64 may be supported by the electrical connector assembly or a component thereof as described above, it will be appreciated that the lossy material may alternatively be disposed on other components of the data communication assembly. For example, referring now to Figure 25A lossy material can be applied around an opening 180 of an electrical cage 182, which is configured to receive a transceiver through the opening 180. The cage 182 can be metallic. In one example, the lossy material can be configured as a collar that surrounds all sides of the cage 182 within a plane perpendicular to the central axis of the opening 180. Alternatively, the lossy material can surround at least one or more, up to all, sides of the cage 182 within the plane. The lossy material can be disposed on an outer surface of the cage 182, which is opposite to an inner surface of the cage 182, which in turn defines the opening 180.

[0195] It should be understood that the above description is merely illustrative of the present invention. Various alternatives and modifications can be envisioned by those skilled in the art without departing from the present invention. In addition, it should be understood that, unless otherwise indicated, all features of all examples disclosed herein can be incorporated into all other examples. Therefore, unless otherwise indicated, lossy materials according to one example of an electrical contact, lead frame assembly, electrical connector, cable assembly, or data communication assembly can be incorporated into any other example disclosed herein. Therefore, the present invention is intended to cover all such alternatives, modifications, and variations that fall within the scope of the appended claims.

Claims

1. A method of applying a lossy material to an electrical contact of an electrical connector, the method comprising the step of applying the lossy material to a tip of a contact body of the electrical contact, whereby the lossy material encapsulates the tip, wherein the tip flares outwardly from a wiping surface of the electrical contact, the electrical contact engages with a corresponding structure to form an electrical connection, wherein the electrical contact is assigned as a ground contact.

2. The method of claim 1, wherein the applying step comprises the step of molding the lossy material onto the electrical contact.

3. The method of any one of claims 1 to 2, wherein the lossy material is electrically conductive.

4. The electrical contact of claim 3, wherein the lossy material has an electrical conductivity of greater than 1 Siemens per meter up to about 6.1 x 10^7 Siemens per meter.

5. The method of any one of claims 1 to 2, wherein the lossy material is non-conductive.

6. The electrical contact of claim 5, wherein the lossy material has an electrical conductivity ranging from 1 Siemens per meter to about 1 x 10^-17 Siemens per meter.

7. A method according to any one of claims 5 to 6, wherein the lossy material is non-conductive and absorbs within ±5 GHz of the first frequency.

8. The method of claim 1, wherein the lossy material comprises a carbon microcoil.

9. The method of claim 3, wherein the lossy material is electrically lossy.

10. The method of any one of claims 1 to 2, wherein the lossy material is magnetically lossy.

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