Plug connector with end node termination module

Abstract

A plug connector (200) includes a plug housing (210) having a power contact channel (212) and a module channel (214) between a mating end and a cable end. The plug connector includes power contacts (300) in the power contact channels, a data module (400) received in the first module channel, and an end node termination module (500) received in the second module channel. The data module includes a data module housing (410) that holds signal contacts terminated to ends of signal lines of a data cable (206). The end node termination module includes a termination module housing (510) having a recess that receives the end node PCB, the end node PCB having a control circuit with an end node control component. The jumper contacts are held by the plug housing and include signal contact mating interfaces electrically connected to the respective signal contacts and end node mating interfaces electrically connected to the end node termination modules to electrically connect the signal contacts to end node control circuitry within the plug connector.

Description

TECHNICAL FIELD

[0001] The subject matter herein relates generally to electrical connector systems. BACKGROUND

[0002] Modern vehicles increasingly rely on complex electronic control systems to manage various engine functions, including fuel injection, ignition timing, emissions control, and turbocharging. At the heart of these systems is the engine control unit (ECU), a microcontroller-based device that interfaces with many sensors and actuators throughout the vehicle. Communication between the ECU and these peripheral components is typically facilitated through a serial communication bus, such as Controller Area Network (CAN), Local Interconnect Network (LIN), or similar proprietary or standardized networks.

[0003] In such systems, proper signal integrity and network performance are essential for accurate and timely data exchange. To achieve this, termination networks are often employed at the end of the communication bus to match impedance, reduce reflections, and ensure reliable data transmission. These termination networks typically include resistive and / or capacitive components configured on the printed circuit board (PCB) of the ECU.

[0004] However, implementing termination and signal conditioning circuits directly on the PCB of the ECU presents several challenges. First, ECUs are highly space-constrained environments where available space on the PCB is at a premium. The addition of termination networks and associated signal processing components consumes valuable board area that could otherwise be allocated to essential processing, memory, or power management components. Second, the design and integration of these components increases the overall complexity of the ECU, adding to design time, cost, and potential points of failure in the system. SUMMARY

[0005] In an embodiment, a plug connector is provided and includes a plug housing having a mating end and a cable end. The mating end is configured to mate with a header connector. The plug housing includes a power contact channel between the mating end and the cable end. The plug housing includes a first module channel and a second module channel between the mating end and the cable end. The plug connector includes a power contact housed in the power contact channel. The power contact is terminated to a power cable. The power contact includes a mating end configured to mate to the header connector. The plug connector includes a data module received in the first module channel. The data module includes a data module housing holding signal contacts that terminate ends of signal wires of a data cable. Each signal contact includes a mating end configured to mate to the header connector. The plug connector includes a common mode end node termination module received in the second module channel. The common mode end node termination module includes a termination module housing having a recess. The common mode end node termination module includes a common mode signal processing assembly received in the recess. The common mode signal processing assembly includes an end node printed circuit board (PCB) having a common mode control circuit. The common mode signal processing assembly includes common mode signal processing components mounted to the end node PCB for processing signals on the common mode control circuit. The plug connector includes a jumper contact held by the plug housing. Each jumper contact includes a signal contact mating interface electrically connected to a respective signal contact and an end node mating interface electrically connected to the common mode end node termination module to electrically connect the signal contact to the common mode control circuit within the plug connector. The plug connector includes a ground jumper contact coupled to an electrical ground component of the plug connector. The ground jumper contact includes a ground contact mating interface electrically connected to the common mode end node termination module to electrically ground the common mode end node termination module. BRIEF DESCRIPTION OF DRAWINGS

[0006] The application will now be described, by way of example, with reference to the accompanying drawings, in which:

[0007] Figure 1 is a perspective view of an electrical connector system according to an example embodiment.

[0008] Figure 2 is a side view of an electrical connector system according to an example embodiment.

[0009] Figure 3 is a cross-sectional view of an electrical connector system according to an example embodiment.

[0010] Figure 4 is a bottom perspective view of a header connector according to an example embodiment.

[0011] Figure 5 is a rear view of a header connector according to an example embodiment.

[0012] Figure 6 is a front view of a header connector according to an example embodiment.

[0013] Figure 7 is a perspective view of a portion of a plug connector showing a pair of power contacts according to an example embodiment.

[0014] Figure 8 is a front perspective view of a plug connector according to an example embodiment.

[0015] Figure 9 is a top view of a plug connector according to an example embodiment.

[0016] Figure 10 is a front view of a plug connector according to an example embodiment.

[0017] Figure 11 is a front view of a plug connector according to an example embodiment.

[0018] Figure 12 is a front view of a plug connector according to an example embodiment.

[0019] Figure 13 is a front view of a plug connector according to an example embodiment.

[0020] Figure 14 is a front view of a plug connector according to an example embodiment.

[0021] Figure 15 is an exploded view of a data module according to an example embodiment.

[0022] Figure 16 is a partially assembled view of a data module according to an example embodiment.

[0023] Figure 17 is an assembled view of a data module according to an example embodiment.

[0024] Figure 18 is a side view of a data module according to an example embodiment.

[0025] Figure 19 is an exploded view of a data module according to an example embodiment.

[0026] Figure 20 is an assembled view of a data module according to an example embodiment.

[0027] Figure 21 is an exploded view of an end node termination module according to an example embodiment.

[0028] Figure 22is a top view of an end termination module housing according to an example embodiment.

[0029] Figure 23 a signal processing assembly according to an example embodiment is shown.

[0030] Figure 24 a signal processing assembly according to an example embodiment is shown.

[0031] Figure 25 a plurality of end node PCBs during manufacturing according to an example embodiment is shown.

[0032] Figure 26 is a perspective view of a signal processing assembly according to an example embodiment showing a jumper contact and a ground jumper contact coupled to the signal processing assembly.

[0033] Figure 27 is a side view of an end node termination module according to an example embodiment.

[0034] Figure 28 is a cross-sectional view of an end node termination module according to an example embodiment.

[0035] Figure 29 is an exploded view of a portion of a plug connector according to an example embodiment.

[0036] Figure 30 is a top view of a position assurance device according to an example embodiment.

[0037] Figure 31 is an end view of a position assurance device according to an example embodiment.

[0038] Figure 32 is a cross-sectional view of a plug connector according to an example embodiment.

[0039] Figure 33 is a perspective view of a portion of a plug connector according to an example embodiment showing internal components of the plug connector.

[0040] Figure 34 is a top view of a portion of a plug connector according to an example embodiment showing internal components of the plug connector.

[0041] Figure 35 is a front view of a portion of a plug connector according to an example embodiment showing internal components of the plug connector.

[0042] Figure 36 is a perspective view of a portion of a plug connector according to an example embodiment showing internal components of the plug connector.

[0043] Figure 37 is a top view of a portion of a plug connector according to an example embodiment, showing internal components of the plug connector.

[0044] Figure 38 is a front view of a portion of a plug connector according to an example embodiment, showing internal components of the plug connector. DETAILED DESCRIPTION

[0045] Figure 1 is a perspective view of an electrical connector system 10 according to an example embodiment. Figure 2 is a side view of an electrical connector system 10 according to an example embodiment. The electrical connector system 10 includes a header connector 100 and a plug connector 200 coupled to the header connector 100. The header connector 100 is coupled to a first electrical component 20 of the electrical connector system 10. The plug connector 200 is coupled to a second electrical component 30 of the electrical connector system 10. The header connector 100 and the plug connector 200 electrically connect the first electrical component 20 and the second electrical component 30.

[0046] In various embodiments, the electrical connector system 10 can be used in automotive applications. For example, the electrical connector system 10 can be used in vehicles, such as electric vehicles. The electrical connector system can form part of a battery system, an engine control unit (ECU), an engine management system, a vehicle infotainment system, a vehicle lighting system, a vehicle heating and cooling system, or other systems within a vehicle. The electrical connector system 10 can be used in other applications besides automotive applications, such as aviation applications, marine applications, military applications, industrial applications, robotics applications, data communication systems, network systems, server systems, building wiring systems, etc. In example embodiments, the electrical connector system 10 is used for data and / or power transmission between the electrical components 20, 30. The electrical connector system 10 can be used for low-speed data transmission and / or high-speed data transmission. In various embodiments, the connectors 100, 200 can form common mode end terminations for the electrical connector system 10. In other various embodiments, the connectors 100, 200 can form differential mode end terminations for the electrical connector system 10.

[0047] In an example embodiment, the plug connector 200 is a cable connector disposed at an end of a cable 202 extending from the plug connector 200 to the second electrical component 30. In an example embodiment, the cable 202 includes one or more power cables 204 and one or more data cables 206. In the illustrated embodiment, the plug connector 200 includes a pair of power cables 204, which represent a positive supply power cable and a negative return power cable. In an example embodiment, the negative power cable can be referenced to ground to provide a ground reference for the plug connector 200. In alternative embodiments, the power cables 204 can include three power cables representing a positive power cable, a negative power cable, and a ground power cable. In other various embodiments, more or fewer power cables 204 can be provided in the plug connector 200. In an example embodiment, the data cables 206 can be a twisted pair of cables having a pair of signal wires twisted along a length of the data cable 206. In an example embodiment, the data cables 206 can be an unshielded twisted pair of cables having a pair of unshielded signal wires. Other types of data cables can be used in alternative embodiments, such as coaxial cables, twinaxial cables, single wire cables, multi-wire cables, etc.

[0048] In an example embodiment, the header connector 100 is mounted to a circuit board 102. The circuit board 102 can be part of the electrical component 20. The electrical component 20 can include one or more electronic devices 22 mounted to the circuit board 102. For example, the electronic devices 22 can be integrated circuits, chips, processors, memory modules, computing devices, network devices, switch devices, data communication devices, or other types of electronic devices. In various embodiments, multiple header connectors 100 can be mounted to the circuit board 102 and electrically connected to the electronic devices 22. The header connector 100 can be mounted to another component, such as a fixture, a panel, a wall, a chassis, or other component of the electrical component 20. In alternative embodiments, the header connector 100 can be a cable connector rather than a board connector, in which the header connector 100 is terminated to an end of a cable.

[0049] Figure 3 is a cross-sectional view of the electrical connector system 10 according to an example embodiment. Figure 3 The plug connector 200 is shown mated with the header connector 100. For example, a portion of the plug connector 200 is plugged into the header connector 100. In an example embodiment, the electrical connector system 10 includes a sealed mating interface between the header connector 100 and the plug connector 200.

[0050] In an example embodiment, the header connector 100 includes a header housing 110 that holds a plurality of header contacts 150. The header housing 110 includes a wall 112 that forms a receptacle 114. The header contacts 150 extend into the receptacle 114. The receptacle 114 receives the plug connector 200. The plug connector 200 mates to the header contacts 150 in the receptacle 114.

[0051] In an example embodiment, the plug connector 200 includes a plug housing 210. In various embodiments, the plug connector 200 includes one or more power contacts 300 held by the plug housing 210, for example held in a power contact channel 212 of the plug housing 210. In various embodiments, the plug connector 200 includes one or more data modules 400 held by the plug housing 210, for example in a module channel 214 of the plug housing 210. In various embodiments, the plug connector 200 includes an end node termination module 500 held by the plug housing 210, for example in the module channel 214 of the plug housing 210. In an example embodiment, the plug connector 200 is modular, allowing the plug connector 200 to be configured by interchangeably receiving various data modules 400 and / or end node termination modules 500. For example, the module channel 214 can be configured to receive different types of data modules 400 and / or different types of end node termination modules 500 therein to vary the configuration of the plug connector 200.

[0052] Figure 4 is a bottom perspective view of a header connector 100 according to an example embodiment. Figure 5 is a rear view of a header connector 100 according to an example embodiment. Figure 6 is a front view of a header connector 100 according to an example embodiment.

[0053] In an example embodiment, the header housing 110 includes a latching element 116 for latchably coupling the plug connector 200 to the header connector 100. In the illustrated embodiment, the latching element 116 is positioned along the top of the header housing 110. Other positions are possible in alternative embodiments. In various embodiments, the latching element 116 is a snap element having a snap surface configured to receive a latch of the plug connector 200. Other types of latching elements can be used in alternative embodiments. For example, the latching element 160 can include a deflectable latch configured to latchably couple to the plug connector 200.

[0054] The header housing 110 extends between a top 120 and a bottom 122. The header housing 110 extends between a front 124 and a back 126. The header housing 110 includes sides 128 between the top 120 and the bottom 122 and / or between the front 124 and the back 126. In an example embodiment, the header housing 110 includes a mating end 130 configured to mate with the plug connector 200. In the illustrated embodiment, the mating end 130 is located at the front 124. In alternative embodiments, other locations are possible. In an example embodiment, the header housing 110 includes a mounting end 132 configured to mount to the circuit board 102 Figure 1 ). In the illustrated embodiment, the mounting end 132 is located at the bottom 122 and / or at the back 126.

[0055] In an example embodiment, the header housing 110 includes end walls 134. The end walls 134 can extend between the sides 128. The end walls 134 can extend between the top 120 and the bottom 122. In an example embodiment, the end walls 134 hold the header contacts 150. For example, the end walls 134 include contact channels 136 that receive the header contacts 150. In an example embodiment, the receptacle 114 is located forward of the end walls 134. The header contacts 150 extend from the end walls 134 into the receptacle 114. The header contacts 150 can extend from the end walls 134 to the mounting end 132 for connection to the circuit board 102.

[0056] In an example embodiment, the header housing 110 includes a shroud 138 extending forward from the end walls 134. The shroud 138 forms a nose cone at the front 124. The shroud 138 surrounds and / or defines the receptacle 114. The shroud 138 surrounds the ends of the header contacts 150 so as to protect the header contacts 150. The shroud 138 can be oval shaped, for example elongated from side to side. In other embodiments, the shroud 138 can be rectangular shaped. In alternative embodiments, the shroud 138 can have other shapes. In an example embodiment, the shroud 138 is configured to be received in the plug connector 200 and is configured to seal to the plug connector 200.

[0057] In example embodiments, the header housing 110 includes a mounting bracket 140 at the mounting end 132. The mounting bracket 140 is configured to mount to the circuit board 102. In example embodiments, the mounting bracket 140 includes one or more mounting legs 142 to support the header housing 110 on the circuit board 102. The mounting legs 142 can extend rearward from the mounting bracket 140 and / or the end wall 134. In example embodiments, the mounting bracket 140 includes one or more mounting posts 144 configured to be received in corresponding openings in the circuit board 102. The mounting posts 144 can extend downward from the mounting legs 142. The mounting posts 144 provide alignment of the header housing 110 with the circuit board 102. The mounting posts 144 can provide mechanical retention for the circuit board 102. For example, the mounting posts 144 can have split beams designed to be configured to be retained in the openings of the circuit board 102 by a spring fit or interference fit. In example embodiments, the mounting bracket 140 can include a mounting flange 146 configured to mount to a panel, wall, or other mounting structure. For example, a front surface or a rear surface of the mounting flange 146 can abut the mounting structure. The mounting flange 146 can extend outward from the end wall 134 and / or the mounting bracket 140. The mounting flange 146 can extend outward from the top 120 and / or the bottom 122 and / or the sides 128. In various embodiments, the mounting flange 146 can extend completely circumferentially around the header housing 110.

[0058] The header contacts 150 are configured to mate with the plug connector 200. The header contacts 150 are configured to connect to the circuit board 102. In example embodiments, the header contacts 150 are stamped contacts. The header contacts 150 can be right angle contacts, for example having a 90° bend. In alternative embodiments, the header contacts 150 can have other shapes. One or more of the header contacts 150 can be power contacts. One or more of the header contacts 150 can be ground contacts. One or more of the header contacts 150 can be signal contacts. Optionally, the signal contacts can be arranged in pairs. The header contacts 150 can be arranged in rows and / or columns within the header housing 110. In the illustrated embodiment, the header contacts 150 are vertically offset in pairs across the header housing 110, for example in three groups of offset.

[0059] In example embodiments, each of the header contacts 150 extends between a mating end 152 and a termination end 154. The header contacts 150 transition between the mating end 152 and the termination end 154. Optionally, the transition can include a bend or a convex-concave portion to account for a contact length skew of the overall length of the header contacts 150.

[0060] The mating end 152 is configured to mate with the header connector 200. In the illustrated embodiment, the mating end 152 includes a mating pin 156. The mating pin 156 can be a square pin or a cylindrical pin. In alternative embodiments, the mating pin 156 can have other shapes. In other various embodiments, the mating end 152 can include different types of interfaces, such as a socket contact, a spring beam, or other types of mating contacts.

[0061] The termination end 154 is configured to terminate to the circuit board 102. In the illustrated embodiment, the termination end 152 includes a solder tail 158 configured to be received in a plated through hole of the circuit board 102. Alternatively, the solder tail 158 can be bent 90° for surface mounting to a pad of the circuit board 102. In other various embodiments, the termination end 154 can include different types of interfaces, such as a compliant pin, a press-fit pin, a pad, a solder ball, a spring beam, or other types of contacts.

[0062] Figure 7 FIG. 17 is a perspective view of a portion of the header connector 200 according to an exemplary embodiment, showing a pair of power contacts 300. The power contacts 300 terminate to the end of the power cable 204. In the illustrated embodiment, the power contacts 300 are crimped to the power cable 204. In alternative embodiments, the power contacts 300 can be soldered or welded to the power cable 204. The power contacts 300 can be arranged in a vertical stack, e.g., on top of each other. One of the power contacts 300 can be a positive contact, and the other of the power contacts 300 can be a negative contact. Optionally, the negative contact can be referenced to ground.

[0063] In the exemplary embodiment, the power contacts 300 are stamped contacts. Each power contact 300 extends between a mating end 310 and a termination end 320. The mating end 310 is configured to mate with a corresponding header contact 150 of the header connector 100. The termination end 320 is configured to terminate to the end of the power cable 204. In the illustrated embodiment, the mating end 310 includes a socket 312. For example, the mating end 310 can include four walls that form the box-shaped socket 312. The mating end 310 includes a mating beam 314 that extends into the socket 312 to electrically connect to the header contact 150. In alternative embodiments, other types of mating interfaces can be provided at the mating end 310, such as a pin, a spring beam, or other types of mating interfaces.

[0064] In the exemplary embodiment, the mating end 310 includes a stop surface 316 configured to engage with a primary latch of the header housing of the header connector 200 to retain the power contact 300 in the header housing. The stop surface 316 can be located at a rear portion of the mating end 310. The stop surface 316 can be rear-facing to prevent the power contact 300 from being pulled out of the header housing.

[0065] In example embodiments, the power contact 300 includes an interface surface 318. The interface surface 318 can be positioned along a side of the mating end 310 of the power contact 300, such as along one of the top, bottom, or side edges. The mating surface 318 can be planar. The mating surface 318 is configured to engage with a jumper contact to provide an electrical connection with another component, such as the end node termination module 500.

[0066] Figure 8 is a front perspective view of a plug connector 200 according to an example embodiment. Figure 9 is a top view of the plug connector 200 according to an example embodiment. Figure 10 is a front view of the plug connector 200 according to an example embodiment. The plug connector 200 includes a plug housing 210, a power contact 300, a data module 400, and an end node termination module 500. In alternative embodiments, other arrangements are possible, such as having multiple data modules 400.

[0067] In example embodiments, the plug housing 210 is a multi-piece housing that includes an outer housing 216 and an inner housing 218 coupled to the housing 216. The outer housing 216 surrounds the inner housing 218, forming a housing well 217 between the inner housing 218 and the outer housing 216. The housing well 217 is configured to receive the shroud 138 of the header housing 110. In example embodiments, a housing seal 219 is positioned in the housing well 217 to engage with the shroud 138 when the plug connector 200 is mated with the header connector 100. The housing seal 219 provides a seal between the plug housing 210 and the header housing 110. The outer housing 216 can surround the shroud 138 of the header housing 110. The inner housing 218 is configured to be inserted into the receptacle 114 of the header housing 110. While the outer housing 216 and the inner housing 218 are separate housing structures that are configured to be coupled together, it should be recognized that in alternative embodiments, the outer housing 216 and the inner housing 218 can be a unitary structure. For example, the outer housing 216 and the inner housing 218 can be co-molded to form a unitary, monolithic, or single-piece housing.

[0068] The plug housing 210 extends between a top 220 and a bottom 222. The plug housing 210 extends between a front 224 and a rear 226. The plug housing 210 includes sides 228 between the top 220 and the bottom 222 and / or between the front 224 and the rear 226. In the example embodiment, the plug housing 210 includes a mating end 230 configured to mate with the header connector 100. In the illustrated embodiment, the mating end 230 is at the front 224. In alternative embodiments, other locations are possible. In the example embodiment, the plug housing 210 includes a cable end 232 at which the cables 202 enter / exit the plug housing 210. In the illustrated embodiment, the cable end 232 is at the rear 226. In alternative embodiments, other locations are possible.

[0069] In the example embodiment, the inner housing 218 includes power contact channels 212 in the module channels 214. The inner housing 218 holds the power contacts 300, the data modules 400, and the end node termination modules 500. The power contact channels 212 and the module channels 214 are open at the mating end 230 (e.g., the front 224) to provide access for mating with the header connector 100. In the example embodiment, the power contact channels 212 and the module channels 214 are open at the rear 226 for loading the power contacts 300 into the power contact channels 212 and loading the data modules 400 and the end node termination modules 500 into the module channels 214. The power cables 204 and the data cables 206 extend from the power contact channels 212 and the module channels 214 at the cable end 232 (e.g., the rear 226).

[0070] In the illustrated embodiment, the plug housing 210 includes a latching element 240 configured to latchably couple to the header connector 100. In the illustrated embodiment, the latching element 240 is located at the top portion 220. In alternative embodiments, other locations are possible. The latching element 240 includes a deflectable latch 242 that is movable between a latched position and an unlatched position. In the illustrated embodiment, the deflectable latch 242 includes an actuator 244 that can be pressed or actuated to move the latch 242 between the latched position and the unlatched position. In the illustrated embodiment, the latching element 240 includes a latch cover 246 that covers the deflectable latch 242. In the illustrated embodiment, the latching element 240 includes a latch lock 248 that is movable from an unlocked position to a locked position. For example, the latch lock 248 can slide along the plug housing 210, such as from front to back or from side to side between the unlocked position and the locked position. When the latch lock 248 is in the locked position, the latch lock 248 prevents movement of the latch 242 (e.g., to the unlatched position). The latch lock 248 can define a position assurance device for ensuring positioning of the latch 242 and / or ensuring proper positioning of the plug connector 200 and the header connector 100 in a mated condition. For example, the latch lock 248 can only move to the locked position when the plug connector 200 is properly mated with the header connector 100.

[0071] In the illustrated embodiment, the data module 400 is located at a central location at the mating end 230 of the plug housing 210. The power contacts 300 are located at a first side of the data module 400, and the end node termination module 500 is located at an opposite second side of the data module 400. In alternative embodiments, other arrangements are possible. In the illustrated embodiment, the end node termination module 500 can be electrically connected to one or more of the data module 400 and / or the power contacts 300. For example, internal contacts or connections can be made between the end node termination module 500 and the data module 400 and / or the power contacts 300 to allow for signal processing within the plug connector 200. For example, the end node termination module 500 can perform common mode signal processing, differential mode signal processing, or other types of signal processing within the plug connector 200. In this way, signal processing need not occur on the circuit board 102 associated with the header connector 100, thereby saving available space on the circuit board 102 and / or reducing the size of the circuit board 102.

[0072] Figure 11is a front view of a plug connector 200 according to an example embodiment. In the illustrated embodiment, the plug connector 200 includes a pair of data modules 400 arranged in respective module channels 214, but does not include an end node termination module 500. In example embodiments, the plug connector 200 is modular in design, allowing the plug connector 200 to be configured by interchanging components to achieve a desired configuration. The same plug housing 210 can be used in various configurations, allowing for savings in design and manufacturing costs of the electrical connector system 10 by using the same components across multiple platforms.

[0073] Figure 12 is a front view of a plug connector 200 according to an example embodiment. In the illustrated embodiment, the plug connector 200 includes a pair of data modules 400 arranged in respective module channels 214, and includes jumper contacts 600 that electrically connect the data modules 400. The jumper contacts 600 are arranged in jumper contact channels 260 of the plug housing 210. The jumper contacts 600 extend into the module channels 214 to engage the data modules 400.

[0074] Figure 13 is a front view of a plug connector 200 according to an example embodiment. In the illustrated embodiment, the plug connector 200 includes data modules 400 and an end node termination module 500 arranged in respective module channels 214. The plug connector 200 includes jumper contacts 600 that electrically connect the data modules 400 with the end node termination module 500. The end node termination module 500 is capable of processing signals from the data modules 400 by connecting to the signals of the data modules 400. In example embodiments, the end node termination module 500 can provide differential mode end node signal processing.

[0075] Figure 14 is a front view of a plug connector 200 according to an example embodiment. In the illustrated embodiment, the plug connector 200 includes data modules 400 and an end node termination module 500 arranged in respective module channels 214. The plug connector 200 includes jumper contacts 600 that electrically connect the data modules 400 with the end node termination module 500. The plug connector 200 includes a ground jumper contact 700 that electrically connects the end node termination module 500 to a ground component of the plug connector 200. In example embodiments, the ground component of the plug connector 200 is one of the power contacts 300 that is connected to a ground reference (e.g., a negative power terminal). The end node termination module 500 is capable of processing signals from the data modules 400 by connecting to the signals of the data modules 400 and the ground reference. In example embodiments, the end node termination module 500 can provide common mode end node signal processing.

[0076] Figure 15 is an exploded view of the data module 400 according to an example embodiment. Figure 16 is a partially assembled view of the data module 400 according to an example embodiment. Figure 17 is an assembled view of the data module 400 according to an example embodiment. Figure 18 is a side view of the data module 400 according to an example embodiment.

[0077] The data module 400 includes a data module housing 410 configured to hold signal contacts 402 and a data cable 206. In the illustrated embodiment, the data cable 206 includes signal wires 404 surrounded by an insulator 406, such as a cable jacket. In an example embodiment, the signal wires 404 are a twisted pair of signal wires. In an example embodiment, the signal wires 404 are an unshielded twisted pair of signal wires. The signal contacts 402 are terminated to the ends of the signal wires 404. For example, the signal contacts 402 can be crimped to the ends of the signal wires 404. In an example embodiment, a portion of the insulator 406 is stripped to expose the ends of the signal wires 404. A length of the signal wires 404 is untwisted from the insulator 406 to be terminated to the signal contacts 402. The untwisted length of the signal wires 404 can be kept relatively short for signal integrity along the signal transmission line.

[0078] In an example embodiment, the signal contacts 402 are stamped and formed contacts. Each signal contact 402 extends between a mating end 470 and a termination end 480. The mating end 470 is configured to mate with a corresponding header contact 150 of the header connector 100. The termination end 480 is configured to be terminated to an end of a corresponding signal wire 404. In an example embodiment, the termination end 480 includes a crimp barrel configured to be crimped to the end of the corresponding signal wire 404. Other types of terminals can be used in alternative embodiments, such as solder, weld, insulation displacement connection, etc. In an example embodiment, one of the signal contacts 402 can form a positive signal transmission line, while the other of the signal contacts 402 can form a negative signal transmission line. The signal contacts 402 can transmit a differential mode signal. In other various embodiments, the signal contacts 402 can transmit a common mode signal.

[0079] In the illustrated embodiment, the mating end 470 includes a socket 472. For example, the mating end 470 can include four walls that form a box-shaped socket 472. The mating end 470 includes one or more mating beams 474 that extend into the socket 472 to electrically connect to the header contacts 150. In the example embodiment, the mating end 470 includes a latch 476 that is configured to latchably couple to the data module housing 410 to retain the signal contacts 402 in the data module housing 410. Alternatively, the mating end 470 can include a stop surface that is configured to engage with a primary latch that extends from the data module housing 410. In alternative embodiments, other types of mating interfaces can be provided at the mating end 470, such as pins, spring beams, or other types of mating interfaces.

[0080] In the example embodiment, the signal contacts 402 include an interface surface 478. The interface surface 478 can be positioned along a side of the mating end 470 of the signal contacts 402, such as along the top, bottom, or one of the side edges. The interface surface 478 can be planar. The interface surface 478 is configured to engage with a corresponding jumper contact 600 (FIG. 6) to provide an electrical connection with another component, such as the end node termination module 500. Figure 12

[0081] The data module housing 410 includes contact channels 412 and associated wire channels 414. The contact channels 412 receive the corresponding signal contacts 402. The wire channels 414 receive the corresponding signal wires 404. The wire channels 414 are separated by a divider wall 416 that separates the signal wires 404 from one another. The divider wall 416 can extend all the way to the insulator 406 to separate the parallel portions of the signal wires 404 in front of the twisted portions of the signal wires 404. The divider wall 416 controls the impedance and other electrical characteristics of the signal transmission lines along the parallel portions of the signal wires 404 as the signal wires 404 transition to the signal contacts 402. The divider wall 416 continues between the contact channels 412 to separate the signal contacts 402 from one another.

[0082] The data module housing 410 extends between a top 420 and a bottom 422. The data module housing 410 extends between a front 424 and a rear 426. The data module housing 410 includes a first side 428 and a second side 430. The front 424 defines a mating end of the data module housing 410 that is configured to mate with the header connector 100. The data cable 206 enters / exists the data module housing 410 at the rear 426.

[0083] ​In example embodiments, the data module housing 410 is a multi-piece housing including a main body 432 and a cover 434 configured to couple to the main body 432 to enclose the contact passages 412 in the wire passage 414 after the signal contacts 402 in the signal wires 404 are loaded into the data module housing 410. In the illustrated embodiment, the cover 434 is at the first side 428. In example embodiments, the cover 434 is integrally formed with the main body 432, such as by a living hinge 436. For example, the cover 434 and the main body 432 can be co-molded during a single injection molding process. The cover 434 can be coupled to the main body 432 by rotating the cover 434 to a closed position. In alternative embodiments, the cover 434 can be manufactured separately from the main body 432 and coupled thereto.

[0084] A securing feature 438 is provided to secure the cover 434 to the main body 432, such as a latch, clip, fastener, or other type of securing feature. In the illustrated embodiment, the securing feature 438 includes latch arms extending from the top and bottom of the cover 434 configured to latchably couple to the top and bottom of the main body 432.

[0085] In example embodiments, the cover 434 includes a groove 440 that receives the distal end of the partition wall 416. The groove 440 and the partition wall 416 can be used to position the cover 434 relative to the main body 432.

[0086] In example embodiments, the cover 434 includes a tab 442 extending from the interior of the cover 434. The tab 442 is configured to engage the signal contacts 402 and / or the signal wires 404 to load the signal contacts 402 or the signal wires 404 into the contact passages 412 or the wire passages 414, respectively. The tab 442 can be used to maintain lateral and / or forward position of the signal contacts 402 and / or the signal wires 404 in the data module housing 410. For example, the tab 442 can prevent the signal contacts 402 from being pulled out of the contact passages 412.

[0087] In example embodiments, the cover 434 includes a retention rib 444 configured to engage the data cable 206. For example, the retention rib 444 can engage the insulator 406 (e.g., cable jacket) when the cover 434 is coupled to the main body 432. The retention rib 444 can slightly gouge into the material of the insulator 406 to lock the insulator 406 in the data module housing 410, such as to provide strain relief and / or to prevent the data cable 206 from being pulled out of the data module housing 410. The retention rib 444 is sized / shaped for retention, but is designed not to damage the wire. The data module 400 can be used with a jacketed cable, in which case the retention rib 444 can engage the conductor, or the retention rib 444 can not be used for wire retention.

[0088] In example embodiments, the main body 432 includes a cable recess 446 at the rear portion 426. The cable recess 446 receives an end of the data cable 206. The cable recess 446 can receive the insulator 406. In example embodiments, the main body 432 includes one or more retention ribs 448 that extend into the cable recess 446. The retention ribs 448 are configured to engage with the data cable 206. For example, the retention ribs 448 can engage with the insulator 406 (e.g., cable jacket) when the cover 434 is coupled to the main body 432. The retention ribs 448 can slightly dig into the material of the insulator 406 to lock the insulator 406 in the data module housing 410, such as to provide strain relief and / or to prevent the data cable 206 from being pulled out of the data module housing 410. The retention ribs 448 are sized / shaped to retain, but not damage, the wire.

[0089] In example embodiments, the data module housing 410 includes an access window 450. The access window 450 provides access to the contact channel 412. The access window 450 provides the jumper contact 600 access to the receptacle contact 402 in the contact channel 412. In the illustrated embodiment, the access window 450 is located at or near the front portion 424 to allow access to the signal contact 402. In the illustrated embodiment, the access window 450 is located at the top portion 420 and the bottom portion 422 to access two signal contacts 402 at the top and bottom of the data module housing 410. In alternative embodiments, the access window 450 can be provided at other locations.

[0090] In example embodiments, the data module housing 410 includes a latch opening 452 that receives the latch 476 of the signal contact 402. In the illustrated embodiment, the latch opening 452 is provided at the first side 428. In alternative embodiments, other locations are also possible. When the signal contact 402 is loaded into the data module housing 410, the latch 476 can snap into the latch opening 452 to secure the signal contact 402 in the contact channel 412. The latch 476 can prevent the signal contact 402 from being pulled out of the contact channel 412.

[0091] In example embodiments, the data module housing 410 includes a locking slot 454 that is configured to receive a locking element for securing the data module 400 in the plug housing 210. In the illustrated embodiment, the locking slot 454 is a recess formed in one of the sides of the data module housing 410. For example, the locking slot 454 can be formed in the cover 434. The locking slot 454 can be positioned along the first side 428. In alternative embodiments, other locations are also possible. The locking slot 454 can be open at the top portion 420 and / or the bottom portion 422 to receive the locking element.

[0092] Figure 19is an exploded view of the data module 400 according to an example embodiment. Figure 20 is an assembled view of the data module 400 according to an example embodiment. Figure 19 and Figure 20 The data module housing 410 is shown as a two-piece housing, with the cover 434 separate and discrete from the main body 432. The cover 434 is configured to be coupled to the side of the main body 432 after the signal contacts 402 and signal wires 404 are loaded into the data module housing 410.

[0093] Figure 21 is an exploded view of the end node termination module 500 according to an example embodiment. The end node termination module 500 includes a termination module housing 510 and a signal processing assembly 550 held by the termination module housing 510. In an example embodiment, the signal processing assembly 550 includes an end node printed circuit board (PCB) 552 having one or more end node control circuits 554 with one or more signal processing components 556 for controlling the end node control circuits 554.

[0094] Reference is additionally made to Figure 22 , Figure 22 is a top view of the termination module housing 510, which includes a main body 512 having a recess 514 that houses the signal processing assembly 550. For example, the end node PCB 552 and corresponding signal processing components 556 are configured to be received in the recess 514. In an example embodiment, the termination module housing 510 includes a handle 516 extending from the main body 512. The handle 516 is used to load and unload the end node termination module 500 into and from the plug housing 210. The handle 516 is inserted into a cable hole of a passageway for the plug housing 210 in order to provide a seal for the passageway.

[0095] In an example embodiment, the termination module housing 510 is similar in size to the data module housing 410 ( Figure 15 ) to allow the end node termination module 500 and the data module 400 to be interchangeably loaded into the module passageways 214 of the plug housing 210. The termination module housing 510 can include similar features as the data module housing 410, such as positioning features, securing features, etc., for positioning and securing the end node termination module 500 and the data module 400 in the module passageways 214 of the plug housing 210.

[0096] The termination module housing 510 extends between a top 520 and a bottom 522. The termination module housing 510 extends between a front 524 and a rear 526. The termination module housing 510 includes a first side 528 and a second side 530. The front 524 defines a connection end of the termination module housing 510 that is configured for connection to the jumper contacts 600 and / or the ground jumper contacts 700. The handle 516 is located at the rear 526.

[0097] In example embodiments, the termination module housing 510 includes a loading opening 532 at the first side 528. The signal processing assembly 550 is configured to be loaded into the recess 514 through the loading opening 532. The loading opening 532 is open at the first side 528. In alternative embodiments, other locations are also possible.

[0098] In example embodiments, the termination module housing 510 includes one or more securing features 534 for securing the signal processing assembly 550 in the recess 514. In example embodiments, the securing features 534 include a post 536 located in the recess 514. The end node PCB 552 can be coupled to the post 536. The post 536 can position the end node PCB 552 fore and / or laterally. In the illustrated embodiment, the post 536 is located near the rear of the recess 514. In alternative embodiments, other locations are also possible. The post 536 can provide mechanical retention to the end node PCB 552. For example, the post 536 can have a split beam designed to be configured to be retained in an opening of the end node PCB 552 by a spring or interference fit. In example embodiments, the securing features 534 include a capture wall 538 configured to capture an end of the end node PCB 552. The capture wall 538 can be located near the front 524. During assembly, the front end of the end node PCB 552 can be loaded into the recess 514 behind the capture wall 538 to capture the front end of the end node PCB 552 while the rear end of the end node PCB 552 is coupled to the post 536. In this way, the front and rear of the end node PCB 552 are retained in the recess 514 by the securing features 534. Other types of securing features can be used in alternative embodiments.

[0099] In example embodiments, the termination module housing 410 includes an access window 540. The access window 540 provides access to the signal processing assembly 550 in the recess 514. The access window 540 provides the jumper contact 600 access to a portion of the end node PCB 552 in the recess 514. In the illustrated embodiment, the access window 540 is located at or near the front 424. In the illustrated embodiment, the access window 540 is located at the top 420 and the bottom 422 to access the top and bottom edges of the end node PCB 552 at the top and bottom of the termination module housing 410. In alternative embodiments, the access window 540 can be provided at other locations.

[0100] In example embodiments, the termination module housing 410 includes one or more ground access windows 542. The ground access windows 542 provide access to the signal processing assembly 550 in the recess 514. The ground access windows 542 provide the ground jumper contact 700 access to a portion of the end node PCB 552 in the recess 514. In the illustrated embodiment, the ground access window 542 is located at the top 420. In alternative embodiments, the ground access window 542 can be provided at other locations.

[0101] In example embodiments, the termination module housing 510 includes a locking slot 544 configured to receive a locking element for securing the termination module 500 in the plug housing 210. In the illustrated embodiment, the locking slot 544 is a recess formed in one of the sides of the termination module housing 510. For example, the locking slot 544 can be positioned along the first side 528. Other locations are possible in alternative embodiments. The locking slot 544 can be open at the top 520 and / or the bottom 522 to receive the locking element.

[0102] Figure 23 A signal processing assembly 550 according to an example embodiment is shown. The signal processing assembly 550 includes an end node PCB 552, an end node control circuit 554, and a signal processing component 556.

[0103] The end node PCB 552 includes a substrate having surfaces 560 at opposite sides of the substrate. The end node PCB 552 can be manufactured by conventional circuit board manufacturing processes. The end node PCB 552 includes circuitry printed on one or more layers of the substrate, such as at the outer surfaces 560. The circuitry can be traces, pads, vias, or other conductive elements that form a circuit pattern on one or more layers of the substrate. The end node PCB 552 includes a front edge 562, a back edge 564, a first edge 566 (e.g., a top edge) between the front edge 562 and the back edge 564, and a second edge 568 (e.g., a bottom edge) between the front edge 562 and the back edge 564. In example embodiments, the signal processing components 556 are mounted to corresponding circuitry at the surfaces 560 of the end node PCB 552 to form the end node control circuitry 554.

[0104] In example embodiments, the end node PCB 552 includes a first signal edge pad 570 at the first edge 566 and a second signal edge pad 572 at the second edge 568. In example embodiments, the end node PCB 552 includes a ground edge pad 574 along the first edge 566 or the second edge 568. Additional signal edge pads and / or ground edge pads can be provided along the first edge 566 and / or the second edge 568. The first signal edge pad 570 can be a positive signal conductor configured to be electrically connected to a positive signal transmission line of the data module 400. The second signal edge pad 572 can be a negative signal conductor configured to be electrically connected to a negative signal transmission line of the data module 400.

[0105] In example embodiments, the end node PCB 552 includes a recess 576 along the first edge 566 and the second edge 568. The signal edge pads 570, 572 and / or the ground edge pad 574 can be located in the recess 576 such that the edge pads are recessed relative to the edges 566, 568. The recess 576 can be formed in the end node PCB 552 to form a space for electroplating the edges 566, 568 to form the edge pads 570, 572, 574.

[0106] In example embodiments, the signal edge pads 570, 572 can span one or more layers of the end node PCB 552. For example, the signal edge pads 570, 572 can span a width of the first edge 566 or the second edge 568 between the opposing surfaces 560 of the end node PCB 552, respectively. A portion of the first signal edge pad 570 can transition to the surface 560 and connect to one or more traces on the surface 560. A portion of the second signal edge pad 572 can transition to the surface 560 and connect to one or more traces on the surface 560. In example embodiments, the ground edge pad 574 can span one or more layers of the end node PCB 552. For example, the ground edge pad 574 can span a width of the first edge 566 or the second edge 568 between the opposing surfaces 560 of the end node PCB 552. A portion of the ground edge pad 574 can transition to the surface 560 and connect to one or more traces on the surface 560.

[0107] The first and second signal edge pads 570, 572 are configured to be electrically connected to respective signal processing components 556, such as through traces or other conductive circuitry of the end node PCB 552. The signal processing components 556 perform signal processing on signals transmitted to / from the jumper contacts 600 via the signal edge pads 570, 572. The signal processing components 556 perform signal processing for the signal processing assembly 550. The signal processing components 556 can include transistors, resistors, capacitors, diodes, integrated circuits, operational amplifiers, filters, microprocessors, microcontrollers, oscillators, switches, transformers, relays, or other types of electrical components for performing signal processing. The signal processing components 556 can be active components and / or passive components. The signal processing components 556 can be electrically connected to the first signal edge pad 570, the second signal edge pad 572, or both the first and second signal edge pads 570, 572. The signal processing components 556 can additionally or alternatively be connected to the ground edge pad 574.

[0108] In example embodiments, the end node PCB 552 includes openings 580. The openings 580 can function as positioning and / or securing features for positioning the end node PCB 552 in the termination module housing 510. For example, the openings 580 can receive the posts 536 to position the end node PCB 552 in the recess 514 of the termination module housing 510. In the illustrated embodiment, the openings 580 are located near the rear of the end node PCB 552. Other locations are possible in alternative embodiments. The openings 580 pass through the end node PCB 552 between the surfaces 560.

[0109] Figure 24 A signal processing assembly 550 according to an example embodiment is shown.Figure 24 An embodiment is shown in which the signal processing components 556 on the end node PCB 552 are arranged differently than in the embodiment shown in FIG. 6. Figure 23 An embodiment is shown in which the signal processing components 556 on the end node PCB 552 are arranged differently than in the embodiment shown in FIG. 6. Figure 24 The arrangement of signal processing components 556 in the embodiment of FIG. 6 performs different types of signal processing than the arrangement of signal processing components 556 in the embodiment of FIG. 7. Figure 23 The arrangement of signal processing components 556 in the embodiment of FIG. 6 performs different types of signal processing than the arrangement of signal processing components 556 in the embodiment of FIG. 7. For example, Figure 24 are used for differential mode signal processing, while Figure 23 are used for common mode signal processing. In the example embodiment, the same end node PCB 552 is utilized in both arrangements, allowing a single end node PCB 552 to be manufactured for different applications. Other arrangements of signal processing components 556 can be used in alternative embodiments for other types of signal processing.

[0110] Figure 25 An embodiment is shown in which the signal processing components 556 on the end node PCB 552 are arranged differently than in the embodiment shown in FIG. 6.

[0111] Figure 26 is a perspective view of a signal processing assembly 550 according to an example embodiment, showing a jumper contact 600 and a ground jumper contact 700 coupled to the signal processing assembly 550. The signal processing assembly 550 includes an end node PCB 552, an end node control circuit 554, and signal processing components 556 mounted to the end node PCB 552. While the signal processing components 556 are shown mounted to one of the surfaces 560, in alternative embodiments the signal processing components 556 can be mounted to both surfaces 560 at opposite sides of the end node PCB 552. Signal edge pads 570, 572 and ground edge pads 574 are shown at first and second edges 566, 568 (e.g., between the opposing surfaces 560 of the end node PCB 552).

[0112] The jumper contact 600 includes an end node spring beam 610 having an end node mating interface 612 electrically connected to a corresponding signal edge pad 570, 572. The end node spring beam 610 is deflectable and has a separable mating interface. The end node spring beam 610 is configured to mate with the signal edge pad 570, 572 when the end node termination module 500 is inserted into the plug housing 210 of the plug connector 200.

[0113] The ground jumper contact 700 includes an end node spring beam 710 having an end node mating interface 712 electrically connected to a corresponding ground edge pad 574. The end node spring beam 610 is deflectable and has a separable mating interface. The end node spring beam 710 is configured to mate with the ground edge pad 574 when the end node termination module 500 is inserted into the plug housing 210 of the plug connector 200.

[0114] Figure 27 is a side view of an end node termination module 500 according to an example embodiment. Figure 28 is a cross-sectional view of an end node termination module 500 according to an example embodiment. Figure 27 and 28 shows the signal processing assembly 550 in the recess 514 of the termination module housing 510.

[0115] When assembled, the end node PCB 552 is coupled to the securing feature 534 of the termination module housing 510. For example, the post 536 is received in the opening 580. The post 536 aligns the end node PCB 552 in the recess 514. In an example embodiment, the distal end of the post 536 includes a capture feature that captures and retains the end node PCB 552 in the recess 514. The capture wall 538 captures the front end of the end node PCB 552 in the recess 514. For example, when the front end of the end node PCB 552 is behind the capture wall 538, the end node PCB 552 cannot be removed through the load opening 532. In an example embodiment, the end node PCB 552 and the signal processing component 556 are fully contained within the footprint of the termination module housing 510. When assembled, the end node PCB 552 is positioned within the recess 514 such that the signal edge pads 570, 572 are aligned with corresponding access windows 540 and the ground edge pads 574 are aligned with corresponding ground access openings 542. The access windows 540, 542 provide access to the edge pads 570, 572, 574.

[0116] Figure 29 is an exploded view of a portion of the plug connector 200 according to an example embodiment. Figure 29 shows the inner housing 218 holding the power contacts 300, the data module 400, and the end node termination module 500. Note that the outer housing 216 (shown in Figure 8 ) is removed to show portions of the inner housing 218. Figure 29A position assurance device 800 is also shown for ensuring that the power contacts 300, data modules 400, and end node termination modules 500 are positioned within the plug housing 210. In example embodiments, the position assurance device 800 is configured to retain the ground jumper contact 700. The position assurance device 800 can additionally or alternatively retain the jumper contact 600.

[0117] In example embodiments, the plug housing 210 includes a position assurance device recess 250 that receives the position assurance device 800. The position assurance device recess 250 can be open at the top 220 to receive the position assurance device 800, for example, in a downward mating direction. The position assurance device recess 250 can additionally or alternatively be open at one or both of the sides 228 to receive the position assurance device 800. In example embodiments, the power contact channels 212 and the module channels 214 access the position assurance device recess 250. In this way, the position assurance device 800 is configured to engage with the power contacts 300 and the power contact channels 212, and with the data modules 400 and the end node termination modules 500 in the corresponding module channels 214.

[0118] During assembly, the power contacts 300 are loaded into the power contact channels 212 through the back 226 of the plug housing 210. The plug housing 210 can include latches or other securing features to retain the power contacts 300 in the plug housing 210. The plug housing 210 can include positioning features, such as stop walls, to position the power contacts 300 in the power contact channels 212, for example, to limit forward loading of the power contacts 300 into the power contact channels 212. The position assurance device 800 is configured to couple to the plug housing 210 to ensure that the power contacts 300 are properly loaded into the plug housing 210. For example, if the power contacts 300 are not fully loaded into the power contact channels 212, the position assurance device 800 can not mate with the plug housing 210. In various embodiments, the position assurance device 800 is configured to engage with latches that retain the power contacts 300 in the power contact channels 212 to prevent the latches from unlocking and / or to prevent the latches from flexing or breaking when the power cable 204 is pulled rearward.

[0119] During assembly, the data module 400 is loaded into the module channel 214 through the rear 226 of the plug housing 210. The plug housing 210 can include latches or other securing features to retain the data module 400 in the plug housing 210. The plug housing 210 can include positioning features, such as a stop wall, to position the data module 400 and the module channel 214, for example, to limit loading of the data module 400 forward into the module channel 214. The position assurance device 800 is configured to couple to the plug housing 210 to ensure that the data module 400 is properly loaded into the plug housing 210. For example, if the data module 400 is not fully loaded into the module channel 214, the position assurance device 800 can not mate with the plug housing 210. In various embodiments, the position assurance device 800 is configured to directly engage with the data module 400 to retain the data module 400 in the module channel 214.

[0120] During assembly, the end node termination module 500 is loaded into the module channel 214 through the rear 226 of the plug housing 210. The plug housing 210 can include latches or other securing features to retain the end node termination module 500 in the plug housing 210. The plug housing 210 can include positioning features, such as a stop wall, to position the end node termination module 500 and the module channel 214, for example, to limit loading of the end node termination module 500 forward into the module channel 214. The position assurance device 800 is configured to couple to the plug housing 210 to ensure that the end node termination module 500 is properly loaded into the plug housing 210. For example, if the end node termination module 500 is not fully loaded into the module channel 214, the position assurance device 800 can not mate with the plug housing 210. In various embodiments, the position assurance device 800 is configured to directly engage with the end node termination module 500 to retain the end node termination module 500 in the module channel 214.

[0121] Further reference is made to Figure 30 and Figure 31 , Figure 30 is a top view of the position assurance device 800, Figure 31is an end view of a position assurance device 800 that retains the ground jumper contact 700. In the example embodiment, the position assurance device 800 includes a body 810 having an end wall 812, a first side wall 814 extending from a first side of the end wall 812, and a second side wall 816 extending from a second side of the end wall 812. The end wall 812 is configured to be coupled to the top portion 220 of the plug housing 210. The side walls 814, 816 are configured to be coupled to the side portions 228 of the plug housing 210. In the example embodiment, the side walls 814, 816 include latching elements 818 that are configured to be latchably coupled to the side portions 228 of the plug housing 210 to secure the position assurance device 800 to the plug housing 210. In alternative embodiments, other types of securing features can be used.

[0122] In the example embodiment, the position assurance device 800 includes a main latching lock 820 extending from the end wall 812. The main latching lock 820 is configured to engage with a latch of the plug housing 210 that secures the power contact 300 in the power contact channel 212. Optionally, multiple main latching locks 820 can be provided, for example for engaging with different latches for securing different power contacts 300. In the illustrated embodiment, the main latching lock 820 is a beam or post extending downward from an inner surface of the end wall 812. The main latching lock 820 can be rectangular in shape. The distal end of the main latching lock 820 can be chamfered to guide assembly. However, in alternative embodiments, the main latching lock 820 can have other shapes.

[0123] In the example embodiment, the position assurance device 800 includes a data module lock 830 extending from the end wall 812. The data module lock 830 is configured to engage with the data module 400 to secure the data module 400 in the module channel 214. For example, the data module lock 830 can be sized and shaped to fit in a locking groove 454 of the data module housing 410 to secure the data module 400 in the module channel 214. In the illustrated embodiment, the data module lock 830 is a beam or post extending downward from an inner surface of the end wall 812. The data module lock 830 can be rectangular in shape. The distal end of the data module lock 830 can be chamfered to guide assembly. However, in alternative embodiments, the data module lock 830 can have other shapes.

[0124] In the illustrated embodiment, the position assurance device 800 includes an end node termination module lock 840 extending from the end wall 812. The end node termination module lock 840 is configured to engage with the end node termination module 500 to secure the end node termination module 500 in the module channel 214. For example, the end node termination module lock 840 can be sized and shaped to fit in the lock groove 544 of the termination module housing 510 to secure the end node termination module 500 in the module channel 214. In the illustrated embodiment, the end node termination module lock 840 is a beam or post extending downward from an inner surface of the end wall 812. The end node termination module lock 840 can be rectangular in shape. The distal end of the end node termination module lock 840 can be chamfered to guide assembly. However, in alternative embodiments, the end node termination module lock 840 can have other shapes. The end node termination module lock 840 can lock other components in the housing, such as a data module when disposed in a two position data module arrangement.

[0125] In the illustrated embodiment, the position assurance device 800 includes a ground jumper contact channel 850 that receives the ground jumper contact 700. The ground jumper contact channel 850 can be open at the front of the position assurance device 800 to receive the ground jumper contact 700. The position assurance device 800 holds and positions the ground jumper contact 700 to mate with the electrical ground components of the end node termination module 500 and the plug connector 200. In the illustrated embodiment, the negative power contact 300 is connected to a reference ground and defines a ground component of the plug connector 200. The ground jumper contact 700 is configured to mate with the negative power contact 300.

[0126] In an example embodiment, the ground jumper contact 700 is a stamped and formed contact. The ground jumper contact 700 includes a connecting beam 720 extending between an end node spring beam 710 and a ground connection spring beam 730. The end node spring beam 710 includes an end node mating interface 712. The ground connection spring beam 730 includes a ground connection mating interface 732. The spring beams 710, 730 are deflectable spring beams. The spring beams 710, 730 can extend downward from the connecting beam 720 to engage with the end node termination module 500 and the power contact 300. When mated to the end node termination module 500 and the power contact 300, the spring beams 710, 730 can deflect upward. In the illustrated embodiment, the spring beams 710, 730 extend in different directions. For example, the end node spring beam 710 extends rearward from the connecting beam 720, while the ground connection spring beam 730 extends forward from the connecting beam 720. However, in alternative embodiments, the spring beams 710, 730 can be oriented differently, such as extending in the same direction. The spring beams 710, 730 can have different lengths such that the mating interfaces 712, 732 are at different vertical heights for mating with the end node termination module 500 and the power contact 300.

[0127] In an example embodiment, the ground jumper contact 700 includes a mating tab 740 for mating the ground jumper contact 700 to the position assurance device 800. In the illustrated embodiment, the mating tab 740 extends from the connecting beam 720, such as rearward from the connecting beam 720. The mating tab 740 includes a barb 742 along a side edge of the mating tab 740. The barb 742 is configured to dig into the plastic material of the position assurance device 800 to secure the ground jumper contact 700 in the ground jumper contact channel 850. Other types of mating features can be used in alternative embodiments to secure the ground jumper contact 700 to the position assurance device 800.

[0128] Figure 32 is a cross-sectional view of the plug connector 200 according to an example embodiment. Figure 32 The position assurance device 800 is shown coupled to the plug housing 210. Figure 32 The position assurance device 800 is shown connected with the power contact 300, the data module 400, and the end node termination module 500. When assembled, the position assurance device 800 is coupled to the plug housing 210. For example, the latch elements 818 at the side walls 814, 816 are configured to couple to the latch features along the side faces 228 of the plug housing 210. Optionally, the latch features along the side faces 228 can have stepped latch positions to allow the position assurance device 800 to be positioned in different stepped positions, such as an initial coupling position and a final coupling position.

[0129] When assembled, the main latch lock 820 is configured to engage with the main latch 213 of the plug housing 210, which secures the power contacts 300 in the power contact channel 212. The main latch lock 820 supports or holds the main latch 213 in the latched position to prevent un-latching and damage to the main latch 213. When assembled, the data module lock 830 is configured to engage with the data module 400 to secure the data module 400 in the module channel 214. For example, the data module lock 830 fits in the locking groove 454 of the data module housing 410 to secure the data module 400 in the module channel 214. When assembled, the end node termination module lock 840 is configured to engage with the end node termination module 500 to secure the end node termination module 500 in the module channel 214. For example, the end node termination module lock 840 fits in the locking groove 544 of the termination module housing 510 to secure the end node termination module 500 in the module channel 214.

[0130] Figure 33 is a perspective view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figure 34 is a top view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figure 35 is a front view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figures 33-35 shows an embodiment of the plug connector 200 operating in a common mode end node configuration. In Figures 33-35 the plug housing 210, the data module housing 410, and the termination module housing 510 are removed to show the power contacts 300, the signal contacts 402, the signal processing assembly 550, the jumper contacts 600, and the ground jumper contacts 700.

[0131] In the common mode end node configuration, the jumper contacts 600 are connected between the signal contacts 402 and the signal processing assembly 550, and the ground jumper contacts 700 are connected between the ground reference power contacts 300 and the signal processing assembly 550. The signal processing components 556 perform signal processing on the signal processing assembly 550 within the plug connector 200, without the need for separate signal processing at the header connector 100 or the circuit board 102 associated with the header connector 100.

[0132] The ground jumper contact 700 is a stamped and formed contact. The jumper contact 700 includes a connecting beam 720 extending between an end node spring beam 710 and a ground connection spring beam 730. The end node spring beam 710 includes an end node mating interface 712. The ground connection spring beam 730 includes a ground connection mating interface 732. The spring beams 710, 730 are deflectable spring beams. The spring beams 710, 730 extend from the connecting beam 720 to engage respective ground edge pads 574 of the end node PCB 552 and the power contact 300, respectively. In an example embodiment, the ground connection spring beam 730 is configured to directly engage the interface surface 478 of the power contact 300. The spring beams 710, 730 can deflect when mated with the signal processing assembly 550 and the power contact 300. The ground jumper contact 700 includes a mating tab 740 having a barb 742 along a side edge of the mating tab 740.

[0133] In an example embodiment, each jumper contact 600 is a stamped and formed contact. The jumper contact 600 includes a connecting beam 620 extending between an end node spring beam 610 and a signal contact spring beam 630. The end node spring beam 610 includes an end node mating interface 612. The signal contact spring beam 630 includes a signal contact mating interface 632. The spring beams 610, 630 are deflectable spring beams. The spring beams 610, 630 extend from the connecting beam 620 to engage respective signal edge pads 570, 572 of the end node PCB 552 and the signal contact 402, respectively. In an example embodiment, the signal contact spring beam 630 is configured to directly engage the interface surface 468 at the mating end 470 of the receptacle contact 402. The spring beams 610, 630 can deflect when mated with the signal processing assembly 550 and the signal contact 402.

[0134] In an example embodiment, the jumper contact 600 includes a mating tab 640 for mating the jumper contact 600 to the plug housing 210. In the illustrated embodiment, the mating tab 640 extends from the connecting beam 620, for example, rearward from the connecting beam 620. The mating tab 640 includes a barb 642 along a side edge of the mating tab 640. The barb 642 is configured to dig into the plastic material of the plug housing 210 to secure the jumper contact 600 in the jumper contact channel of the plug housing 210. Other types of mating features can be used in alternative embodiments to secure the jumper contact 600 to the plug housing 210 or other components, such as the position assurance device 800.

[0135] Figure 36 is a perspective view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figure 37is a top view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figure 38 is a front view of a portion of the plug connector 200 according to an example embodiment, showing internal components of the plug connector 200. Figures 36-38 An embodiment of the plug connector 200 is shown operating in a differential end node configuration. In the differential end node configuration, the plug connector 200 is configured to provide differential signals to the header connector 100. Figures 36-38 The plug housing 210, the data module housing 410, and the termination module housing 510 are removed in to show the power contacts 300, the signal contacts 402, the signal processing assembly 550, and the jumper contacts 600. The ground jumper contacts 700 are not necessary for the differential end node configuration. For example, in the differential end node configuration, the end node PCB 552 does not need to be grounded.

[0136] In the differential end node configuration, the jumper contacts 600 are connected between the signal contacts 402 and the signal processing assembly 550. The signal processing components 556 perform signal processing on the signal processing assembly 550 within the plug connector 200, without the need for separate signal processing at the header connector 100 or the circuit board 102 associated with the header connector 100.

[0137] CROSS-REFERENCE TO RELATED APPLICATIONS

[0138] This application claims the benefit of U.S. Application No. 63 / 704,605, filed October 8, 2024, U.S. Application No. 63 / 704,608, filed October 8, 2024, U.S. Application No. 63 / 704,623, filed October 8, 2024, U.S. Application No. 63 / 704,641, filed October 8, 2024, U.S. Application No. 63 / 704,634, filed October 8, 2024, U.S. Application No. 63 / 704,646, filed October 8, 2024, and U.S. Application No. 63 / 706,100, filed October 17, 2024, the subject matter of which is incorporated by reference herein in its entirety.

Claims

1. A plug connector (200) comprising: a plug housing (210) having a mating end (230) configured to mate with a header connector (100) and a cable end (232), the plug housing including a power contact passage (212) between the mating end and the cable end, the plug housing including a first module passage (214) between the mating end and the cable end, the plug housing including a second module passage between the mating end and the cable end; a power contact (300) received in the power contact passage, the power contact terminated to a power cable (204), the power contact including a mating end configured to mate to the plug connector; a data module (400) received in the first module passage, the data module including a data module housing (410) holding signal contacts (402), the signal contacts (402) terminated to ends of signal wires (404) of a data cable (206), each signal contact including a mating end configured to mate with the plug connector; an end node termination module (500) received in the second module passage, the end node termination module including a termination module housing (510) having a recess (514), the end node termination module including an end node printed circuit board (PCB) (552) received in the recess, the end node PCB including an end node control circuit (554) having end node control components (556) mounted to the end node PCB to control the end node control circuit; jumper contacts (600) held by the plug housing, each jumper contact including a signal contact mating interface (632) electrically connected to a corresponding signal contact and an end node mating interface (712) electrically connected to the end node termination module to electrically connect the signal contact to the end node control circuit within the plug connector.

2. The plug connector (200) of claim 1, wherein, the first module passage (214) and the second module passage are identical such that the data module (400) and the end node termination module (500) are interchangeably receivable in the first module passage and the second module passage.

3. The plug connector (200) of claim 1, wherein, the data module (400) is a first data module, the plug connector further including a second data module received in a third module passage (214) of the plug housing (210).

4. The plug connector (200) of claim 1, wherein, the end node control components (556) are one of common node end node control components or differential node end node control components.

5. The plug connector (200) of claim 1, wherein the plug housing (210) includes a jumper contact passage (260) extending between the first module passage (214) and the second module passage, the jumper contact passage receiving the jumper contacts (600).

6. The plug connector (200) of claim 1, wherein the end node PCB (552) includes a first surface and a second surface, the end node PCB including a first edge and a second edge between the first surface and the second surface, the end node control component (556) mounted to the first surface, the end node PCB including a first signal edge pad (570) along the first edge and a second signal edge pad (572) along the second edge, the first signal edge pad and the second signal edge pad coupled to the end node control circuit (554), the jumper contact (600) coupled to the first signal edge pad and the second signal edge pad.

7. The plug connector (200) of claim 6, wherein the end node control component (556) is coupled to the end node control circuit (554) between the first signal edge pad (570) and the second signal edge pad (572).

8. The plug connector (200) of claim 6, wherein the end node PCB (552) includes a ground edge pad (574) along the first edge, the plug connector further comprising a ground jumper contact (700) configured to be coupled to an electrical ground component of the plug connector, the ground jumper contact coupled to the ground edge pad.

9. The plug connector (200) of claim 8, wherein the ground jumper contact (700) is coupled to the power contact (300), the power contact connected to a ground return path and defining the electrical ground component of the plug connector.

10. The plug connector (200) of claim 1, wherein, the end node PCB (552) and the end node control component (556) housed within a recess (514) of the termination module housing (510).

11. The plug connector (200) of claim 1, wherein, the termination module housing (510) includes an access window (450) through which the jumper contact (600) passes to electrically connect with the end node PCB (552).

12. The plug connector (200) of claim 1, wherein, the termination module housing (510) includes a loading opening (532) on a side of the termination module housing through which the end node PCB (552) is loaded into the recess (514).

13. The plug connector (200) of claim 12, wherein, the termination module housing (510) includes a securing mechanism to retain the end node PCB (552) in the recess (514).

14. The plug connector (200) of claim 1, further comprising a ground jumper contact (700) coupled to an electrical ground component of the plug connector, the ground jumper contact (850) including a ground contact mating interface (732) electrically connected to the end node termination module (500) to electrically ground the end node termination module.

15. The plug connector (200) of claim 1, further comprising a position assurance device (800) coupled to the plug housing (210), the position assurance device engaging the data module (400) to ensure the data module is positioned in the first module channel (214) and to retain the data module in the plug housing, the position assurance device engaging the end node termination module (500) to ensure the end node termination module is positioned in the second module channel and to retain the end node termination module in the plug housing.

16. The plug connector (200) of claim 15, wherein, the data module housing (410) includes a recess (576), the position assurance device (800) includes a first positioning tab configured to be received in the recess of the data module housing, the termination module housing (510) includes a recess, the position assurance device includes a second positioning tab configured to be received in the recess of the termination module housing.

17. The plug connector (200) of claim 1, wherein the jumper contact (600) includes a signal contact mating beam (630) and an end node mating beam, the signal contact mating beam (630) includes the signal contact mating interface (632), the end node mating beam includes the end node mating interface (612), the jumper contact includes a connecting beam between the signal contact mating beam and the end node mating beam, the signal contact mating beam and the end node mating beam are deflectable relative to the connecting beam.

18. An end node termination module (500) for a plug connector (200), comprising: a termination module housing (510) including a main body (512) having a recess (514), the main body including an access window (450) to the recess; and an end node printed circuit board (PCB) (552) received in the recess, the end node PCB including an end node control circuit (554) having end node control components (556) mounted to the end node PCB to control the end node control circuit; wherein the end node PCB is configured to be electrically connected to at least one of a power contact (300) of the plug connector and a signal contact (402) of the plug connector by at least one jumper contact (600) of the plug connector through the access window (450).

19. The end node termination module (500) of claim 18, wherein the end node PCB (552) includes a first surface and a second surface, the end node PCB including a first edge and a second edge between the first surface and the second surface, the end node PCB including an end node control circuit (554) having end node control components (556) mounted to the first surface, the end node PCB including a first signal edge pad (570) along the first edge and a second signal edge pad (572) along the second edge, the first signal edge pad and the second signal edge pad coupled to the end node control circuit, the at least one jumper contact (600) including a first signal jumper contact coupled to the first signal edge pad and a second signal jumper contact coupled to the second signal edge pad.

20. The end node termination module (500) of claim 19, wherein the end node PCB (552) includes a ground edge pad (574) along the first edge, the ground edge pad (574) configured to be coupled to a ground jumper contact (700) of the at least one jumper contact (600), the ground jumper contact coupled to a ground component of the plug connector (200).

21. An electrical connector system, comprising: a header connector (100) including a header housing (110) holding header contacts (150), the header housing (110) including a receptacle (114), the header contacts including mating ends (152) in the receptacle; and a plug connector (200) received in the receptacle and mated with the header contacts, the plug connector including: a plug housing (210) having a mating end (230) and a cable end (232), the mating end configured to mate with the header connector, the plug housing including a power contact passage (212) between the mating end and the cable end, the plug housing including a first module passage (214) between the mating end and the cable end, the plug housing including a second module passage between the mating end and the cable end; power contacts (300) received in the power contact passage (212), the power contacts terminated to power cables (204), the power contacts including mating ends configured to mate to corresponding header contacts of the header connector; a data module (400) received in the first module passage, the data module including a data module housing (410) holding signal contacts (402), the signal contacts (402) terminated to ends of signal wires (404) of a data cable (206), each signal contact including a mating end configured to mate with a corresponding plug contact of the plug connector; an end node termination module (500) received in the second module channel, the end node termination module including a termination module housing (510) having a recess (514), the end node termination module including an end node printed circuit board (PCB) (552) received in the recess, the end node PCB including an end node control circuit (554) having end node control components (556) mounted to the end node PCB to control the end node control circuit; a jumper contact (600) held by the plug housing, each jumper contact including a signal contact mating interface (632) electrically connected to a corresponding signal contact and an end node mating interface (712) electrically connected to the end node termination module to electrically connect the signal contact to the end node control circuit within the plug connector.

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