Plug connector with data module

Abstract

A plug connector is provided that includes a plug housing having a mating end and a cable end. The mating end is mated with the header connector. The plug housing includes a module channel between the mating end and the cable end. The plug connector includes a data cable including a pair of unshielded signal lines in an insulator. The pair of signal lines are twisted along the length of the data cable. The plug connector includes a data module in a module channel. The data module includes a data module housing extending between a front portion and a rear portion. The data module housing includes a signal contact channel holding a pair of signal contacts and a signal line channel holding a pair of signal lines. Each signal contact includes a mating end that mates with a header contact of the header connector and a terminating end that terminates an end of a signal line of the data cable. And the signal contact channel is opened at the front part of the data module shell and is matched with the headstock contact. The data module housing includes access windows along its sides that open to the signal contact channels for accessing the signal contacts in the signal contact channels.

Description

Technical Field

[0001] The main topic of this article is electrical connector systems. Background Technology

[0002] Modern vehicles increasingly rely on sophisticated 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 interacts with numerous sensors and actuators throughout the vehicle. Communication between the ECU and these peripheral components is typically facilitated via serial communication buses, 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, terminating networks are typically used at the ends of the communication bus to match impedance, reduce reflections, and ensure reliable data transmission. These terminating networks usually include resistors and / or capacitors configured on the ECU's printed circuit board (PCB).

[0004] However, implementing termination and signal conditioning circuitry directly on the ECU's PCB presents several challenges. First, the ECU is a highly space-constrained environment where available space on the PCB is extremely valuable. The addition of termination networks and associated signal processing components consumes precious board space that would otherwise be allocated to basic processing, memory, or power management components. Second, the design and integration of these components increases the overall complexity of the ECU, raising design time, cost, and potential points of failure in the system. Summary of the Invention

[0005] In one embodiment, a plug connector is provided, comprising a plug housing having a mating end and a cable end. The mating end is configured to mate with a headstock 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 power contacts received in the power contact channels. The power contacts terminate to a power cable. The power contacts include a mating end configured to mate with the headstock connector. The plug connector includes a data module received in the first module channel. The data module includes a data module housing that holds signal contacts terminated to the ends of signal lines of a data cable. Each signal contact includes a mating end configured to mate with the headstock 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 common-mode control circuitry. The common-mode signal processing assembly includes a common-mode signal processing component mounted to the end-node PCB for processing signals on the common-mode control circuitry. The plug connector includes jumper contacts held by a plug housing. Each jumper contact includes a signal contact mating interface electrically connected to a corresponding 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 circuitry within the plug connector. The plug connector includes a ground jumper contact connected to an electrically grounded 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. Attached Figure Description

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

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

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

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

[0010] Figure 4 This is a bottom perspective view of a head connector according to an exemplary embodiment.

[0011] Figure 5 This is a rear view of the head connector according to an exemplary embodiment.

[0012] Figure 6 This is a front view of the head connector according to an exemplary embodiment.

[0013] Figure 7 This is a perspective view of a portion of a plug connector according to an exemplary embodiment, showing a pair of electrical contacts.

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

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

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

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

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

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

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

[0021] Figure 15 This is an exploded view of the data module according to an exemplary embodiment.

[0022] Figure 16 This is a partial assembled view of the data module according to an exemplary embodiment.

[0023] Figure 17 This is an assembled view of the data module according to an exemplary embodiment.

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

[0025] Figure 19 This is an exploded view of the data module according to an exemplary embodiment.

[0026] Figure 20 This is an assembled view of the data module according to an exemplary embodiment.

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

[0028] Figure 22This is a top view of the termination module housing according to an exemplary embodiment.

[0029] Figure 23 A signal processing component according to an exemplary embodiment is shown.

[0030] Figure 24 A signal processing component according to an exemplary embodiment is shown.

[0031] Figure 25 A PCB with multiple end nodes during manufacturing is shown according to an exemplary embodiment.

[0032] Figure 26 This is a perspective view of a signal processing component according to an exemplary embodiment, showing jumper contacts and ground jumper contacts connected to the signal processing component.

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

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

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

[0036] Figure 30 This is a top view of a position guarantee device according to an exemplary embodiment.

[0037] Figure 31 This is an end view of a position guarantee device according to an exemplary embodiment.

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

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

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

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

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

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

[0044] Figure 38 This is a front view of a portion of a plug connector according to an exemplary embodiment, showing the internal components of the plug connector. Detailed Implementation

[0045] Figure 1 This is a perspective view of an electrical connector system 10 according to an exemplary embodiment. Figure 2 This is a side view of an electrical connector system 10 according to an exemplary embodiment. The electrical connector system 10 includes a head connector 100 and a plug connector 200 coupled to the head connector 100. The head 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 head 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 be part of a battery system, engine control unit (ECU), engine management system, vehicle infotainment system, vehicle lighting system, vehicle heating and cooling system, or other systems within the vehicle. The electrical connector system 10 can be used in applications other than automotive applications, such as aerospace applications, marine applications, military applications, industrial applications, robotics applications, data communication systems, network systems, server systems, building wiring systems, etc. In an exemplary embodiment, the electrical connector system 10 is used for data and / or power transmission between 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, connectors 100, 200 can form common-mode end terminations for the electrical connector system 10. In other various embodiments, connectors 100, 200 can form differential-mode end terminations for the electrical connector system 10.

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

[0048] In an exemplary embodiment, the head-mount connector 100 is mounted to a circuit board 102. The circuit board 102 may be part of an electrical component 20. The electrical component 20 may include one or more electronic devices 22 mounted to the circuit board 102. For example, the electronic device 22 may be an integrated circuit, a chip, a processor, a memory module, a computing device, a network device, a switching device, a data communication device, or other types of electronic devices. In various embodiments, multiple head-mount connectors 100 may be mounted to the circuit board 102 and electrically connected to the electronic devices 22. The head-mount connector 100 may be mounted to another component, such as a mounting device, panel, wall, chassis, or other component of the electrical component 20. In an alternative embodiment, the head-mount connector 100 may be a cable connector instead of a board connector, wherein the head-mount connector 100 terminates at the end of a cable.

[0049] Figure 3 This is a cross-sectional view of an electrical connector system 10 according to an exemplary embodiment. Figure 3 A plug connector 200 is shown that mates with the head connector 100. For example, a portion of the plug connector 200 is inserted into the head connector 100. In an exemplary embodiment, the electrical connector system 10 includes a sealed mating interface between the head connector 100 and the plug connector 200.

[0050] In an exemplary embodiment, the headstock connector 100 includes a headstock housing 110 that holds a plurality of headstock contacts 150. The headstock housing 110 includes a wall 112 forming a receiver 114. The headstock contacts 150 extend into the receiver 114. The receiver 114 receives a plug connector 200. The plug connector 200 mates with the headstock contacts 150 in the receiver 114.

[0051] In an exemplary embodiment, the plug connector 200 includes a plug housing 210. In various embodiments, the plug connector 200 includes one or more electrical contacts 300 held by the plug housing 210, for example, held in an electrical 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 end node termination modules 500 held by the plug housing 210, for example, in the module channel 214 of the plug housing 210. In an exemplary embodiment, the plug connector 200 is modular, thereby 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 change the configuration of the plug connector 200.

[0052] Figure 4 This is a bottom perspective view of the head connector 100 according to an exemplary embodiment. Figure 5 This is a rear view of the head connector 100 according to an exemplary embodiment. Figure 6 This is a front view of the head connector 100 according to an exemplary embodiment.

[0053] In an exemplary embodiment, the headstock housing 110 includes a latching element 116 for latchably engaging the plug connector 200 to the headstock connector 100. In the illustrated embodiment, the latching element 116 is positioned along the top of the headstock housing 110. Other locations are possible in alternative embodiments. In various embodiments, the latching element 116 is a snap-fit ​​element with a snap-fit ​​surface configured to receive a latch from the plug connector 200. Other types of latching elements may be used in alternative embodiments. For example, the latching element 160 may include a deflectable latch configured to latchably engage with the plug connector 200.

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

[0055] In an exemplary embodiment, the headstock housing 110 includes an end wall 134. The end wall 134 may extend between sides 128. The end wall 134 may extend between a top 120 and a bottom 122. In an exemplary embodiment, the end wall 134 holds a headstock contact 150. For example, the end wall 134 includes a contact channel 136 for receiving the headstock contact 150. In an exemplary embodiment, a receiver 114 is located in front of the end wall 134. The headstock contact 150 extends from the end wall 134 into the receiver 114. The headstock contact 150 may extend from the end wall 134 to a mounting end 132 for connection to a circuit board 102.

[0056] In an exemplary embodiment, the headstock housing 110 includes a shroud 138 extending forward from the end wall 134. The shroud 138 forms a nose cone at a front portion 124. The shroud 138 surrounds and / or defines a receiver 114. The shroud 138 surrounds the end of the headstock contact 150 to protect the headstock contact 150. The shroud 138 may be elliptical, for example, extending from one side to the other. In other embodiments, the shroud 138 may be rectangular. In alternative embodiments, the shroud 138 may have other shapes. In an exemplary embodiment, the shroud 138 is configured to be received in the plug connector 200 and configured to seal to the plug connector 200.

[0057] In an exemplary embodiment, the headstock housing 110 includes a mounting bracket 140 at a mounting end 132. The mounting bracket 140 is configured to be mounted to a circuit board 102. In an exemplary embodiment, the mounting bracket 140 includes one or more mounting legs 142 for supporting the headstock housing 110 on the circuit board 102. The mounting legs 142 may extend rearward from the mounting bracket 140 and / or the end wall 134. In an exemplary embodiment, 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 may extend downward from the mounting legs 142. The mounting posts 144 provide alignment of the headstock housing 110 with the circuit board 102. The mounting posts 144 may provide mechanical retention of the circuit board 102. For example, the mounting posts 144 may have a split beam designed to be retained in the opening of the circuit board 102 by a spring fit or interference fit. In an exemplary embodiment, the mounting bracket 140 may include a mounting flange 146 configured to be mounted to a panel, wall, or other mounting structure. For example, a front or rear surface of the mounting flange 146 may abut against a mounting structure. The mounting flange 146 may extend outward from the end wall 134 and / or the mounting bracket 140. The mounting flange 146 may extend outward from the top 120 and / or the bottom 122 and / or the side 128. In various embodiments, the mounting flange 146 may extend circumferentially around the headstock housing 110.

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

[0059] In an exemplary embodiment, each headstock contact 150 extends between a mating end 152 and a terminating end 154. The headstock contact 150 transitions between the mating end 152 and the terminating end 154. Optionally, the transition may include a bend or a protrusion to accommodate a contact length skew that accounts for the overall length of the headstock contact 150.

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

[0061] Termination terminal 154 is configured to terminate to circuit board 102. In the illustrated embodiment, termination terminal 152 includes a solder tail 158 configured to be received in a plated through-hole of circuit board 102. Alternatively, solder tail 158 may be bent 90° for a pad surface-mount to circuit board 102. In various other embodiments, termination terminal 154 may include different types of interfaces, such as compliant pins, press-fit pins, pads, solder balls, spring beams, or other types of contacts.

[0062] Figure 7 This is a perspective view of a portion of a plug connector 200 according to an exemplary embodiment, showing a pair of power contacts 300. The power contacts 300 terminate at the end of a power cable 204. In the illustrated embodiment, the power contacts 300 are crimped to the power cable 204. In an alternative embodiment, the power contacts 300 may be fused or soldered to the power cable 204. The power contacts 300 may be arranged in a vertically stacked manner, for example, one above the other. One of the power contacts 300 may be a positive contact, and the other power contact 300 may be a negative contact. Optionally, the negative contact may be grounded.

[0063] In an exemplary embodiment, the power contact 300 is a stamped contact. Each power contact 300 extends between a mating end 310 and a terminating end 320. The mating end 310 is configured to mate with a corresponding headstock contact 150 of the headstock connector 100. The terminating end 320 is configured to terminate at an end of the power cable 204. In the illustrated embodiment, the mating end 310 includes a receptacle 312. For example, the mating end 310 may include four walls forming a box-shaped receptacle 312. The mating end 310 includes a mating beam 314 extending into the receptacle 312 for electrical connection to the headstock contact 150. In alternative embodiments, other types of mating interfaces, such as pins, spring beams, or other types of mating interfaces, may be provided at the mating end 310.

[0064] In an exemplary embodiment, the mating end 310 includes a stop surface 316 configured to engage with a master latch of the plug housing of the plug connector 200 to retain the power contact 300 within the plug housing. The stop surface 316 may be located at the rear of the mating end 310. The stop surface 316 may be rearward-facing to prevent the power contact 300 from being pulled out of the plug housing.

[0065] In an exemplary embodiment, the power contact 300 includes an interface surface 318. The interface surface 318 may be positioned along one 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 may be planar. The mating surface 318 is configured to engage with a jumper contact to provide electrical connection to another component, such as the end node termination module 500.

[0066] Figure 8 This is a front perspective view of a plug connector 200 according to an exemplary embodiment. Figure 9 This is a top view of a plug connector 200 according to an exemplary embodiment. Figure 10 This is a front view of a plug connector 200 according to an exemplary embodiment. The plug connector 200 includes a plug housing 210, power contacts 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 an exemplary embodiment, the plug housing 210 is a multi-piece housing including 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 a shield 138 of the headstock housing 110. In an exemplary embodiment, a housing seal 219 is located in the housing well 217 to engage with the shield 138 when the plug connector 200 mates with the headstock connector 100. The housing seal 219 provides a seal between the plug housing 210 and the headstock housing 110. The outer housing 216 may surround the shield 138 of the headstock housing 110. The inner housing 218 is configured to insert into a receiver 114 of the headstock housing 110. Although the outer shell 216 and the inner shell 218 are configured as separate shell structures joined together, it should be recognized that in alternative embodiments, the outer shell 216 and the inner shell 218 may be an integral structure. For example, the outer shell 216 and the inner shell 218 may be co-molded to form an integral, monolithic, or single-piece shell.

[0068] The plug housing 210 extends between a top 220 and a bottom 222. The plug housing 210 also extends between a front portion 224 and a rear portion 226. The plug housing 210 includes a side 228 between the top 220 and the bottom 222 and / or between the front portion 224 and the rear portion 226. In an exemplary embodiment, the plug housing 210 includes a mating end 230 configured to mate with the headstock connector 100. In the illustrated embodiment, the mating end 230 is located at the front portion 224. In alternative embodiments, other locations are also possible. In an exemplary embodiment, the plug housing 210 includes a cable end 232 at which the cable 202 enters / exits the plug housing 210. In the illustrated embodiment, the cable end 232 is located at the rear portion 226. In alternative embodiments, other locations are also possible.

[0069] In an exemplary embodiment, the inner housing 218 includes a power contact channel 212 within a module channel 214. The inner housing 218 holds the power contact 300, the data module 400, and the end node termination module 500. The power contact channel 212 and the module channel 214 open at mating ends 230 (e.g., front 224) to provide access for mating with the headstock connector 100. In an exemplary embodiment, the power contact channel 212 and the module channel 214 open at a rear 226 for loading the power contact 300 into the power contact channel 212 and loading the data module 400 and the end node termination module 500 into the module channel 214. Power cables 204 and data cables 206 extend from the power contact channel 212 and the module channel 214 at cable ends 232 (e.g., rear 226).

[0070] In an exemplary embodiment, the plug housing 210 includes a latching element 240 configured to be latchably coupled to the headstock connector 100. In the illustrated embodiment, the latching element 240 is located at the top 220. In alternative embodiments, other locations are also possible. The latching element 240 includes a deflectable latch 242 movable between a latched position and an unlocked position. In an exemplary 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 unlocked position. In the illustrated embodiment, the latching element 240 includes a latch cover 246 covering the deflectable latch 242. In an exemplary embodiment, the latching element 240 includes a latch locking member 248 that can be moved from the unlocked position to the locked position. For example, the latch locking member 248 can slide along the plug housing 210, for example, from front to back or from side to side between the unlocked and locked positions. When latch 248 is in the locked position, it prevents movement of latch 242 (e.g., movement to the unlocked position). Latch 248 may define a position-guaranteeing device to ensure the positioning of latch 242 and / or to ensure the correct positioning of plug connector 200 and headstock connector 100 in their mating states. For example, latch 248 may move to the locked position only when plug connector 200 is properly mated with headstock connector 100.

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

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

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

[0074] Figure 13 This is a front view of a plug connector 200 according to an exemplary embodiment. In the illustrated embodiment, the plug connector 200 includes a data module 400 and an end node termination module 500 disposed in a respective module channel 214. The plug connector 200 includes a jumper contact 600 electrically connecting the data module 400 and the end node termination module 500. The end node termination module 500 is capable of processing signals from the data module 400 via signals connected to the data module 400. In the exemplary embodiment, the end node termination module 500 can provide differential end node signal processing.

[0075] Figure 14 This is a front view of a plug connector 200 according to an exemplary embodiment. In the illustrated embodiment, the plug connector 200 includes a data module 400 and an end node termination module 500 disposed in a respective module channel 214. The plug connector 200 includes a jumper contact 600 electrically connecting the data module 400 to 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 grounding component of the plug connector 200. In the exemplary embodiment, the grounding component of the plug connector 200 is one of the power contacts 300 connected to a ground reference (e.g., a negative power supply terminal). The end node termination module 500 is capable of processing signals from the data module 400 via signals connected to the data module 400 and the ground reference. In the exemplary embodiment, the end node termination module 500 can provide common-mode end node signal processing.

[0076] Figure 15 This is an exploded view of the data module 400 according to an exemplary embodiment. Figure 16 This is a partial assembly view of data module 400 according to an exemplary embodiment. Figure 17 This is an assembly view of the data module 400 according to an exemplary embodiment. Figure 18 This is a side view of the data module 400 according to an exemplary embodiment.

[0077] 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 lines 404 surrounded by an insulator 406 (such as a cable sheath). In an exemplary embodiment, signal lines 404 are a stranded pair of signal lines. In an exemplary embodiment, signal lines 404 are an unshielded stranded pair of signal lines. Signal contacts 402 terminate at the ends of signal lines 404. For example, signal contacts 402 may be crimped to the ends of signal lines 404. In an exemplary embodiment, a portion of the insulator 406 is stripped to expose the ends of signal lines 404. A length of signal line 404 is unstretched forward from the insulator 406 to terminate at signal contacts 402. For signal integrity along the signal transmission line, the unstretched length of signal lines 404 may be kept relatively short.

[0078] In an exemplary embodiment, the signal contact 402 is a stamped contact. Each signal contact 402 extends between a mating end 470 and a terminating end 480. The mating end 470 is configured to mate with a corresponding headstock contact 150 of the headstock connector 100. The terminating end 480 is configured to terminate at the end of a corresponding signal line 404. In an exemplary embodiment, the terminating end 480 includes a crimping sleeve configured to crimp to the end of the corresponding signal line 404. In alternative embodiments, other types of terminals may be used, such as brazing, soldering, insulation displacement connections, etc. In an exemplary embodiment, one of the signal contacts 402 may form a positive signal transmission line, while the other of the signal contacts 402 may form a negative signal transmission line. The signal contacts 402 may transmit differential mode signals. In various other embodiments, the signal contacts 402 may transmit common mode signals.

[0079] In the illustrated embodiment, the mating end 470 includes a socket 472. For example, the mating end 470 may include four walls forming a box-shaped socket 472. The mating end 470 includes one or more mating beams 474 extending into the socket 472 for electrical connection to the headstock contact 150. In an exemplary embodiment, the mating end 470 includes a latch 476 configured to be latchably coupled to the data module housing 410 to retain the signal contact 402 within the data module housing 410. Alternatively, the mating end 470 may include a stop surface configured to engage with a main latch extending from the data module housing 410. In alternative embodiments, other types of mating interfaces, such as pins, spring beams, or other types of mating interfaces, may be provided at the mating end 470.

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

[0081] The data module housing 410 includes contact channels 412 and associated line channels 414. Contact channels 412 receive corresponding signal contacts 402. Line channels 414 receive corresponding signal lines 404. Line channels 414 are separated by partition walls 416, which separate the signal lines 404 from each other. The partition walls 416 may extend to an insulator 406 to separate parallel portions of the signal lines 404 in front of their twisted portions. As the signal lines 404 transition to the signal contacts 402, the partition walls 416 control the impedance and other electrical characteristics of the signal transmission line along the parallel portions of the signal lines 404. The partition walls 416 continue between the contact channels 412 to separate the signal contacts 402 from each other.

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

[0083] In an exemplary embodiment, the data module housing 410 is a multi-piece housing including a body 432 and a cover 434, the cover 434 being configured to be coupled to the body 432 to close the contact channel 412 in the line channel 414 after the signal contact 402 in the signal line 404 is loaded into the data module housing 410. In the illustrated embodiment, the cover 434 is located at a first side 428. In an exemplary embodiment, the cover 434 is integrally formed with the body 432, for example, connected by a movable hinge 436. For example, the cover 434 and the body 432 can be co-molded during a single injection molding process. The cover 434 can be coupled to the body 432 by rotating the cover 434 to a closed position. In an alternative embodiment, the cover 434 can be manufactured separately from and coupled to the body 432.

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

[0085] In an exemplary embodiment, the cover 434 includes a recess 440 that receives the distal end of the partition wall 416. The recess 440 and the partition wall 416 can be used to position the cover 434 relative to the body 432.

[0086] In an exemplary embodiment, cover 434 includes a tab 442 extending from the interior of cover 434. Tab 442 is configured to engage with signal contact 402 and / or signal line 404 to load signal contact 402 or signal line 404 into contact channel 412 or line channel 414, respectively. Tab 442 may be used to maintain the signal contact 402 and / or signal line 404 in a lateral and / or forward position within the data module housing 410. For example, tab 442 may prevent signal contact 402 from being pulled out of contact channel 412.

[0087] In an exemplary embodiment, the cover 434 includes a retaining rib 444 configured to engage with the data cable 206. For example, when the cover 434 is attached to the body 432, the retaining rib 444 may engage with the insulator 406 (e.g., cable sheath). The retaining rib 444 may be slightly recessed into the material of the insulator 406 to lock the insulator 406 within the data module housing 410, such as to provide strain relief and / or prevent the data cable 206 from being pulled out of the data module housing 410. The retaining rib 444 is sized / shaped for retention but is designed not to damage the wire. The data module 400 may be used with unsheathed cables, in which case the retaining rib 444 may engage the conductor, or the retaining rib 444 may not be used for wire retention.

[0088] In an exemplary embodiment, body 432 includes a cable recess 446 at a rear portion 426. The cable recess 446 receives an end of data cable 206. The cable recess 446 may receive insulator 406. In an exemplary embodiment, body 432 includes one or more retaining ribs 448 extending into the cable recess 446. The retaining ribs 448 are configured to engage with data cable 206. For example, when cover 434 is attached to body 432, retaining ribs 448 may engage with insulator 406 (e.g., cable sheath). Retaining ribs 448 may be slightly recessed into the material of insulator 406 to lock insulator 406 within data module housing 410, such as to provide strain relief and / or prevent data cable 206 from being pulled out of data module housing 410. The retaining ribs 448 are sized / shaped for retention but not for damaging the cable.

[0089] In an exemplary embodiment, 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 with access to the socket contact 402 in the contact channel 412. In the illustrated embodiment, the access window 450 is located at or near the front 424 to allow access to the signal contact 402. In the illustrated embodiment, the access window 450 is located at the top 420 and bottom 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 may be located at other locations.

[0090] In an exemplary embodiment, the data module housing 410 includes a latch opening 452 that receives a latch 476 of the signal contact 402. In the illustrated embodiment, the latch opening 452 is located at a 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 spring outward into the latch opening 452 to secure the signal contact 402 in the contact channel 412. The latch 476 prevents the signal contact 402 from being pulled out of the contact channel 412.

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

[0092] Figure 19This is an exploded view of the data module 400 according to an exemplary embodiment. Figure 20 This is an assembly view of the data module 400 according to an exemplary embodiment. Figure 19 and Figure 20 A data module housing 410 is shown as a two-piece housing, in which a cover 434 is separate and independent from the body 432. The cover 434 is configured to be attached to the side of the body 432 after the signal contacts 402 and signal lines 404 are loaded into the data module housing 410.

[0093] Figure 21 This is an exploded view of an end node termination module 500 according to an exemplary 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 exemplary embodiment, the signal processing assembly 550 includes an end node printed circuit board (PCB) 552 having one or more end node control circuits 554, the end node control circuits 554 having one or more signal processing components 556 for controlling the end node control circuits 554.

[0094] For further reference Figure 22 , Figure 22 This is a top view of the termination module housing 510, which includes a body 512 having a recess 514 for receiving a signal processing component 550. For example, an end node PCB 552 and a corresponding signal processing component 556 are configured to be received in the recess 514. In an exemplary embodiment, the termination module housing 510 includes a handle 516 extending from the body 512. The handle 516 is used for loading and unloading the end node termination module 500 into and from the plug housing 210. The handle 516 is inserted into a cable hole for a channel in the plug housing 210 to provide a seal for the channel.

[0095] In an exemplary embodiment, the termination module housing 510 is similar in size to the data module housing 410. Figure 15 This allows the end node termination module 500 and the data module 400 to be interchangeably loaded into the module channel 214 of the plug housing 210. The termination module housing 510 may include features similar to those of the data module housing 410, such as positioning features, fixing features, etc., for positioning and fixing the end node termination module 500 and the data module 400 in the module channel 214 of the plug housing 210.

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

[0097] In an exemplary embodiment, the termination module housing 510 includes a loading opening 532 at a first side 528. The signal processing component 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 an exemplary embodiment, the termination module housing 510 includes one or more securing features 534 for securing the signal processing assembly 550 within a recess 514. In an exemplary embodiment, the securing feature 534 includes a post 536 located within the recess 514. An end node PCB 552 may be coupled to the post 536. The post 536 may position the end node PCB 552 rear-facing 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 may provide mechanical retention to the end node PCB 552. For example, the post 536 may have a split beam designed to be retained in an opening of the end node PCB 552 by a spring fit or interference fit. In an exemplary embodiment, the securing feature 534 includes a capture wall 538 configured to capture the end of the end node PCB 552. The capture wall 538 may be located near the front portion 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. Thus, the front and rear portions of the end node PCB 552 are held in the recess 514 by a fixing feature 534. Other types of fixing features may be used in alternative embodiments.

[0099] In an exemplary embodiment, the termination module housing 410 includes an access window 540. The access window 540 provides access to a signal processing component 550 within a recess 514. The access window 540 also provides access for the jumper contact 600 to a portion of the end node PCB 552 within the recess 514. In the illustrated embodiment, the access window 540 is located at or near the front portion 424. In the illustrated embodiment, the access window 540 is located at the top 420 and 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 may be located at other locations.

[0100] In an exemplary embodiment, the termination module housing 410 includes one or more ground access windows 542. The ground access windows 542 provide access to signal processing components 550 within the recess 514. The ground access windows 542 also provide ground jumper contacts 700 with access to a portion of the end node PCB 552 within 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 may be located at other locations.

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

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

[0103] The end node PCB 552 includes a substrate having surfaces 560 on opposite sides of the substrate. The end node PCB 552 can be manufactured using 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 surface 560. The circuitry can be traces, pads, vias, or other conductive elements patterned on one or more layers of the substrate. The end node PCB 552 includes a leading edge 562, a trailing edge 564, a first edge 566 (e.g., a top edge) between the leading edge 562 and the trailing edge 564, and a second edge 568 (e.g., a bottom edge) between the leading edge 562 and the trailing edge 564. In an exemplary embodiment, signal processing components 556 are mounted to corresponding circuitry at the surface 560 of the end node PCB 552 to form end node control circuitry 554.

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

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

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

[0107] The first and second signal edge pads 570, 572 are configured to be electrically connected to the respective signal processing component 556, such as through traces or other conductive circuitry on the end node PCB 552. The signal processing component 556 performs signal processing on signals transmitted to / from jumper contacts 600 via the signal edge pads 570, 572. The signal processing component 556 performs signal processing for the signal processing assembly 550. The signal processing component 556 may 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 component 556 may be an active component and / or a passive component. The signal processing component 556 may 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 component 556 may be additionally or alternatively connected to the ground edge pad 574.

[0108] In an exemplary embodiment, the end node PCB 552 includes an opening 580. The opening 580 can serve as a positioning and / or fixing feature for positioning the end node PCB 552 within the termination module housing 510. For example, the opening 580 can receive a post 536 to position the end node PCB 552 within a recess 514 of the termination module housing 510. In the illustrated embodiment, the opening 580 is located near the rear of the end node PCB 552. In alternative embodiments, other locations are also possible. The opening 580 extends through the end node PCB 552 between surfaces 560.

[0109] Figure 24 A signal processing component 550 according to an exemplary embodiment is shown. Figure 24 It shows the relationship with Figure 23 The embodiment shown features a different arrangement of the signal processing components 556 on the end node PCB 552 compared to the embodiment shown. Figure 24 The arrangement of the signal processing unit 556 in the middle performs the execution and Figure 23 The signal processing unit 556 in the middle is arranged to process different types of signals. For example, Figure 24 Used for differential signal processing, while Figure 23 For common-mode signal processing. In the exemplary embodiment, the same end node PCB 552 is used in both arrangements, thereby allowing a single end node PCB 552 to be fabricated for different applications. Other arrangements of the signal processing component 556 may be used for other types of signal processing in alternative embodiments.

[0110] Figure 25 A plurality of end node PCBs 552 during manufacturing is shown according to an exemplary embodiment. The end node PCBs 552 are manufactured as part of a common circuit board structure, and each end node PCB 552 is segmented or separated from the structure. Other manufacturing techniques may be used in alternative embodiments.

[0111] Figure 26 This is a perspective view of a signal processing assembly 550 according to an exemplary embodiment, showing jumper contacts 600 and ground jumper contacts 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 a signal processing component 556 mounted to the end node PCB 552. Although the signal processing component 556 is shown as being mounted to one of the surfaces 560, in an alternative embodiment, the signal processing component 556 may be mounted to both surfaces 560 at opposite sides of the end node PCB 552. Signal edge pads 570, 572 and ground edge pad 574 are shown at the first and second edges 566, 568 (e.g., between opposite 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 corresponding signal edge pads 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 pads 570, 572 when the end node termination module 500 is inserted into the plug housing 210 of the plug connector 200.

[0113] The grounding jumper contact 700 includes an end node spring beam 710, which has an end node mating interface 712 electrically connected to a corresponding grounding edge pad 574. The end node spring beam 710 is deflectable and has a separable mating interface. The end node spring beam 710 is configured to mate with the grounding 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 This is a side view of the end node termination module 500 according to an exemplary embodiment. Figure 28 This is a cross-sectional view of the end node termination module 500 according to an exemplary embodiment. Figure 27 and 28 The signal processing component 550 is shown in the recess 514 of the termination module housing 510.

[0115] During assembly, the end node PCB 552 is coupled to a fixing feature 534 of the termination module housing 510. For example, a post 536 is received in an opening 580. The post 536 aligns the end node PCB 552 in a recess 514. In an exemplary embodiment, the distal end of the post 536 includes a capture feature that captures and holds the end node PCB 552 in the recess 514. A 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 loading opening 532. In an exemplary embodiment, the end node PCB 552 and the signal processing component 556 are completely contained within the coverage area of ​​the termination module housing 510. During assembly, the end node PCB 552 is positioned within the recess 514 such that signal edge pads 570, 572 are aligned with the corresponding access window 540, and ground edge pad 574 is aligned with the corresponding ground access opening 542. Access windows 540 and 542 provide access to edge pads 570, 572, and 574.

[0116] Figure 29 This is an exploded view of a portion of a plug connector 200 according to an exemplary embodiment. Figure 29 The inner housing 218 that holds the power contact 300, data module 400, and end node termination module 500 is shown. It should be noted that, for clarity, the outer housing 216 ( Figure 8 () is removed to show a portion of the inner housing 218. Figure 29Also shown is a position assurance device 800 for ensuring the positioning of the power contact 300, data module 400, and end node termination module 500 within the plug housing 210. In an exemplary embodiment, the position assurance device 800 is configured to hold the ground jumper contact 700. The position assurance device 800 may additionally or alternatively hold the jumper contact 600.

[0117] In an exemplary embodiment, the plug housing 210 includes a position guaranteeing recess 250 for receiving a position guaranteeing device 800. The position guaranteeing recess 250 may be open at the top 220 to receive the position guaranteeing device 800, for example, in a downward mating direction. The position guaranteeing recess 250 may additionally or alternatively be open at one or both of the sides 228 to receive the position guaranteeing device 800. In an exemplary embodiment, the power contact channel 212 and the module channel 214 are accessible from the position guaranteeing recess 250. Thus, the position guaranteeing device 800 is configured to engage with the power contact 300 and the power contact channel 212, and with the data module 400 and the end node termination module 500 in the corresponding module channel 214.

[0118] During assembly, the electrical contact 300 is loaded into the electrical contact channel 212 via the rear portion 226 of the plug housing 210. The plug housing 210 may include a latch or other securing feature to retain the electrical contact 300 within the plug housing 210. The plug housing 210 may include positioning features, such as a stop wall, to position the electrical contact 300 within the electrical contact channel 212, for example, to limit the forward loading of the electrical contact 300 into the electrical contact channel 212. A position ensuring device 800 is configured to engage with the plug housing 210 to ensure that the electrical contact 300 is correctly loaded into the plug housing 210. For example, if the electrical contact 300 is not fully loaded into the electrical contact channel 212, the position ensuring device 800 may not engage with the plug housing 210. In various embodiments, the position securing device 800 is configured to engage with a latch that holds the power contact 300 in the power contact channel 212 to prevent the latch from unlocking and / or to prevent the latch from buckling or breaking when the power cable 204 is pulled back.

[0119] During assembly, the data module 400 is loaded into the module channel 214 via the rear portion 226 of the plug housing 210. The plug housing 210 may include latches or other securing features to hold the data module 400 within the plug housing 210. The plug housing 210 may include positioning features, such as stop walls, to position the data module 400 and the module channel 214, for example, to limit the forward loading of the data module 400 into the module channel 214. A position ensuring device 800 is configured to engage with the plug housing 210 to ensure that the data module 400 is correctly loaded into the plug housing 210. For example, if the data module 400 is not fully loaded into the module channel 214, the position ensuring device 800 may not engage with the plug housing 210. In various embodiments, the position ensuring device 800 is configured to engage directly with the data module 400 to hold the data module 400 within the module channel 214.

[0120] During assembly, the end node termination module 500 is loaded into the module channel 214 via the rear portion 226 of the plug housing 210. The plug housing 210 may include latches or other securing features to hold the end node termination module 500 within the plug housing 210. The plug housing 210 may include positioning features, such as stop walls, to position the end node termination module 500 and the module channel 214, for example, to limit the forward loading of the end node termination module 500 into the module channel 214. A position ensuring device 800 is configured to engage with the plug housing 210 to ensure that the end node termination module 500 is correctly 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 ensuring device 800 may not engage with the plug housing 210. In various embodiments, the position ensuring device 800 is configured to engage directly with the end node termination module 500 to hold the end node termination module 500 within the module channel 214.

[0121] For further reference Figure 30 and Figure 31 , Figure 30 This is a top view of the position guarantee device 800. Figure 31This is an end view of a position securing device 800 that holds a ground jumper contact 700. In an exemplary embodiment, the position securing 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 engage with a top 220 of a plug housing 210. The side walls 814, 816 are configured to engage with a side surface 228 of the plug housing 210. In an exemplary embodiment, the side walls 814, 816 include a latching element 818 configured to be latchably engaged with the side surface 228 of the plug housing 210 to secure the position securing device 800 to the plug housing 210. In alternative embodiments, other types of securing features may be used.

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

[0123] In an exemplary embodiment, the position securing 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 protect the data module 400 in the module channel 214. For example, the size and shape of the data module lock 830 may be designed to fit into a locking slot 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 column extending downward from the inner surface of the end wall 812. The data module lock 830 may be rectangular in shape. The distal end of the data module lock 830 may be chamfered to guide assembly. However, in alternative embodiments, the data module lock 830 may have other shapes.

[0124] In an exemplary 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 within the module channel 214. For example, the size and shape of the end node termination module lock 840 may be designed to fit within a locking groove 544 of the termination module housing 510 to secure the end node termination module 500 within the module channel 214. In the illustrated embodiment, the end node termination module lock 840 is a beam or column extending downward from the inner surface of the end wall 812. The end node termination module lock 840 may be rectangular in shape. The distal end of the end node termination module lock 840 may be chamfered to guide assembly. However, in alternative embodiments, the end node termination module lock 840 may have other shapes. The end node termination module lock 840 may lock other components within the housing, such as data modules when configured as a two-position data module arrangement.

[0125] In an exemplary embodiment, the position assurance device 800 includes a ground jumper contact channel 850 for receiving a ground jumper contact 700. The ground jumper contact channel 850 can be opened 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 grounding portion of the end node termination module 500 and the plug connector 200. In an exemplary embodiment, a negative power contact 300 is connected to a reference ground and defines the grounding portion of the plug connector 200. The ground jumper contact 700 is configured to mate with the negative power contact 300.

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

[0127] In an exemplary embodiment, the grounding jumper contact 700 includes a mating tab 740 for engaging the grounding jumper contact 700 with the position securing device 800. In the illustrated embodiment, the mating tab 740 extends from the connecting beam 720, for example, rearwardly from the connecting beam 720. The mating tab 740 includes barbs 742 along the side edges of the mating tab 740. The barbs 742 are configured to dig into the plastic material of the position securing device 800 to secure the grounding jumper contact 700 in the grounding jumper contact channel 850. In alternative embodiments, other types of mating features may be used to secure the grounding jumper contact 700 to the position securing device 800.

[0128] Figure 32 This is a cross-sectional view of a plug connector 200 according to an exemplary embodiment. Figure 32 A position guarantee device 800 connected to the plug housing 210 is shown. Figure 32 A position assurance device 800 is shown connected to the power contact 300, data module 400, and end node termination module 500. During assembly, the position assurance device 800 is coupled to the plug housing 210. For example, latching elements 818 at sidewalls 814, 816 are configured to be coupled to a latching feature along the side surface 228 of the plug housing 210. Optionally, the latching feature along the side surface 228 may have graded latching positions to allow the position assurance device 800 to be positioned in different graded positions, such as an initial connection position and a final connection position.

[0129] During assembly, the main latch locking member 820 is configured to engage with the main latch 213 of the plug housing 210, which secures the power contact 300 in the power contact channel 212. The main latch locking member 820 supports or holds the main latch 213 in the latched position to prevent unlocking and damage to the main latch 213. During assembly, 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 into a locking slot 454 in the data module housing 410 to secure the data module 400 in the module channel 214. During assembly, 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 is fitted in the locking groove 544 of the termination module housing 510 to fix the end node termination module 500 in the module channel 214.

[0130] Figure 33 This is a perspective view of a portion of a plug connector 200 according to an exemplary embodiment, showing the internal components of the plug connector 200. Figure 34 This is a top view of a portion of a plug connector 200 according to an exemplary embodiment, showing the internal components of the plug connector 200. Figure 35 This is a front view of a portion of a plug connector 200 according to an exemplary embodiment, showing the internal components of the plug connector 200. Figure 33-35 An embodiment of a plug connector 200 operating in a common-mode end node configuration is shown. Figure 33-35 The plug housing 210, data module housing 410, and termination module housing 510 have been removed to show the power contact 300, signal contact 402, signal processing component 550, jumper contact 600, and ground jumper contact 700.

[0131] In the common-mode end node configuration, jumper contact 600 is connected between signal contact 402 and signal processing component 550, and ground jumper contact 700 is connected between ground reference power contact 300 and signal processing component 550. Signal processing component 556 performs signal processing on signal processing component 550 within plug connector 200, eliminating the need for separate signal processing at headstock connector 100 or the circuit board 102 associated with headstock connector 100.

[0132] The grounding jumper contact 700 is a stamped 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 and 730 are deflectable spring beams. The spring beams 710 and 730 extend from the connecting beam 720 to engage with corresponding ground edge pads 574 of the end node PCB 552 and the power contact 300, respectively. In an exemplary embodiment, the ground connection spring beam 730 is configured to directly engage with the interface surface 478 of the power contact 300. The spring beams 710 and 730 can be deflected when mating with the signal processing assembly 550 and the power contact 300. The grounding jumper contact 700 includes a mating tab 740 having barbs 742 along the side edges of the mating tab 740.

[0133] In an exemplary embodiment, each jumper contact 600 is a stamped 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 and 630 are deflectable spring beams. The spring beams 610 and 630 extend from the connecting beam 620 to engage with corresponding signal edge pads 570 and 572 of the end node PCB 552 and the signal contact 402, respectively. In an exemplary embodiment, the signal contact spring beam 630 is configured to directly engage with an interface surface 468 at the mating end 470 of the socket contact 402. The spring beams 610 and 630 can be deflected when mating with the signal processing assembly 550 and the signal contact 402.

[0134] In an exemplary embodiment, the jumper contact 600 includes a mating tab 640 for engaging the jumper contact 600 into the plug housing 210. In the illustrated embodiment, the mating tab 640 extends from the connecting beam 620, for example, rearwardly from the connecting beam 620. The mating tab 640 includes barbs 642 along its side edges. The barbs 642 are configured to dig into the plastic material of the plug housing 210 to secure the jumper contact 600 in a jumper contact channel of the plug housing 210. In alternative embodiments, other types of mating features may be used to secure the jumper contact 600 to the plug housing 210 or other components, such as the position securing device 800.

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

[0136] In the differential end node configuration, jumper contact 600 is connected between signal contact 402 and signal processing assembly 550. Signal processing component 556 performs signal processing on signal processing assembly 550 within plug connector 200, without the need for separate signal processing at headstock connector 100 or the circuit board 102 associated with headstock connector 100.

[0137] Cross-reference to related applications

[0138] This application claims the benefits of U.S. Application Nos. 63 / 704,605, 63 / 704,608, 63 / 704,623, 63 / 704,641, 63 / 704,634, 63 / 704,646, and 63 / 704,100, filed on October 8, 2024, the subject of which is incorporated herein by reference 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 module passageway (214) between the mating end and the cable end; a data cable (206) including an unshielded pair of signal wires (404) disposed in an insulator (406), the pair of signal wires being twisted along a length of the data cable; and a data module (400) housed in the module passageway, the data module including a data module housing (410) extending between a front portion (424) and a rear portion (426), the data module housing including a signal contact passageway (412) holding a pair of signal contacts (402) and a signal wire passageway (414) holding the pair of signal wires, each signal contact including a mating end (152) configured to mate with a header contact (150) of the header connector and a termination end (154) terminated to an end of a signal wire of the data cable, the signal contact passageway opening at a front portion of the data module housing for mating with the header contact, the data module housing including an access window (450) along a side of the data module housing that opens to the signal contact passageway for accessing the signal contacts in the signal contact passageway. the data module housing (410) includes a top side (428) and a bottom side (430), the access window (450) being disposed at the top side and the bottom side.

2. The plug connector (200) of claim 1, wherein, 3. The plug connector (200) of claim 1, wherein the access window (450) is configured to receive a jumper contact (600) to electrically connect to the signal contacts (402). the data module housing (410) includes a latch recess open to the signal contact passageway (412), the signal contacts (402) including a latch (466) received in the latch recess.

4. The plug connector (200) of claim 1, wherein, the data module housing (410) includes a main body (432) and a cover (434) coupled to the main body, the main body receiving the signal contacts (402) and the signal wires (404), the cover covering the signal contacts and the signal wires.

5. The plug connector (200) of claim 1, wherein, 6. The plug connector (200) of claim 5, wherein the data module housing (410) includes a hinge (436) between the cover (434) and the main body (432), the cover being pivotably coupled to the main body at the hinge. the main body (432) includes a partition wall (416) separating a first wire passageway (414) and a second wire passageway, the first wire passageway and the second wire passageway receiving corresponding signal wires, the cover (434) including a groove (440) receiving a distal end of the partition wall.

7. The plug connector (200) of claim 5, wherein, ​ 8. The plug connector (200) of claim 5, wherein, The main body (432) includes a cable channel that receives the data cable (206), the main body including retention ribs (444, 448) that extend into the cable channel to engage the data cable and retain the data cable in the cable channel.

9. The plug connector (200) of claim 1, wherein, The data module housing (410) includes a divider wall (416) that separates a first wire channel and a second wire channel that receive corresponding signal wires (404), the divider wall extending into the insulation (406) of the data cable (206) to separate un-twisted portions of the signal wires from one another.

10. The plug connector (200) of claim 1, wherein, The data module housing (410) includes a cable channel that receives the data cable (206), the data module housing including retention ribs (444, 448) that extend into the cable channel to engage the data cable and retain the data cable in the cable channel.

11. A plug connector (200) comprising: a plug housing (210) having a mating end (230) and a cable end (232), the mating end configured to mate with a header connector (100), the plug housing including a module channel (214) between the mating end and the cable end; a data cable (206) including an unshielded pair of signal wires (404) disposed in an insulation (406), the pair of signal wires twisted along a length of the data cable; and a data module (400) housed in the module channel, the data module including a data module housing (410) extending between a front (424) and a back (426), the data module housing including a signal contact channel (412) that retains a pair of signal contacts (402) terminated to end portions of the signal wires of the data cable, each signal contact including a mating end (152) configured to mate to the header connector and a termination end (154) terminated to a corresponding signal wire, the data module housing including a divider wall (416) that separates a first wire channel and a second wire channel that house corresponding signal wires, the divider wall extending into the insulation.

12. The plug connector (200) of claim 11, wherein, The signal contact channel (412) is open at a front (424) of the data module housing (410) for mating with the header contacts (150), the data module housing including access windows (450) along sides (428, 430) of the data module housing that open into the signal contact channel to access the signal contacts (402) in the signal contact channel.

13. The plug connector (200) of claim 12, wherein, The data module housing (410) includes a top side and a bottom side, the access windows (450) disposed at the top side and the bottom side.

14. The plug connector (200) of claim 12, wherein, The access window (450) is configured to receive a jumper contact (600) to electrically connect to the signal contact (402).

15. The plug connector (200) of claim 11, wherein, The data module housing (410) includes a latching recess to the signal contact channel (412), the signal contact (402) including a latch (466) received in the latching recess.

16. The plug connector (200) of claim 11, wherein, The data module housing (410) includes a main body (432) and a cover (434) coupled to the main body, the main body receiving the signal contact (402) and the signal wire (404), the cover covering the signal contact and the signal wire.

17. The plug connector (200) of claim 16, wherein the data module housing (410) includes a hinge (436) between the cover (434) and the main body (432), the cover pivotably coupled to the main body at the hinge.

18. The plug connector (200) of claim 16, wherein the main body (432) includes the divider wall (416) and the first and second wire channels (414), the cover (434) including a groove (440) receiving a distal end of the divider wall.

19. The plug connector (200) of claim 11, wherein, The data module housing (410) includes a cable channel receiving the data cable (206), the data module housing including retention ribs (444, 448) extending into the cable channel to engage with and retain the data cable in the cable channel.

20. A plug connector (200) comprising: a plug housing (210) having a mating end (230) and a cable end (232), the mating end configured to mate with a header connector (100), the plug housing including a power contact channel (212) between the mating end and the cable end, the plug housing including a first module channel (214) between the mating end and the cable end, the plug housing including a second module channel between the mating end and the cable end; a power contact (300) received in the power contact channel, 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 channel, the data module including a data module housing (410) extending between a front portion (424) and a rear portion (426), the data module including a data cable (206) extending from the rear portion, the data cable including an unshielded pair of signal wires (404) disposed in an insulator (406), the pair of signal wires twisted along a length of the data cable, the data module housing including a signal contact channel (412) holding a pair of signal contacts and a signal wire channel (414) holding the pair of signal wires, each signal contact including a mating end (152) configured to mate to a header contact (150) of the plug connector and a termination end (154) terminated to an end of a signal wire of the data cable, the signal contact channel open at the data module housing front portion for mating with the header contact, the data module housing including access windows (450) along sides (428, 430) of the data module housing to the signal contact channel, the access windows (450) open to the signal contact channel to access the signal contacts in the signal contact channel; 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 a signal processing assembly (550) received in the recess, the signal processing assembly including an end node printed circuit board (PCB) (552) having an end node control circuit (554), the signal processing assembly having signal processing components mounted to the end node PCB to control the end node control circuit; and a jumper contact (600) held by the plug housing (210), each jumper contact including a signal contact mating interface (632) received in a corresponding access window of the data module housing to electrically connect to a corresponding signal contact, each jumper contact including 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.

Images