Cable termination module for a plug connector

Abstract

A plug connector (100) for mating with an electrical connector (200) includes cable termination modules (150), each having a contact module (400) having a contact holder holding a contact having a connection end (432) configured to mate with a mating contact of the electrical connector and a termination end (434) terminated to a signal conductor (104) of a cable (102) at a termination interface. Each cable termination module includes a ground cage (500) providing a circumferential shield around the termination interface and around the corresponding contact module. Each cable termination module includes a termination support (426) at the termination interface surrounding the contact and the termination end of the signal conductor with a support material (428).

Description

Technical Field

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

[0002] The current trend is towards smaller, lighter, and higher-performance communication components and higher-density systems, such as Ethernet switches or other system components. Typically, a system comprises an electronic package connected to a circuit board, for example, via a receptacle connector. Electrical signals are transmitted between the electronic package and the circuit board. The electrical signals are then transmitted along traces on the circuit board to another component, such as a transceiver connector. The long electrical path across the main circuit board degrades the system's electrical performance. Furthermore, losses occur between connector interfaces and along the electrical signal path along the transceiver. Traditional systems struggle to meet the signal and power output requirements of the electronic package.

[0003] Some known systems utilize electronic components with cable assemblies to transmit signals along cables rather than signal traces on the host circuit board. However, electronic components comprise numerous cables terminated to the circuit card. There are limitations on the spacing of the contact pads to allow cabling from the circuit card using conventional cable termination techniques. For example, sufficient spacing is required between rows on the circuit card to allow cable routing along the circuit card. Furthermore, as data speeds increase, shielding (e.g., return paths) along signal paths (especially at numerous interfaces) proves ineffective, particularly at higher frequencies. Summary of the Invention

[0004] In one embodiment, a plug connector for mating with an electrical connector is provided. The plug connector includes cable termination modules. Each cable termination module includes a contact module with a contact retainer having a retaining contact. The contact extends between a connecting end configured to mate with a mating contact of the electrical connector and a termination end opposite the connecting end. Each cable termination module includes a cable with a signal conductor that terminates at a termination interface to the termination end of a corresponding contact. The cable has a cable shield surrounding the signal conductor. Each cable termination module includes a grounding cage that provides circumferential shielding around the termination interface and around the corresponding contact module. Each cable termination module includes a termination support at the termination interface. The termination support surrounds the signal conductor and the termination end of the contact with a support material. The plug connector includes a grounding block that includes a recess for receiving a corresponding cable termination module. The grounding block is conductive and provides shielding around the recess for shielding the cable termination module. The grounding block is electrically connected to the grounding cage. The grounding blocks organize the cable termination modules relative to each other and position the cable termination modules to mate with the electrical connectors.

[0005] In another embodiment, a cable termination module for a plug connector configured to mate with an electrical connector is provided. The cable termination module includes a contact module having a contact retainer for holding the contacts. The contacts extend between a connecting end configured to mate with mating contacts of the electrical connector and a termination end opposite the connecting end. The cable termination module includes a cable having a signal conductor that terminates at a termination interface to the termination end of a corresponding contact. The cable includes a cable shield surrounding the signal conductor. The cable termination module includes a termination support located at the termination interface. The termination support surrounds the signal conductor and the termination end of the contact with a support material. The cable termination module includes a grounding cage that provides circumferential shielding around the termination interface and around the corresponding contact module. The mating end of the grounding cage is configured to insert into a recess in a grounding block at the bottom of the plug connector to electrically connect the grounding cage to the grounding block. The grounding cage includes a clamp, a front cover connected to the clamp, and a rear cover connected to the clamp. The end support is connected to at least one of the sleeve, front cover, and rear cover.

[0006] In a further embodiment, a communication system is provided, including an electrical connector comprising a receptacle frame that retains mating contacts. The mating contacts include a mating interface. The mating contacts include a signal contact and a ground contact. The communication system includes a plug connector configured for pluggable connection to the electrical connector. The plug connector includes a cable termination module and a grounding block, the grounding block including a recess for receiving a corresponding cable termination module. Each cable termination module includes a contact module with a contact retainer having a retaining contact. The contact extends between a connecting end configured to mate with the mating contact of the electrical connector and a termination end opposite the connecting end. Each cable termination module includes a cable having a signal conductor that terminates at the termination interface to the termination end of the corresponding contact. The cable has a cable shield surrounding the signal conductor. Each cable termination module includes a grounding cage providing circumferential shielding around the termination interface and around the corresponding contact module. Each cable termination module includes a termination support at the termination interface. The termination support surrounds the signal conductor and the termination end of the contact with a support material. The grounding block is conductive and provides shielding around the recess for shielding the cable termination module. The grounding block is electrically connected to the grounding cage. The grounding block organizes the cable termination modules relative to each other and positions the cable termination modules to mate with the electrical connector. Attached Figure Description

[0007] Figure 1 This is a perspective view of a communication system with electronic components according to an exemplary embodiment.

[0008] Figure 2 This is an exploded view of a communication system according to an exemplary embodiment.

[0009] Figure 3 This is a perspective view of a plug connector according to an exemplary embodiment.

[0010] Figure 4 This is a perspective view showing a portion of a plug connector of a cable assembly according to an exemplary embodiment.

[0011] Figure 5 This is an exploded view of a grounding block according to an exemplary embodiment.

[0012] Figure 6 This is a top perspective view of the grounding block assembly according to an exemplary embodiment.

[0013] Figure 7 This is a bottom view of a portion of one of the grounding plates according to an exemplary embodiment.

[0014] Figure 8 This is a bottom view of a portion of the bottom ground plane according to an exemplary embodiment.

[0015] Figure 9 This is a perspective view of a portion of a contact module according to an exemplary embodiment.

[0016] Figure 10 This is a rear perspective view of a portion of a contact module according to an exemplary embodiment.

[0017] Figure 11 This is a front perspective view of a portion of a contact module according to an exemplary embodiment.

[0018] Figure 12 An end of one of the cables according to an exemplary embodiment is shown.

[0019] Figure 13 This is a perspective view of the clamp of the grounding cage according to an exemplary embodiment.

[0020] Figure 14 This is a perspective view of a portion of a cable termination module according to an exemplary embodiment, showing a clamp positioned relative to the cable.

[0021] Figure 15 This is a perspective view of a portion of a cable termination module according to an exemplary embodiment, showing a clamp positioned relative to the cable.

[0022] Figure 16 This is a perspective view of a portion of a cable termination module according to an exemplary embodiment, showing the contact module positioned relative to the clamp and the cable.

[0023] Figure 17 This is a front perspective view of a portion of a cable termination module according to an exemplary embodiment, showing the front cover connected to the sleeve.

[0024] Figure 18 This is a rear perspective view of a portion of a cable termination module according to an exemplary embodiment, showing the front cover connected to the sleeve.

[0025] Figure 19 This is a front perspective view of a cable termination module according to an exemplary embodiment, showing the rear cover connected to the sleeve.

[0026] Figure 20 This is a rear perspective view of a cable termination module according to an exemplary embodiment, showing the rear cover connected to the sleeve.

[0027] Figure 21 A portion of a cable assembly according to an exemplary embodiment is shown, illustrating a plurality of cable termination modules mounted in a grounding block.

[0028] Figure 22 A portion of a cable assembly according to an exemplary embodiment is shown, illustrating a plurality of cable termination modules mounted in a grounding block.

[0029] Figure 23 This is a cross-sectional view of a portion of a plug connector according to an exemplary embodiment, showing multiple cable termination modules mounted in a grounding block.

[0030] Figure 24 This is a cross-sectional view of a portion of a plug connector according to an exemplary embodiment, showing one of the cable termination modules mounted in a grounding block.

[0031] Figure 25 This is a bottom perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable termination module in a grounding block.

[0032] Figure 26 This is a bottom perspective view of a portion of a connector housing according to an exemplary embodiment.

[0033] Figure 27 This is a bottom perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable assembly ready to be loaded into the housing cavity of an outer plug housing.

[0034] Figure 28 This is a bottom perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable assembly loaded into a housing cavity of an outer plug housing.

[0035] Figure 29 This is a front perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable assembly loaded into a housing cavity of an outer plug housing.

[0036] Figure 30This is a rear perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable assembly loaded into a housing cavity of an outer plug housing.

[0037] Figure 31 This is a top perspective view of a portion of a plug connector according to an exemplary embodiment, showing a cable strain relief element and a cable assembly coupled to an external plug housing.

[0038] Figure 32 This is a perspective view of a group of cable termination modules integrated as a common cable termination module according to an exemplary embodiment.

[0039] Figure 33 This is a side view of a plurality of common cable termination modules according to an exemplary embodiment.

[0040] Figure 34 This is a perspective view of a cable assembly according to an exemplary embodiment, showing multiple common cable termination modules connected to a grounding block. Detailed Implementation

[0041] Figure 1 This is a perspective view of a communication system 10 having electronic components 20 according to an exemplary embodiment. Figure 2 This is an exploded view of a portion of a communication system 10 according to an exemplary embodiment. In the illustrated embodiment, electronic component 20 ( Figure 1 The communication system 10 includes a circuit board 22 and an electronic package 30 mounted to the circuit board 22. The communication system 10 includes electrical connectors, such as a plug connector 100 and a receptacle connector 200, electrically connected to the electronic component 20. In various embodiments, the mating electrical connector 200 can be another type of electrical connector besides a receptacle connector, such as a socket connector, a headstock connector, or other types of electrical connectors configured to mate with the plug connector 100. In various embodiments, the receptacle connector 200 is mounted to the circuit board 22 and is used to electrically connect the plug connector 100 to the electronic package 30 of the electronic component 20. The plug connector 100 and the receptacle connector 200 allow high-speed signal transmission between components. In various embodiments, the communication system 10 can be used as part of data center applications, high-performance computing applications, or other high-speed, high-density data communication applications. The plug connector 100 and the receptacle connector 200 can be used for data communication between GPU and CPU chip devices or other communication components. Compared to conventional plug connectors, the plug connector 100 is designed to provide improved signal integrity, better impedance control, enhanced EMI shielding, high density, effective high-frequency performance, reduced crosstalk, and improved reliability.

[0042] In an exemplary embodiment, plug connector 100 is a cable connector located at the end of cable 102. Plug connector 100 is configured to connect to receptacle connector 200 at a separable mating interface, such as a planar grid array (LGA) interface, spring beam array interface, conductive elastomer connector interface, or other type of separable connector interface. The mating end of plug connector 100 is configured to insert into receptacle connector 200 to mate with the mating contact array of receptacle connector 200. In an exemplary embodiment, plug connector 100 includes a cable assembly 110 configured to mate with receptacle connector 200. In an exemplary embodiment, plug connector 100 utilizes differential pairs with individually terminated high-speed signal transmission lines. These pairs can be configured as a single unit or modularized, such as configured in a 1x4 or 1x8 arrangement, thereby providing scalability and adaptability to various connectivity requirements. These pairs can be densely arranged within plug connector 100 for ultra-high density within the form factor of plug connector 100 and receptacle connector 200 to meet the growing demand for miniaturization of electronic devices.

[0043] In an exemplary embodiment, receptacle connector 200 is a board connector mounted to a circuit board 22 of electronic component 20. Receptacle connector 200 may be a receptacle connector or a head connector. In an exemplary embodiment, receptacle connector 200 is mounted to circuit board 22. For example, receptacle connector 200 may include a ball grid array (BGA) interface, an LGA interface, a spring beam array interface, a conductive elastomer connector interface, or other types of connector interfaces. Plug connector 100 is configured to insert into a receptacle 212 of receptacle connector 200. Receptacle connector 200 is used to electrically connect cable assembly 110 to circuit board 22. In various other embodiments, receptacle connector 200 may be a cable connector located at the end of a cable (not shown), rather than a board connector.

[0044] In an exemplary embodiment, the communication system 10 includes an electronic package 30 electrically connected to a circuit board 22. In various embodiments, the electronic package 30 may be an integrated circuit assembly, such as an ASIC. However, the electronic package 30 may be another type of communication component, such as a processor, memory module, or other type of communication component. The electronic package 30 may be directly mounted to the circuit board 22. For example, the electronic package 30 may be soldered to the circuit board 22. The cable assembly 110 is electrically connected to the electronic package 30 via the receptacle connector 200 and the circuit board 22. In various embodiments, a plurality of plug connectors 100 and receptacle connectors 200 may be provided on one or more sides of the electronic package 30, for example, all four sides.

[0045] Cable assembly 110 is an electrical module that uses electrical conductors to transmit electrical data signals to / from electronic package 30. In an exemplary embodiment, receptacle connector 200 and the corresponding cable assembly 110 are low-profile connectors having a low profile or height measured from the top of circuit board 22, for example to allow other components (e.g., heat sinks or other heat transfer devices) to be thermally coupled to electronic package 30.

[0046] In an exemplary embodiment, a compression element (not shown) is used to load the cable assembly 110 against the receptacle connector 200 to electrically connect the cable assembly 110 to the receptacle connector 200 and / or electrically connect the receptacle connector 200 to the circuit board 22. For example, the compression element may include springs and / or clips and / or compression hardware that presses down on a member to load the receptacle connector 200 and create a mechanical and electrical connection between the cable assembly 110 and the receptacle connector 200. In various embodiments, the cable assembly 110 is individually clamped or compressed against the receptacle connector 200 by the compression element, and is therefore individually maintainable and removable from the receptacle connector 200.

[0047] In an exemplary embodiment, the communication system 10 includes a heat dissipation element (not shown) to dissipate heat from the electronic package 30 and / or the cable assembly 110. The heat dissipation element may be a heat sink, a cold plate, or other type of heat transfer element.

[0048] A receptacle connector 200 is used to electrically connect cable assembly 110 to circuit board 22. The receptacle connector 200 is mounted to circuit board 22. For example, the receptacle connector 200 is mounted to a mounting area on the upper surface 24 of circuit board 22. The mounting area may be located near electronic package 30. Circuit board 22 includes board contacts (not shown) at the mounting area. The board contacts may be arranged in an array, such as rows and columns. The board contacts may be pads or traces on circuit board 22. In an alternative embodiment, the board contacts may be spring beams. The board contacts may be ball grid array (BGA), planar grid array (LGA), or other types of interfaces. The board contacts may be high-speed signal contacts, low-speed signal contacts, ground contacts, or power contacts. The board contacts may include pairs of high-speed signal board contacts surrounded by a ring or fence of ground plane contacts and / or a ground plane.

[0049] In an exemplary embodiment, the receptacle connector 200 is part of a receptacle assembly 210. The receptacle assembly 210 includes the receptacle connector 200 and a cage 220 having a cavity 224. The receptacle connector 200 is received in the cavity 224. The cavity 224 is configured to receive a plug connector 100 to mate with the receptacle connector 200. For example, a cable assembly 110 can be inserted into the cavity 224 through the top of the cage 220 to mate with the receptacle connector 200 from above in a downward mating direction. The cage 220 guides the mating of the cable assembly 110 with the receptacle connector 200.

[0050] In an exemplary embodiment, the cage 220 is a stamped cage configured to be stamped from a sheet of metal. The cage 220 includes a cage wall 240 defining a cavity 224. The cage wall 240 extends between a top 242 and a bottom 244 of the cage 220. The bottom 244 is configured to connect to a circuit board 22. In an exemplary embodiment, the cage 220 includes a top opening 248 located at the top 242. The top opening 248 is configured to receive a cable assembly 110. For example, the cable assembly 110 is top-loaded into the cavity 224 through the top opening 248. In alternative embodiments, the cage 220 may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining.

[0051] In an exemplary embodiment, cage 220 includes sidewalls 250, 252 and endwalls 254, 256. Sidewalls 250, 252 may be shorter than endwalls 254, 256. In the illustrated embodiment, endwall 256 includes an opening 258. Opening 258 is configured to receive a portion of cable assembly 110, such as a cable. In an exemplary embodiment, cage 220 includes a latching feature 260 for latchably engaging with cable assembly 110. For example, latching feature 260 engages with a latch of cable assembly 110 and / or a spring clip for securing cable assembly 110 in cage 220. The spring clip engages and presses against the top of cable assembly 110. The spring clip presses cable assembly 110 against receptacle connector 200 to electrically connect cable assembly 110 to receptacle connector 200. Latching feature 260 may be a deflectable latch. In alternative embodiments, other types of latching features, such as latch openings, may be used. In the illustrated embodiment, the latching feature 260 is disposed at the sidewalls 250, 252. However, in an alternative embodiment, the latching feature 260 may be disposed at other locations.

[0052] Electrical connector 200 includes an array of mating contacts 270. For example, in an embodiment of a receptacle connector, receptacle connector 200 includes an array of receptacle contacts 270, which may be held by a base plate 272. Receptacle connector 200 may include a housing or receptacle frame 274 that holds the base plate 272 or is configured to directly hold the receptacle contacts 270. Receptacle frame 274 may be rectangular. Receptacle frame 274 is configured to be coupled to cage 220. Additionally or alternatively, receptacle frame 274 may be coupled to circuit board 22. Receptacle frame 274 includes frame members 278 that define a space 276 for receiving plug connector 100 (such as cable assembly 110). In the illustrated embodiment, receptacle frame 274 is rectangular and has frame members 278 arranged around the periphery of receptacle frame 274 (e.g., configured rectangularly). Receptacle frame 274 is configured to be coupled to cage 220 and / or circuit board 22. The socket frame 274 may include positioning features for positioning the plug connector 100 in the space 276, such as alignment walls, alignment openings, alignment slots, etc.

[0053] In various embodiments, substrate 272 is a printed circuit board that includes receptacle contacts 270 coupled to the printed circuit board. The receptacle contacts 270 may be defined by circuitry, traces, vias, etc., of the printed circuit board. The receptacle contacts 270 may be individual contacts soldered to the printed circuit board. In other embodiments, substrate 272 is a film or plate, and the receptacle contacts 270 are individual contacts that may be held or coupled to a film or plate. Substrate 272 is made of an insulating material, such as polyimide, to electrically isolate the receptacle contacts 270 from each other.

[0054] In an exemplary embodiment, the receptacle contact 270 is a compressible contact. In various embodiments, the receptacle contact 270 may be a stamped and formed contact, such as a double compressible contact, having spring beams at both ends of the contact, and the body of the contact between the spring beams being held in a substrate 272. The receptacle contact 270 may be an LGA contact. In other various embodiments, the receptacle contact 270 may be a conductive polymer pillar, such as a conductive elastomer connector having conductive (metallic) particles embedded in an elastomer material (such as silicone rubber). Each receptacle contact 270 includes an upper mating interface and a lower mating interface. In various embodiments, the receptacle contact 270 is a double compressible contact that is compressible at both the upper and lower mating interfaces, for example, for mating with cable assembly 110 and circuit board 22, respectively. Optionally, the receptacle contacts 270 may be arranged in groups, wherein each group includes a pair of signal contacts surrounded by a ring or fence of ground contacts. These groups may be arranged in rows and columns. In alternative embodiments, other arrangements are feasible.

[0055] Figure 3This is a perspective view of a plug connector 100 according to an exemplary embodiment. The plug connector 100 includes a cable assembly 110 and a connector housing 120, the connector housing 120 receiving and / or surrounding a portion of the cable assembly 110.

[0056] In an exemplary embodiment, cable assembly 110 includes a plurality of cables 102 having corresponding contact modules and grounding structures for providing circumferential shielding for each cable and contact module via cable assembly 110. The contact modules and grounding structures are configured for electrical connection to receptacle connector 200 to provide a high-speed signal path through shielding of communication system 10. The grounding structure provides circumferential or 360° shielding around each pair of signal transmission lines (such as along the entire transition area between cable 102 and receptacle connector 200), thereby providing robust signal integrity along the signal transmission lines. The grounding structure may be made of a sheet metal structure, enabling high-tolerance product design and control over the shielding structure to achieve adjustable EMI shielding and signal integrity. The grounding structure provides effective shielding around the signal transmission lines to improve high-frequency performance, making plug connector 100 suitable for applications requiring high data rates and bandwidth. The materials and design of the contact modules and grounding structure result in reduced crosstalk between adjacent signal transmission lines to maintain signal integrity in high-density, high-speed applications. The grounding structure provides consistent and gapless conductive shielding around the signal transmission lines, thereby ensuring improved signal transmission and reduced signal attenuation. The contact module provides stable impedance control along the signal transmission line by controlling the dielectric material surrounding the signal transmission line via a grounding structure, thereby maintaining signal quality in high-speed data applications.

[0057] Connector housing 120 may retain or support cable assembly 110. For example, connector housing 120 includes a cable strain relief element 122 surrounding and retaining cable 102. Cable strain relief element 122 supports cable 102, for example at cable exit, to reduce stress or strain on the contact module at the mating end. Cable strain relief element 122 may be an in-situ molded overlay formed around cable assembly 110, such as around cable 102. Alternatively, cable strain relief element 122 may be pre-formed, such as a molded overlay having a cable channel formed therethrough, which receives cable 102.

[0058] In an exemplary embodiment, the connector housing 120 includes an outer plug housing 140 surrounding other components of the plug connector 100, such as the cable assembly 110 and the cable strain relief element 122. In various embodiments, the outer plug housing 140 may be conductive to provide shielding around the cable assembly 110. The outer plug housing 140 may be electrically connected to the cable assembly 110. In an exemplary embodiment, the outer plug housing 140 is configured to be coupled to a receptacle assembly 210, for example, to a cage 220. Figure 1 The external plug housing 140 can be electrically connected to the receptacle connector 200. In an exemplary embodiment, the external plug housing 140 includes a housing cavity 142 for retaining the cable assembly 110. The external plug housing 140 can be a metal housing or cage for receiving the cable assembly 110, such as a stamped housing. Alternatively, the connector housing 120 can be an electroplated plastic part, a die-cast part, etc.

[0059] In an exemplary embodiment, connector housing 120 extends between a top 124 and a bottom 126. The bottom 126 may be open to define an access port to allow access to cable assembly 110 for mating with receptacle connector 200. Connector housing 120 extends between a front portion 130 and a rear portion 132. The rear portion 132 may be open to allow cable 102 to enter / exit cavity 142. In another example, the top 124 may be open to allow cable 102 to pass through it, for example, when cable 102 extends vertically from connector housing 120. Connector housing 120 includes sides 134, 136 between the front portion 130 and the rear portion 132. Connector housing 120 includes latching features 138 at sides 134, 136 configured to abut with receptacle connector 200 or spring clips or other retaining features. In alternative embodiments, connector housing 120 may have other shapes and / or walls.

[0060] Figure 4 This is a perspective view of a portion of the plug connector 100, showing the cable assembly 110. Connector housing 120 ( Figure 3 The internal components of the plug connector 100 are shown below. In an exemplary embodiment, the cable assembly 110 includes a plurality of cables 102, cable termination modules 150 configured to be electrically connected to a receptacle connector 200 at the ends of the cables 102, and a grounding block 300 holding the cable termination modules 150. The grounding configuration of the cable termination modules 150 is configured to be electrically connected to the grounding block 300. The grounding configuration of each cable termination module 150 is configured to be at the same potential as the grounding block 300. In an exemplary embodiment, the grounding block 300 is configured to directly mate with the receptacle connector 200 to electrically connect the grounding configuration of the plug connector 100 to the grounding configuration of the receptacle connector 200. For example, the bottom of the grounding block 300 forms a mating interface directly connected to the receptacle connector 200.

[0061] In an exemplary embodiment, each cable termination module 150 includes a contact module 400 and a grounding cage 500 associated with the contact module 400. The contact module 400 is configured to be coupled to the end of a corresponding cable 102. The grounding cage 500 is configured to be coupled to the cable 102. The grounding cage 500 provides circumferential shielding for the ends of the cable 102 and the contact module 400. The grounding cage 500 is configured to be coupled to a grounding block 300 to electrically connect the cable termination module 150 to the grounding block 300. The grounding cage 500 and / or the contact module 400 may control the cable exit direction, for example, in a vertical direction or at a non-vertical exit angle. The grounding cage 500 and / or the contact module 400 may be angled to allow the cable 102 to exit at any desired or designed angle, for example, an angle between 0° and 90°. In various embodiments, the cable 102 may exit at an angle between 30° and 60° relative to the grounding block 300. Alternatively, cables 102 in different rows can exit at different angles. The grounding cage 500 and / or contact module 400 hold the cables 102 at an angle relative to the grounding block 300, allowing the cables 102 to be lifted off and away from the grounding block 300, rather than lying flat or parallel to it. This arrangement allows for a tighter encapsulation of the cable assembly, increasing the density of the cable assembly 110 for a given footprint.

[0062] Grounding block 300 supports contact module 400, grounding cage 500, and cable 102. In one exemplary embodiment, grounding block 300 is conductive to form part of a shielding structure for signal transmission lines, providing shielding through cable termination module 150 together with grounding cage 500. For example, grounding block 300 can provide shielding from grounding cage 500 to receptacle connector 200. Grounding cage 500 may include mating elements configured to mate with grounding block 300, such as spring beams, grounding beams, connecting tabs, solder tabs, or other types of connecting elements. In an exemplary embodiment, grounding block 300 may be a solid metal block. Grounding block 300 may be machined or die-cast. In alternative embodiments, grounding block 300 may be a laminated structure. For example, grounding block 300 may include multiple flat metal plates arranged in a plate stack. Laminated structures allow for customization of the electrical and mechanical properties of the device to suit specific application requirements. In various other embodiments, grounding block 300 may be an electroplated plastic or conductive plastic structure.

[0063] The grounding block 300 includes recesses 320 for receiving corresponding contact modules 400 and grounding cage 500. Recesses 320 can be arranged in an array, such as multiple rows and / or columns. Recesses 320 may have varying hole patterns, allowing for adjustable geometry of the plug connector 100. Recesses 320 can be designed for tight tolerances to fit into small-pitch interconnect coverage areas. Recesses 320 may open at the top and / or bottom to receive components. Recesses 320 position contact modules 400 relative to each other, for example, for alignment and mating with receptacle connector 200. Contact modules 400 can maintain precise alignment within recesses 320 to ensure proper mating and signal transmission with receptacle connector 200, thereby improving performance. In an exemplary embodiment, the contact module 400 can be precisely vertically arranged within the grounding block 300 such that the mating portion of the contact module 400 is coplanar with the bottom surface of the grounding block 300, allowing the mating portion of the contact module 400 and the bottom surface of the grounding block 300 to mate with the socket connector 200. In an exemplary embodiment, the bottom surface of the grounding block 300 can maintain a strict coplanarity requirement for mating with the socket connector 200 (e.g., coplanarity less than + / - 0.020 mm).

[0064] In an exemplary embodiment, the grounding cage 500 is made of multiple components. For example, each grounding cage 500 includes a clamp 510, a front cover 550 coupled to the front of the clamp 510, and a rear cover 580 coupled to the rear of the clamp 510. The front and rear covers 550, 580 are configured to be coupled to the clamp 510 to provide circumferential shielding around the ends of the corresponding cable 102 and the corresponding contact module 400. In various embodiments, multiple front covers 550 and / or multiple rear covers 580 may be combined together in the form of a strip configured to be coupled to the corresponding clamp 510 and hold the grounding cage 500 together as a unit.

[0065] The clamp 510 may be a stamped element configured to receive the end of the cable 102 and / or at least a portion of the contact module 400. The clamp 510 is configured to be electrically connected to the cable shield 106, for example at multiple contact points (e.g., along the bottom and / or right and / or left side of the cable). The clamp 510 is configured to be electrically connected to the grounding block 300, for example by welding, soldering, press fitting, connection via a spring beam, or other means. In alternative embodiments, the clamp 510 may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining.

[0066] The front cover 550 may be a stamped element configured to cover the front end and / or contact module 400 of the cable 102. The rear cover 580 may be a stamped element configured to cover the rear end and / or contact module 400 of the cable 102. In alternative embodiments, the front cover 550 and the rear cover 580 may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining. The front cover 550 is configured to be electrically connected to the clamp 510, for example, at one or more contact points. The front cover 550 may be directly electrically connected to the cable shield 106, for example, at one or more contact points (e.g., at the top of the cable). The rear cover 580 is configured to be electrically connected to the clamp 510, for example, at one or more contact points. The rear cover 580 may be electrically connected to the cable shield 106, for example, at one or more contact points (e.g., at the bottom of the cable). The front cover 550 and the rear cover 580 are configured to be electrically connected to the sleeve 510, for example, by welding or soldering to the sleeve 510 or by press-fit attachment or compression connection. The front cover 550 and the rear cover 580 are configured to be electrically connected to the ground block 300, for example, by welding, soldering, press-fit, spring beam or by other means.

[0067] In an exemplary embodiment, the grounding cage 500 is used for electrical connection to the cable 102, for example, to improve the electrical performance of the cable assembly 110. For example, the grounding cage 500 can reduce excessive insertion loss and crosstalk due to tighter control of the electromagnetic field at the termination area. The grounding cage 500 can be electrically connected to the cable 102 at multiple locations. For example, the grounding cage 500 can be electrically connected at the top, bottom, and sides to provide a nearly circumferential connection between the cable 102 and the grounding cage 500. The grounding cage 500 provides a short ground return path between the cable 102 and the receptacle connector 200 (via the grounding block 300) to improve electrical characteristics. The grounding cage 500 cooperates with the grounding block 300 to provide shielding at the transition between the cable 102 and the receptacle connector 200, for example, along the end of the cable 102 and along the contact module 400.

[0068] Figure 5 This is an exploded view of the grounding block 300 according to an exemplary embodiment. Figure 6 This is a top perspective view of the assembly of a grounding block 300 according to an exemplary embodiment. In the illustrated embodiment, the grounding block 300 is a laminated structure. For example, the grounding block 300 includes a plurality of flat metal plates 302 arranged in a plate stack 303. In an alternative embodiment, the grounding block 300 may be a solid metal block, such as a machined or die-cast component.

[0069] In the illustrated embodiment, the grounding block 300 comprises twelve plates 302 arranged in a plate stack 303. However, in alternative embodiments, more or fewer plates 302 may be provided. The plates 302 may have a uniform thickness. Alternatively, one or more of the plates 302 may have different thicknesses. The plates 302 are made of a conductive material such as a metallic material. For example, the plates 302 may be made of copper or a copper alloy. In an exemplary embodiment, the conductive material is a phosphor bronze alloy, such as CuSn8 containing about 8% tin. The conductive material may contain between 7% and 9% tin. The conductive material may contain between 0.01% and 0.35% phosphorus. The conductive material may contain less than 0.01% iron. The conductive material may contain less than 0.005% lead. The conductive material may contain less than 0.02% zinc. The conductive material may have a conductivity greater than 5.0 m / Ω•mm² (9% IACS). The conductive material may have high strength properties, good wear resistance, good corrosion resistance, and good spring properties. In an exemplary embodiment, the conductive material is configured to be solderable and to be fusion-welded.

[0070] A grounding block 300 extends between a top 304 and a bottom 306. The grounding block 300 has an upper surface 305 at the top 304 and a lower surface 307 at the bottom 306. The lower surface 307 defines a mating interface configured to mate with a receptacle connector 200 to electrically connect the grounding configuration of the plug connector 100 to the grounding configuration of the receptacle connector 200. The grounding block 300 includes a side 308 extending between the top 304 and the bottom 306.

[0071] In an exemplary embodiment, plate 302 includes openings 322 with tracks 324 between the openings 322. Some or all of the openings 322 may pass through plate 302. The tracks 324 form a grid and extend longitudinally and laterally through plate 302 between sides 308. The tracks 324 may be stacked on top of each other. The tracks may be joined together, for example, by welding. Plate 302 is arranged in a plate stack 303, wherein the openings 322 are aligned to form recesses 320. The recesses 320 pass through the plate stack 303 between a top 304 and a bottom 306 and are configured to retain corresponding cable termination modules 150 (e.g., Figure 3 (As shown).

[0072] In an exemplary embodiment, the ground block 300 includes sidewalls 314 and endwalls 316 forming recesses 320. Recesses 320 are arranged in a multi-row, multi-column array between sidewalls 308. In an exemplary embodiment, the ground block 300 has a thickness between its top and bottom. The recesses 320 may have a lateral width and a longitudinal width across the recesses 320. In various embodiments, the lateral width and longitudinal width dimensions may be within 10% of the thickness of the ground block 300. The lateral width and / or longitudinal width may be equal to a measured thickness of the ground block 300. In various embodiments, the ground block 300 has a thickness of approximately 1.2 mm. In alternative embodiments, the ground block 300 may have other thicknesses. Each plate may have a thickness of approximately 0.1 mm. The recesses 320 may have a lateral width of approximately 1.3 mm. The recesses 320 may have a longitudinal width of approximately 1.0 mm. In alternative embodiments, the recesses 320 may have other widths.

[0073] In an exemplary embodiment, the grounding block 300 includes a groove 330 adjacent to the recess 320. The groove 330 is formed in the track 324. The groove 330 may pass through some or all of the plate 302. The groove 330 is configured to receive a portion of the grounding cage 500. For example, a portion of the grounding cage 500 may be press-fitted into the groove 330. The groove 330 may be rectangular. In alternative embodiments, other shapes are feasible, such as dog bone or hourglass shapes, which are smaller in the central region and wider at the ends. The dog bone shape may provide a central region for press-fitting and / or welding to a portion of the grounding cage 500 inserted into the groove 330 to establish a mechanical and electrical connection with the grounding cage 500. In the illustrated embodiment, the groove 330 opens at the top 304 of the grounding block 300 to receive the grounding cage 500. The groove 330 may also open at the bottom 306 of the grounding block 300, for example for welding the grounding cage 500 to the grounding block 300.

[0074] In an exemplary embodiment, the grounding block 300 includes a recess 340. The recess 340 is configured to receive a plug 342 or other securing tool for aligning and / or engaging plates 302 in a plate stack 303. The plug 342 may be welded or soldered to the plate 302 to hold the plate 302 in the plate stack 303. The recess 340 may receive other components, such as an external plug housing 140, to connect the grounding block 300 to the external plug housing 140. In the illustrated embodiment, the recess 340 is located in the side 308. In alternative embodiments, other locations are also possible. In an exemplary embodiment, the hole 340 opens at the top 304 to receive the plug 342. The recess 340 may open at the side 308.

[0075] In an exemplary embodiment, the grounding block 300 includes alignment elements 350 at a top 304 and / or a bottom 306. Alignment elements 350 are used to align the grounding block 300 with the receptacle connector 200 and / or the connector housing 120. Alignment elements 350 may be pins, posts, tabs, slots, recesses, openings, or other types of positioning features. Alignment elements 350 may interact with corresponding alignment elements of the receptacle connector 200 for alignment with the receptacle connector 200, such as posts extending from the receptacle connector 200.

[0076] In an exemplary embodiment, plate 302 is a stamped plate. In alternative embodiments, plate 302 may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining. Plate 302 may be thin and planar. Providing different stamped plates instead of machined thick metal blocks allows the ground block 300 to be manufactured to precise tolerances, as plate 302 can be manufactured more precisely than machined thick metal blocks. High-precision manufacturing ensures that each dwelling cavity within the structure is nearly identical to its adjacent cavities, thereby promoting signal integrity and minimizing variations in electrical performance. Each plate 302 includes an upper surface 360 ​​and a lower surface 362. An opening 322 passes through plate 302 between the upper surface 360 ​​and the lower surface 362. Plate 302 has a thickness between the upper surface 360 ​​and the lower surface 362. Optionally, the thickness of each plate 302 may be the same for all plates 302 within a plate stack 303. Alternatively, the thickness of each plate 302 may be different for some plates 302 within a plate stack 303. For example, the thickness may vary for mechanical reasons, such as to form a mechanical connection layer with the grounding cage 500 or to provide rigidity or stability to the board stack 303. The thickness can be selected to control impedance or other electrical characteristics along signal lines passing through the grounding block 300. The size of the opening 322 may be the same for all boards 302 within the board stack 303. Alternatively, the size of the opening 322 in each board 302 may differ for some boards 302 within the board stack 303. For example, in some boards 302, the size of the opening 322 may be larger or smaller to control impedance or other electrical characteristics along signal lines passing through the grounding block 300.

[0077] In an exemplary embodiment, the plates 302 in the plate stack 303 include a top plate 302t, a bottom plate 302b, and an inner plate 302i between the top plate 302t and the bottom plate 302b. The top plate 302t may differ from the other plates 302. The bottom plate 302b may differ from the other plates 302. For example, the opening 322b in the bottom plate 302b may be smaller in the longitudinal and / or transverse directions, such that the bottom opening 322b reduces the size of the recess 320 at the bottom layer.

[0078] In an exemplary embodiment, positioning surface 326 ( Figure 6The base plate 302b is formed at the bottom of the recess 320. A positioning surface 326 can be used to position the cable termination module 150 relative to the grounding block 300. For example, the positioning surface 326 can be used to vertically position the cable termination module 150 in the recess 320. For example, the positioning surface 326 can form a loading stop for loading the cable termination module 150 into the recess 320. In alternative embodiments, other types of positioning features can be used, such as features for longitudinally and / or laterally positioning the cable termination module 150 in the recess 320. The positioning feature can be part of the grounding block 300, or it can be a separate positioning or securing tool for positioning the cable termination module 150 in the recess 320.

[0079] In an exemplary embodiment, the base plate 302b includes an opening 328 instead of a groove 330. The opening 328 may have a different shape than the groove 330. For example, the opening 328 may be circular. In alternative embodiments, the opening 328 may have other shapes. The size and shape of the opening 328 may be designed to prevent the grounding cage 500 from passing through the opening 328. For example, the base plate 302b may have a stop surface formed for the grounding cage 500 during assembly. The opening 328 is aligned with the groove 330. For example, the portion of the groove 330 and the inner plate 302i located in the groove 330 can be accessed from below through the opening 328, for example, for welding.

[0080] Figure 7 This is a bottom view of a portion of one of the grounding plates 302 according to an exemplary embodiment. The plate 302 may be held by a carrier 301 during the stamping and manufacturing process, wherein the carrier 301 is removed or detached at a later stage.

[0081] Plate 302 includes openings 322 arranged in rows and columns, and tracks 324 between the openings 322. A slot 330 is formed in the track 324 adjacent to the openings 322. In the illustrated embodiment, the slot 330 is dog-bone or hourglass shaped, smaller in the central region and wider at the ends. When a connecting portion is inserted into the slot 330, the central region can extend inward to engage or press against the connecting portion of the grounding cage 500 to form a tight fit with the connecting portion for welding to the grounding cage 500. In an exemplary embodiment, the size of the slot 330 around the outer periphery (outer slot) can be smaller than the slot 330 inside plate 302 (inner slot) because the outer slot can receive connecting portions from a single grounding cage 500, while the inner slot receives connecting portions from two grounding cages 500.

[0082] Figure 8 This is a bottom view of a portion of the bottom mounting plate 302b according to an exemplary embodiment. The bottom plate 302b may be held by a carrier 301b during the stamping and manufacturing process, wherein the carrier 301b is removed or separated at a later stage.

[0083] The base plate 302 includes openings 322 arranged in rows and columns, and tracks 324 between the openings 322. In an exemplary embodiment, the openings 322 are larger than the openings 322 of the other plates 302 (in... Figure 7 (as shown in the figure) smaller (shorter and / or narrower in the longitudinal and / or lateral directions).

[0084] Opening 328 is formed adjacent to opening 322 in track 324. In the illustrated embodiment, opening 328 has a groove 330 ( Figure 7 Different shapes are possible. For example, opening 328 can be circular. In alternative embodiments, opening 328 can have other shapes. The size and shape of opening 328 can be designed to prevent the connecting portion of the grounding cage 500 from passing through opening 328. Opening 328 can be aligned with slot 330 to allow access from below through opening 328 to the connecting portion of the grounding cage 500 and the track 324 of plate 302 surrounding slot 330 for welding.

[0085] Figure 9 This is a perspective view of a portion of the contact module 400 according to an exemplary embodiment. Figure 10 This is a rear perspective view of a portion of the contact module 400 according to an exemplary embodiment. Figure 11 This is a front perspective view of a portion of the contact module 400 according to an exemplary embodiment.

[0086] Contact module 400 includes contact retainer 410 for holding one or more contacts 430. Figure 10 and 11In an exemplary embodiment, contact holder 410 holds a pair of contacts 430. Contacts 430 may be stamped contacts. Contacts 430 are made of a conductive material such as a metallic material. For example, contacts 430 may be made of copper or a copper alloy. In an exemplary embodiment, the conductive material is a phosphor bronze alloy, such as CuSn8 containing about 8% tin. The conductive material may contain between 7% and 9% tin. The conductive material may contain between 0.01% and 0.35% phosphorus. The conductive material may contain less than 0.01% iron. The conductive material may contain less than 0.005% lead. The conductive material may contain less than 0.02% zinc. The conductive material may have a conductivity greater than 5.0 m / Ω•mm² (9% IACS). The conductive material may have high strength properties, good wear resistance, good corrosion resistance, and good spring properties. In an exemplary embodiment, the conductive material is configured to be solderable and fusion-weldable. Contact 430 may be a differential pair configured to transmit differential signals. Contact retainer 410 holds the relative position of contact 430, for example, along a parallel path through contact module 400. Contact retainer 410 may be overmolded onto contact 430. In an alternative embodiment, contact 430 may be inserted into contact retainer 410, for example, into a channel formed in contact retainer 410. Contact 430 is configured to be electrically connected to a corresponding cable 102. Contact 430 is configured to be electrically connected to receptacle connector 200. Figure 2 ).

[0087] The contact retainer 410 is made of a dielectric material, such as a plastic material. For example, the contact retainer 410 can be a molded structure, such as an injection molded part. The contact retainer 410 can be an overmolded body overmolded onto the contact 430. For example, the contact retainer 410 can be formed in place around the contact 430. The contact retainer 410 extends between a top 412 and a bottom 414. The contact retainer 410 includes a first end or front portion 416 and a second end or rear portion 418. The contact retainer 410 includes a first side 417 between the first end 416 and the second end 418 and a second side 419 between the first end 416 and the second end 418.

[0088] In an exemplary embodiment, the contact retainer 410 includes one or more securing features 420 for securing the contact retainer 410 to the grounding cage 500. In the illustrated embodiment, the securing feature 420 includes a heat-fused tab projecting from a front portion 416 and / or a rear portion 418, configured to heat-fused to the grounding cage 500. In alternative embodiments, other types of securing features 420 may be used, such as compression ribs, clips, latches, fasteners, etc. The contact retainer 410 is configured to be securely fixed relative to the grounding cage 500 to ensure a stable electrical connection and maintain the desired impedance characteristics throughout the cable termination module 150.

[0089] In an exemplary embodiment, the contact holder 410 includes a recess 422 at its bottom, which is configured to receive a portion of the contact 430. The contact 430 may be flush with the bottom 414 of the contact holder 410 within the recess 422. In an exemplary embodiment, the contact holder 410 includes an alignment element 424 for aligning or positioning the contact module 400 within the grounding cage 500 and / or the grounding block 300. The alignment element 424 may include a wall, surface, tab, pin, post, opening, recess, slot, or other type of alignment feature. The alignment element 424 may be used for vertically aligning the contact holder 410, longitudinally aligning the contact holder 410, and / or laterally aligning the contact holder 410 relative to the grounding cage 500 and / or the grounding block 300.

[0090] Contacts 430 pass through contact retainer 410. Each contact 430 includes a connecting end 432 and a terminating end 434. The connecting end 432 is configured to directly mate with receptacle connector 200. In the illustrated embodiment, the connecting end 432 includes a connecting pad configured to engage with a corresponding receptacle contact of receptacle connector 200. The connecting pad may be bent at an angle, such as a right angle, such that the connecting pad extends along the bottom of contact module 400 and is configured to press downward against the compressible interface of receptacle connector 200. However, in alternative embodiments, other types of connecting ends may be used, such as spring beams, solder tails, solder balls, pins, receptacles, or another type of connecting end. The connecting end 432 is exposed at the bottom 414 of contact retainer 410 for connection to receptacle connector 200.

[0091] Termination end 434 is configured to be electrically connected to the conductor of cable 102. In the illustrated embodiment, termination end 434 includes a pad (e.g., a solder pad) configured to be soldered or welded to the conductor of cable 102. In alternative embodiments, other types of termination ends may be provided, such as crimp sleeves and IDC connectors. In an exemplary embodiment, termination end 434 extends from contact retainer 410, for example, from top 412. Thus, termination end 434 is exposed above top 412 of contact retainer 410 for connection to the conductor of cable 102.

[0092] In the illustrated embodiment, the termination end 434 is bent at an angle relative to the connection end 432 for connection to the conductor of the cable 102. For example, the termination end 434 may be bent at an angle corresponding to the exit angle of the cable 102 to allow the conductor to extend parallel to the axis of the cable 102. In the illustrated embodiment, the termination end 434 forms an angle between 30° and 60° relative to the vertical axis; however, the termination end 434 may be oriented at other angles, such as any angle between 0° and 90°. In various embodiments, the termination end 434 may be oriented vertically or horizontally.

[0093] Figure 12 An end of one of the cables 102 according to an exemplary embodiment is shown. The cable 102 includes at least one signal conductor and a shielding structure providing electrical shielding for the at least one signal conductor. In an exemplary embodiment, the cable 102 is a biaxial cable. For example, the cable 102 includes first and second signal conductors 104 held by one or more insulators. The signal conductors 104 carry differential signals. The signal conductors 104 are configured to terminate at the ends of corresponding contacts 430.

[0094] Cable 102 includes a cable shield 106 surrounding an insulator and a signal conductor 104 to provide circumferential shielding around the signal conductor 104. Cable 102 includes a cable sheath 108 surrounding the cable shield 106. In various embodiments, cable 102 may or may not include one or more strippers electrically connected to the cable shield 106, such as a pair of strippers extending along opposite sides of cable 102 between the cable shield 106 and the cable sheath 108. In an exemplary embodiment, at an end of cable 102, the cable sheath 108, cable shield 106, and insulator may be removed (e.g., stripped) to expose a portion of the signal conductor 104. The exposed portion of the signal conductor 104 is configured to be mechanically and electrically coupled (e.g., welded, soldered, crimped, etc.) to a corresponding contact of contact module 400. For example, the exposed portion of the signal conductor 104 may be butt-welded or lap-welded to contact 430 at a weld joint.

[0095] Figure 13 This is a perspective view of the clamp 510 of a grounding cage 500 according to an exemplary embodiment. The clamp 510 is made of a conductive material such as a metal. For example, the clamp 510 may be made of copper or a copper alloy. In an exemplary embodiment, the conductive material is a phosphor bronze alloy, such as CuSn8 containing about 8% tin. The conductive material may contain between 7% and 9% tin. The conductive material may contain between 0.01% and 0.35% phosphorus. The conductive material may contain less than 0.01% iron. The conductive material may contain less than 0.005% lead. The conductive material may contain less than 0.02% zinc. The conductive material may have a conductivity greater than 5.0 m / Ω•mm² (9% IACS). The conductive material may have high strength properties, good wear resistance, good corrosion resistance, and good spring properties. In an exemplary embodiment, the conductive material is configured to be solderable and fusion-weldable. In an exemplary embodiment, the clamp 510 is a stamped part.

[0096] The clamp 510 includes a base wall 512, a first sidewall 514 extending from a first side of the base wall 512, and a second sidewall 516 extending from a second side of the base wall 512. The clamp 510 includes a bracket 518 formed by the base wall 512, the first sidewall 514, and the second sidewall 516. The bracket 518 is configured to receive a cable 102. The base wall 512 may be disposed at the top or bottom of the clamp 510. The bracket 518 may be open relative to the base wall 512, for example, at the top or bottom between the first sidewall 514 and the second sidewall 516, to receive the cable 102. The base wall 512 is used to engage and support a portion of the cable 102. The first sidewall 514 is used to engage and support a first side of the cable 102. The second sidewall 516 is used to engage and support a second side of the cable 102. In the illustrated embodiment, the first sidewall 514 and the second sidewall 516 extend substantially perpendicularly from the base wall 512. The corners where the first sidewall 514 and the second sidewall 516 intersect with the base wall 512 can be curved, such as generally following the curvature of the cable 102. In alternative embodiments, the sleeve 510 can be multiple pieces instead of a single piece, for example having separate first and second sidewalls 514, 516, which are configured to be joined together by other pieces, such as the base wall 512 or the front cover 550 and the rear cover 580. Figure 4 ).

[0097] In an exemplary embodiment, the sleeve 510 includes a shielding wall 520 at its bottom 522. The shielding wall 520 extends downward from a first sidewall 514 and a second sidewall 516. The shielding wall 520 may support a portion of the contact module 400. The shielding wall 520 provides shielding along a portion of the contact module 400. The shielding wall 520 may be coupled to a grounding block 300.

[0098] In an exemplary embodiment, the clamp 510 includes a crimping tab 524 at its top 526. The crimping tab 524 extends from the base wall 512. The crimping tab 524 is located above the side walls 514, 516. The crimping tab 524 is configured to crimp onto the cable 102 to mechanically secure the clamp 510 to an end of the cable 102. The crimping tab 524 can be electrically connected to the cable 102, for example, by crimping onto the cable shield of the cable 102.

[0099] In an exemplary embodiment, the clamp 510 includes a connecting tab 530 extending from the sidewalls 514, 516. The connecting tab 530 is configured to connect to the front cover 550 and / or the rear cover 580 of the grounding cage 500 (both within...). Figure 4(As shown in the diagram). For example, the connecting tab 530 may be welded to the front cover 550 and / or the rear cover 580. In the illustrated embodiment, the connecting tab 530 is rectangular. However, in alternative embodiments, the connecting tab 530 may have other shapes. The connecting tab 530 may include a recess or spring beam configured to form a mechanical press-fit connection with the cover 550.

[0100] In an exemplary embodiment, the shielding wall 520 includes one or more grounding beams 540. The grounding beams 540 may extend downwards from the bottom of the shielding wall 520. In an exemplary embodiment, the grounding beams 540 are deflectable and configured to engage with the grounding block 300. For example, when the grounding cage 500 is inserted into the grounding block 300, the grounding beams 540 may abut against the grounding block 300 to deflect and electrically connect the grounding cage 500 to the grounding block 300. The grounding beams 540 may include bent ends to form mating interfaces configured to directly engage the grounding block 300. In the illustrated embodiment, a plurality of grounding beams 540 are disposed on each shielding wall 520. The grounding beams 540 extend parallel to each other. The grounding beams 540 are separated by slots to allow independent movement of the grounding beams 540. The grounding beams 540 may serve as positioning or alignment features to position or align the cable termination module 150 in the recesses 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0101] In various embodiments, the shielding wall 520 may include retaining barbs (not shown) extending therefrom, for example, from a side edge of the shielding wall 520. The retaining barbs may press-fit into a recess in the grounding block 300 to create a mechanical and electrical connection with the grounding block 300. The retaining barbs may serve as positioning or alignment features to position or align the cable termination module 150 in the recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0102] Figure 14 This is a perspective view of a portion of the cable termination module 150, showing the clamp 510 positioned relative to the cable 102. Figure 15 This is a perspective view of a portion of the cable termination module 150, showing the clamp 510 positioned relative to the cable 102. Figure 14 The sleeve 510 is shown in an unpressed state. Figure 15 The sleeve 510 is shown in a crimped state.

[0103] During assembly, cable 102 is received in bracket 518. Bracket 518 is positioned against base wall 512, first sidewall 514, and second sidewall 516. During assembly, crimp tab 524 is crimped onto cable 102 to mechanically secure ferrule 510 to the end of cable 102. Crimping tab 524 may be electrically connected to cable 102, for example, by crimping to cable shield 106 of cable 102. In various embodiments, crimp tab 524 may be welded to cable shield 106.

[0104] Figure 16 This is a perspective view of a portion of the cable termination module 150, showing the contact module 400 positioned relative to the clamp 510 and the cable 102 at the termination interface 436. The termination interface 436 is located between the top 412 of the contact retainer 410 and the end of the cable 102. The exposed portion of the signal conductor 104 and the exposed portion of the termination end 434 of the contact 430 extend into the termination region to define the termination interface 436. The sidewalls 514, 516 of the clamp 510 provide shielding along the termination region.

[0105] Figure 16 An assembly tool 600 used during the assembly process is shown. The assembly tool 600 includes an edge 602 for supporting the end of the conductor 104 and the termination end 434 of the contact 430 to position the contact module 400 relative to the cable 102. The assembly tool 600 is removed after the contact 430 is terminated at the end of the cable 102.

[0106] During assembly, contact module 400 is loaded into bracket 518 between sidewalls 514, 516. Shielding wall 520 may extend along sides 417, 419 of contact retainer 410. Grounding beam 540 extends along sides 417, 419. Grounding beam 540 may extend along contact 430, for example, along both sides of contact 430. Contact retainer 410 electrically isolates shielding wall 520 from contact 430. The material of contact retainer 410 and the spacing between shielding wall 520 and contact 430 control the impedance along the signal transmission line. In an exemplary embodiment, termination end 434 of contact 430 may be welded or soldered to the end of conductor 104 at a termination area. For example, termination end 434 may be butt-welded to the end of conductor 104 at butt weld joint 438 (e.g., butt weld joint). Alternatively, the termination end 434 can be lap-welded to the end of the conductor 104 at a lap-welded joint.

[0107] Figure 17 This is a front perspective view of a portion of a cable termination module 150 according to an exemplary embodiment, showing a front cover 550 connected to a sleeve 510. Figure 18This is a rear perspective view of a portion of a cable termination module 150 according to an exemplary embodiment, showing a front cover 550 connected to a sleeve 510.

[0108] During assembly, the front cover 550 is coupled to the front of the sleeve 510. The front cover 550 is electrically connected to the sleeve 510. For example, the front cover 550 may be welded or fused to the sleeve 510. In an alternative embodiment, the front cover 550 may be stamped and formed together with the sleeve 510, for example, as an integral part of the sleeve 510. The front cover 550 may cover a portion of the bracket 518. The front cover 550 covers a portion of the contact module 400 to provide electrical shielding, for example, along the front of the contact module 400.

[0109] The front cover 550 is made of a conductive material, such as a metal. For example, the front cover 550 may be made of copper or a copper alloy. In an exemplary embodiment, the conductive material is a phosphor bronze alloy, such as CuSn8 containing about 8% tin. The conductive material may contain between 7% and 9% tin. The conductive material may contain between 0.01% and 0.35% phosphorus. The conductive material may contain less than 0.01% iron. The conductive material may contain less than 0.005% lead. The conductive material may contain less than 0.02% zinc. The conductive material may have a conductivity greater than 5.0 m / Ω•mm² (9% IACS). The conductive material may have high strength properties, good wear resistance, good corrosion resistance, and good spring properties. In an exemplary embodiment, the conductive material is configured to be solderable and fusion-weldable. In an exemplary embodiment, the front cover 550 is a stamped component. Multiple front covers 550 may be stamped from a single sheet of metal and connected by a tie rod or other connecting structure.

[0110] The front cover 550 includes a cover wall 554 configured to extend along the front of the cable 102 and a corresponding clamp 510 to cover the front of the cable 102. In an exemplary embodiment, the cover wall 554 includes one or more pressing tabs 556 configured to be pressed by a pressing tool during loading of the cable termination module 150 into the grounding block 300. In an alternative embodiment, the front cover 550 may include additional walls, such as sidewalls configured to extend along the side of the cable 102.

[0111] In an exemplary embodiment, the front cover 550 includes a shielding wall 560 extending from the cover wall 554. In the illustrated embodiment, the shielding wall 560 may extend downward from the front portion of the cover wall 554. The shielding wall 560 may extend at an angle relative to the cover wall 554. The shielding wall 560 provides shielding along the front portion of the contact module 400. In an exemplary embodiment, the shielding wall 560 includes an opening 562. The opening 562 receives a fixing feature 420 of the contact holder 410. The fixing feature 420 may be heat-fused to the front cover 550.

[0112] The shielding wall 560 is configured to be coupled to the grounding block 300. For example, the shielding wall 560 may include one or more grounding beams 564. The grounding beams 564 may extend downward from the bottom of the shielding wall 560. The grounding beams 564 may extend along a first side 416 (e.g., the front) of the contact holder 410. The grounding beams 564 may extend along the contact 430 (e.g., in front of the contact 430). In an exemplary embodiment, the grounding beams 564 are aligned with the contact 430, such as with the corresponding contact 430.

[0113] In an exemplary embodiment, the grounding beam 564 is deflectable and configured to engage with the grounding block 300. For example, when the grounding cage 500 is inserted into the grounding block 300, the grounding beam 564 can abut against the grounding block 300 to deflect and electrically connect the grounding cage 500 to the grounding block 300. The grounding beam 564 may include a bent end to form a mating interface configured to directly engage the grounding block 300. In the illustrated embodiment, a plurality of grounding beams 564 are disposed on each shielding wall 560. The grounding beams 564 extend parallel to each other. The grounding beams 564 are separated by slots to allow independent movement of the grounding beams 564. The grounding beams 564 can be used as positioning or alignment features to position or align the cable termination module 150 in the recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0114] In various embodiments, the shielding wall 560 may include one or more retaining barbs (not shown) extending therefrom, for example, from a side edge of the shielding wall 560. The retaining barbs may press-fit into recesses in the grounding block 300 to establish a mechanical and electrical connection with the grounding block 300. The retaining barbs may also press-fit into recesses 320 in the grounding block 300 to establish a mechanical and electrical connection with the grounding block 300. The retaining barbs may serve as positioning or alignment features to position or align the cable termination module 150 in the recesses 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0115] In an exemplary embodiment, the front cover 550 includes one or more positioning or alignment features to position or align the cable termination module 150 in a recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning). In an exemplary embodiment, the positioning or alignment features include a connecting leg 566 extending from the shielding wall 560 or the cover wall 554. The connecting leg 566 is configured to insert into the grounding block 300, for example, into a corresponding slot 330 in the grounding block 300. The connecting leg 566 is configured to be mechanically and / or electrically connected to the grounding block 300 in the slot 330. For example, the connecting leg 566 may be welded or soldered to the grounding block 300, for example, along the side(s), along the edge(s), and / or at its distal end. In other embodiments, the connecting leg 566 may be connected by an interference fit.

[0116] In an exemplary embodiment, the front cover 550 includes a connecting tab 568 extending from the side edges of the cover wall 554 and / or the shielding wall 560. The connecting tab 568 is configured to connect to the sleeve 510. For example, the connecting tab 568 may be welded to the sleeve 510. The connecting tab 568 may nest with the connecting tab 530 to form a weld surface or recess. In the illustrated embodiment, the connecting tab 568 is rectangular. However, in alternative embodiments, the connecting tab 568 may have other shapes.

[0117] In an exemplary embodiment, after the front cover 550 is attached to the sleeve 510, a termination area or space surrounding the termination interface 436 may receive a termination support 426. For example, the termination area surrounding the exposed portions of the conductor 104 and the contact 430 may be filled with support material 428 supporting the termination interface 436. In an exemplary embodiment, the front cover 550, the sidewalls 514, 516 of the sleeve 510, the top 412 of the contact holder 410, and the end of the cable 102 form a recess 529 for receiving and accommodating the support material 428. The termination support 426 is configured to attach to the front cover 550 and / or the sleeve 510 and / or the contact holder 410 and / or the end of the cable 102.

[0118] Termination support 426 provides strain relief for the weld between conductor 104 and contact 430. For example, termination support 426 can provide support for butt weld joint 438. Termination support 426 can be formed in place in the termination area / space. For example, support material 428 can be injected, cast, or otherwise loaded into the termination area around termination interface 436. Support material 428 is adaptable to conform to the exposed portion of signal conductor 104 and the termination end 434 of contact 430. Support material 428 can be accommodated by front cover 550 and / or clamp 510 and / or contact retainer 410 and / or the end of cable 102. For example, support material 428 can fill the internal space between sidewalls 514, 516 and behind front cover 550. Support material 428 can be cured or hardened after placement to remain fixed in the termination area. Support material 428 is a dielectric material. In various embodiments, the support material 428 may be a hot melt, epoxy resin, room temperature vulcanizing (RVT) material, or other formable material. The support material 428 may be cured by exposure to air, ultraviolet light, or other curing methods. The type of material is selected to control the impedance along the signal transmission line. The support material 428 may have a dielectric constant greater than 1.0 to control the impedance through the termination region. In various embodiments, the support material 428 may have a dielectric constant greater than 2.0 to control the impedance through the termination region. In various embodiments, the support material 428 may have a dielectric constant greater than 3.0 to control the impedance through the termination region. The dielectric constant of the support material 428 may be similar to the dielectric constant of the insulator of the contact retainer 410 and / or the cable 102.

[0119] Figure 19 This is a front perspective view of a cable termination module 150 according to an exemplary embodiment, showing a rear cover 580 connected to a sleeve 510. Figure 20 This is a rear perspective view of the cable termination module 150 according to an exemplary embodiment, showing the rear cover 580 connected to the sleeve 510.

[0120] During assembly, the rear cover 580 is coupled to the rear of the clamp 510. The rear cover 580 is electrically connected to the clamp 510. For example, the rear cover 580 may be welded or soldered to the clamp 510. The rear cover 580 may cover a portion of the bracket 518. The rear cover 580 covers a portion of the contact module 400 to provide electrical shielding, for example, along the rear of the contact module 400. Once assembled, the assembled cable termination module 150 is a testable component. For example, the cable termination module 150 may be inserted into a test fixture to test signal transmission and grounding structures. The electrical characteristics of the cable termination module 150, such as reliability, transmission speed, bandwidth, delay, signal integrity, shielding, crosstalk, impedance, and resistance to vibration / shock / temperature fluctuations, can be tested.

[0121] The back cover 580 is made of a conductive material, such as a metal. For example, the back cover 580 may be made of copper or a copper alloy. In an exemplary embodiment, the conductive material is a phosphor bronze alloy, such as CuSn8 containing about 8% tin. The conductive material may contain between 7% and 9% tin. The conductive material may contain between 0.01% and 0.35% phosphorus. The conductive material may contain less than 0.01% iron. The conductive material may contain less than 0.005% lead. The conductive material may contain less than 0.02% zinc. The conductive material may have a conductivity greater than 5.0 m / Ω•mm² (9% IACS). The conductive material may have high strength properties, good wear resistance, good corrosion resistance, and good spring properties. In an exemplary embodiment, the conductive material is configured to be solderable and fusion-weldable. In an exemplary embodiment, the back cover 580 is a stamped part. Multiple back covers 580 may be stamped from a single sheet of metal and connected by a tie rod or other connecting structure.

[0122] The rear cover 580 includes a cover wall 584 configured to extend along the rear of the cable 102 and a corresponding clamp 510 to cover the rear of the cable 102. In an alternative embodiment, the rear cover 580 may include additional walls, such as sidewalls configured to extend along the side of the cable 102.

[0123] In an exemplary embodiment, the rear cover 580 includes a shielding wall 590 extending from the cover wall 584. In the illustrated embodiment, the shielding wall 590 may extend downward from the rear portion of the cover wall 584. The shielding wall 590 may extend at an angle relative to the cover wall 584. The shielding wall 590 provides shielding along the rear portion of the contact module 400. In an exemplary embodiment, the shielding wall 590 includes an opening 592. The opening 592 receives a fixing feature 420 of the contact holder 410. The fixing feature 420 may be heat-fused to the rear cover 580.

[0124] The shielding wall 590 is configured to connect to the grounding block 300. For example, the shielding wall 590 may include one or more grounding beams 594. The grounding beams 594 may extend downward from the bottom of the shielding wall 590. The grounding beams 594 may extend along a second side 418 (e.g., rear) of the contact holder 410. The grounding beams 594 may extend along the contact 430 (e.g., behind the contact 430). In an exemplary embodiment, the grounding beams 594 are aligned with the contact 430, such as with the corresponding contact 430. The grounding beams 594 may be aligned with the grounding beam 564 of the front cover 550 on the opposite side of the contact holder 410. The grounding beams 564 and 594 are located on opposite sides (front and rear) of the contact 430. In an exemplary embodiment, grounding beams 564 and 594 operate together with grounding beam 540 of sleeve 510 to provide shielding and grounding mating interfaces for grounding block 300 on all sides of contact 430, thereby forming a 360° fence-type grounding structure around contact 430.

[0125] In an exemplary embodiment, the grounding beam 594 is deflectable and configured to engage with the grounding block 300. For example, when the grounding cage 500 is inserted into the grounding block 300, the grounding beam 594 can abut against the grounding block 300 to deflect and electrically connect the grounding cage 500 to the grounding block 300. The grounding beam 594 may include a bent end to form a mating interface configured to directly engage the grounding block 300. In the illustrated embodiment, a plurality of grounding beams 594 are disposed on each shielding wall 590. The grounding beams 594 extend parallel to each other. The grounding beams 594 are separated by slots to allow independent movement of the grounding beams 594. The grounding beams 594 can be used as positioning or alignment features to position or align the cable termination module 150 in the recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0126] In various embodiments, shielding wall 590 may include one or more retaining barbs (not shown) extending therefrom, for example, from a side edge of shielding wall 590. The retaining barbs may press-fit into recesses in grounding block 300 to create a mechanical and electrical connection with grounding block 300. Retaining barbs may press-fit into recesses 320 in grounding block 300 to create a mechanical and electrical connection with grounding block 300. Retaining barbs may serve as positioning or alignment features to position or align cable termination module 150 in the recesses 320 of grounding block 300 (e.g., for lateral or longitudinal positioning). In the illustrated embodiment, shielding walls 590 and 560 include openings receiving retaining barbs 528 extending from shielding wall 520 of sleeve 510. Retaining barbs 528 pass through shielding walls 560, 590 of front cover 550 and rear cover 580 to abut against grounding block 300.

[0127] In an exemplary embodiment, the rear cover 580 includes one or more positioning or alignment features to position or align the cable termination module 150 in a recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning). In an exemplary embodiment, the positioning or alignment features include a connecting leg 596 extending from the shielding wall 590 or the cover wall 584. The connecting leg 596 is configured to insert into the grounding block 300, for example, into a corresponding slot 330 in the grounding block 300. The connecting leg 596 is configured to be mechanically and / or electrically connected to the grounding block 300 in the slot 330. For example, the connecting leg 596 may be welded or soldered to the grounding block 300, for example, along the side(s), along the edge(s), and / or at its distal end. In other embodiments, the connecting leg 596 may be connected by an interference fit.

[0128] In an exemplary embodiment, the sleeve 510 includes a connecting tab 598 extending from the side edge of the cover wall 584 and / or the shielding wall 590. The connecting tab 598 is configured to connect to the sleeve 510. For example, the connecting tab 598 may be welded to the sleeve 510. The connecting tab 598 may nest with the connecting tab 530 to form a weld surface or recess. In the illustrated embodiment, the connecting tab 598 is rectangular. However, in alternative embodiments, the connecting tab 598 may have other shapes.

[0129] Figure 21 A portion of a cable assembly 110 according to an exemplary embodiment is shown, illustrating a plurality of cable termination modules 150 mounted in a grounding block 300. Figure 22 A portion of a cable assembly 110 according to an exemplary embodiment is shown, illustrating a plurality of cable termination modules 150 mounted in a grounding block 300. In the exemplary embodiment, each of the cable termination modules 150 is independently testable before being assembled with the grounding block 300 into the cable assembly 110. For example, electrical characteristics of the cable termination module 150, such as reliability, transmission speed, bandwidth, delay, signal integrity, shielding, crosstalk, impedance, and resistance to vibration / shock / temperature fluctuations, can be tested. Testing the individual termination modules 150 prior to assembly improves manufacturing yield and reduces product output or rework.

[0130] During assembly, the cable termination module 150 can be individually loaded into the corresponding recess 320 of the grounding block 300. For example, the cable termination module 150 can be loaded into the recess 320 from above. In an exemplary embodiment, an assembly tool 610 can be used to assist assembly. The assembly tool 610 can be located below the grounding block 300 and is used to align components during assembly. For example, the assembly tool 610 can be used to position the grounding block 300 and / or the cable termination module 150 during assembly. In an exemplary embodiment, the assembly tool 610 includes a plate 612 and a contact locator 614 held by the plate 612. The plate 612 is located below the grounding block 300. The plate 612 can be used to provide a flat surface to support the plate 302 of the plate stack 303. The contact locator 614 can extend from the plate 612 into the recess 320 to mate with and position the cable termination module 150 during assembly. Contact positioner 614 can maintain the X, Y, and Z positioning of cable termination module 150 during assembly. Contact positioner 614 can hold all contacts 430 of contact module 400 coplanar within grounding block 300 during assembly. Cable termination module 150 can be pressed into grounding block 300 until cable termination module 150 bottoms against assembly tool 610. Other types of positioning elements can be used to position components relative to each other in one or more directions, including features that are part of grounding block 300 and / or cable termination module 150, rather than separate tools or fixing elements.

[0131] In one exemplary embodiment, a pressing tool 620 is used to press the cable termination module 150 into the recess 320. The pressing tool 620 may press against the pressing tab 556 of the front cover 550 to press the cable termination module 150 downward and load the grounding cage 500 and contact module 400 into the recess 320. During assembly, the connecting legs 566, 596 of the front cover 550 and the rear cover 580 are loaded into corresponding slots 330. In an exemplary embodiment, the first and second connecting legs 566, 596 are configured to be received in different slots 330 of the grounding block 300. Optionally, the connecting legs 566, 596 of adjacent cable termination modules 150 may be received in the same slot 330 and connected to each other. For example, the connecting legs 566, 596 of adjacent cable termination modules 150 may be welded together in the slots 330 while being welded to the grounding block 300. For example, the welding may be laser welding or ultrasonic welding. In an alternative embodiment, connecting legs 566 and 596 may be received in different slots 330.

[0132] Figure 23 This is a cross-sectional view of a portion of a plug connector 100 according to an exemplary embodiment, showing a plurality of cable termination modules 150 mounted in a grounding block 300. Figure 23A grounding block 300 is shown, which includes a plurality of plates 302 arranged in a plate stack 303. The grounding block 300 provides circumferential (e.g., 360°) shielding for the mating ends of the cable termination module 150.

[0133] Figure 23 The connecting legs 566, 596 of the front cover 550 and rear cover 580 of the cable termination module 150, which is loaded into the corresponding slot 330 of the grounding block 300, are shown. The position of the connecting legs 566, 596 within the slot 330 can be controlled to control the longitudinal and / or lateral and / or vertical positioning of the cable termination module 150 relative to the grounding block 300. Other alignment features of the cable termination module 150 and / or the grounding block 300 can be provided to control the longitudinal and / or lateral and / or vertical positioning. For example, the positioning surface 326 of the base plate 302b can be used to control the vertical positioning. In an exemplary embodiment, the connecting legs 566, 596 can be welded to each other and / or welded to the plate(s) 302 of the grounding block 300 to mechanically and electrically connect the cable termination module 150 to the grounding block 300. In an exemplary embodiment, one or more of the connecting legs 566, 596 may include retaining barbs configured to abut against the plates 302(a) of the grounding block 300, for example, via an interference fit. However, in various other embodiments, the connecting legs 566, 596 may not be provided with retaining barbs.

[0134] In an exemplary embodiment, the base plate 302b includes an opening 328 aligned with the groove 330. The opening 328 has a different size / shape than the groove 330 to prevent connecting legs 566, 596 from passing through the opening 328. The opening 328 is aligned with the groove 330 to allow access from below through the opening 328 to the connecting legs 566, 596 and the track 324 of the plate 302 surrounding the groove 330 for welding.

[0135] Figure 24 This is a cross-sectional view of a portion of a plug connector 100 according to an exemplary embodiment, showing one of the cable termination modules 150 loaded into a grounding block 300. During assembly, the cable termination module 150 is loaded into the recess 320, for example, from above. The shielding wall of the grounding cage 500 is received in the recess 320.

[0136] In an exemplary embodiment, the grounding beams 540, 564, and 594 of the grounding cage 500 are configured such that the abutment plate 302 is outwardly deflected and resiliently biased to electrically connect the grounding cage 500 to the grounding block 300. The grounding beams 540, 564, and 594 provide contact points with the grounding block 300. The grounding beams 540, 564, and 594 can be aligned with the contact 430, for example, around all four sides of the contact 430. The grounding beams 540, 564, and 594 can be used as positioning or alignment features to position or align the cable termination module 150 in the recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0137] In an exemplary embodiment, the retaining hook 528 is configured to abut against the grounding block 300, for example, via an interference fit. The retaining hook 528 may be part of the sleeve 510 and / or the front cover 550 and / or the rear cover 580. The retaining hook 528 forms a mechanical and / or electrical connection between the grounding cage 500 and the grounding block 300. The retaining hook 528 may be used as a positioning or alignment feature to position or align the cable termination module 150 in the recess 320 of the grounding block 300 (e.g., for lateral or longitudinal positioning).

[0138] In an exemplary embodiment, during assembly, the contact module 400 is configured to pass through the recess 320 to engage with the receptacle connector 200 (e.g., Figure 2 (As shown) mating. For example, the bottom end of the contact module 400 is exposed at the bottom 306 of the ground block 300 for mating with the receptacle connector 200. In an exemplary embodiment, the connecting end 432 of the contact 430 is coplanar with the lower surface 307 of the ground block 300 for mating with the receptacle connector 200. The lower surface 307 defines a mating interface configured to mate with the receptacle connector 200. The lower surface 307 is configured to form a direct electrical path with the receptacle connector 200, for example, to form a direct electrical path with a grounding receptacle contact. In an exemplary embodiment, the base plate 302b is configured to be kept planar to provide a planar mating interface with the receptacle connector 200. The connecting end 432 of the contact 430 is located in the bottom opening 322 of the base plate 302b such that the bottom surface of the contact 430 is coplanar with the bottom surface of the ground block 300.

[0139] Figure 25 This is a bottom perspective view of a portion of a plug connector 100 according to an exemplary embodiment, showing a cable termination module 150 in a grounding block 300. Figure 25 The contact 430 at the bottom of the contact module 400 is shown in the bottom opening 322 of the base plate 302b of the grounding block 300. Figure 25The opening 328 in the base plate 302b is shown to be aligned with the slot 330 in the corresponding connecting legs 566, 596 of the grounding cage 500. The connecting legs 566, 596 can be welded to each other and / or welded to the plate 302 in the slot 330 and / or welded to the base plate 302b through the opening 328.

[0140] Figure 26 This is a bottom perspective view of a portion of the connector housing 120 according to an exemplary embodiment. Figure 26 An external plug housing 140 is shown. The external plug housing 140 includes a plurality of walls forming a housing cavity 142. The housing cavity 142 is configured to receive a cable assembly 110. Figure 4 The housing cavity 142 can receive a portion of the cable strain relief element 122. Figure 3 ).

[0141] In an exemplary embodiment, the external plug housing 140 includes a top wall 125 at a top 124, a front wall 131 at a front 130, a rear wall 133 at a rear 132, a first side wall 135 at a first side 134, and a second side wall 137 at a second side 136. The external plug housing 140 may include a bottom wall at a bottom 126. The walls generally surround and define a housing cavity 142. The walls may include openings to allow access to the cable assembly 110, for example, at the bottom 126 and / or the rear 132. In an exemplary embodiment, the walls are conductive to provide shielding around the housing cavity 142. For example, the walls may be stamped walls. In alternative embodiments, the walls may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining. In the illustrated embodiment, the external plug housing 140 is generally rectangular in shape. In alternative embodiments, the external plug housing 140 may have other shapes and / or may include other walls to form different shapes.

[0142] One or more of the walls may be coupled to the cable assembly 110, such as to the grounding block 300, to transmit mating force during engagement with the receptacle connector 200. For example, the front wall 131 and / or the first side wall 135 and / or the second side wall 137 and / or the rear wall 133 may be coupled to the grounding block 300. One or more of the walls may be electrically coupled to the cable assembly 110, such as to the grounding block 300. In an exemplary embodiment, one or more of the walls includes an upper shoulder 143 and / or a lower shoulder 145 configured to be coupled to the grounding block 300. In an exemplary embodiment, one or more of the walls includes a welding tab 139 configured to be welded to the grounding block 300.

[0143] In various embodiments, one or more of the walls may be integrally formed with each other. For example, the first sidewall 135 and the second sidewall 137 may be integral with the top wall 125. In alternative embodiments, the other walls may be integral with each other. In the illustrated embodiment, the first sidewall 135 and the second sidewall 137 include latching elements 138 extending therefrom. In alternative embodiments, other walls may include latching elements 138.

[0144] In various embodiments, one or more of the walls may be separable from and electrically connected to the other walls. For example, front wall 131 and / or rear wall 133 may be coupled to top wall 125 and / or first side wall 135 and / or second side wall 137. In various embodiments, the walls may be welded together, for example, by laser welding. The walls may be secured together by clips, crimp tabs, fasteners, latches, or other means. In an exemplary embodiment, front wall 131 is separated from the other walls to allow access to housing cavity 142, for example, to fill housing cavity 142 with epoxy resin, hot melt adhesive, or other dielectric material to form cable strain relief element 122 in situ in housing cavity 142 after cable assembly 110 is positioned in housing cavity 142.

[0145] In an exemplary embodiment, the external plug housing 140 includes an internal support wall 144 received within a housing cavity 142. The internal support wall 144 may be generally centered between a first sidewall 135 and a second sidewall 137. In various embodiments, the internal support wall 144 may extend vertically (e.g., between a top 124 and a bottom 126). The internal support wall 144 may extend longitudinally, for example, between a front portion 130 and a rear portion 132. In the illustrated embodiment, the internal support wall 144 is coupled to a top wall 125 and / or a front wall 131. For example, the internal support wall 144 may be welded to a front wall 131 and / or a top wall 125. In alternative embodiments, the internal support wall 144 may extend in other directions and / or between other walls. The internal support wall 144 may be coupled to a cable assembly 110, such as to a grounding block 300, to transmit mating forces during mating with a receptacle connector 200. The internal support wall 144 may be electrically connected to the cable assembly 110, for example, to the grounding block 300. In an exemplary embodiment, the internal support wall 144 includes an upper shoulder 143 and / or a lower shoulder 145 configured to be connected to the grounding block 300.

[0146] In an exemplary embodiment, one or more walls of the outer plug housing 140 include protrusions 146 extending therefrom. For example, the first sidewall 135 and the second sidewall 137 may include protrusions 146. Protrusions 146 may project inward, for example, into the housing cavity 142. Alternatively, protrusions 146 may project outward. The front wall 131 may additionally or alternatively include protrusions 146. The inner support wall 144 may additionally or alternatively include protrusions 146. Protrusions 146 may increase the mechanical strength or rigidity of the wall, for example, to reduce bending or buckling, such as due to pressure during mating of the plug connector 100 and the socket connector 200.

[0147] Figure 27 This is a bottom perspective view of a portion of the plug connector 100, showing a cable assembly 110 ready to be loaded into the housing cavity 142 of the outer plug housing 140. Figure 28 This is a bottom perspective view of a portion of the plug connector 100, showing the cable assembly 110 loaded into the housing cavity 142 of the outer plug housing 140. Figure 29 This is a front perspective view of a portion of a plug connector 100, showing a cable assembly 110 loaded into a housing cavity 142 of an outer plug housing 140. Figure 30 This is a rear perspective view of a portion of the plug connector 100, showing the cable assembly 110 loaded into the housing cavity 142 of the outer plug housing 140.

[0148] In an exemplary embodiment, the cable assembly 110 is loaded into the housing cavity 142 via the bottom 126. In an exemplary embodiment, an internal support wall 144 divides the housing cavity 142 into different cable chambers receiving different groups of cable termination modules 150. The first sidewall 135, the second sidewall 137, and the internal support wall 144 are configured to mate with different portions of the grounding block 300 to evenly distribute downward engagement forces from the outer plug housing 140 to the grounding block 300 during engagement with the receptacle connector 200.

[0149] During assembly, the first sidewall 135 and the second sidewall 137 are coupled to the grounding block 300. For example, a welding tab 139 may be received in a corresponding recess 340 along the side of the grounding block 300. The welding tab 139 may be welded to the grounding block 300 to create a mechanical and electrical connection between the first and second sidewalls 135, 137 and the grounding block 300. In an exemplary embodiment, the upper shoulder 143 of the first and second sidewalls 135, 137 is configured to engage the top 304 of the grounding block 300. For example, the upper shoulder 143 may be disposed on the upper surface of the top plate 302t of the plate stack 303. In an exemplary embodiment, the lower shoulder 145 of the first and second sidewalls 135, 137 is configured to be coupled to the grounding block 300. For example, the lower shoulder 145 may be defined by the bottom edge of the welding tab 139. The lower shoulder 145 may be disposed on the upper surface of the base plate 302b to press the base plate 302b downward during mating.

[0150] During assembly, the inner support wall 144 is coupled to the grounding block 300. For example, a wall tab 149 of the inner support wall 144 may be received in a corresponding recess or opening in the grounding block 300. The wall tab 149 may be welded to the grounding block 300 to create a mechanical and electrical connection between the inner support wall 144 and the grounding block 300. In an exemplary embodiment, the upper shoulder 143 of the inner support wall 144 is configured to engage the top 304 of the grounding block 300. For example, the upper shoulder 143 may be disposed on the upper surface of the top plate 302t of the plate stack 303. In an exemplary embodiment, the lower shoulder 145 of the inner support wall 144 is configured to be coupled to the grounding block 300. For example, the lower shoulder 145 may be defined by the bottom edge of the wall tab 149. The lower shoulder 145 may be disposed on the upper surface of the base plate 302b to press the base plate 302b downward during mating.

[0151] During assembly, the anterior wall 131 ( Figure 29 The front wall 131 can be connected to the grounding block 300. For example, the front wall 131 can be welded to the front of the grounding block 300. In various embodiments, the front wall 131 may include a welding tab (not shown) received in a corresponding groove in the grounding block 300.

[0152] During assembly, the rear wall 133 ( Figure 30 The rear wall 133 can be connected to the grounding block 300. For example, the rear wall 133 can be welded to the front of the grounding block 300. In various embodiments, the rear wall 133 may include a welding tab (not shown) received in a corresponding groove in the grounding block 300.

[0153] Figure 31This is a top perspective view of a portion of the plug connector 100, showing the cable assembly 110 and a cable strain relief element 122 coupled to an external plug housing 140. In an exemplary embodiment, the cable strain relief element 122 is coupled to the cable 102 of the cable assembly 110. The cable strain relief element 122 provides strain relief for the cable 102. The cable strain relief element 122 may hold a portion of the cable termination module 150, for example, fixing the position of the cable termination module 150 relative to the grounding block 300, to prevent movement of the cable termination module 150 relative to the grounding block 300 and the receptacle connector 200, thereby improving signal integrity and electrical performance.

[0154] In an exemplary embodiment, the cable strain relief element 122 extends from the outer plug housing 140. For example, the cable strain relief element 122 may extend rearward from the rear portion 132. As the cable 102 exits the outer plug housing 140, the cable strain relief element 122 covers a portion of the cable 102. In various embodiments, the cable strain relief element 122 may be formed in place around the cable 102 and / or the cable termination module 150 after the cable assembly 110 is received in the housing cavity 142 of the outer plug housing 140. For example, the cable strain relief element 122 may be injection molded, insert-molded, or formed by filling the housing cavity 142 with a support material that is cured or otherwise hardened to form the cable strain relief element 122. The cable strain relief element 122 may fill the gap or space between the adjacent cable 102 and the cable termination module 150. In an alternative embodiment, the cable strain relief element 122 may be formed separately from the outer plug housing 140. For example, before the cable assembly 110 is loaded into the external plug housing 140, the cable strain relief element 122 can be pre-formed and coupled to the cable 102 and the cable termination module 150.

[0155] In an exemplary embodiment, the cable strain eliminator 122 may be overmolded onto a portion of the outer plug housing 140, such as the rear wall 133, to secure the cable strain eliminator 122 to the outer plug housing 140. Optionally, the rear wall 133 may include fingers, tabs, or other extensions extending between the cables 102 to organize the cables 102 and maintain their relative positions before the cables 102 are overmolded with the cable strain eliminator material. For example, a U-shaped groove or channel may extend from the rear wall 133 to hold the individual rows of cables, thereby appropriately spaced the cables 102 to allow material of the cable strain eliminator 122 to flow between the rows of cables 102.

[0156] Figure 32 This is a perspective view of a set of cable termination modules 150, which are integrated into a common cable termination module 151. Figure 33This is a side view of multiple common cable termination modules 151. Figure 34 This is a perspective view of a cable assembly 110 according to an exemplary embodiment, showing a plurality of common cable termination modules 151 connected to a grounding block 300. In the illustrated embodiment, four cable termination modules 150 are combined together to form each of the common cable termination modules 151. In alternative embodiments, more or fewer cable termination modules 150 may be combined together to form the common cable termination module 151. In the illustrated embodiment, groups of cable termination modules 150 are arranged together in a single row (e.g., a 1x4 array, a 1x8 array, etc.); however, cable termination modules 150 may be arranged together in multiple rows (e.g., 2×2, 2×4, 4×4, etc.).

[0157] In an exemplary embodiment, the common cable termination module 151 includes a module retainer 153 and holds a plurality of cable termination modules 150 together in a group. In various embodiments, the module retainer 153 includes a dielectric material, such as a molded overlay body over portions of the cable termination modules 150 and / or the cable 102. In alternative embodiments, the module retainer 153 may be a conductive, such as a stamped metal frame, coupled to a grounding cage 500 of the cable termination modules 150. In alternative embodiments, the module retainer 153 may be manufactured by other processes, such as molding (e.g., casting, injection molding, etc.) and / or machining. The group of cable termination modules 150 may be loaded as a unit into corresponding recesses 320 in the grounding block 300.

Claims

1. A plug connector (100) for mating with an electrical connector (200), the plug connector comprising: Cable termination modules (150), each cable termination module including a contact module (400) having a contact retainer (410) for retaining a contact (430) extending between a connection end (432) and a termination end (434) opposite to the connection end, the connection end (432) being configured to mate with a mating contact of the electrical connector, each cable termination module including a cable (102) having a signal conductor (104) terminating at a termination interface to a termination end of a corresponding contact, the cable having a cable shield (106) surrounding the signal conductor, each cable termination module including a grounding cage (500) providing circumferential shielding around the termination interface and around the corresponding contact module, each cable termination module including a termination support (426) at the termination interface surrounding the termination end of the contact and the signal conductor using a support material (428); and A grounding block (300) includes a recess (320) for receiving a corresponding cable termination module. The grounding block is conductive and provides shielding around the recess to shield the cable termination module. The grounding block is electrically connected to the grounding cage. The grounding block organizes the cable termination modules relative to each other and positions the cable termination modules to mate with the electrical connector.

2. The plug connector (100) according to claim 1, wherein, The termination support (426) fills the space (276) between the end of the contact retainer (410) and the end of the cable (102), or wherein, The termination support (426) fills the internal space (276) of the grounding cage (500) at the termination interface.

3. The plug connector (100) according to claim 1, wherein, After the termination end is terminated to the signal conductor, the termination support (426) is formed in place around the termination end (434) of the contact (102) and the corresponding signal conductor (104), wherein the termination end (434) is welded to the end of the signal conductor (104) at a weld joint, and the termination support (426) surrounds the weld joint.

4. The plug connector (100) according to claim 1, wherein, The termination end (434) is butt-welded to the end of the signal conductor (104), and the termination support (426) extends along the termination end and the signal conductor across the butt-welded joint.

5. The plug connector (100) according to claim 1, wherein, The termination support (426) is heat-fused to conform to the termination end (434) of the signal conductor (104) and the signal contact at the termination interface.

6. The plug connector (100) according to claim 1, wherein, The termination support (426) is an epoxy resin that fills the space (276) around the termination end (434) of the signal conductor (104) and the signal contact at the termination interface, the epoxy resin being cured to harden around the termination end of the signal conductor and the signal contact.

7. The plug connector (100) according to claim 1, wherein, The grounding cage (500) includes a sleeve (510), a front cover (550) connected to the sleeve, and a rear cover (580) connected to the sleeve. The sleeve is connected to the cable shield (106), and the end support (426) is connected to at least one of the sleeve, the front cover, and the rear cover.

8. The plug connector (100) according to claim 11, wherein, The clamp (510) includes a base wall (512), a first side wall (514) extending from a first side (417) of the base wall, and a second side wall (516) extending from a second side (419) of the base wall. The base wall, the first side wall, and the second side wall form a bracket (518) for receiving the end of the cable (102). The first side wall covers a first side of the contact module (400), and the second side wall covers a second side of the contact module. A front cover (550) is connected to the first side wall and the second side wall to cover the front side of the contact module, and a rear cover (580) is connected to the first side wall and the second side wall to cover the rear side of the contact module. The termination support (426) is located between the first side wall and the second side wall and between the front cover and the rear cover.

9. The plug connector (100) according to claim 11, wherein, The sleeve (510) includes a base wall (512), a first side wall (514) extending from a first side (417) of the base wall, and a second side wall (516) extending from a second side (419) of the base wall. A front cover (550) is connected to the first side wall and the second side wall to cover the front side of the contact module (400), and a rear cover (580) is connected to the first side wall and the second side wall to cover the rear side of the contact module. A groove (340) is formed between the first side wall and the second side wall and between the contact holder and the end of the cable (102). The end support (426) fills the groove. The rear cover covers the rear portion of the groove, and the front cover covers the front portion of the groove.

10. A cable termination module (150) for a plug connector (100) configured to mate with an electrical connector (200), the cable termination module comprising: The contact module (400) has a contact retainer for holding a contact that extends between a connecting end (432) and a termination end (434) opposite to the connecting end, the connecting end (432) being configured to mate with a mating contact of the electrical connector; The cable (102) has a signal conductor (104) that terminates at a termination interface to a termination end of a corresponding contact, and the cable includes a cable shield (106) surrounding the signal conductor. The termination support (426) at the termination interface surrounds the termination end of the signal conductor and the contact using a support material (428); and A grounding cage (500) provides circumferential shielding around the termination interface and around the corresponding contact module. The mating end of the grounding cage is configured to insert into a recess (320) of a grounding block (300) at the bottom of the plug connector to electrically connect the grounding cage to the grounding block. The grounding cage includes a sleeve (510), a front cover (550) connected to the sleeve, and a rear cover (580) connected to the sleeve. The termination support is connected to at least one of the sleeve, the front cover, and the rear cover.

11. The cable termination module (150) according to claim 10, wherein, The termination support (426) fills the space (276) between the end of the contact holder and the end of the cable (102), and wherein the termination support (426) fills the internal space (276) of the grounding cage (500) at the termination interface.

12. The cable termination module (150) according to claim 10, wherein, After the termination end is terminated to the signal conductor, the termination support (426) is formed in place around the termination end (434) of the contact and the corresponding signal conductor (104).

13. The cable termination module (150) according to claim 10, wherein, The clamp (510) includes a base wall (512), a first side wall (514) extending from a first side (417) of the base wall, and a second side wall (516) extending from a second side (419) of the base wall. The base wall, the first side wall, and the second side wall form a bracket (518) for receiving the end of the cable (102). The first side wall covers a first side of the contact module (400), and the second side wall covers a second side of the contact module. A front cover (550) is connected to the first side wall and the second side wall to cover the front side of the contact module, and a rear cover (580) is connected to the first side wall and the second side wall to cover the rear side of the contact module. The termination support (426) is located between the first side wall and the second side wall and between the front cover and the rear cover.

14. A communication system (10), comprising: An electrical connector (200) includes: a housing for retaining mating contacts, the mating contacts including a mating interface, the mating contacts including a signal contact and a ground contact; and a plug connector (100) configured to be coupled to the electrical connector, the plug connector including a cable termination module (150) and a ground block (300), the ground block (300) including a recess (320) for receiving a corresponding cable termination module. Each cable termination module includes a contact module (400) having a contact retainer for holding the contact, the contact extending between a connecting end (432) and a termination end (434) opposite to the connecting end, the connecting end (432) being configured to mate with a mating contact of the electrical connector; each cable termination module includes a cable (102) having a signal conductor (104) terminating at a termination interface to a termination end of a corresponding contact; the cable has a cable shield (106) surrounding the signal conductor; each cable termination module includes a grounding cage (500) providing circumferential shielding around the termination interface and around the corresponding contact module; each cable termination module includes a termination support (426) at the termination interface, the termination support surrounding the termination end of the contact and the signal conductor using a support material (428); and The grounding block is conductive and provides shielding around the recess to shield the cable termination module. The grounding block is electrically connected to the grounding cage. The grounding block organizes and positions the cable termination modules relative to each other to mate with the electrical connector.

15. The communication system (10) according to claim 14, wherein, The termination support (426) fills the space (276) between the end of the contact holder and the end of the cable (102), and wherein the termination support fills the internal space of the grounding cage (500) at the termination interface.

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