High Speed ​​Rugged Connectors

Abstract

A modular connector system with components that can be economically assembled to provide high signal integrity in harsh environments such as automotive. In some connectors, electrical conductors serving as signal conductors may be at least partially surrounded by a conductive sheet formed into a tube. The tube may be formed by joining opposite edges of the sheet with tab portions extending from the edges. The tab portions may be bent to extend radially outward from the cavity and crimped together to provide mechanical integrity to the shield, as well as tabs that polarize the shield to prevent incorrect insertion into the insulating housing and that can engage components in the insulating housing to retain the shield in the housing. Other disclosed techniques economically and stably position electrical conductors relative to a ground structure that can serve as signal terminals, electrically and mechanically connect to the shield, or compensate for impedance changes.

Description

[Technical field]

[0001] This application relates generally to interconnection systems, such as those including electrical connectors, used to interconnect electronic assemblies, and more particularly to interconnection systems for harsh environments, such as vehicles. [Background technology]

[0002] Electrical connectors are used in many electronic systems. It is generally easier and more cost-effective to manufacture a system as separate electronic assemblies that can be joined together with electrical connectors. Connectors may be used to interconnect assemblies so that the assemblies can operate together as part of a system. Connectors may be mounted, for example, on printed circuit boards in two assemblies that are connected by mating connectors. In other systems, it may be impractical to connect two printed circuit boards by directly mating connectors on the printed circuit boards. For example, when the system is assembled, the printed circuit boards may be separated due to the distance being too great for a direct connection between the connectors mounted on the printed circuit boards.

[0003] In some systems, the connections between the assemblies can be made through cables. The cables can be terminated with connectors that mate with connectors mounted on the printed circuit boards. In this manner, the connections between the assemblies can be made by plugging a connector that is part of the cable assembly into a connector mounted on the printed circuit board. In other system architectures, a connector terminating a cable can mate with another connector terminating another cable.

[0004] An example of a system in which assemblies are connected through cables is a modern automobile. For example, an automobile vehicle includes electronic control units (ECUs) for controlling various vehicle systems, such as the engine, transmission (TCU), safety systems, emission control systems, lighting, advanced driver assistance systems (ADAS), entertainment systems, navigation systems, and cameras. These control units can be manufactured as separate assemblies and connected across one or more vehicle networks formed with cables routed between these assemblies. To simplify the manufacture of the automobile, the assemblies can be formed separately and then connected via cables terminated with mating connectors that terminate other cables or connectors that allow connection to mating connectors mounted on printed circuit boards within the assemblies.

[0005] Automobiles present a tough environment for electrical connectors. Automobiles can vibrate, which can loosen connectors and cause them to stop functioning altogether. Even if the vibrations do not completely prevent the operation of the connectors, they can cause electronic noise that can interfere with the operation of electronic devices connected through interconnects that include the connectors. Noise can result, for example, from relative movement of components within the connector, which can change the electrical properties of the connector. The changes in electrical properties further cause signals passing through the interconnect to experience vibrations, a form of noise that interferes with the processing of the underlying signals.

[0006] In an automotive environment, electrical noise can also come from automotive components that generate electromagnetic radiation. That radiation can couple with the conductive structures of connectors and create noise in signals passing across the conductive structures. In an automobile, numerous components such as spark plugs, alternators, or power switches can all generate electromagnetic radiation. The noise can be particularly disruptive to high-speed signals, such as those used to communicate data across automotive networks. Summary of the Invention [Means for solving the problem]

[0007] The concepts as disclosed herein may be embodied in an electrical connector comprising at least one electrical conductor and a shield comprising a sheet with a first edge and a second edge. The first edge may be bonded to the second edge to at least partially enclose a cavity at a perimeter bounded by the sheet. At least a portion of the at least one electrical conductor may be disposed within the cavity, and the sheet may include a tab extending away from the cavity in a direction perpendicular to the perimeter.

[0008] Such an electrical connector may include one or more of the following features.

[0009] The tabs may have a retention feature.

[0010] The first edge may be coupled to the second edge via interlocking projections and apertures in the first and second edges.

[0011] The tab can extend from a first edge of the sheet.

[0012] The tab may comprise a first tab portion extending from the sheet and a second tab portion extending from the sheet, the first tab portion being adjacent and parallel to the second tab portion. Optionally, the first tab portion extends from the sheet at a first edge and the second tab portion extends from the sheet at a second edge.

[0013] The electrical connector may have a mating end, the cavity may be open at the mating end of the connector, the tab may have a first edge facing the mating end and a second edge opposite the first edge, and the first edge of the tab may be tapered toward the mating end of the connector and the second edge of the tab may be perpendicular to the perimeter.

[0014] The electrical connector may further comprise an insulating housing with an opening. The insulating housing may comprise a beam with a cantilevered end and a catch at the cantilevered end that extends into the opening. The shield is inserted into the opening, the beam configured such that the catch is aligned with a second edge of the tab when the shield is fully inserted into the cavity. Optionally, the catch may comprise a cam surface, and the beam may be configured such that a first edge of the tab is aligned with the cam surface of the catch when the shield is partially inserted into the cavity.

[0015] At least one electrical conductor may comprise a pair of signal terminals. Optionally, the shield may comprise a first shield and the tab may comprise a first tab. The electrical connector may comprise a second shield at least partially surrounding the cavity and the second shield may comprise a second tab extending away from the cavity in a direction perpendicular to the perimeter. The electrical connector may further comprise a positioning device comprising a member extending into the cavity and engaging the second tab.

[0016] The first shield may have an axis of extension, the first shield being concentric with and electrically connected to the second shield, and the first tab being aligned with the second tab in the direction of the axis of extension.

[0017] In another aspect, the concepts as disclosed herein can be embodied as an electrical connector comprising a mating end and a cable termination end opposite the mating end. The electrical connector can comprise at least one electrical conductor, a first shield comprising a first sheet surrounding a first portion of a cavity, and a second shield comprising a second sheet. The second sheet can surround the second portion of the cavity, the second portion of the cavity overlapping the first portion of the cavity in an area of ​​overlap. At least a portion of the at least one electrical conductor can be disposed within the cavity. In the area of ​​overlap, the second shield is inside the first shield, the second shield comprising an embossment extending outwardly.

[0018] Such an electrical connector may include one or more of the following features.

[0019] The embossment can electrically connect the first shield and the second shield.

[0020] The second shield may have an axis of extension and a perimeter, and the embossment may comprise a ridge extending around at least 40% of the perimeter. Optionally, the second shield may have an oval cross-section comprising first and second curved sections joined by first and second linear sections in the region of overlap, and the embossment may comprise first and second ridges extending from the first and second curved sections, respectively.

[0021] Alternatively or additionally, the first shield may comprise a beam and the second shield may comprise a slot, and a distal portion of the beam may extend through the slot such that the first shield is mechanically connected to the second shield.

[0022] Alternatively or additionally, the beam may be cut in the first sheet, with the slot of the second shield being located in a first linear section of the second shield.

[0023] Alternatively or additionally, the beam may comprise a first section parallel to the first sheet and a second section transverse to the first section, the second section extending through the opening.

[0024] Alternatively or additionally, the beam can be a first beam, the first shield can include a second beam, the slot can be a first slot, the second shield can include a slot parallel to the first slot, and a distal end of the second beam can extend through the second slot.

[0025] In other aspects, the electrical connector may be terminated to a cable that includes a cable shield, where the end of the cable with the cable shield exposed may be inserted into the cavity, the second shield may surround the cable inserted into the cavity and may be electrically connected to the exposed cable shield, the first shield may include contact beams configured to mate with a ground structure of a complementary connector, and the contact beams of the first shield may be electrically coupled to the cable shield through the first shield, the embossment, and the second shield.

[0026] Alternatively or additionally, the first shield may comprise at least one beam and the second shield may comprise at least one slot, and a distal portion of each beam of the at least one beam may extend through a respective slit of the at least one slot.

[0027] The mechanical attachment of the first shield to the second shield may consist essentially of engagement of at least one beam with at least one slot and friction between the embossment and the first shield.

[0028] In another aspect, the concepts as disclosed herein may be embodied in a cable assembly comprising a cable terminated with an electrical connector. The electrical connector may comprise a connector shield at least partially surrounding a first portion of a cavity and a metal member within the cavity, the metal member comprising an opening therethrough. The cable may comprise a first portion outside the cavity comprising a first insulated conductor, a second insulated conductor, and a cable shield at least partially surrounding the first and second insulated conductors, with the first and second insulated conductors spaced apart at a first center-to-center spacing. The cable may comprise a second portion disposed within the cavity comprising the first and second insulated conductors, with the first and second insulated conductors spaced apart at a second center-to-center spacing. The second portion of the cable may pass through the opening in the metal member.

[0029] Such a cable assembly may include one or more of the following features.

[0030] The second center-to-center spacing may be greater than the first center-to-center spacing, and the metallic members may be configured to match an impedance of the second portion of the cable to the first portion of the cable.

[0031] The cable shield may be absent from the second portion.

[0032] Alternatively or additionally, the connector shield is electrically connected to the cable shield.

[0033] Alternatively or additionally, the connector may further comprise a ferrule comprising a first annular portion, a second annular portion, and a plurality of arms coupling the first annular portion to the second annular portion. The cable may pass through the first annular portion and the second annular portion, and the second annular portion may be between the first annular portion and the metal member.

[0034] Alternatively or additionally, the first annular portion may contact the cable shield.

[0035] Alternatively or additionally, the connector shield may be crimped around the first annular portion, and the connector may further comprise first and second contacts crimped to the respective conductors of the first and second insulated conductors.

[0036] Alternatively or additionally, the metallic member may be an impedance adapter.

[0037] Alternatively or additionally, the ferrule may comprise a first metal sheet formed into a tube and the impedance adapter comprises a second metal sheet formed into the tube, the first metal sheet and the second metal sheet being of the same material and having the same thickness.

[0038] The metal member may have a first end and a second end with an aperture extending between the first end and the second end, the aperture at the first end may be shaped as an oval and the aperture at the second end may be shaped as an oval with a major axis and an embossment extending toward the major axis, the embossment may be between the first and second insulated conductors.

[0039] In another aspect, the concepts as disclosed herein may be embodied in an electrical connector comprising a conductive housing comprising a chamber, a shielding member within the conductive housing electrically and mechanically engaged to the conductive housing, and a terminal assembly disposed within the chamber, the terminal assembly comprising an insulating member and a conductor carried by the insulating member. The insulating member may comprise a spacer separating at least a portion of the conductor and the shielding member.

[0040] Such an electrical connector may include one or more of the following features.

[0041] The insulating member may include a body and the spacer may include ribs extending from the body.

[0042] The conductor may comprise a terminal having a mating contact portion, a contact rear portion, and an intermediate portion joining the mating contact portion and the contact rear portion, the mating contact portion and the contact rear portion may extend in a vertical direction, and a spacer may separate the shielding member and a portion of the conductor parallel to the contact rear portion.

[0043] Alternatively or additionally, the impedance of a first portion of the conductor parallel to the contact tail may be matched to the impedance of a second portion of the conductor parallel to the mating contact portion.

[0044] Alternatively or additionally, the second portion of the conductor may be disposed within a chamber of the conductive housing, and the first portion of the conductor is separated from the shielding member by a spacer.

[0045] The electrical connector may be a right-angle connector having a mating interface and a mounting interface at a right angle to the mating interface, and the shielding member may be perpendicular to the mounting interface.

[0046] The chamber may be a first chamber, and the conductive housing may include a plurality of chambers arranged in a row extending in the column direction, including the first chamber. The shielding member may be a first shielding member, and the electrical connector may include a plurality of shielding members in the conductive housing and electrically and mechanically engaged with the conductive housing, and the plurality of shielding members may include the first shielding member. Each of the plurality of shielding members may include a planar portion extending in a direction parallel to the column direction. The terminal assembly may be a first terminal assembly, and the electrical connector may include a plurality of terminal assemblies, including the first terminal assembly. Each of the plurality of terminal assemblies may be disposed in a respective chamber of the plurality of chambers, and each of the plurality of terminal assemblies may include a spacer adjacent to a planar portion of a respective shielding member of the plurality of shielding members.

[0047] Alternatively or additionally, the row may be a first row. The plurality of chambers may be a first plurality of chambers. The conductive housing may include a second plurality of chambers arranged in a second row extending in the row direction, and the electrical connector may include a second plurality of shielding members within the conductive housing and electrically and mechanically engaged to the conductive housing. The electrical connector may include a second plurality of terminal assemblies, each of the second plurality of terminal assemblies disposed in a respective one of the second plurality of chambers. Each of the second plurality of terminal assemblies may include a spacer adjacent a shielding member of the second plurality of shielding members.

[0048] Alternatively or additionally, each terminal assembly of the first plurality of terminal assemblies and the second plurality of terminal assemblies may include one pair of conductors, with each conductor of the pair positioned the same distance from an adjacent shielding member by a spacer of the terminal assembly.

[0049] The electrical connector may be a board connector including mounting joints configured for mounting to a printed circuit board. The conductive housing may include inwardly facing surfaces, at least two of the inwardly facing surfaces may include grooves. The shield may include a lip disposed in the grooves of the inwardly facing surfaces so as to be held perpendicular to the mounting joints.

[0050] In another aspect, the concepts as disclosed herein may be embodied in an electrical connector comprising a conductive housing with a chamber and a terminal assembly disposed within the chamber. The terminal assembly may comprise an insulating member with a passage therethrough, a conductor with a mating contact portion and a rear portion, and a middle section connecting the mating contact portion and the rear portion. The contact portion and the rear portion may extend from the insulating member. The middle section may be disposed within the passage and may have a first width over more than 50% of its length within the passage, may comprise a barb with a second width greater than the first width that engages the insulating member, and may comprise a conductor portion adjacent the barb with a third width less than the first width.

[0051] Such an electrical connector may include one or more of the following features.

[0052] The conductor portion may comprise an impedance compensating portion.

[0053] The passage may have a first passage portion with a first passage width, the passage may have a second passage portion with a second passage width narrower than the first passage width, a portion of an intermediate section of the conductor with the first width may be disposed in the first passage portion, and a conductor portion may be disposed in the second passage portion.

[0054] Alternatively or additionally, the passage may be a first passage, the insulating member includes a second passage parallel to the first passage, the conductor is a first conductor, and the terminal assembly includes a second conductor disposed within the second passage.

[0055] Alternatively or additionally, the first conductor and the second conductor may be configured as a differential pair.

[0056] Alternatively or additionally, the first conductor and the second conductor may have the same shape and the first passageway and the second passageway may have the same shape.

[0057] Alternatively or additionally, the electrical connector may be a right-angle connector, and the mating contact portion and the rear portion of the first conductor and the rear portion of the second conductor may extend from the first passage and the second passage, respectively, in perpendicular directions.

[0058] The accompanying drawings are not drawn to scale and for purposes of clarity, every component may not necessarily be labeled in every drawing. [Brief description of the drawings]

[0059] [Figure 1] FIG. 1 is a perspective view of an exemplary interconnect system according to some embodiments. [Diagram 2] 2 is an exploded perspective view of the board connector 100 of FIG. 1 according to some embodiments. [Figure 3A] 1 is a cross-sectional view of an example board connector according to some embodiments. [Figure 3B] FIG. 3B is a rear view of the board connector of FIG. 3A according to some embodiments. [Figure 3C] 3B is a cross-sectional view of the board connector of FIG. 3A according to some embodiments. [Figure 3D] FIG. 3B is a perspective view of the electrical contacts of the board connector of FIG. 3A according to some embodiments. [Figure 4A] 1 is a perspective view of an exemplary multi-port board connector according to some embodiments. [Figure 4B] 4B is a cross-sectional view of the multi-port board connector of FIG. 4A taken along line 4B-4B in FIG. 4A. [Diagram 5] 2 is a perspective view of the cable connector 200 of FIG. 1 according to some embodiments. [Figure 6]FIG. 6 is an exploded perspective view of the cable connector of FIG. 5 according to some embodiments. [Figure 7] 7 is a cross-sectional view of the example cable connector of FIG. 6 according to some embodiments. [Figure 8A] 7 is a perspective cross-sectional view of the cable connector of FIG. 6 with a carrier contact position assurance device (CCPA) partially inserted according to some embodiments. [Figure 8B] 7 is a perspective cross-sectional view of the cable connector of FIG. 6 with a carrier contact position assurance device (CCPA) fully inserted, according to some embodiments. [Figure 9A] 7 is a perspective view of an example rear shield of the cable connector of FIG. 6 connected to an example front shield of the cable connector according to some embodiments. [Figure 9B] 9B is a cross-sectional view of the cable connector of FIG. 9A at plane 262 in FIG. 9A according to some embodiments. [Figure 9C] 9B is a cross-sectional view of the cable connector of FIG. 9A at plane 272 in FIG. 9A according to some embodiments. [Figure 9D] 9B is a perspective view of an example conductor of the cable connector of FIG. 9A according to some embodiments. [Figure 9E] 9B is a perspective view of an example ferrule of the cable connector of FIG. 9A according to some embodiments. [Figure 10A] FIG. 9B is a top perspective view of the rear shield of FIG. 9A attached to a cable, including an exemplary embossing, according to some embodiments. [Figure 10B] FIG. 9B is a bottom perspective view of the rear shield of FIG. 9A according to some embodiments. [Figure 10C] FIG. 10B is a cross-sectional view of a portion of the cable connector of FIG. 10A including embossments according to some embodiments. [Figure 10D] FIG. 10B is another cross-sectional view of the cable connector of FIG. 10A according to some embodiments. [Figure 11A] FIG. 1 illustrates a perspective view of a stripped cable according to some embodiments. [Figure 11B] FIG. 11B is a perspective view of the cable of FIG. 11A with a terminal crimped onto the cable conductor according to some embodiments. [Figure 11C] FIG. 11C is a perspective view of the cable of FIG. 11B with a ferrule assembled to the cable according to some embodiments. [Figure 11D] FIG. 11D is a perspective view of the cable of FIG. 11C with the braid of the cable bent over the ferrule in accordance with some embodiments. [Figure 11E] FIG. 11E is a perspective view of the cable of FIG. 11D with an impedance adapter assembled to the cable in accordance with some embodiments. [Figure 11F] FIG. 11E is a perspective view of the cable of FIG. 11E with a contact carrier housing and rear shield with the rear shield partially attached to the cable, according to some embodiments. [Figure 11G] FIG. 11F is a top perspective view of the cable of FIG. 11F with a portion of the front shield slid over a portion of the back shield, according to some embodiments. [Figure 11H] FIG. 11G is a bottom perspective view of the cable of FIG. 11G before the front shield is latched onto the back shield, according to some embodiments. [Figure 11I] FIG. 11H is a perspective view of the cable of FIG. 11H with the front shield latched onto the back shield, according to some embodiments. [Figure 11J] FIG. 11I is a cross-sectional view of a portion of the cable of FIG. 11I showing additional detail of the front shield being retained to the rear shield in accordance with some embodiments. [Figure 12A] FIG. 2 illustrates a rear perspective view of an impedance adapter according to some embodiments. [Figure 12B] FIG. 2 illustrates a front perspective view of an impedance adapter according to some embodiments. [Figure 13] 6 is a perspective view of example cable connector components for configuring a cable connector to mate with the cable connector of FIG. 5 according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0060] The present inventors have recognized and appreciated techniques for making connectors for providing high data rate transmission that are economical to manufacture yet capable of operating reliably in the harsh environment provided by an automobile. Such connectors are suitable for interconnecting assemblies in, for example, automobile networks. These techniques can be applied in modular connector systems in which a set of components can be combined to form a connector in any of a number of configurations. This modularity reduces the costs associated with manufacturing connectors of the type described herein.

[0061] Each connector configuration may be formed with an insulating outer housing that establishes at least the mating interface of the connector. The outer housing may be insulating and may provide a retention feature. The component set may include insulating outer housings in a complementary configuration that may be used to form two connector configurations that mate and retain with each other.

[0062] A conductive structure may be positioned in the outer housing, at least partially surrounding the cavity. The cavity may be open at a mating end that extends to the mating joint. The set of components may comprise the conductive structures in one or more configurations that fit together. The conductive structures may be, for example, die-cast with cavities or may be one or more sheets of metal formed into tubes. The tube forming one conductive structure of the set may be sized to fit into an opening to the cavity of the other conductive structure so that the conductive structures can fit together. Alternatively, the set may include a tube of one radius sized to fit into a tube of a larger radius. In some embodiments, multiple conductive structures may be incorporated into the same insulating outer housing to form connectors of different sizes. Alternatively or additionally, different numbers of cavities may be formed in the die-cast conductive structures. By providing a variable number of cavities in the mating joints, some connectors can be configured with 1x1 mating joints, while other connectors may be formed with other sized mating joints, such as, for example, 2x2 mating joints or 2x3 mating joints.

[0063] Regardless of the number of cavities incorporated in the housing, terminal assemblies may be inserted into the cavities. Each terminal assembly may have an insulating member serving as a terminal carrier to receive one or more conductors, each of which may serve as a terminal of the connector. The set of connector components may include at least two styles of terminals configured to mate with one another, such as pin and receptacle style terminals. The terminals may have different styles of rear ends, with the rear ends configured to be attached to a printed circuit board or to a conductor of a cable.

[0064] Different mating or mounting configurations may be used in combination to form board or cable connectors with mating interfaces that allow the connectors to mate with one another. For example, a board connector can mate with a cable connector, or two cable connectors can mate.

[0065] In some embodiments, each terminal carrier may be configured to carry one signal, whether as a single-ended signal or as a differential signal. In the exemplary embodiment shown below, each terminal carrier has a pair of conductors suitable for carrying a differential signal. The conductive structure bounding the cavity into which the terminal carrier is inserted may serve as a shield for the signal carried by the terminal carrier. The mating joint may be such that the terminals of the mating connector mate both mechanically and electrically when the conductive structure forms a shield around the terminals.

[0066] The present inventors have recognized and appreciated various techniques that can be applied to the components of a connector system to provide high signal integrity (SI) to the connections. SI improvement can result from controlling the electrical properties of the signal path through the connector and / or from configuring the connector to operate effectively despite the harsh automotive environment in which it is used.

[0067] For example, in embodiments in which the shield comprises a tube formed from one or more metal sheets, the sheets may be stamped with tabs extending from the edges of the sheets, and when the sheets are formed into a sheet and joined at the edges, the tabs may be bent away from the cavity enclosed by the shield.

[0068] The tabs can serve as anti-retention features that can help retain the shield in the insulating housing. One or more such tabs may be provided along the tubular shield. In some embodiments, the anti-retention feature may form a stop for contact against the connector housing. Additionally, the shield anti-retention feature and a corresponding recess in the connector housing may be used as a polarizing feature to ensure proper orientation of the shield relative to the outer insulating housing. For example, the anti-retention feature may be provided on one side of the shield with a corresponding recess on one side of the housing, thereby ensuring that the shield can only be inserted into the housing in a desired orientation.

[0069] In some embodiments, the tab portions may extend from two edges of the metal sheet that abut when the sheet is formed into a tube. Both tab portions may be bent so that they are parallel and adjacent to each other. In this position, the tab portions may be crimped to form the tab and to provide mechanical integrity to the resulting tube, which further increases signal integrity by reducing the change in the relative position of the shield and the conductor in the cavity formed by the shield. Thus, a simply formed tab can provide multiple functions in some embodiments. Furthermore, fixing the edges of the sheet through the use of tab portions extending from the edges of the sheet allows for secure joining of the opposing sides of the sheet without cutting a large opening in the portion of the sheet that surrounds the cavity. Joining the edges of the sheet through the tabs contributes to high signal integrity, since the opening in the portion of the sheet intended to shield the cavity reduces the shielding effect.

[0070] As an example of another technique, a tubular shield may be formed as a first shield and a second shield that are reliably, yet economically, electrically and mechanically connected. The first shield may be, for example, a front shield and may include, for example, a mating joint. The second shield may be a back shield and may be configured to be attached to a cable. A portion of the second shield may fit into a portion of the first shield, and vice versa. One of the shields may include an embossment in the area of ​​overlap. The embossment may provide contact, friction, and / or electrical connectivity between the shields. A mechanical connection between the first and second shields may be provided by one or more beams having a cantilevered end that is cut into one of the shields and bent to fit into a slot in the other of the shields.

[0071] Further techniques may be applied in connectors that terminate cables as part of a cable assembly. In such connectors, the end of the cable may be inserted into a cavity that is at least partially folded and surrounded by the shield. The end of the cable may be prepared for attachment to the cable connector in a manner that changes the electrical properties of the cable in that portion compared to the bulk of the cable. For example, the cable shield may be removed and, for Twinax cables, the conductors of the cable may be separated so that terminals can be attached to the conductors. This manipulation of the cable structure may change the impedance of this portion of the cable, which may degrade the signal integrity. A separate metal member may be placed in this portion of the cable and electrically coupled to the shield. The metal member reduces the spacing between the conductors of the cable and the shield, which may be connected to ground. As a result of this change in signal-ground spacing, the impedance in the portion of the cable termination may be better matched to the impedance in the bulk cable. In this manner, the separate metal member may serve as an impedance adapter. The impedance adapter can avoid the need for complex manufacturing operations required to shape the shield to provide signal-ground spacing for impedance matching.

[0072] In some embodiments, the shield may be crimped onto the cable. A ferrule may be mounted over the cable in electrical contact with the cable shield, and the connector shield may be crimped around the ferrule. In some embodiments, both the ferrule and the impedance adapter may comprise a sheet of metal formed into a tube. The metal used to form the impedance adapter and the ferrule may have the same material properties and thickness, and both can be economically formed from strips cut from the same sheet of metal.

[0073] Other techniques may be used in connectors such as board connectors formed of die-cast conductive structures configured as conductive housings. In such connectors, the terminal assemblies may be inserted into cavities in the conductive housing that may form a portion of the shielding around the terminal assemblies. A separate shielding member may be inserted into the conductive housing. In some embodiments, a spacer may be formed in the insulating member of the terminal assembly. The connector may be configured such that the spacer establishes a separation between the inserted shielding member and one or more conductors in the terminal assembly. The spacer may be, for example, a rib. In this manner, the components of the connector may be manufactured separately and easily assembled in a manner that provides the desired electrical properties as a result of establishing the desired signal-ground spacing.

[0074] Other techniques may provide mechanical stability of the conductor within the terminal assembly without introducing impedance changes that may result in poor signal integrity. One or more retention features, such as a barb, may be provided at an intermediate portion of the conductor that is retained in the insulating member of the terminal assembly. Such retention features may be large enough to produce stable contact positioning, including withstanding forces and vibrations during normal use of the connector in harsh environments. Alternatively or additionally, the conductor may be inserted into a passage in the insulating member, which may be narrower in the area surrounding the barb than in other parts of the insulating material. However, such a barb may be large enough to appreciably change the impedance along the conductor. An impedance compensation section may be included adjacent to the barb. In the impedance compensation section, the conductor may be narrowed.

[0075] These techniques may be used alone or in combination and are illustrated below in the context of an interconnect system that may be used to make physical connections between assemblies in, for example, an automobile.

[0076] 1 is a perspective view of an exemplary interconnect system, according to some embodiments. The interconnect system may be used to connect two electronic devices to each other. In some embodiments, the interconnect system 100 is used in high data rate transmission applications (e.g., applications involving ECUs in automotive vehicles). In this example, the interconnect system comprises a board connector 100 mounted on a printed circuit board 160 and a cable connector 200 terminating a cable 213. For simplicity of illustration, only a portion of the printed circuit board 160 and a portion of the cable 213 are shown.

[0077] 2 is an exploded perspective view of the example board connector 100 of FIG. 1 when not mated with a cable connector 200 according to some embodiments. The board connector 100 includes an opening 158 in the housing 150, which may be positioned to allow passage of an electrical conductor. A mating interface of the board connector 100 may be disposed within the opening 158. As shown in FIG. 1, a mating interface of a second connector, such as the cable connector 200, may be inserted into the opening 158 to mate with the board connector 100.

[0078] The board connector 100 also includes a conductive housing 140. The conductive housing 140 can be, for example, a die-cast component. In this example, the conductive housing 140 has a mating portion 146 that extends into an opening 158 when the insulating housing 150 is attached to the conductive housing 140. In the embodiment of FIG. 2, the conductive housing 140 is shown as a single component. In other embodiments, the conductive housing 140 can be formed from multiple components, which may be bonded together or held together by other structures of the insulating housing or board connector 100.

[0079] The conductive housing 140 may include one or more chambers into which one or more terminal assemblies are inserted, each of which may include one or more conductors that serve as terminals for a connector. In this example, the conductive housing 140 has one chamber that receives one terminal assembly. The terminal assembly may be formed by the insulator 120 and one or more conductors carried by the insulator 120.

[0080] As shown, the board connector 100 includes electrical conductors that can serve as signal conductors. In this example, pairs of conductors are shown such that the illustrated terminal assembly is configured to pass differential signals. In addition to carrying one or more signals through the connector, the conductors can have a mating contact portion at one end, a back portion at the opposite end, and an intermediate portion therebetween. Thus, the conductors can serve as contacts for the connector.

[0081] 2, the mating contact portions of the conductors are shaped as pins such that the board connector 100 is configured as a header. In other embodiments, the mating contact portions of the conductors in a header connector may be shaped as blades or have other shapes. Alternatively or additionally, in some embodiments, the board connector may have conductors with mating contact portions shaped as receptacles.

[0082] 2 shows a number of electrical conductors including signal conductors 110A and 110B. Mating contact portions of the signal conductors extend into aperture 158. Rear portions of signal conductors 110A and 110B extend from mounting joints of board connector 100 for mounting to a substrate, shown here as a printed circuit board 160. Signal conductors 110A and 110B may be electrically connected to traces or other conductive structures in printed circuit board 160 via conductive plated holes 162 and 163, respectively, in board 160.

[0083] Opening 158 may be shaped and sized to receive a mating connector, which may in turn include electrical conductors configured to electrically connect to mating contact portions of signal conductors 110A and 110B when the interconnection system is in a mated configuration.

[0084] A number of electrical conductors may be held within the insulator 120 to form a terminal assembly. The insulator may be shaped and sized to receive the electrical conductors. For example, the signal conductors 110A and 110B may pass through openings in the insulator 120 and / or may be inserted into passages along a surface of the insulator 120. The insulator 120 may be inserted into a cavity within the conductive housing 140. In this manner, the conductive housing at least partially surrounds the terminal assembly and the electrical conductors therein. In this example, the conductive housing substantially surrounds the terminal assembly on three sides and on the top, as the back and bottom of the conductive housing are open.

[0085] Conductive housing 140 may include features to facilitate attachment to a substrate. In this example, one or more mounting posts 141 are configured to electrically and mechanically couple conductive housing 140 to substrate 160. For example, one or more mounting posts 141 may extend to one or more holes 161, which may be ground vias, in substrate 160. By grounding conductive housing 140, the conductive housing can serve as a shield for a terminal assembly and as a pair of conductors in the terminal assembly.

[0086] The board connector 100 may include one or more additional shielding members. Here, the additional shielding is shown as a shield 130. The shielding 130 is also inserted into the cavity of the conductive housing 140 to further surround the terminal assembly. Here, the shielding 130 is sized to close the rear of the cavity and can be installed after the terminal assembly is inserted. The shielding 130 is electrically and mechanically coupled to the conductive housing 140 so that it can also be grounded. The shielding 130, in conjunction with the spacer in the insulator 120, can also serve to position the terminal assembly in the cavity and, in doing so, can establish a signal-ground spacing for the conductors in the terminal assembly. Such a configuration can provide a desired stable impedance.

[0087] According to some embodiments, conductive housing 140 may include inwardly facing surfaces. In some embodiments, at least two of the inwardly facing surfaces may each include a groove 131 (FIG. 3C). Shield 130 may include a lip that is disposed in the groove of the inwardly facing surface such that it is held perpendicular to the mounting joint. Shield 130 may be sized to form a friction fit in groove 131, facilitating mechanical and electrical connection between shield 130 and insulating housing 150.

[0088] FIG. 3A is a cross-sectional view of the exemplary board connector 100 of FIGS. 1 and 2 taken along line 3A-3A in FIG. 2. In the illustrated embodiment, the insulator 120 forming a portion of the terminal assembly may include a spacer, herein formed as a rib 121. The rib 121 or other spacer positions the terminal assembly relative to the shield 130. The spacer may be sized and positioned to establish a distance between the shield 130 and the signal conductors 110A and 110B within the terminal assembly. In this example, the rib 121 establishes a separation between the shield 130 and portions of the signal conductors 110A and 110B that are perpendicular to the board 160, the separation being parallel to the contact backs of the signal conductors 110A and 110B. This separation is an important factor in establishing the impedance of those portions of the connector, since the shield 130 is the adjacent ground for those portions of the signal conductors. The appropriate size and shape of the rib 121 may be selected to provide a desired impedance. The shield 130 may contact one side of the rib feature 121 .

[0089] As described herein, the insulator 120 and the shield 130 may be engaged in the conductive housing 140. The conductive housing 140 and / or the insulator 120 may include one or more other features that aid in stably positioning the terminal assembly in the conductive housing 140, which contributes to the stability of the signal passing through the connector and reduces noise introduced by the connector. In this example, the conductive housing 140 includes a retention feature 141 to prevent movement of the insulator 120 and absorb the force of the insulator 120. The retention feature 141 may be a rib configured to contact the wall of the insulator 120. In the example of FIG. 3A, the retention feature has a flat edge that faces toward the flat surface of the insulator 120. These surfaces engage to establish the position of the insulator 120 in the conductive housing 140. The opposite edge of the retention feature 141 may be removed to facilitate insertion of the terminal assembly into a cavity in the insulating housing 150, as also shown in FIG. 3A.

[0090] Conductive housing 140 may further include features for engaging insulating housing 150. In this example, conductive housing 140 includes a recess 152. Housing 150 may include a retention feature 151 configured to extend into recess 152 of conductive housing 140. In this example, recess 152 and corresponding retention feature 151 extend substantially around the perimeter of conductive housing 140.

[0091] 3B is a rear view of the board connector 100 of FIG. 3A, according to some embodiments. Either or both of the shield 130 and the conductive housing 140 may also include retention features that help retain the shield 130 in the conductive housing 140. The shield 130 may include ridges, embossments, spring fingers, or other protruding structures that increase friction between the shield 130 and the conductive housing 140. Such features may additionally, or in some embodiments alternatively, bias the shield 130 forward against the spacers of the terminal assembly. In these embodiments, the retention features may protrude above the rear surface of the shield 130.

[0092] Alternatively or additionally, conductive housing 140 may have retention features, such as retention features 142 and 143, to retain shield 130. In this example, the retention features are deformable structures that create an interference fit for shield 130. Retention features 142 and 143 may be, for example, insulating material in groove 131 to ensure a snug fit of shield 130 within conductive housing 140. In this example, the retention features may be formed by injecting a thermoplastic or hardenable material into groove 131. In other embodiments, retention features 142 and 143 may alternatively or additionally be formed by insulating material molded over shield 130 or otherwise applied to shield 130.

[0093] 3C is a cross-sectional view of the board connector 100 along line 3C-3C of FIG. 3B, in accordance with some embodiments. In this view, groove 131 configured to receive an edge of shield 130 is visible, although shield 130 is not shown for simplicity.

[0094] 3C also shows that the terminal assembly is visible being inserted into the chamber 145 of the conductive housing 140. Also visible is an additional retention feature 341 for retaining the insulating housing 150 to the conductive housing 140. The retention feature 341 may include a protruding section that is inserted into a corresponding recess 342 in the housing 150.

[0095] Each of the signal conductors 110A and 110B may include one or more retention features configured to prevent movement of the contacts in the insulator 120 of the terminal assembly. For example, the signal conductor 110A includes a barb 112 configured to provide retention of the contacts in the insulator. In this example, the insulator 120 includes a passage that receives each of the signal conductors 110A and 110B. The barb 112 is recessed into the insulator on the side of the passage to securely hold the contacts. In this example, the passage is narrower adjacent the barb 112 and wider away from the barb. The passage that receives the signal conductor 110A may be parallel to the passage that receives the signal conductor 110B.

[0096] In some embodiments, the barb and / or width of the passage can appreciably affect the impedance along the signal conductors 110A and 110B. The signal conductors and / or the insulator may be provided with an impedance compensation area adjacent to the retention feature. In this example, the impedance compensation area is formed by narrow portions 111 in each of the signal conductors 110A and 110B.

[0097] In the illustrated embodiment, the signal conductors 110A or 110B have the same shape. Thus, the signal conductors 110A or 110B may have the same retention features and the same impedance compensation areas. Similarly, the passages receiving each of the signal conductors 110A and 110B may have the same shape, being narrower proximate the barb 112 and wider away from the barb. For example, in FIG. 3C, the passage for the signal conductor 110B has a first portion 343 having a first width and a second portion 344 having a second width. The second width is narrower than the first width. The narrower portion may provide, for example, adequate retention, while the wider portion may provide desired electrical properties, such as impedance and / or loss.

[0098] 3D is a perspective view of the electrical contacts of the board connector of FIG. 3A according to some embodiments. The electrical signal conductor 110A can include a mating contact portion 115, a rear portion 113, and a middle section 114 that couples the mating contact portion 115 and the rear portion 113. The middle section has a first width 117B that spans more than 50% of its length within the passage and is disposed within the passage.

[0099] The middle section may also include a barb 112. The barb may have a width 117A that is greater than the width 117B of the middle section. The barb 112 may engage with the insulating member 120. The middle section may further include a conductor portion 118 that has a third width 117C that is less than the first width 117B and is proximate to the barb 112. According to the example of FIG. 3D, the mating contact portion 115 and the rear portion 113 may extend in a direction that intersects at a right angle or in a direction that intersects at a substantially right angle. In some embodiments, a portion of the middle section of the conductor 110B is disposed in the first portion 343 of the corresponding passage. In some examples, the conductor portion is disposed in the second portion 344 of the corresponding passage. Similarly, a portion of the middle section of the conductor 110A is disposed in a portion that corresponds to the first portion 343 of the passage that receives the conductor 110A.

[0100] In the example of Figure 3D, the barb 112 is at the end of the middle section near the mating contact portion. There may be more than one retention feature along the length of the signal conductor. Each retention feature and the impedance compensation area adjacent to the retention feature may be similarly shaped. However, in some embodiments, the retention features along the length of the contact may have different sizes or shapes.

[0101] According to some embodiments, the connector 100 is a right-angle connector. In some examples, the mating joint of the board connector 100 disposed in the opening 158 may be at a right angle to the mounting joint for mounting to the printed circuit board 160. According to some embodiments, the shielding member may be aligned perpendicular to the mounting joint. The mating contact portions and rear portions of the signal conductors 110A and 110B may each extend in an orthogonal direction from the respective passages.

[0102] 3D shows a signal conductor 110A shaped for use in a right angle board mount connector. In addition to the barb 112, there is a second barb 112' near the bend in the signal conductor and an additional retention feature 112" near the rear.

[0103] The board connectors shown in Figures 2-3D are configured to pass differential signals. The board connector has one port configured to pass one differential signal. In other embodiments, similar connector construction techniques may be used to construct connectors suitable for passing multiple differential signals. Figure 4A is a perspective view of an example multi-port board connector 400, according to some embodiments. For example, Figure 4A shows a two-row, two-column connector 400 that includes four ports arranged in two columns of two ports.

[0104] Connector 400 similarly includes an insulating housing and a conductive housing. The conductive housing is shown with ports 470A-470D, each configured to receive a mating element. Each of the ports may have the same configuration as mating portion 146 of board connector 100, such that the same mating element can mate with either connector. Like board connector 100, conductive housing 440 is configured to be mounted to board 460. Attached to conductive housing 440 is insulating housing 450, which provides the same functionality as insulating housing 150 for the larger connector.

[0105] FIG. 4B shows a portion of a cross-sectional view taken along line 4B-4B of FIG. 4A, according to some embodiments. In the view of FIG. 4B, the contacts in each of two of the ports are visible. Similar to connector 100, connector 400 has a pair of contacts in each port. In this example, the contacts in each port are held in separate insulators so that there are four terminal assemblies, one for each of the ports. In the illustrated embodiment, a shield corresponding to each of the terminal assemblies may be inserted into conductive housing 440 that prevents removal of the terminal assemblies. However, in some embodiments, components forming the structure of multiple ports may be combined. For example, an insulator may hold the signal conductors for more than one port, or a shield may be inserted after the insulators for more than one port.

[0106] The insulators for the terminal assemblies of the connector 400 may have the same function as the insulator 120 described above for the connector 100. For example, the conductor 410A is disposed in the insulator 420A with the rib 421A serving as a spacer. The conductor 410B is disposed in the insulator 420B with the rib 421B. The ribs 421A and 421B position the respective terminal assemblies with respect to the respective shields 430A and 430B, respectively. The ribs 421A and 421B may perform the same function as the rib 121 described above for the connector 100. Each of the shields 430A-430B and the insulators 420A-420B are engaged in a conductive housing 440, which is further disposed in an insulating housing 450.

[0107] Although the illustrated embodiment shows a board connector with one row and one column with one port and a board connector with two rows and two columns with four ports, a multi-port board connector can include any number of ports with any configuration. For example, in an alternative embodiment, a multi-port board connector may include six ports, such as two rows and three columns with six ports arranged in three columns of two ports. Regardless of the number of ports, each of the ports may have the same configuration as the mating portion 146 of the board connector 100.

[0108] For example, the conductive housing may include two or more chambers arranged in a row. For example, in the example of FIG. 4A, a port 470C corresponding to a first chamber and a port 470D corresponding to a second chamber are arranged in a row in a first direction. A shielding member, such as shielding member 130, may be disposed in each of the chambers. The shielding members may be electrically and / or mechanically engaged to the conductive housing. In some examples, the shielding members each include a planar portion that extends in a direction parallel to the first direction in which the rows of chambers are arranged. In such an embodiment, the shielding body may extend in the row direction a sufficient distance to align with a plurality of chambers such that there are fewer shields than there are chambers.

[0109] In some embodiments, a terminal assembly may be disposed in each respective chamber, such as those described herein, and in some examples, each of the terminal assemblies includes a spacer adjacent a planar portion of a respective shield member.

[0110] As described herein, the conductive housing may include two or more chambers arranged in a row. The conductive housing may include two or more rows. For example, in FIG. 4A, the connector may include a first row with chambers corresponding to ports 470C and 470D, and may also include a second row with chambers corresponding to ports 470A and 470B. As described herein, each terminal assembly may include one pair of conductors, and each conductor of the pair may be positioned the same distance from an adjacent shield member by a spacer of the terminal assembly.

[0111] A connector having a mating joint as described above can be mated with a second connector having a complementary mating joint. The complementary mating joint can similarly include one or more ports. The mating joint of each port of the second connector can include, for example, a shield at least partially surrounding a cavity in which the terminal assembly is disposed. The terminal assembly can include signal conductors with mating contact portions that are aligned to mate with mating contact portions of the signal conductors of the first connector as described above. When the second connector is mated with the first connector, the shield of the second connector can fit into the chamber of the conductive housing, making electrical and mechanical contact between the conductive housing and the shield. Similarly, electrical and mechanical connections can be formed between the signal conductors of each port of the first connector and the corresponding port of the second connector.

[0112] The second connector can be, for example, a cable connector. Figure 5 is a perspective view of a cable connector 200, according to some embodiments. The cable connector 200 is a single port connector and is configured to mate with the single port board connector 100, as shown in Figure 1.

[0113] The cable connector 200 may have similar components as those previously described for the board connector 100, including an outer insulating housing, an inner conductive housing acting as a shield, and a terminal assembly inside a cavity within the shield. However, the outer insulating housing may have mating joints and retention features that are complementary to the mating joints and retention features in the board connector 100 so that the cable connector 200 can mate with the board connector 100. Similarly, the inner conductive housing may have a mating portion configured to mate with the mating portion 146. Additionally, the terminal assembly as well as other components may be configured to terminate the cable 213 rather than mounted on a printed circuit board. For example, the contacts may be electrically coupled to one or more conductors of the cable.

[0114] 6 is an exploded perspective view of an example cable connector 200, according to some embodiments. As shown in FIGS. 5 and 6, the example cable connector 200 is configured to terminate a cable 213. The cable connector 200 includes a mating end 520 and a cable termination end 522 opposite the mating end. A cavity 279 (FIG. 9B) is open at the mating end 520. The connector terminates the cable 213 at the cable termination end 522.

[0115] The ends of the cable may be handled to facilitate termination to connector 200. The bulk of the cable may include one or more insulated conductors, shown here as insulated conductors 210A and 210B. In the example provided, the cable includes a pair of insulated conductors that are surrounded by a cable shield and then covered by an insulating sheath. The cable shield may be, for example, a braided shield. For termination, the sheath may be removed to expose the cable shield. The insulated conductors may be separated at the distal end and the insulation may be removed at the end of the conductor. For cables in which the insulated conductors are twisted together in the bulk cable, separating the insulated conductors may involve unwinding the conductors.

[0116] This handling of the cable allows the conductors of the insulated conductors to be attached to the terminals of the connector. The terminals 240 can be crimped onto the conductors of the cable. The terminals can be part of a terminal assembly with the insulator, shown here as a contact carrier housing 250. The housing 250 can be formed, for example, around the terminals 240 with the crimp ends exposed, or the terminals 240 can be inserted into holes in the housing 250 after being crimped onto the conductors of the cable 213.

[0117] The conductive inner housing of the cable connector 200 is shown here formed from a rear shield 260 and a front shield 270, which may be electrically and mechanically coupled. The front shield 270 may include a mating joint for mating with a complementary connector, and the rear shield 260 may be crimped to a cable and may be electrically coupled to the cable shield. The cable connector 200 further includes a ferrule 220. A portion of the cable shield (not shown in FIG. 6 ) exposed by removing a portion of the cable jacket may be folded over the ferrule 220, and the rear shield 260 may then be crimped around the ferrule 220 to form a connection between the cable shield and the connector shield.

[0118] The cable connector 200 further includes an impedance adapter 230 that may be disposed about the cable 213. According to some embodiments, the impedance adapter may be metallic and may be an electrical contact with the connector shield. The impedance adapter 230 may be closer to the insulated conductors of the cable 213 than the connector shield and may substantially cover a portion of the insulated cable conductors where the cable shield has been removed or folded back. The impedance adapter may be spaced from the cable conductors to provide an impedance that matches the impedance of the conductors in the bulk of the cable.

[0119] These components, namely, terminals 240 attached to conductors of cable 213, contact carrier housing 250, ferrules 220, impedance adapter 230, back shield 260, and front shield 270, can be assembled together as a subassembly. The subassembly can be inserted into cable connector housing 290. Features on the subassembly can engage features on housing 290. The subassembly can be locked into housing 290 using Contact Carrier Position Assurance (CCPA) 280. When the subassembly is inserted into a desired position in housing 290, CCPA 280 can be pushed into housing 290 and can prevent the subassembly from being pulled back. If the subassembly is only partially inserted into housing 290, the subassembly can prevent the insertion of CCPA 280.

[0120] FIG. 7 is a cross-sectional view of the example cable connector of FIG. 6, according to some embodiments. The impedance adapter 230 is in a separated and / or unwound area 231 of the cable termination. The cable handled area 231 provides an area for performing the process of crimping the contacts to the cable's conductors. However, handling of the cable changes the impedance of the conductors. The impedance adapter 230 is provided in close proximity to the cable to prevent this change in impedance. The impedance adapter brings the metal closer to the cable's conductors. In the illustrated embodiment, the impedance adapter also makes contact with the shield after connecting the impedance adapter to ground, establishing a signal-ground spacing for the cable's conductors, which in turn establishes a desired impedance to match the bulk cable's impedance. As used herein, impedances do not have to be identical to be matched. Rather, the impedances need only be close enough to not provide impedance discontinuities that destroy performance. For example, the matched impedance may be within ±5% or ±3 ohms in some embodiments.

[0121] To terminate the cable 213, the end of the cable may be prepared for termination and may be inserted through the ferrule 220 and the impedance adapter 230. The cable shield may be folded over the ferrule 220 and the conductors of the cable 213 may be crimped to the terminals 240. The terminals 240 may then be inserted into the contact carrier housing 250. The rear shield 260 may then be crimped around the ferrule 220. The front shield 270 may then be engaged with the rear shield 260 and retained in place. These components may form a terminated cable subassembly that is inserted into the housing 290. The housing 290 may include an opening 292 for receiving the terminated cable subassembly.

[0122] The terminated cable subassembly can be retained in the housing 290, such as by a beam on the housing being retained by a tab extending from one of the connector shields. The housing 290 may include, for example, a beam 294 with a cantilevered end 291 and a retainer 293 at the cantilevered end 291 that extends into the opening 292. The retainer 293 can have a camming surface 295, and the tab of the terminated cable subassembly can have a tapered forward edge. When the terminated cable subassembly is inserted into the housing 290, the tapered surface of the tab can engage the camming surface of the retainer 293, pushing the retainer 293 upward until the trailing edge of the tab clears the camming surface. In that position, the spring force in the deflected beam 294 will urge the beam downward, retaining the tab in place.

[0123] Alternatively or additionally, a positioning device may be used to engage the terminated cable subassembly in the housing 290. For example, a contact carrier positioning device (CCPA) may provide additional mechanical integrity by interfering with the movement of the beam in a direction to unlatch from the tab once engaged. In the illustrated embodiment, the CCPA 280 has two retention arms 284 (FIG. 6) each with a hook-type retention portion at a distal end. The housing 290 has two windows 524 and 524' on each side (FIG. 5) that can each receive the hook-type retention end of the retention arm 284. In the operational state shown in FIG. 5, the CCPA 280 is fully inserted into the housing 290 and the hook end of the retention arm 284 is retained in the window 524'. In this state, the terminated cable subassembly may be locked to the housing 290. When CCPA 280 is only partially inserted into housing 290, the hook end of latch arm 284 may be latched in window 524. In this condition, the terminated cable subassembly may be inserted into housing 290.

[0124] 8A is a perspective cross-sectional view of the cable connector of FIG. 6 with a contact carrier positioning aid (CCPA) partially inserted. The CCPA may include a member 282 that may be inserted into an opening 281 in a connector housing 290. In the partially inserted state, the member 282 does not block the opening 281 and provides clearance for a terminated cable subassembly to be properly inserted into the housing 290. The CCPA may also include a beam support member 285 that may inhibit distortion of the beam 294. However, in the partially inserted state of FIG. 8A, the beam support member 285 is separated from the beam 294 such that the beam 294 may flex sufficiently to allow the tab 271 to be pushed past the catch 293, thereby allowing the catch 293 to engage the tab 271 when the terminated cable subassembly is inserted into the housing 290.

[0125] When the terminated cable subassembly is properly inserted into the housing 290, the tabs of the rear shield will be in front of the opening 281. The CCPA can secure the contact carrier housing 250 in the housing 290 by preventing rearward movement of the tabs of the rear shield. FIG. 8B is a perspective cross-sectional view of the cable connector of FIG. 6 with the contact carrier positioning assurance (CCPA) fully inserted, according to some embodiments. The catch 293 function of the tab 271 can provide a stop function configured to prevent the front shield 270 and the connector components disposed in the cavity formed by the front shield 270 from moving relative to the connector housing 290. Additionally, in this state, the beam support member 285 prevents movement of the beam 294 such that the beam 294 does not flex sufficiently to allow the catch 293 to disengage the tab 271.

[0126] 9A is a perspective view of an example rear shield of the cable connector of FIG. 6 electrically and mechanically connected to an example front shield of the cable connector, according to some embodiments. As described herein, shielding components such as front shield 270 and rear shield 260 can each be constructed by forming a sheet of metal into a tube that at least partially encloses a cavity at a perimeter bounded by the sheet. A first edge can be bonded to a second edge of the metal sheet. In the illustrated embodiment, the first edge abuts the second edge such that the resulting tube substantially encloses the cavity.

[0127] One or more conductive terminals may be disposed within the cavity. In the example of Figure 9A, a pair of signal terminals, such as terminal 240, may be disposed within the cavity and may be shaped as receptacles for mating with pins of signal conductors 110A and 110B.

[0128] In some examples, the first and second edges of the metal sheet may have one or more interlocking features, such as one or more interlocking protrusions and apertures. For example, front shield 270 has protrusion 266a and corresponding aperture 266b. When forming front shield 270, the first and second edges may be joined such that protrusion 266a fits into aperture 266b, which, once interlocked, may provide additional mechanical integrity to the resulting tube.

[0129] The sheet may be stamped and formed to provide a tab extending away from the cavity in a direction perpendicular to the perimeter. Forming the shielding component in this manner can simplify the manufacturing process. According to some embodiments, the tab may extend from the sheet at a first edge. In some embodiments, the tab may be formed from a first tab portion extending from the sheet and / or a second tab portion extending from the sheet. Forming the tab at the edge of the sheet avoids forming holes in the sheet, which can increase the shielding efficiency of the resulting shield.

[0130] In some embodiments, the tab can be constructed from a first and a second tab portion. The first tab portion can extend from a first edge of the sheet and the second tab portion can extend from a second edge of the sheet. In some examples, the tab portion can be bent so that the first tab portion is adjacent to the second tab portion in parallel. In this state, the two tab portions can be crimped or otherwise bonded together to provide greater integrity to the tab and / or the shield. In some embodiments, the tab can be formed at the first and / or second edge and the tab can be configured to form a retention feature that can engage with a complementary retention feature (such as a beam) of the connector housing and / or can be engaged by a portion of the CCPA. In the example of FIG. 9A, tabs 261 extend from both edges of the sheet forming the rear shield 260 and include retention features. Tabs 271 extend from both edges of the sheet forming the front shield 270 to form another retention feature. The multiple retention features can secure the terminated cable subassembly in multiple ways. Tab 271 can be retained by an inner beam and tab 261 of housing 290, for example, to engage the CCPA. According to some embodiments, front shield 270 has an axis of extension 300 and is concentric with and electrically connected to rear shield 260. Tab 261 of the rear shield can be aligned with tab 271 of front shield 270 in the direction of axis of extension 300.

[0131] The tab 271 has a first edge 277a facing the mating end 520 and a second edge 277b opposite the first edge. The first edge 277a can be tapered toward the mating end of the connector and the second edge 277b can be perpendicular to the perimeter 278. The tapered edge 277a can form a camming surface that deflects the beam during insertion of a terminated cable subassembly into the housing 290, as described above. When the shield 270 is placed in the housing 290 by inserting the shield into the opening, the beam 294 of the housing is configured such that the stop 293 at the cantilevered end 291 is aligned with the second edge 277b of the tab 271 when the shield 270 is fully inserted into the opening. In some embodiments, when the front shield 270 is partially inserted into the cavity 279 of the housing 290, the beam 294 is configured such that the first edge 277a of the tab 271 is aligned with the cam surface 295 of the stop 293.

[0132] In some embodiments, the tab or tabs can extend to form a stop for contact with the connector housing. Alternatively or additionally, the tab or tabs on the shield and a corresponding recess in the connector housing 290 can be used as guides for connecting the shield and the housing. For example, a latch feature can be provided on one side of the shield with a corresponding recess on one side of the housing. This can guide the shield into the housing in the proper orientation (e.g., correct polarity) by sliding the latch feature into the respective recess.

[0133] According to some embodiments, in the terminated cable subassembly, the contact carrier housing 250 extends into a cavity 279 of the front shield 270. The front shield 270 surrounds the mating end of the terminal 240. The front shield 270 includes contact beams 310 configured to mate with a ground structure of a complementary connector, such as the board connector 100. In some embodiments, the contact beams 310 of the front shield 270 are electrically coupled to the cable shield through the front shield 270, the embossments 962, and the back shield 260. In the illustrated embodiment, the beams 310 are at a distal portion of the front shield 270 and have a contact surface that extends radially outward to mate with a conductive housing of a mating connector upon insertion into a chamber that forms a port of the connector.

[0134] 9B is a cross-sectional view of the cable connector of FIG. 9A taken along plane 272 in FIG. 9A according to some embodiments. As described herein, sheet 274 of front shield 270 has first edge 273a and second edge 273b. First edge 273a of sheet 274 of front shield 270 is bonded to second edge 273b of sheet 274 to at least partially enclose cavity 279 with perimeter 278 bounded by the sheet. In the cross-section of FIG. 9B, tab 271 of front shield 270 with anti-removal feature is visible.

[0135] Tab 271 extends away from cavity 279 in a direction perpendicular to perimeter 278. Tab 271 may include a first tab portion 275a extending from sheet 274 at first edge 273a and / or a second tab portion 275b extending from sheet 274 at second edge 273b. The first tab portion may be adjacent and parallel to the second tab portion.

[0136] 9B, a portion of rear shield 260 is inserted into cavity 279. Front shield 270 is concentric with rear shield 260 and is electrically connected thereto.

[0137] 9C is a cross-sectional view of the cable connector of FIG. 9A taken along plane 262 in FIG. 9A according to some embodiments. As described herein, sheet 264 of rear shield 260 has first edge 263a and second edge 263b. First edge 263a of sheet 264 of rear shield 260 is bonded to second edge 263b of sheet 264 to at least partially enclose a portion 269 of cavity 279 with a perimeter 268 bounded by the sheet. In the cross-section of FIG. 9C, tab 261 of rear shield 260 includes a locking feature. The rear shield has an axis of extension 301.

[0138] The tab 261 extends away from the cavity 279 in a direction perpendicular to the perimeter. The tab 261 may include a first tab portion 265a extending from the sheet 264 at a first edge 263a and / or a second tab portion 265b extending from the sheet 264 at a second edge 263b. The first tab portion may be adjacent and parallel to the second tab portion. The tab 261 may be engaged by a member 282 of a positioning device, such as a contact carrier positioning portion 280.

[0139] FIG. 9D is a perspective view of example conductors of the cable connector of FIG. 9A according to some embodiments. As described herein, the conductors can be insulated in the bulk of the cable 213 and over a portion of their length in the connector 200. The conductors 210A and 210B can be separated by the same distance throughout the length of the cable. The distance can be established, for example, by a uniform thickness insulation that covers the insulated conductors and twists the insulated conductors to hold them together. According to the same embodiment, the conductors 210A and 210B insulated with the insulation 217A and 217B can be provided at a first distance from each other in a first region and a second distance in a second region. For example, the portion 288A of FIG. 9D can depict a portion of the cable disposed in a cavity of a shield, such as the cavity 269 of the rear shield 260. In some examples, the portion 288B can include a portion of the cable from which the cable shield has been removed. Portion 288B may depict a portion of the cable forward of the portion of the ferrule 220 where the cable shield is folded back.

[0140] In portion 288A, first insulated conductor 210A and second insulated conductor 210B can be separated by a first center-to-center spacing 289A, and in portion 288B, first insulated conductor 210A and second insulated conductor 210B can be separated by a second center-to-center spacing 289B. According to some examples, spacing 289B can be greater than spacing 289A.

[0141] 9D, cable portion 288B can pass through an opening in a metal member, such as an impedance adapter (e.g., impedance adapter 230). In some examples, the metal member can be configured to match the impedance of cable portion 288A to cable portion 288B.

[0142] 9E is a perspective view of an example ferrule 220 of the cable connector 200 of FIG. 9A, according to some embodiments. The cable connector may include a ferrule, such as ferrule 220, which may include one or more annular portions. According to some embodiments, the ferrule 220 may be metallic. In some examples, the ferrule may comprise a metal sheet formed into a tube.

[0143] In the example of Figure 9E, the ferrule 220 comprises a first annular portion 221A and a second annular portion 221B. The first and second annular portions may be connected, for example, using one or more arms. The two annular portions provide a reliable electrical connection between the ground conductors of the terminated cable and also provide mechanical support, which together reduce noise in the cable assembly, even in environments with substantial vibration.

[0144] The ferrule 220 includes arms 222A and 222B that connect the annular portions 221A and 221B. In this example, the annular portions 221A and 221B are of different diameters but are concentric. According to some examples, a cable passes through the first annular portion 221A and the second annular portion 221B. In the configuration shown in FIG. 6, the second annular portion 221B is provided between the first annular portion and a metal member, such as an impedance adapter 230.

[0145] According to some embodiments, a portion of cable 213 passing through ferrule 220 has its jacket removed, exposing the cable shield. First annular portion 221A fits over the exposed shield and contacts the cable shield such that the exposed shield and the cable shield are electrically connected. In some embodiments, the cable shield can be pulled through an opening between annular portions 221A and 221B and folded back over annular portion 221B.

[0146] In some embodiments, the connector shield is crimped around annular portion 221 B. Annular portion 221 A can provide mechanical support and shielding to a portion of the cable with the cable shield removed.

[0147] As described above, the terminated cable subassembly will be shielded by the rear shield 260 attached to the cable shield and the front shield 270 electrically and mechanically coupled to the rear shield. In some embodiments, a simple yet robust mechanism may be provided to electrically and mechanically connect the front and rear shields. The mechanism may include an embossment on one of the shields and / or one or more beams of one shield that fit into a slot of the other shield. FIG. 10A is a top perspective view of an embossment 962 of the example rear shield of FIG. 9A according to some embodiments. The embossment 962 may be provided on the outer surface of the rear shield 260. For example, the embossment may protrude outward in a direction away from a cavity formed by joining two edges of a sheet of the rear shield 260. As can be seen in FIGS. 10A and 10B, the embossments can be shaped as ridges and can extend around a substantial portion of the perimeter of the rear shield 260, such as more than 40%, more than 50%, or more than 60%.

[0148] 10B is a bottom perspective view of rear shield 260 of FIG. 9A, according to some embodiments. According to some examples, the rear shield may include one or more features for receiving a securing member from the front shield. In this example, the features are shaped as slots. In some examples, the one or more slots may be disposed in first linear section 303a of rear shield 260.

[0149] 10B, the rear shield 260 includes two slots 267a and 267b. The slots can be used to secure a front shield (e.g., the example front shield 270) to the rear shield. For example, a distal portion (e.g., a distal end) of a beam of the front shield may be inserted into the slot of the rear shield 260 such that the front shield 270 is mechanically connected to the rear shield. In some embodiments, the mechanical attachment of the front shield 270 to the rear shield 260 consists essentially of an engagement of one or more beams of the front shield 270 with one or more slots of the rear shield 260 and friction between the embossment 962 and the front shield 270.

[0150] 10C is a cross-sectional view of a portion of the cable connector of FIG. 10A including an embossment 962. As described herein, the front shield 270 comprises a sheet 274 surrounding a first portion of a cavity 279, and a second sheet surrounding a second portion 269 of the cavity. The front and rear shields overlap at an area of ​​overlap 259. The embossment 962 is formed in the area of ​​overlap 259. The embossment 962 is configured to provide contact, friction, and / or electrical connectivity with the front shield 270 to electrically connect the front and rear shields 270 and 260. According to some embodiments, the embossment comprises a ridge extending around at least 40% of the perimeter of the rear shield 260.

[0151] Other features of the shields may be formed in the overlap region such that an opening in one of the front and back shields resulting from the formation of the feature is at least partially blocked by the other shield. Slots 267a and 267b, for example, may be formed in the overlap region. Similarly, beams 272a and 272b (FIG. 11I) may be formed in the overlap region.

[0152] 10D is another cross-sectional view of the cable connector in FIG. 10A, according to some embodiments. The rear shield 260 may have an oval cross-section at the overlap region 259. The oval cross-section may include a first curved section 304a and a second curved section 304b joined by a first linear section 303a and a second linear section 303b, respectively. The embossment 962 may include a first ridge 305a and a second ridge 305b such that the first ridge 305a and the second ridge 305b extend from the first curved section 304a and the second curved section 304b, respectively.

[0153] 11A-11K illustrate methods of assembling a cable connector. For example, cable connector 200 may be assembled using methods provided herein. FIG. 11A is a perspective view of a stripped cable 213, according to some embodiments. Cable 213 may include a ground portion 211. The cable may include multiple conductors 210A and 210B, each insulated with insulation 212. Insulation 212 may be stripped in area 214 to expose a portion of conductors 210A and 210B.

[0154] 11B is a perspective view of terminal 240 of cable connector 200 following a crimping operation, according to some embodiments. Exposed conductors 210A and 210B can be inserted into terminal 240 and crimped to secure the conductors in terminal 240.

[0155] FIG 11C is a perspective view of an assembled ferrule 220 of cable connector 200, according to some embodiments. The ferrule 220 can be slid onto the cable until the shielded portion 211 of the cable is disposed within the second annular portion 221B of the ferrule. (The ground braid, which provides shielding for the cable 213, is not shown in FIG 11C for simplicity.) The ground braid of the cable can then be pulled through an opening in the ferrule between the first annular portion 221A and the second annular portion 221B and then folded back over the second annular portion 221B. For example, FIG 11D is a perspective view of the braid 214 of the ground connection 211 after an operation to fold the braid over, according to some embodiments.

[0156] 11E is a perspective view of an impedance adapter 230 assembled in a cable, according to some embodiments. The impedance adapter 230 is in an unwound region 231 of the cable termination. The impedance adapter 230 can cover a portion of the conductors 210A and 210B with insulation 212, which makes it impossible for the impedance adapter 230 to short with the conductors 210A and 210B. The impedance adapter 230 can comprise metal and is configured to provide metal in close proximity to the cable conductors carrying the signal. In some embodiments, the impedance adapter will also be in contact with a rear shield that also connects the impedance adapter to ground.

[0157] 12A and 12B, impedance adapter 230 may be annular and may be slid over terminal 240 and the insulating portions of conductors 210A and 210B. Impedance adapter 230 may be retained by a rear shield or in any other suitable manner.

[0158] The terminals 240 can then be inserted into the contact carrier housing 250 and then the back shield can be attached. Figure 11F is a perspective view of the attached contact carrier housing 250 and back shield in the process of being secured, according to some embodiments. As described herein, two edges of the sheet forming the back shield 260 can be joined to form a cavity surrounded by the sheet. The joining can be accomplished by crimping a tab portion to a tab and / or by interlocking a protrusion and a recess.

[0159] With the rear shield attached, the front shield may then be attached. The front shield may be formed into a tube and slid onto the front portion of the rear shield. As described herein, two edges of the sheet of front shield 270 may be joined to form a cavity surrounded by the sheet. For example, a portion of the rear shield 260 may be placed into the cavity. FIG. 11G is a top perspective view of the front shield of the cable slid onto the rear shield, according to some embodiments.

[0160] The front shield can be electrically and mechanically coupled to the rear shield as a result of friction between the outer surface of the embossment 962 and the inner surface of the front shield. Alternatively or additionally, the connection may be made through other engagement features. FIG. 11H is a perspective view from below of the front shield of FIG. 11G of the cable, according to some embodiments. The front shield 270 may further include beams 272a and 272b cut in the sheet 274. In some examples, each of the beams 272a and 272b has a distal portion 276a and 276b, respectively. The distal portions 276a and 276b are configured to extend through respective slots (e.g., slots 215a and 215b) of the rear shield 260 such that the first shield is mechanically connected to the second shield. Beam 272a can include a first section 277aa parallel to first sheet 274 and a distal portion including a second section 277ab that transverses the first section. Beam 272b can include a first section 277ba parallel to first sheet 274 and a distal portion including a second section 277bb that transverses the first section. In some examples, more than one beam and corresponding slots can be provided.

[0161] 11H, beams 272a and 272b are deflected outward from the periphery of front shield 270. In this configuration, distal portions 276a and 276b are removed from cavities within front shield 270 so that front shield 270 can be slid over rear shield 260. Once front shield 270 is positioned relative to rear shield 260, beams 272a and 272b can be returned to an undeflected state such that distal portions 276a and 276b engage features on rear shield 260, locking the front and rear shields together.

[0162] FIG. 11I is a perspective view of a terminated cable subassembly with the front shield latched onto the back shield, according to some embodiments.

[0163] 11J is a cross-sectional view with additional detail of the front shield being latched onto the back shield, according to some embodiments. In some embodiments, recesses 251 may be provided in contact carrier housing 250 to ensure that first section 277ba and first section 277bb do not hit contact carrier housing 250 and allow sections 277aa and 277ba to return flush with the perimeter of front housing 270.

[0164] FIG. 12A is a rear perspective view of an example impedance adapter, such as impedance adapter 230, according to some embodiments. FIG. 12B is a front perspective view of an example impedance adapter. As described herein, the impedance adapter 230 can be disposed around the cable 213 and can be adjacent to the ferrule such that the opening of the ferrule aligns with the opening 233 of the impedance adapter. According to some embodiments, the impedance adapter can be metallic, for example, the impedance adapter can comprise a metal sheet formed into a tube. The metal sheet can be of the same or substantially the same thickness and / or material as the metal sheet forming the ferrule. Such a configuration can simplify manufacturing as the ferrule and the impedance adapter can be formed from the same sheet of metal. The impedance adapter 230 can be provided in an unwound region 231 of the cable termination.

[0165] In some embodiments, the impedance adapter 230 may have a generally oval cross-section. For example, the impedance adapter 230 across the first end 238 may have an oval cross-section with first and second curved sections, such as 237A and 237B, respectively, joined by a first linear section 236A and a second linear section 236B. This shape allows the impedance adapter to fit across two insulated conductors of the cable 213 that are positioned next to each other in the unwound state.

[0166] The impedance adaptor 230 may have an oval cross-section across the second end 239. The oval may have a major axis 235. The impedance adaptor may have one or more embossments, such as embossment 232A and embossment 232B. The embossments may extend toward the major axis (e.g., in the direction of the cavity formed by the periphery of the metal). The embossments 232A and 232B may be between the first and second insulated conductors 212.

[0167] In this example, the embossments 232A and 232B extend along only a portion of the length of the impedance adapter, such as between 25 and 75% of the length, or in some embodiments 40-60%. In this configuration, the embossments align with locations of the conductors of the cable that are more widely separated. Areas of the impedance adapter without the embossments align with locations of the conductors of the cable that are less widely separated. The impedance adapter 230 attempts to match the impedance of the unshielded portion of the cable not only to the shielded portion, but also along the length of the unshielded portion of the cable.

[0168] In the illustrated example, the embossments are generally uniform along a portion of the length of the impedance adapter 230. This configuration has been found to provide an adequate impedance match along the length of the unshielded portion of the cable. However, in other embodiments, the embossments may vary in volume, becoming taller and / or wider, with respect to the separation between the conductors of the cable. Alternatively or additionally, the embossments may extend along the entire length of the impedance adapter 230 or may be omitted.

[0169] The cable connector 200 is shown as a receptacle connector configured to mate with the board connector 100 configured as a pin header. The construction techniques described herein may be applied to cable connectors with mating contacts configured with pins by replacing a few components with respect to those shown in FIG. 6. FIG. 13 is a perspective view of illustrated components that may replace the components shown in FIG. 6 to form a cable connector 1300 configured to mate with the cable connector 200 of FIG. 5, according to some embodiments. The cable connector 1300 may be formed with a housing 1390 instead of the housing 290, a front shield 1370 instead of the front shield 270, and terminals 1340 instead of the terminals 240. In some embodiments, other components may be substituted or replaced in addition. For example, a contact carrier housing configured to hold the terminals 1340 may be used in place of the contact carrier housing 250.

[0170] The front shield 1370 can be disposed in the housing 1390 and can have an opening 1371 configured to mate with the mating end 520 of the connector 200. The housing 1390 can also include an opening 1391 configured to mate with the mating end 520 of the connector 200. The terminals 1340 can be disposed in the front shield 1370. In this example, the terminals have mating contact portions shaped as pins to facilitate mating with a cable connector with terminals configured as receptacles. The mating joints and retention features of the cable connector 1300 are similarly complementary to the mating joints and retention features of the connector 200. Other components such as the back shield, ferrules, and impedance adapters can be the same or substantially the same as those used in the connector 200.

[0171] The techniques described herein may be used in connectors having configurations other than those previously described. For example, the techniques described herein may be used in mezzanine or backplane connectors. Such alternative connector configurations may be used with all of the features described herein, or with any suitable number of subsets of the features. Additionally, while all of the structures, materials, and construction techniques described herein may be used together, in some embodiments, some or all of the structures, materials, or techniques may be omitted.

[0172] Additional mating features are described to electrically and / or mechanically mating the two components. For purposes of illustration, exemplary embodiments are described in which the mating features are on one component or the other. The location of the mating features may be reversed.

[0173] As another example, a cable connector is shown with tabs 261 on the rear shield and tabs 271 on the front shield. Each tab can be configured to form a retention feature that can engage with a complementary retention feature (such as a beam) on the connector housing and / or can be engaged by a portion of the CCPA. As described herein, the front shield can have an axis of extension, can be concentric with the rear shield, can be electrically connected to the rear shield, and the tabs on the front shield are shown extending in the same direction as the tabs on the rear shield. However, the tabs on the front shield and the tabs on the rear shield do not have to be aligned in the same direction or extend in the same direction. With different configurations of the front and rear tabs, a housing that receives a terminated cable assembly with the front shield secured to the rear shield has multiple slots to receive the tabs. By providing multiple possible positions for the tabs on the front and rear shields, multiple terminated cable assembly configurations are possible, each of which will only fit into a housing with a particular configuration of slots that receive the tabs. In this manner, multiple keyed configurations can be created. In some embodiments, the tabs on the rear shield can be on the opposite side of the terminated cable subassembly relative to the tabs on the front shield and / or can extend away from the cavity in a direction opposite that of the tabs on the front shield.

[0174] Another example is a board connector in which the contact portion and rear portion are oriented at right angles. In alternative embodiments, the contact portion and rear portion may extend in the same direction. The contact portion and rear portion may alternatively extend from the passage of the insulating member of the terminal subassembly in opposite directions along the same axis.

[0175] Such modifications, improvements, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Moreover, although advantages of the invention have been indicated, it should be understood that not all embodiments of the invention include all of the described advantages. Some embodiments may not implement features that are described herein as advantageous in some examples. Thus, the foregoing description and drawings are by way of example only.

[0176] Various aspects of the invention may be used alone, in combination, or in various arrangements not expressly contemplated in the embodiments described above, and therefore are not limited in their application to the details and arrangements of components set forth in the foregoing description or shown in the drawings, For example, aspects described in one embodiment can be combined in any manner with aspects described in other embodiments.

[0177] All definitions, as defined and used herein, should be understood to control for any dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meaning of the defined terms.

[0178] The use of ordinal terms such as "first," "second," "third," etc. in the claims to vary claim elements does not, in and of itself, imply a priority, precedence, or ranking of one claim element over another claim element, or a temporal order in which method actions are performed, but is merely used as a label to distinguish one claim element having a particular name from other elements having the same name (for purposes of ordinary terminology) to distinguish between the claim elements.

[0179] The indefinite articles "a" and "an" as used in the specification and claims, unless expressly indicated to the contrary, should be understood to mean "at least one."

[0180] As used herein and in the claims, the phrase "at least one" in reference to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element expressly listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements other than the elements expressly identified in the list of elements to which the phrase "at least one" refers can optionally be present, whether or not related to those expressly identified elements.

[0181] The term "and / or" as used herein and in the claims should be understood to mean "either or both" of the elements so conjoined, i.e., conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so conjoined. Other elements other than the elements expressly identified by the "and / or" clause may be optionally present, whether related to the elements expressly identified. Thus, as a non-limiting example, a reference to "A and / or B", when used in conjunction with open-ended language such as "comprising", may in one embodiment refer only to A (optionally including elements other than B), in other embodiments may refer only to B (optionally including elements other than A), in yet other embodiments may refer to both A and B (optionally including other elements), and so forth.

[0182] As used herein and in the claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as being inclusive, i.e., including at least one, but also including more than one, of an element or list of elements, and optionally including additional items not listed. Only terms that are clearly indicative of the opposite, such as "only one of" or "exactly one of," or, in the claims, "consisting of," will refer to including exactly one element of an element or list of elements. In general, the term "or" as used herein, when preceded by an exclusivity expression, such as "either," "one of," "only one of," or "exactly one of," should only be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both"). "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0183] Also, the phraseology and terminology used herein is for descriptive purposes only and should not be construed as limiting. The use of "including," "comprising," "having," "including," "with," and variations thereof herein are meant to encompass not only the items listed thereafter and equivalents thereof, but also additional items. [Explanation of symbols]

[0184] 100 Interconnect Systems, Board to Board Connectors 110A, 110B Signal Conductors 111 Narrow Part 112, 112', 112" Hanging part 113 Rear 114 Intermediate division 115 Mating contact part 117A Width of the hook 117B Width of middle section 117C Conductor width 118 Conductor Part 120 Insulators, insulating materials 121 Rib, rib feature 130 Shielding body, shielding member 131 Groove 140 Conductive housing 141 Mounting post, retention feature 142, 143 Retention features 145 rooms 146 Mating part 150 Insulated housing 151 Retention Features 152 Recess 158 Aperture 160 Printed Circuit Board 161 holes 162, 163 Conductive plated holes 200 Cable Connector 210A, 210B Insulated Conductors 211 Grounding part, shielding part 212 Insulators, insulated conductors 213 Cable 214 Braid 220 Ferrule 221A First annular part 221B Second annular part 222A, 222B arm 230 Impedance Adapter 231 Separated Areas, Solved Areas 232A, 232B Embossed 235 Main axis 236A First Linear Section 236B Second Linear Section 237A First curved section 237B Second curved section 238 First Edge 240 Terminals 250 Contact Carrier Housing 259 Area of ​​overlap 260 Rear shield 261 tabs 262 plane 263a The First Edge 263b The second edge 264 seats 265a First tab portion 265b Second tab portion 266a protrusion 266b aperture 267a, 267b Slots 268a, 268b Slots 269 ​​Part of cavity 279 270 Front Cover 271 tabs 272 plane 272a, 272b beam 273a First Edge 273b The second edge 274 First Sheet 275a First tab portion 275b Second tab portion 276a, 276b Distal part 277a First Edge 277aa First division 277ab Second division 277b The second edge 277ba 1st division 277bb Second Division 278 Nearby 279 Cavity 280 Contact Carrier Positioning Unit, CCPA 284 Anti-slip arm 285 Beam support member 288A, 288B Cable section 289A First Center Spacing 289B Second Center Distance 290 Cable Connector Housing 291 Cantilever End 292 opening, cavity 293 Stopper 294 Beam 295 Cam Surface 300 Axis of Extension 301 Axis of Extension 303a First Linear Section 303b Second Linear Section 304a First curved section 304b Second curved section 310 Contact beam 341 Retention Features 342 Recess 343 First Part 344 Second Part 400 Multi-port PCB Connector 410A, 410B Conductor 420A, 420B Insulator 421A, 421B Ribs 440 Conductive Housing 450 Insulated housing 460 Substrate 470A, 470B, 470C, 470D Ports 520 Mating End 522 Cable Termination 524, 524' Window 962 Emboss 1300 Cable Connector 1340 Terminal 1370 Front Shield 1371 Aperture 1390 Case 1391 Aperture

Claims

1. 1. An electrical connector having a mating end and a cable termination end opposite the mating end, at least one electrical conductor; a first shield comprising a first sheet surrounding a first portion of the cavity; a second shield comprising a second sheet surrounding a second portion of the cavity, the second portion of the cavity overlapping the first portion of the cavity in an area of ​​overlap; at least a portion of the at least one electrical conductor is disposed within the cavity; In the overlapping region, the second shield is inside the first shield, and the second shield has an embossment extending outward. A second shield and An electrical connector comprising:

2. The embossment electrically connects the first shield and the second shield.

2. The electrical connector of claim 1.

3. the second shield having an axis of elongation and a periphery; the embossment comprises a ridge extending around at least 40% of the perimeter; 3. The electrical connector of claim 2.

4. the second shield has an oval cross-section comprising first and second curved sections joined by first and second linear sections in the region of overlap; the embossment comprises a first ridge and a second ridge extending from the first curved section and the second curved section, respectively; 3. The electrical connector of claim 2.

5. the first shield comprises a beam; the second shield comprises a slot; a distal portion of the beam extends through the slot such that the first shield is mechanically connected to the second shield; 5. The electrical connector of claim 4.

6. the beam is cut in the first sheet; the slot of the second shield is disposed in the first linear section of the second shield; 6. The electrical connector of claim 5.

7. the beam includes a first section parallel to the first sheet and a second section transverse to the first section, the second section extending through the opening; 7. The electrical connector of claim 6.

8. the beam is a first beam; the first shielding body includes a second beam; the slot is a first slot; the second shield includes a slot parallel to the first slot; a distal end of the second beam extending through the second slot; 8. The electrical connector of claim 7.

9. the electrical connector is terminated to a cable having a cable shield; the end of the cable where the cable shield is exposed is inserted into the cavity; the second shield surrounds the cable inserted into the cavity and is electrically connected to the exposed cable shield; the first shield includes contact beams configured to mate with ground structures of a complementary connector; the contact beam of the first shield is electrically coupled to the cable shield through the first shield, the embossment, and the second shield; 9. The electrical connector of claim 8.

10. the first shield comprises at least one beam; the second shield comprises at least one slot; a distal portion of each of the at least one beam extends through a respective slit of the at least one slot; the mechanical attachment of the first shield to the second shield consists essentially of engagement of the at least one beam with the at least one slot and friction between the embossment and the first shield; 2. The electrical connector of claim 1.

11. 1. A cable assembly comprising a cable terminated in an electrical connector, The electrical connector comprises: a connector shield at least partially surrounding a first portion of the cavity; a metal member within the cavity, the metal member having an opening therethrough; Equipped with The cable a first portion outside the cavity, a first insulated conductor; a second insulated conductor; and a cable shield at least partially enclosing the first and second insulated conductors, with the first and second insulated conductors spaced apart by a first center-to-center spacing; a first portion comprising: a second portion disposed within the cavity, the second portion comprising the first insulated conductors and the second insulated conductors, with the first insulated conductors and the second insulated conductors spaced apart by a second center-to-center spacing; Equipped with the second portion of the cable passes through the opening in the metal member; Cable assembly.

12. the second center-to-center spacing is greater than the first center-to-center spacing; the metallic member is configured to match the impedance of the second portion of the cable to the first portion of the cable. The cable assembly of claim 11.

13. the cable shield is absent from the second portion; The cable assembly of claim 11.

14. the connector shield is electrically connected to the cable shield; The cable assembly of claim 13.

15. The connector comprises: a ferrule comprising a first annular portion, a second annular portion, and a plurality of arms connecting the first annular portion to the second annular portion; the cable passes through the first annular portion and the second annular portion; the second annular portion is between the first annular portion and the metal member; The cable assembly of claim 14.

16. the first annular portion contacts the cable shield; The cable assembly of claim 15.

17. the connector shield is crimped around the first annular portion; The connector further includes a first contact and a second contact crimped onto the first insulated conductor and the second insulated conductor, respectively.

17. The cable assembly of claim 16.

18. The metal member is an impedance adapter.

17. The cable assembly of claim 16.

19. the ferrule comprising a first metal sheet formed into a tube; the impedance adapter comprises a second metal sheet formed into a tube; the first metal sheet and the second metal sheet are of the same material and have the same thickness; 20. The cable assembly of claim 18.

20. the metal member has a first end and a second end with the opening extending between the first end and the second end; the opening at the first end is shaped as an oval; the opening is shaped as an oval at the second end with a major axis and an embossment extending toward the major axis; the embossment is between the first insulated conductor and the second insulated conductor; The cable assembly of claim 11.

21. a conductive enclosure having a chamber; a shielding member within the conductive housing, the shielding member being electrically and mechanically engaged with the conductive housing; a terminal assembly disposed within the chamber, the terminal assembly including an insulating member and a conductor carried by the insulating member, the insulating member including a spacer separating at least a portion of the conductor from the shielding member; An electrical connector comprising:

22. the insulating member comprises a body, and the spacer comprises a rib extending from the body; 22. The electrical connector of claim 21.

23. the electrical conductor comprises a terminal having a mating contact portion, a rear contact portion, and an intermediate portion connecting the mating contact portion and the rear contact portion; the mating contact portion and the contact rear portion extend in a vertical direction; the spacer separates the shielding member from a portion of the conductor parallel to the contact tail; 22. The electrical connector of claim 21.

24. an impedance of a first portion of the conductor parallel to the contact tail matches an impedance of a second portion of the conductor parallel to the mating contact portion; 24. The electrical connector of claim 23.

25. the second portion of the electrical conductor is disposed within the chamber of the conductive housing; the first portion of the conductor is separated from the shielding member by the spacer; 25. The electrical connector of claim 24.

26. the electrical connector is a right-angle connector having a mating interface and a mounting interface perpendicular to the mating interface; the shielding member is perpendicular to the mounting joint; 22. The electrical connector of claim 21.

27. the chamber is a first chamber, and the conductive housing includes a plurality of chambers arranged in a row extending in a row direction, including the first chamber; the shielding member is a first shielding member, and the electrical connector includes a plurality of shielding members within the conductive housing that are electrically and mechanically engaged with the conductive housing, the plurality of shielding members including the first shielding member; each of the plurality of shielding members includes a planar portion extending in a direction parallel to the column direction; the terminal assembly is a first terminal assembly, the electrical connector includes a plurality of terminal assemblies including the first terminal assembly, each of the plurality of terminal assemblies being disposed in a respective one of the plurality of chambers; each of the plurality of terminal assemblies includes a spacer adjacent to the planar portion of a respective one of the plurality of shielding members; 22. The electrical connector of claim 21.

28. the column is a first column; the plurality of chambers is a first plurality of chambers; the conductive housing includes a second plurality of chambers arranged in a second row extending in the row direction; the electrical connector includes a second plurality of shielding members within the conductive housing, the second plurality of shielding members being electrically and mechanically engaged with the conductive housing; the electrical connector includes a second plurality of terminal assemblies, each of the second plurality of terminal assemblies disposed in a respective one of the second plurality of chambers; each of the second plurality of terminal assemblies includes a spacer adjacent to a shielding member of the second plurality of shielding members; 28. The electrical connector of claim 27.

29. each terminal assembly of the first plurality of terminal assemblies and the second plurality of terminal assemblies includes a pair of conductors, the conductors of each of the pairs being positioned the same distance from an adjacent shield member by the spacer of the terminal assembly; 29. The electrical connector of claim 28.

30. the electrical connector is a board connector having a mounting interface configured for mounting to a printed circuit board; the conductive housing has inwardly facing surfaces, at least two of the inwardly facing surfaces having grooves; the shield includes a lip disposed within the groove in the inwardly facing surface so as to be held perpendicular to the mounting joint.

22. The electrical connector of claim 21.

31. a conductive enclosure having a chamber; a terminal assembly disposed within the chamber, the terminal assembly including an insulating member with a passageway therethrough, and a conductor including a mating contact portion, a rear portion, and an intermediate section joining the mating contact portion and the rear portion; the contact portion and the rear portion extend from the insulating member; The intermediate section is disposed within the passageway; the passageway has a first width over more than 50% of its length; a second width greater than the first width and a hook portion adapted to engage with the insulating member; a conductor portion adjacent to the hook portion with a third width narrower than the first width; Terminal assembly and An electrical connector comprising:

32. the conductor portion comprises an impedance compensating portion; 32. The electrical connector of claim 31.

33. the passageway has a first passageway portion with a first passageway width; the passageway has a second passageway portion with a second passageway width that is narrower than the first passageway width; a portion of the intermediate section of the electrical conductor with the first width disposed in the first passage portion; the conductor portion is disposed within the second passage portion; 32. The electrical connector of claim 31.

34. the passage is a first passage, and the insulating member includes a second passage parallel to the first passage; the electrical conductor is a first electrical conductor, and the terminal assembly includes a second electrical conductor disposed within the second passage.

34. The electrical connector of claim 33.

35. the first conductor and the second conductor are configured as a differential pair; 35. The electrical connector of claim 34.

36. the first conductor and the second conductor have the same shape; The first passage and the second passage have the same shape.

35. The electrical connector of claim 34.

37. the electrical connector is a right-angle connector, and the mating contact portion, the rear portion of the first conductor, and the rear portion of the second conductor extend from the first passage and the second passage, respectively, in perpendicular directions; 37. The electrical connector of claim 36.

38. at least one electrical conductor; a shield comprising a sheet with a first edge and a second edge; Equipped with the first edge is joined to the second edge to at least partially enclose a cavity at a periphery bounded by the sheet; at least a portion of the at least one electrical conductor is disposed within the cavity; The sheet includes a tab extending away from the cavity in a direction perpendicular to the periphery.

39. the tab has a retaining feature; 39. The electrical connector of claim 38.

40. the first edge is coupled to the second edge via interlocking protrusions and openings in the first and second edges; 39. The electrical connector of claim 38.

41. 39. The electrical connector of claim 38, wherein the tab extends from the first edge of the sheet.

42. the tab includes a first tab portion extending from the sheet and a second tab portion extending from the sheet; the first tab portion is adjacent and parallel to the second tab portion; 39. The electrical connector of claim 38.

43. the first tab portion extends from the sheet at the first edge; the second tab portion extends from the sheet at the second edge; 43. The electrical connector of claim 42.

44. the electrical connector having a mating end; the cavity is open at the mating end of the connector; the tab has a first edge facing the mating end and a second edge opposite the first edge; the first edge of the tab tapers toward the mating end of the connector; the second edge of the tab is perpendicular to the perimeter; 44. The electrical connector of claim 43.

45. The electrical connector further comprises an insulating housing having an opening; the insulating housing includes a beam having a cantilevered end and a stopper portion at the cantilevered end extending into the opening; The shield is inserted into the opening; the beam is configured such that the detent is aligned with the second edge of the tab when the shield is fully inserted into the cavity.

45. The electrical connector of claim 44.

46. the catch comprises a cam surface; the beam is configured such that the first edge of the tab is aligned with the cam surface of the detent when the shield is partially inserted into the cavity.

46. ​​The electrical connector of claim 45.

47. the at least one electrical conductor comprises a pair of signal terminals; 47. The electrical connector of claim 46.

48. the shield comprises a first shield; the tab comprises a first tab; the electrical connector includes a second shield at least partially surrounding the cavity; the second shield includes a second tab extending away from the cavity in a direction perpendicular to the perimeter.

48. The electrical connector of claim 47.

49. a positioning device including a member extending into the cavity and engaging the second tab; 49. The electrical connector of claim 48.

50. the first shield has an axis of elongation; the first shield is concentric with and electrically connected to the second shield; the first tab is aligned with the second tab in the direction of the axis of extension; 39. The electrical connector of claim 38.

Images