Cable assembly with dielectric clamshell connector for impedance control - Patent Application 20070122997

Abstract

A connector for controlling impedance for use in a connector assembly includes a housing (44) formed from a dielectric material. The housing (44) has first and second conductor receiving openings (68) sized to receive exposed conductors (18, 20) of a cable (10). The first and second conductor receiving openings (68) have conductor receiving portions (41, 49) that extend at an angle (71) relative to a longitudinal axis (45) of the housing (44). The first and second conductor receiving openings (68) have conductor spacing portions (43, 51) extending from the conductor receiving portions (41, 49). The conductor spacing portions (43, 51) extend in a direction essentially parallel to the longitudinal axis (45) of the housing (44). The spacings (43, 51) are spaced apart by a distance, the dielectric material and the distance (47) that the conductor spacings are separated by are selected to match the impedance of the cable (10).

Description

[Technical Field]

[0001] The present invention relates to a cable assembly that controls impedance, and more particularly, to a cable assembly that uses a dielectric clamshell component to control cable termination impedance. [Background technology]

[0002] Maintaining signal integrity in communications is always desirable. Factors that affect signal integrity include the cable design and the process used to terminate or install the cable. Cables are typically formed from at least one plated or unplated center conductor covered by a foil shield protector that includes a dielectric and braid and / or an overall non-conductive jacket. Terminating the braid to a device such as a printed circuit board (PCB) or connector can significantly affect the performance of the cable.

[0003] Various methods are known for terminating shields and components, including soldering wire ends to PCB / connector terminations and laser-terminated parallel-gap resistance welding. Another common method of termination is the use of ferrules. One significant issue with ferrules is that the cable dielectric tends to collapse when the wire is crimped to attach the ferrule. Another issue with existing methods of terminating the braid is the tendency for the placement of the differential pair within the cable jacket to change. Both issues can affect signal integrity by affecting impedance and other electrical parameters. Summary of the Invention [Problem to be solved by the invention]

[0004] The problem to be solved is to provide a cable assembly that controls impedance and does not damage or displace the conductors. In particular, a cable assembly that uses dielectric clamshell components to control cable termination impedance would be advantageous. [Means for solving the problem]

[0005] This problem is solved by a connector for controlling impedance used in a connector assembly, the connector having a housing with a first conductor receiving opening and a second conductor receiving opening. The first conductor receiving opening and the second conductor receiving opening are sized to receive exposed conductors of a cable. The first conductor receiving opening and the second conductor receiving opening have conductor receiving portions, the conductor receiving portions extending at an angle relative to a longitudinal axis of the housing. The first conductor receiving opening and the second conductor receiving opening have conductor spacing portions extending from the conductor receiving openings. The conductor spacing portions extend in a direction essentially parallel to the longitudinal axis of the housing. The spacing portions are spaced apart by a distance. The spacing distance between the spacing portions is selected to match the impedance of the cable.

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

[0007] [Figure 1] 1 is an exploded perspective view of a cable assembly according to the present invention; [Figure 2] 2 is a cross-sectional view of the cable taken along line 2-2 of FIG. 1. [Figure 3] FIG. 2 is an enlarged perspective view of a clamshell connector of the cable assembly. [Figure 4] FIG. 10 is an enlarged perspective view of the conductor locations in the first portion of the clamshell connector with the second portion of the clamshell connector disassembled. [Figure 5] FIG. 1 is an enlarged perspective view of a clamshell connector fully inserted into a conductor. [Figure 6] FIG. 1 is a perspective view of a fully assembled cable assembly. [Figure 7] 7 is a cross-sectional view of the cable assembly taken along line 7-7 of FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0008] Cable 10 is shown in Figures 1 and 6. Cable 10 can transfer data between storage devices, switches, routers, printed circuit boards (PCBs), analog-to-digital converters, connectors, and other devices. In various embodiments, cable 10 can support data rates of 100 Mbps or greater. In some embodiments, cable 10 can support data rates of approximately 4.25 Gbps to approximately 25 Gbps. Cable 10 may be used at data rates above or below these exemplary rates. As shown in Figure 2, cable 10 has a cable jacket 12, a braided shield 16, a metalized foil 14, and two center conductors 18, 20. The conductors 18, 20 are spaced apart and extend essentially parallel to one another. The conductors 18, 20 are surrounded by a braided metal shield 16, such as, but not limited to, a braided copper shield. The center conductors 18, 20 may be surrounded by respective dielectric layers 22, 23.

[0009] 1 and 7, the end of cable 10 has cable jacket 12 removed. A portion 24 of cable 10 may include a ferrule 26 disposed adjacent the end of cable 10. In such applications, braided shield 16 is folded back over ferrule 26. The dielectric of conductors 18, 20 is also removed, thereby exposing portions of conductors 18, 20.

[0010] With the conductors 18, 20 exposed, terminals 30 are positioned on the ends of the conductors 18, 20. As shown in FIG. 4, wire termination portions 32 of terminals 30 are crimped onto the conductors 18, 20. However, other methods of terminating terminals 30 to conductors 18, 20 may be used. In the exemplary embodiment shown, terminals 30 are male terminals having pin portions 34 extending from wire termination portions 32. However, other configurations of terminals may be used, including, but not limited to, female socket terminals.

[0011] With terminals 30 properly terminated to conductors 18, 20, the exposed portions of conductors 18, 20 are aligned within a clamshell connector or housing 44. Clamshell connector 44 is formed from a dielectric material. As shown in FIG. 3, clamshell connector 44 has a first or lower portion 42 and a second or upper portion 46.

[0012] As shown in Figures 3 and 4, the lower portion 42 has a conductor-receiving recess 40 for receiving the conductors 18, 20. The conductor-receiving recess 40 has a conductor-receiving portion 41 and a conductor transition or spacing portion 43. The conductor-receiving portion 41 extends at an angle relative to a longitudinal axis 45 of the housing 44 to receive and space the conductors 18, 20 as they exit the cable 10. The conductor spacing portion 43 extends in a direction essentially parallel to the longitudinal axis 45 of the housing 44. The spacing portions 43 are spaced apart by a distance 47.

[0013] Lower portion 42 has conductor-receiving recesses 40 for receiving conductors 18, 20. Conductor-receiving recesses 40 extend to terminal-receiving recesses 58 sized to receive wire terminations 32 of terminals 30. Latch-receiving openings 60 are positioned between conductor-receiving recesses 40. Latch-receiving openings 60 have latch shoulders 61 extending from the sidewalls of latch-receiving openings 60. Latch-receiving recesses 62 are positioned between terminal-receiving recesses 58. Latch-receiving recesses 62 have latch shoulders 63 extending from the sidewalls of latch-receiving recesses 62.

[0014] Upper portion 46 has a conductor receiving recess 48 for receiving conductors 18, 20. Conductor receiving recess 48 has a conductor receiving portion 49 and a conductor transition or spacing portion 51. Conductor receiving portion 49 extends at an angle relative to longitudinal axis 45 of housing 44 to receive and space conductors 18, 20 as they exit cable 10. Conductor spacing portion 51 extends in a direction essentially parallel to longitudinal axis 45 of housing 44. Spacer portions 51 are spaced apart by distance 47.

[0015] Conductor receiving recess 48 extends to terminal receiving recess 50 sized to receive wire termination 32 of terminal 30. Latches 52, 54 extend from upper portion 46 and are positioned between conductor receiving recesses 48. Latches 52, 54 have latch shoulders 53, 55. Latch 56 extends from upper portion 46 and is positioned between terminal receiving recesses 50. Latch 56 has latch shoulder 57. In the exemplary embodiment shown, latches 52, 54, 56 have similar configurations. However, other latch configurations may be used.

[0016] As shown in FIG. 5 , lower portion 42 and upper portion 46 are configured to be secured together to surround exposed portions of conductors 18, 20. When secured, the exposed portions of conductors 18, 20 are positioned in first and second conductor receiving openings 66 ( FIG. 7 ) formed by conductor receiving recesses 40, 48. Conductor receiving openings 66 include first and second conductor transitions or separations 65, which are formed by first and second conductor transitions or separations 43, 51 when lower portion 42 is mated with upper portion 46. The conductor receiving opening 66 also includes a first conductor receiving portion 67 and a second conductor receiving portion 67, which are formed by the first conductor receiving portion 41 and the second conductor receiving portion 49 when the lower portion 42 is mated with the upper portion 46. The wire termination portion 32 of the terminal 30 is positioned in the first and second terminal-receiving openings 68 (FIG. 7) formed by the terminal-receiving recesses 50,58.

[0017] The lower and upper portions 42, 46 are held in the closed position by cooperation of latch shoulders 53, 55 of latches 52, 54 with latch shoulder 61 of latch-receiving opening 60, and by cooperation of latch shoulder 57 of latch 56 with latch shoulder 63 of latch-receiving recess 62.

[0018] Positioning the exposed portions of the conductors 18, 20 in the first and second conductor receiving portions 67 of the first and second conductor receiving openings 66, 66 of the clamshell connector 44 maintains proper positioning and a desired spacing of the exposed portions of the conductors 18, 20 to enable mating with a mating connector. In the exemplary embodiment, the exposed portions of the conductors 18, 20 in the first and second conductor receiving portions 67, 67 extend generally parallel to one another and generally coplanar. Because the housing 44 surrounds the exposed portions of the conductors 18, 20, the housing protects and prevents damage to the exposed portions of the conductors 18, 20, thereby maintaining the integrity of the exposed portions of the conductors 18, 20 and the signal path provided thereby.

[0019] Because the spacing and dimensions of the first and second conductor receiving portions 67 of the first and second conductor receiving openings 66, 69 of the clamshell connector 44 are controlled during manufacture of the clamshell connector 44, the spacing of the exposed portions of the conductors 18, 20 is also controlled when the conductors are positioned in the first and second conductor receiving portions 67 of the first and second conductor receiving openings 66, 69. Thus, by appropriately selecting the dielectric material used in the clamshell connector 44 and appropriately determining the spacing between the first and second conductor receiving portions 67, 67 formed by the first and second conductor receiving portions 41, 49, the impedance of the clamshell connector 44 can be adjusted to match or approximately match the impedance of the cable 10.

[0020] Positioning the exposed portions of the conductors 18, 20 in the first and second conductor transition or separation portions 65 of the first and second conductor receiving openings 66 of the clamshell connector 44 provides a controlled transition between the conductors 18, 20 provided in the cable 10 and the exposed conductors 18, 20 positioned in the first and second conductor receiving portions 67 of the first and second conductor receiving openings 66, 66, with a controlled transition angle 71. The transition angle 71 is the angle measured between the longitudinal axis 45 of the housing 44 and the surface of the transition portion 65.

[0021] Because the transition angle 71, spacing, and dimensions of the first and second conductor receiving openings 66, 66 of the clamshell connector 44 are controlled during manufacture of the clamshell connector 44, the transition angle 71 and spacing of the exposed portions of the conductors 18, 20 are also controlled when the conductors are positioned in the first and second conductor transitions or separations 65 of the first and second conductor receiving openings 66, 66. Thus, by appropriately selecting the dielectric material used in the clamshell connector 44 and appropriately determining the transition angle 71 and spacing between the first and second conductor transitions or separations 65, 65 formed by the first and second conductor transitions or separations 43, 51, the impedance of the clamshell connector 44 can be tailored to match or approximately match the impedance of the cable 10.

[0022] With the clamshell connector 44 properly positioned over the exposed portions of the conductors 18, 20 and the wire terminations 32 of the terminals 30, a terminal housing 70 (FIG. 7) is provided to provide stability to the free ends of the contacts 30.

[0023] An outer metallic shield member 72 of a cable assembly 74 is secured to the cable 10. As shown in Figures 6 and 7, a fixed portion 76 of the outer metallic member 72 is positioned over a portion of the cable 10 and the ferrule 26. The fixed portion 76 is then secured, for example, by crimping, to hold the outer metallic member 72 to the cable 10. A necked portion 78 of the outer metallic member 72 is positioned over the clamshell connector 44 to provide additional shielding and to maintain the clamshell connector 44 in place. In the illustrated embodiment, the outer metallic member 72 has two portions that are mechanically and electrically connected by latches, adhesive, or other known attachment methods.

[0024] The cable assembly 74, and particularly the clamshell connector 44, provides impedance control and does not damage or dislocate the conductors 18, 20. By properly selecting the dielectric material used in the clamshell connector 44 and properly determining the spacing between the recesses 40, 48, the conductors 18, 20 can be properly positioned and the impedance of the clamshell connector 44 can be adjusted to match or nearly match the impedance of the cable 10, thereby optimizing the performance of the cable 10 and the cable assembly 74.

Claims

1. 1. A connector for controlling impedance for use in a connector assembly, comprising: a housing (44) having a first conductor receiving opening (66) and a second conductor receiving opening (66), said first conductor receiving opening (66) and said second conductor receiving opening (66) being sized to receive exposed conductors (18, 20) of a cable (10); the first conductor receiving opening (66) has a pair of first conductor receiving portions (41, 41), the second conductor receiving opening (66) has a pair of second conductor receiving portions (49, 49), the pair of first conductor receiving portions (41, 41) and the pair of second conductor receiving portions (49, 49) each extending at an angle (71) relative to a longitudinal axis (45) of the housing (44); the first conductor receiving opening (66) has a pair of first conductor spacing portions (43, 43) extending from the pair of first conductor receiving portions (41, 41); the second conductor receiving opening (66) has a pair of second conductor spacing portions (51, 51) extending from the pair of second conductor receiving portions (49, 49); the pair of first conductor spacing portions (43, 43) extend in a direction essentially parallel to the longitudinal axis (45) of the housing (44), and the pair of first conductor spacing portions (43, 43) are spaced apart from each other by a distance (47); the pair of second conductor spacing portions (51, 51) extend in a direction essentially parallel to the longitudinal axis (45) of the housing (44), and the pair of second conductor spacing portions (51, 51) are spaced apart from each other by the distance (47); the distance (47) between the pair of first spaced portions (43, 43) and the distance (47) between the pair of second spaced portions (51, 51) are each selected to match the impedance of the cable (10); The housing (44) It further has a first terminal receiving opening (68) and a second terminal receiving opening (68); the first terminal receiving opening (68) and the second terminal receiving opening (68) are configured to position a wire termination (32) of a terminal (30) to be terminated to an end of the exposed conductor (18, 20) of the cable (10); the first conductor receiving opening (66) extends to the first terminal receiving opening (68), and the second conductor receiving opening (66) extends to the second terminal receiving opening (68); The housing (44) has a first portion (42) and a second portion (46); the first portion (42) has a pair of first conductor receiving recesses (40, 40) for receiving the exposed conductors (18, 20), and the second portion (46) has a pair of second conductor receiving recesses (48, 48) for receiving the exposed conductors (18, 20); the pair of first conductor receiving recesses (40, 40) have the pair of first conductor spacing portions (43, 43), the pair of second conductor receiving recesses (48, 48) have the pair of second conductor spacing portions (51, 51); the pair of first conductor receiving recesses (40, 40) are spaced apart from each other by the distance (47), and the pair of second conductor receiving recesses (48, 48) are spaced apart from each other by the distance (47); a first latch (52, 54) extending from the second portion (46) and positioned between the pair of second conductor receiving recesses (48, 48); The first portion (42) has a latch-receiving opening (60) positioned between the pair of first conductor-receiving recesses (40, 40) for cooperating with the first latch (52, 54). connector.

2. A connector for controlling impedance as described in claim 1, wherein the second portion (46) has a pair of second conductor receiving recesses (48, 48) aligned to form the first conductor receiving opening (66) and the second conductor receiving opening (66).

3. the first terminal receiving opening (68) and the second terminal receiving opening (68) include a pair of first terminal receiving recesses (58, 58) and a pair of second terminal receiving recesses (50, 50); 3. The connector for controlling impedance according to claim 2, wherein the pair of first conductor receiving recesses (40, 40) extend to the pair of first terminal receiving recesses (58, 58), the pair of second conductor receiving recesses (48, 48) extend to the pair of second terminal receiving recesses (50, 50), and the pair of first terminal receiving recesses (58, 58) and the pair of second terminal receiving recesses (50, 50) are sized to receive the wire termination portions (32) of the terminals (30) terminated to the ends of the exposed conductors (18, 20) of the cable (10).

4. 4. The connector for controlling impedance as set forth in claim 3, wherein a second latch (56) extends from said second portion (46) and is positioned between said pair of second terminal receiving recesses (50, 50).

5. 5. The connector for controlling impedance according to claim 4, wherein said first latch (52, 54) and said second latch (56) have latch shoulders (53, 55, 57).

6. 4. A connector for controlling impedance as set forth in claim 3, wherein a latch receiving recess (62) is positioned between said pair of first terminal receiving recesses (58, 58).

7. 7. The connector for controlling impedance as recited in claim 6, wherein the latch-receiving opening (60) and the latch-receiving recess (62) have latch shoulders (61, 63) extending from side walls of the latch-receiving opening (60) and the latch-receiving recess (62).

8. A cable assembly (74) for terminating a cable (10) having exposed conductors (18, 20), comprising: The connector according to any one of claims 1 to 7; a shield member (72) extending from the cable (10) and positioned on the housing (44) formed from a dielectric material; Equipped with The dielectric material, the distance (47) between the pair of first conductor spacing portions (43, 43) and the distance (47) between the pair of second conductor spacing portions (51, 51) are selected to match the impedance of the cable (10).

9. The cable assembly of claim 8, wherein the fixed portion (76) of the shield member (72) is positioned over a portion of the cable (10) and a ferrule (26) of the cable (10).

10. 10. The cable assembly of claim 9, wherein a necked-down portion (78) of the shield member (72) is positioned over the housing (44) to provide additional shielding and to maintain the housing (44) in place.

11. The cable assembly of claim 10 , wherein the shielding member has two portions that are mechanically and electrically connected to each other.

Images