Hybrid coaxial cable

Abstract

An electrical conductor assembly can include a first connector and a coupler configured to couple to the first connector and a second conductor so as to electrically connect the first connector to the second conductor. The first connector can be a coaxial cable. The second conductor can be a coaxial cable. The first connector can be more rigid than the second conductor. The first connector can be configured to couple to a substrate. An end of the first connector can include an engagement surface configured to remove oxidation on the substrate.

Description

HYBRID COAXIAL CABLECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This claims priority to U.S. Patent Application Serial No. 63 / 582,253 filed September 13, 2023, the disclosure of which is hereby incorporated by reference as if set forth in its entirety herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to electrical connectors, and more specifically, to a hybrid coaxial cable.BACKGROUND

[0003] Electrical cables are used to electrically connect one electrical component to another electrical component. Electrical cables typically include an electrical conductor surrounded by an insulative layer. Some electrical cable assemblies include an outer conductive layer disposed outside of the insulative layer. The electrical conductor is typically movable relative to the outer conductive layer to allow both the conductor and the outer conductive layer to electrically couple to another component. However, the relative movement between the conductors can be expensive or take a relatively long time to produce. What is therefore needed is an improved electrical cable or electrical conductor assembly with an improved mating interface.SUMMARY

[0004] An electrical conductor assembly can include a first electrical conductor configured to be placed in electrical communication with a substrate. The assembly can include a coupler configured to couple to the first connector to a second electrical connector so as to place the first electrical conductor in electrical communication with the second electrical conductor. The first electrical conductor can be configured to be placed against an electrical contact member of the substrate. The first electrical conductor can include first and second conductor ends opposite each other along a central axis, where the first conductor end can be spaced from the second conductor end in a first direction and the second conductor end can be spaced from the first conductor end in a second direction opposite the first direction. The first conductor end can include a plurality of peaks and valleys, the valleysbeing recessed in the second direction relative to the peaks. The peaks are configured to be placed against the electrical contact member.

[0005] The electrical conductor assembly may include a first electrical cable that includes the first electrical conductor. The first electrical cable can be a first coaxial cable. The first electrical cable can include an insulative layer disposed about the first electrical conductor. The insulative layer can surround the first electrical conductor along a majority of a length of the first electrical conductor along the central axis. The insulative layer can include first and second insulative layer ends opposite each other along the central axis. The second insulative layer end can be spaced from the second conductor end in the second direction so as to define a recess. The insulative layer can be a dielectric.

[0006] The first electrical cable can include an outer electrical conductor disposed about the insulative layer. The outer electrical conductor can surround the insulative layer along a majority of a length of the insulative layer along the central axis. The outer electrical conductor can include first and second outer conductor ends opposite each other along the central axis. The outer electrical conductor can be configured to be placed in electrical communication with the substrate. The outer electrical conductor can be configured to be placed against the substrate. The outer electrical conductor can be configured to be placed against a second electrically conductive contact member of the substrate. The second electrically conductive contact member may be configured as an electrical contact pad, or can be otherwise suitably constructed as desired. The first outer electrical conductor end can include a plurality of peaks and valleys, the valleys being recessed in the second direction relative to the peaks. The second outer electrical conductor end and the second insulative layer end are coplanar in a plane perpendicular to the central axis.

[0007] The electrical conductor assembly may include the second conductor. The electrical conductor assembly may include a second electrical cable that may include the second electrical conductor. The second cable can be a flexible cable. The second cable can be a coaxial cable. The second electrical conductor can include a second conductor first and a second conductor second end opposite the second conductor first end a central axis, where the second conductor first end can be spaced from the second conductor second end in the first direction and the second conductor second end can be spaced from the second conductor first end in the second direction.

[0008] The second electrical cable can include an insulative layer disposed about the second electrical conductor. The insulative layer can surround the second electrical conductor along a majority of a length of the second electrical conductor along the central axis. The insulative layer can include first and second insulative layer ends opposite each other along the central axis. The second conductor first end can be spaced from the first insulative layer end in the first direction such that the second conductor can extend from the insulative layer in the first direction. The insulative layer can be a dielectric. The second electrical cable can include an outer electrical conductor disposed about the insulative layer. The outer electrical conductor can surround the insulative layer along a majority of a length of the insulative layer along the central axis. The outer electrical conductor of the second electrical cable can be configured to be placed in electrical communication with the outer electrical conductor of the first electrical cable. The outer electrical conductor of the second electrical cable can be configured to be placed in physical contact with the outer electrical conductor of the first electrical cable. The first cable can have a first rigidity and the second cable can have a second rigidity less than the first rigidity. The first cable can have a first bending flexibility so as to change the central axis and the second cable can have a second bending flexibility that can be greater than the first bending flexibility.

[0009] A communication assembly may include the electrical conductor assembly and a housing configured to couple to electrical conductor assembly. The housing can be configured to receive at least a portion of the electrical conductor assembly. The housing can include opposing first and second housing ends, the first housing end spaced from the second housing end in the second direction. The housing can include a housing channel configured to receive at least a portion of electrical conductor assembly. The housing channel can extend from the first housing end toward the second housing end. The housing channel can extend from the first housing end to the second housing end. The housing channel can extend through each of the first and second housing ends. The first end of the first conductor can extend from the first housing end in the first direction. The second end of the first cable can be positioned within the housing channel. The first end of the second cable can be positioned within the housing channel. The second end of the second cable can be positioned outside of the housing channel. The coupler can be positioned in the housing channel. The housing channel can include a first channel portion having a first width and a second channel portion having a second width different than the first width. The second width can be greater than thefirst width. The housing can include a first shoulder at the junction of the first and second channel portions. The housing can include a third channel portion having a third width that can be different than the second width. The third width can be less than the second width. The third width can be greater than the first width. The housing can include a second shoulder at the junction of the second and third channel portions.

[0010] The coupler can be positioned in the second channel portion. The first width can be less than a maximum width of the coupler. The third width can be less than a maximum width of the coupler. The electrical conductor assembly can include a biasing element configured to bias the first end of the first cable away from the housing in the first direction. The biasing element can urge the coupler in the first direction. The biasing element can urge the coupler into contact with the first shoulder. The biasing element can engage the second shoulder and the coupler. The biasing element can exert a biasing force on the coupler shoulder. The biasing element defines an opening to receive at least a portion of the coupler. The second portion of the coupler can be positioned within the opening defined by the biasing element. A portion of the second cable can be positioned within the opening defined by the biasing element.

[0011] The housing can be configured to couple to the substrate. The housing can include an opening configured to receive a coupling member. The communication assembly may include a coupling member positioned within the opening, the coupling member configured to couple the housing to the substrate The housing can include a housing channel configured to receive at least a portion of the first cable. The housing can include a plurality of housing channels, each housing channel configured to receive one of the electrical conductor assemblies. The electrical conductor assembly may include a coupler configured to couple the first and second cables together. The first insulative layer end can be spaced from the first conductor end in the second direction. The first electrical conductor can be configured to be placed against an electrically conductive contact member of the substrate. The contact member may include an electrical contact pad, or can be alternatively constructed as desired.

[0012] A method of manufacturing a conductor assembly can include preparing a first cable. The method can include preparing a second cable. The method can include electrically coupling the first and second cables to each other with a coupler. The first cable can be a coaxial cable including first and second ends opposite each other along a centralaxis, the first end spaced from the second end in a first direction, where the first cable can include a first cable inner electrical conductor, a first cable insulative layer, and a first cable outer electrical conductor, and the method can include removing a portion of the first cable insulative layer and the first cable outer electrical conductor shield such that the first cable inner electrical conductor can extend from the first cable insulative layer in the first direction.

[0013] Preparing the first cable can include removing a portion of the first cable inner electrical conductor so as to define a recess at the second end of the first electrical cable. Preparing the first cable can include creating an engagement surface on the first end of the first cable inner electrical conductor. Creating the engagement surface can include removing a portion of the first end of the first cable inner electrical conductor so as to create at least one peak and at least one valley. Preparing the first cable can include creating an engagement surface on a first end of the first cable outer electrical conductor. Creating the engagement surface can include removing a portion of the first end of the first cable outer electrical conductor so as to create at least one peak and at least one valley. The second cable can be a coaxial cable with first and second ends opposite each other along a central axis, the first end spaced from the second end in a first direction, the second cable including a second cable inner electrical conductor, a second cable insulative layer, and a second cable outer electrical conductor, and the method can include removing a portion of the second cable insulative layer and the second cable outer electrical conductor such that the second cable inner electrical conductor can extend from the second cable insulative layer in the first direction.

[0014] The coupler can include a recess and the electrically coupling step can include positioning a portion of each of the first and second cables within the recess so as to place the first cable inner electrical conductor in electrical communication with the second cable inner electrical conductor. The method further can include fixing each of the first and second cables to the coupler. The method further can include welding each of the first and second cables to the coupler. The method may include positioning a portion of the first cable within a housing such that the first end of the first cable can extend from the housing in the first direction.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present application is further understood when read in conjunction with the appended drawings. For the purpose of illustrating the subject matter, there are shown inthe drawings exemplary aspects of the subject matter; however, the presently disclosed subject matter is not limited to the specific methods, devices, and systems disclosed. In the drawings:

[0016] Fig. 1 A is an exploded perspective view of an interconnect system including a substrate and a communication assembly configured to be mounted to the substrate;

[0017] Fig. IB is a perspective view of the interconnect system of Fig. 1A, but showing the communication assembly mounted to the substrate;

[0018] Fig. 1C is a perspective view of the communication assembly of Fig. 1A;

[0019] Fig. 2A is a perspective view of an electrical cable assembly of the communication assembly of Fig. 1A;

[0020] Fig. 2B is an exploded view of the electrical cable assembly of Fig. 2A including a first electrical cable, a second electrical cable, a coupler configured to join the first electrical cable to the second electrical cable, and a biasing element;

[0021] Fig. 3 is a bottom perspective view of the second electrical cable of Fig. 2A;

[0022] Fig. 4A is a bottom perspective view of the first cable of Fig. 2A;

[0023] Fig. 4B is a sectional perspective view of the first cable of Fig. 4A;

[0024] Fig. 5 is a perspective view of the coupler of Fig. 2B;

[0025] Fig. 6 is a sectional side elevation view of a portion of the electrical cable assembly of Fig. 2A, showing the coupler securing the first and second electrical cables to each other;

[0026] Fig. 7 is a side elevation view of the communication assembly of Fig. 1 A;

[0027] Fig. 8 is a cross-sectional view of the communication assembly of Fig. 1A;

[0028] Fig. 9A is an enlarged sectional view of a portion of the communication assembly of Fig. 1C, showing a housing and a plurality of electrical cable assemblies supported by the housing;

[0029] Fig. 9B is an enlarged sectional view of a portion of the communication assembly of Fig. 1C, showing the housing and one of the plurality of electrical cable assemblies supported by the housing;

[0030] Fig. 10 is a flow chart depicting a method of manufacturing the communication assembly of Fig. 1A; and

[0031] Fig. 11 is a perspective view of a double-ended electrical cable assembly in accordance with another example including a pair of first electrical cables, a second electricalcable, first and second couplers securing the second electrical cable to respective first and second ones of the first electrical cables, and second biasing elements each coupled to a second cable.

[0032] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.DETAILED DESCRIPTION

[0033] The present disclosure can be understood more readily by reference to the following detailed description taken in connection with the accompanying figures and examples, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, applications, conditions or parameters described and / or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the scope of the present disclosure. Further, reference to a plurality as used in the specification including the appended claims includes the singular “a,” “an,” “one,” and “the,” and further includes “at least one.” Further still, reference to a particular numerical value in the specification including the appended claims includes at least that particular value, unless the context clearly dictates otherwise.

[0034] The term “plurality”, as used herein, means more than one. When a range of values is expressed, the range extends from the one particular value to the other particular value, including each whole integer between the one particular value to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another example. All ranges are inclusive and combinable.

[0035] The term “substantially,” “approximately,” and derivatives thereof, and words of similar import, when used to described sizes, shapes, spatial relationships, distances, directions, and other similar parameters includes the stated parameter in addition to a range up to 10% more and up to 10% less than the stated parameter, such as up to 9% more and up to 9% less, such as up to 8% more and up to 8% less, such as up to 7% more and up to 7% less, such as up to 6% more and up to 6% less, such as up to 5% more and up to 5% less, such as up to 4% more and up to 4% less, such as up to 3% more and up to 3% less, such as up to 2% more and up to 2% less, such as up to 1% more and up to 1% less than the statedparameter. If terms such as “equal”, “perpendicular”, or a numerical value associated with a given dimension are used to compare or describe elements of the invention, the terms should be interpreted as referring to the stated value both alone and within manufacturing tolerances.

[0036] Referring to Figs. 1A-1C, an interconnect system 100 can include a substrate 104 and one or more communication assemblies 113 configured to be mounted to the substrate 104. The substrate 104 can be configured as a printed circuit board in some examples. The substrate 104 can define a first major surface 108 and a second major surface 110 opposite the first major surface 108 along a transverse direction T. The first and second surfaces 108 and 110 can be planar along respective planes defined by a longitudinal direction L and a lateral direction A. The longitudinal direction L can be perpendicular to the transverse direction T and the lateral direction A can be perpendicular to each of the transverse direction T and the longitudinal direction L.

[0037] Each communication assembly 113 can include a housing 120 and at least one electrically conductive electrical conductor assembly 102 such as a plurality of electrical conductor assemblies 102 supported by the housing 120. The housing 120 can be dielectric or electrically insulative in one example. In another example, the housing 120 can be electrically conductive As will be described in more detail below, each electrical conductor assembly 102 can be configured as an electrically conductive electrical cable assembly 112 (see also Fig. 2A). Each electrical conductor assembly 102 can be configured to transmit electrical signals along its length. Each electrical conductor assembly 102 can extend through the housing 120. When the communication assembly 113 is mounted to the substrate 104, each electrical conductor assembly 102 can be placed in electrical communication with the substrate 104. Further, when the communication assembly 113 is mounted to the substrate 104, each electrical conductor assembly 102 can be oriented along the transverse direction T.

[0038] The substrate 104 is configured to be electrically connected to an electrical component, thereby placing the conductor assembly 102 in electrical communication with the electrical component when the electrical conductor assembly 102 is mounted to the substrate 104. For instance, the substrate 104 can include electrical traces in electrical communication with the electrical conductor assembly 102 and terminate at respective electrical contact member, which can be configured as surface mount technology (SMT) members such as electrical contact pads, or can be configured as electrically conductive vias, or the like. Eachelectrical conductor assembly 102 can be placed in electrical communication with the contact members of the substrate 104 when the electrical conductor assembly 102 is mounted to the substrate 104. As shown, the contact members can be configured as electrical contact pads103 at the first major surface 108 of the substrate 104. The electrical contact pads 103 can include electrical ground contact pads and electrical signal contact pads. In one example, each of the ground contact pads can surround a respective electrical signal contact pad of the plurality of electrical signal contact pads. For instance, the ground contact pads can extend along a circular circumferential path that is radially spaced from the respective electrical signal contact pads.

[0039] The housing 120 can define a first end 114 and a second end opposite the first end 116 along a select direction. In some examples, the select direction can be defined by the transverse direction T when the communication assembly 113 is mounted to the substrate 104. The housing 120 can be oriented such that the first end 114 faces the substrate104 when the communication assembly 113 is mounted to the substrate 104. Each conductor assembly 102 can extend out with respect to the first end 114 so as to be placed in physical and electrical contact with a respective one of the contact members of the substrate 104.

[0040] The communication assembly 113 can further define one or more channels 115 that extend through the housing 120. For instance, each of the channels 115 can extend from the first end 114 to the second end 116 along the transverse direction T. Each of the channels 115 can be configured to receive a respective at least one, such as a respective one, of the conductor assemblies 102. Because the connector assemblies 102 can be configured as electrical cable assemblies, each of the channels 115 can be configured to receive a respective at least one, such as a respective one, of the electrical cable assemblies 112. It should be appreciated that the channels 115 extend through the first end 114 of the housing 120, so that the cable assemblies 112, and thus the conductor assemblies 102, can extend out the housing 120 so as to be configured to be mounted to the substrate 104. The channels 115 can further extend through the opposite second end 116 of the housing 120. Accordingly, the cable assemblies 112, and thus the conductor assemblies 102, can extend out the second end 116 of the housing 120 opposite the first end 114. It should be appreciated that the other end of the housing 120 can be defined by any suitable surface of the housing 120 so as to route the cable assemblies 112 as desired. Alternatively, the channels 115 can be open only at the first end 114 of the housing 120, such that the cable assemblies 112, and thus the conductorassemblies 102, terminate in the housing 120. In this example, the housing 120 can include electrical traces in communication with the respective electrical conductor assemblies 102 of the cable assemblies 112.

[0041] The housing 120 can include one or more alignment members configured to couple to the substrate 104. The alignment members can include a first alignment member 117a and a second alignment member 117b. Each of the first and second alignment members 117a and 117b can extend from the housing 120 toward the substrate 104 in a first direction, which can be defined by the transverse direction T or any suitable alternative direction. In one example, each of the first and second alignment members 117a and 117b can extend from the first end 114 of the housing 120. The first and second alignment members 117a and 117b can have different shapes or sizes with respect to each other. The substrate 104 can have openings having different shapes or sizes so as to correspond to the shape and / or size of a respective one of the first and second alignment members 117a and 117b. Thus, the housing 120 is only able to be mounted to the substrate in a single predetermined orientation whereby the first and second alignment members 117a and 117b can be received in the respective openings of the substrate 104.

[0042] The housing 120 can include one or more coupling members 119 (see also Fig. 8) that are configured to couple the housing 120, directly or indirectly, to the substrate 104 when the communication assembly 113 has been mounted to the substrate 104. In some examples, the housing 120 is coupled directly to the substrate 104. In other examples, the housing 120 is coupled indirectly to the substrate 104 through an intermediate component that is coupled to the substrate 104. Thus, it is understood that that a method step of coupling the housing 120 to the substrate 104 includes coupling the housing 120 to the substrate 104 directly or to the intermediate component.

[0043] Each coupling member 119 can extend along a respective central axis, which can be oriented along the transverse direction. Each coupling member 119 can define first and second ends 119a and 119b that are opposite each other along the central axis of the coupling member 119. The first end 119a can be configured to removably secure the housing 120 to the substrate 104. The coupling member 119 can detachably couple the housing 120 to the substrate 104. In some examples, the first end 119a is threaded to threadedly mate with a corresponding threaded opening of or supported by the substrate 104. The threaded opening can be defined by a nut, recess, or any suitable alternative structure having athreaded opening. In other examples, the first end 119a of the coupling member 119 is a magnetic coupler configured to engage a ferromagnetic material of the substrate 104 or of a structure supported by the substrate 104. The coupling member 119 can extend from the housing 120 in the first direction. The coupling member 119 can extend through the housing 120 in the transverse direction T such that the second 119b of the coupling member 119 is configured to be seated against the housing 120, thereby capturing the housing between the second end 119b of the coupling member 119 and the substrate 104. In one example, the second end 119b can be seated in a recess 102 of the housing 120 (see Fig. 8). In another example, the second end 119b can be seated against the second end 116 of the housing 120. The second end 119 can extend from the second end 116 of the housing 120 in a second direction opposite the first direction, so as to be easily accessible by a user to secure the housing 120 to the substrate 104, and to remove the housing 120 from the substrate 104. The second end 119b of the coupling member 119 can include a recess sized and shaped to receive to a tool (e.g., hex bit or Phillips bit) so as to move the coupling member 119. Moving the coupling member 119 can include rotating the coupling member 119 about its central axis in a first direction of rotation so as to secure the coupling member 119 to the substrate 104, and a second direction of rotation opposite the first direction of rotation to remove the coupling member 119 from the substrate 104.

[0044] As described above, the communication assembly 113 can be mounted to the substrate 104 when the coupling member 119 couples the housing 120 to the substrate. In particular, the cable assembly 112 can be electrically coupled to the contact pads 103 when the coupling member 119 couples the housing 120 to the substrate 104. The cable assembly 112 can include a first end 112a and a second end 112b opposite the first end 112a along a central axis of the cable assembly 112. The central axis of the cable assembly 112 can be oriented along the transverse direction T in some examples.

[0045] Referring to Fig. 1C, the portion of the cable assembly 112 that defines the first end 112a can extend out from the first end 114 of the housing 120 in the first direction (see also Fig. 7) such that the first end 112a is offset from the housing 120. The first end 112a can be offset from the housing 120 in the first direction to define a distance Di (see Fig. 7). The second end 112b can extend from the housing 120 in in the second direction along the transverse direction T and is opposite the first direction, or in any suitable alternative direction as desired. The first direction can be referred to as a mounting direction alongwhich the electrical conductor assembly 102, or the cable assembly 112, is mounted to the substrate 104. The second direction can be referred to as a removal direction along which the electrical conductor assembly 102, or the cable assembly 112, can be removed from the substrate 104. The cable assembly 112 can be configured to establish a robust electrical connection with the contact pads 103 of the substrate 104 when the communication assembly 113 is mounted to the substrate 104. For example, the cable assembly 112 can be configured to penetrate oxidation on the contact pads 103 of the substrate 104. The cable assembly 112 can be rigid enough along its length to penetrate any oxidation. However, it may be desirable for some portions of the cable assembly 112 to be rigid while other portions are flexible so as to allow the cable assembly 112 to bend or flex to a desired shape while still establishing a robust connection with the contact pads 103.

[0046] Referring to Fig. 2A, the electrical cable assembly 112 can include a distal or first portion 112c of an electrical conductor, a proximal or second portion 112d of an electrical conductor opposite the first portion 112c, and an intermediate portion 112e of an electrical conductor. The first portion 112c can be axially aligned with the second portion 112d. Thus, a distal direction can be established from the second portion 112d toward the first portion 112c. Conversely, a proximal direction can be established from the first portion 112c toward the second portion 112d. The term “distal” and like terms and derivatives thereof as used herein refer to the distal direction unless otherwise indicated. The term “proximal” and like terms and derivatives thereof refer to the proximal direction unless otherwise indicated. The first portion 112c can define the first end 112a of the cable assembly 112, and the second portion 112d can define the second end 112b of the cable assembly 112 The first portion 112c can extend out from the housing 120, such that the end 112a is offset from the housing 120 in the manner described above.

[0047] The intermediate portion 112e can extend from the first portion 112c to the second portion 112d along a central axis AL In some examples, the intermediate portion 112e can extend along a longitudinal middle portion of the electrical cable assembly 112, and thus can be referred to as a middle portion of the electrical cable assembly. In some examples, the first portion 112c, the second portion 112d, and the intermediate portion 112e can have equal lengths along the central axis Ai. In other examples, the first portion 112c, the second portion 112d, and the intermediate portion can each have different lengths as desired.

[0048] The first portion 112c can have a higher rigidity than the intermediate portion 112e. Thus, the intermediate portion 112e can be more flexible than the first portion 112c. The intermediate portion 112e can also be more flexible than the second portion 112d. A rigid first portion 112c can help ensure a robust electrical connection between the cable assembly 112 and the contact pads 103 of the substrate 104 while the flexible intermediate portion 112e can allow the cable assembly 112 to bend or flex into a desired shape.

[0049] In some examples, the cable assembly 112 includes a plurality of electrical conductors in electrical communication with each other, at least one of the electrical conductors having a different rigidity than another electrical conductor. For instance, referring to Figs. 2A and 2B, the cable assembly 112 can include a first cable 118 that defines a first electrical conductor, and a second electrical cable 122 that defines a second electrical conductor in electrical communication with the first cable 118. The cable assembly 112 can include a coupler 124 that is configured to couple to each of the first cable 118 and the second electrical cable 122, thereby electrically coupling the first cable 118 to the second electrical cable 122, such that a first electrical conductor 142 of the first cable 118 is placed in electrical communication with a second electrical conductor 126 of the second cable 122, as described in more detail below (see Fig. 6). The first cable 118 can have a distal end that defines the distal end 112a of the cable assembly 112. The distal end 112a is configured to contact and electrically couple to the mounting portions of the substrate 104, thereby placing the first cable 118 in electrical communication with the substrate 104. The first cable 118 can have a greater rigidity than the second electrical cable 122. Further, in some examples, the first electrical conductor 142 and the first electrical cable 118 can be substantially non- compressible.

[0050] In one example, the first electrical cable 118 can have a first Young’s modulus of approximately 100 GPa to approximately 140 Gpa. The second electrical cable 122 can have a second Young’s modulus that is less than the first Young’s modulus, such as approximately 5 GPa to approximately 10 GPa. The first cable 118 can define the first portion 112c described above. The second electrical cable 122 can define the second portion 112d and the intermediate portion 112e, which can thus be monolithic with each other. Because the first electrical cable 118 can be more rigid than the second electrical cable 122, the first electrical cable 118 can be configured to be pressed against the mounting portion of the substrate. The monolithic body can define an electrical conductor of a flexible cable.Thus, the first portion 112c can define a rigid mounting interface that can be coupled to a more flexible electrical cable to place the flexible electrical cable in electrical communication with the substrate. The second electrical cable 122 can therefore be referred to as a flexible cable, and the first cable 118 can be referred to as a rigid cable that is more rigid than the flexible cable.

[0051] Referring to Fig. 3, the second electrical cable 122 can include first and second ends 128 and 130 opposite each other along a central axis Ai. The second end 130 of the second electrical cable 122 can define the second end 112b of the cable assembly 112. The first end 128 can also define the first end of the second electrical conductor of the second cable 122, and thus can also be referred to as a second conductor first end 128. Similarly, the second end 130 can also define the second end of the second electrical conductor of the second cable 122, and can thus also be referred to as a second conductor second end 130. The second electrical cable 122 can have a length as measured between the first and second ends 128 and 130 along the central axis of the cable 122. The second electrical cable 122 can include a second electrical conductor 126 configured to transmit a data communication signal. In one example, the second electrical conductor 126 can be defined by the second portion 112d and the intermediate portion 112e described above (see Figs. 2A-2B). The second electrical conductor 126 can be an electrical signal conductor that is configured to carry electrical signals during operation. Thus, the second electrical conductor 126 can be referred to as a second electrical signal conductor. The second electrical conductor 126 extends along the central axis Ai that can be said to extend along an axial direction. It is recognized that the axial direction can be straight or curved, or can have straight sections and curved sections. The second electrical conductor 126 can extend along the axial direction between the first and second ends 128 and 130 of the second electrical cable 122. The second electrical conductor 126 can be silver plated copper, bare copper, CuNi alloys, Cu alloys, Ag allolys, Tin, Tin alloys, or any suitable alternative materials.

[0052] The second electrical cable 122 can include a first or inner electrical insulator 132. The electrical insulator 132 can surround the second electrical conductor 126. The electrical insulator 132 can be a dielectric layer. The insulator 132 can extend in the axial direction between the first and second ends 128 and 130. Thus, both the second electrical conductor 126 and the second electrical cable 122 can be said to be elongate along the axial direction. The insulator 132 can be fluorinated ethylene propylene (FEP) solid orfoamed, perfluoroalkoxy (PF A) solid or foamed, low density polyethylene (LDPE), polypropylene (PP), polyethylene (PE), expanded polytetrafluoroethylene (ePTFE) tape, polytetrafluoroethylene (PTFE), or any suitable alternative electrical isolator.

[0053] In some examples, the insulator 132 entirely surrounds at least a majority of the length of the second electrical conductor 126 with respect to a plane that is oriented perpendicular to the axial direction. Thus, the insulator 132 can define a radially inner surface 133a that faces the second electrical conductor 126, and a radially outer surface 133b opposite the radially inner surface 133a. The insulator 132 can have a thickness as measured between the radially inner and outer surfaces 133a and 133b. In this regard, the term “radially inner” and derivatives thereof as used herein can refer to a direction toward the central axis Ai unless otherwise indicated. The term “radially outer” and derivatives thereof as used herein can refer to a direction away from the central axis Ai unless otherwise indicated. The insulator 132 can surround a majority of the length of the second electrical conductor 126, such that a portion of the second electrical conductor 126 extends axially out from the insulator 132 so as to establish an electrical connection with a complementary electrical component, such as the first cable 118, an electrical connector, transceiver, printed circuit board, or alternative device. Thus, it can be said that the insulator 132 can surround the at least one conductor 126 along at least a portion of a length of the second electrical conductor 126. Typically, the insulator 132 surrounds the second electrical conductor 126 along a majority of its length.

[0054] While Fig. 3 illustrates the second electrical cable 122 as having a single electrical conductor, it is recognized that such connectors can alternatively be configured as twin-axial cables in which first and second electrical signal conductors are surrounded by the insulator 132 or by separate electrically insulative layers so that the electrical signal conductors are electrically isolated from each other. The first and second signal conductors can be constructed in any manner described above. The first and second signal conductors can be arranged side-by-side and substantially parallel to each other insulator 132. This, it can be said that the second electrical cable 122 can include at least one electrical signal conductor.

[0055] With continuing reference to Fig. 3, the second electrical cable 122 can further include an electrical shield 134 that surrounds the insulator 132 along at least a majority of the length of the insulative layer along a plane that is normal to the axialdirection. The electrical shield 134 can be defined by at least one electrical conductor. The electrical shield 134 can provide electrical shielding, and in particular EMI (electromagnetic interference) shielding, to the second electrical conductor 126 during operation. The electrical shield 134 can be made of copper, silver, silver plated copper, CuNi alloys, Cu alloys, Ag alloys, Tin, Tin alloys or any suitable alternative electrically conductive material or combination thereof.

[0056] In some examples, the electrical shield 134 can include a first electrically conductive layer 134a and a second electrically conductive layer 134b. The first layer 134a can be positioned radially inwardly of the second layer 134b. Accordingly, the first layer 134a can be positioned between the insulator 132 and the second layer 134b in a plane perpendicular to the central axis Ai. Thus, it can be said that the electrical shield 134 includes two layers adjacent each other in the lateral direction A. The first layer 134a can be a foil shield. The second layer 134b can be a braided shield. The first and second layers 134a and 134b can be manufactured from different materials. The first and second layers 134a and 134b can be manufactured from the same material.

[0057] The second electrical cable 122 can include a second or outer electrically insulative jacket 136 that surrounds the electrical shield 134 along at least a majority of the length of the electrical shield along a plane that is oriented normal to the axial direction. Thus, the electrical shieldl 34 is disposed radially between the inner insulator 132 and the outer jacket 136. The outer jacket 136 can be polyvinyl chloride (PVC), a terpolymer including tetrafluoroethylene, hexafluoropropylene and vinylidene fluoride (THV), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PF A), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), sealable polymer tapes, and non-sealable polymer tapes. The outer insulator 136 can be an electrical insulator. The outer jacket 136 defines a radially inner surface 136a that faces the electrical shieldl34, and a radially outer surface 136b opposite the radially inner surface 136a that defines the radially outer surface of the second electrical cable.

[0058] The second electrical cable 122 can be secured in electrical communication with the first cable 118. Referring to Figs. 4A and 4B, the first cable 118 can include first and second ends 138 and 140, respectively, opposite each along a central axis A2 of the first cable 118. The first end 138 can also define the first end of the first electrical conductor of the first fable 118, and can thus also be referred to as a first conductor first end 138.Similarly, the second end 140 can also define the second end of the first electrical conductor of the first cable 118, and can thus also be referred to as a first conductor second end 140. The first end 138 can be spaced from the second end 140 in a third direction. The third direction can be referred to as a proximal direction. In some examples, the first and third directions are the same direction. The second end 140 can be spaced from the first end 138 in a fourth direction opposite the third direction. The fourth direction can be referred to as a distal direction. In some examples, the second and fourth direction are the same direction. It is recognized that the third and fourth directions can be straight or curved, or can have straight sections and curved sections. The third and fourth directions can be parallel to the transverse direction T. The first cable 118 can include a length as measured between the first and second ends 138 and 140. A ratio of the length of the first cable 118 to the length of the second electrical cable 122 can be about 1:1 to about 1 :5, about 1 :5 to about 1: 10, about 1: 10 to about 1:25, about 1:25 to about 1:50, about 1 :50 to about 1 :100, about 1 :100 to about 1 :500, about 1 :500 to about 1 : 1,000 or greater than about 1 : 1,000.

[0059] The first electrical cable 118 can include a first electrical conductor 142, an insulator 144 that surrounds the first electrical conductor 142, and an electrical shield 146 that surrounds the insulator 144 The first electrical conductor 142 can be defined by the first portion 112c described above with respect to Figs. 2A-2B. The first electrical conductor 142 can be an electrical signal conductor that is configured to carry electrical signals during operation. Thus, the first electrical conductor 142 can be referred to as a first electrical signal conductor. The first electrical conductor 142 can be silver plated copper, bare copper, CuNi alloys, Cu alloys, Ag alloys, Tin, Tin alloys, or any suitable alternative materials. The first electrical conductor 142 can also be referred to as an inner conductor. Referring to Fig. 4B, the first electrical conductor 142 can include first and second ends 142a and 142b opposite each other along a central axis A3 of the first electrical cable 118. The first end 142a can be spaced from the second end 142b in the third direction. The second end 142b can be spaced from the first end 142a in the fourth direction.

[0060] The electrically insulator 144 can be positioned adjacent the first electrical conductor 142. The insulator 144 can be a dielectric layer. The insulator 144 can extend in the axial direction between the first and second ends 138 and 140. The insulator 144 can be FEP solid or foamed, PFA solid or foamed, LDPE, PP, PE, ePTFE tape, PTFE, or any suitable alternative electrical isolator. The insulator 144 can include opposing first andsecond ends 141a and 141b. The first end 141a can be spaced from the second end 141b in the third direction. The second end 141b can be spaced from the first end 141a in the fourth direction. The second end 141b can be spaced from the second end 142b of the first electrical conductor 142 in the fourth direction. The first end 141a can be spaced from the first end 142a of the first electrical conductor 142 in the fourth direction. The first end 142a of the first electrical conductor 142 can be spaced from the first end 141a of the insulator 144 in the third direction.

[0061] The insulator 144 can entirely surround at least a majority of the length of the first electrical conductor 142 with respect to a plane that is oriented perpendicular to the axial direction. Thus, the insulator 144 can define a radially inner surface 144a that faces the first electrical conductor 142, and a radially outer surface 144b opposite the radially inner surface 144a. The insulator 144 can have a thickness as measured from the radially inner surface 114a to the radially outer surface 144b along a direction perpendicular to the central axis of the cable. The insulator 144 can surround a majority of the length of the first electrical conductor 142, such that a portion of the first electrical conductor 142 extends axially out from the insulator 144 in the first direction so as to establish an electrical connection with one of the contact pads 103, a complementary electrical component, an electrical connector, transceiver, printed circuit board, or alternative device. Thus, it can be said that the insulator 144 can surround the at least one conductor 142 along at least a portion of a length of the first electrical conductor 142. Typically, the insulator 144 surrounds the at least one conductor 142 along a majority of its length.

[0062] While Figs. 4A and 4B illustrate the first cable 118 as having a single conductor, it is recognized that such electrical connectors can alternatively be configured as a twin-axial cable in which first and second electrical conductors are surrounded by the insulator 144. The first and second signal conductors can be arranged side-by-side and substantially parallel to each other, and surrounded by the insulator 144 such that the signal conductors are electrically isolated from each other.

[0063] The insulator 144 of the first cable 118 and the insulator 132 of the second electrical cable 122 can be manufactured from the same material. The thicknesses of the insulator 144 of the first cable 118 and the insulator 132 of the second connector 122 can be equal. The thickness of the insulator 144 can be greater than the thickness of the insulator 132. The thickness of the insulator 144 can be less than the thickness of the insulator 132.

[0064] Referring to Fig. 4B, the outer electrical shield 146 surrounds the insulator 144 along at least a majority of the length of the insulator 144 along a plane that is normal to the axial direction. The outer electrical shield 146 can provide electrical shielding, and in particular EMI shielding, to the at least one electrical conductor 142 during operation. The electrical shield 146 can be made of copper, silver, silver plated copper, CuNi alloys, Cu alloys, Ag alloys, Tin, Tin alloys or any suitable alternative material or combination thereof. The electrical shield 146 can be a single electrically conductive, such as a metallic, layer in a select direction perpendicular to the central axis As. Alternatively, the electrical shield 146 can be defined by first and second electrically conductive, such as metallic, layers. The thickness of the electrical shield 146 can be equal to the thickness of the electrical shield 134. The thickness of the electrical shield 146 can be equal to the thickness of the electrical shield 134.

[0065] The electrical shield 146 can include first and second ends 146a and 146b opposite each other along the central axis As. The first end 146a can be spaced from the second end 146b in the third direction. The second end 146b can be spaced from the first end 146a in the fourth direction. The conductor first end 142a and the electrical shield first end 146a can be coplanar in a plane perpendicular to the central axis As. The conductor first end 142a and the electrical shield first end 146a can be configured to electrically connect to a planar surface. For example, the conductor first end 142a and the electrical shield first end 146a can electrically couple to a planar contact pad 103 on the substrate 104. Existing designs having respective ends of inner and outer conductive layers offset in the fourth direction can require relative movement in the fourth direction between the conductor and the outer conductor to electrically connect the conductor and outer conductive layer to the contact pads 103 of a substrate. The conductor first end 142a and the electrical shield first end 146a being coplanar can eliminate the need for relative movement in the fourth direction between the first electrical conductor 142 and the electrical shield 146. The conductor first end 142a can be fixed in the third and fourth directions relative to the electrical shield first end 146a. The conductor first end 142a can be fixed in the third and fourth directions relative to the insulator 144. The insulative layer first end 141a can be spaced from the electrical shield first end 146a in the fourth direction. The second ends 146b and 141b, of the electrical shield 146 and the insulator 144 can be coplanar in a plane perpendicular to the central axis A2.

[0066] Referring to Fig. 4A, the first electrical conductor 142 can include an engagement surface 1 configured to bear against or otherwise engage the contact member, such as an electrical signal contact pad of the plurality of contact pads 103 of the substrate 104 (see Fig. IB). The engagement surface 148 can be defined by the conductor first end 142a. The engagement surface 148 can be configured to remove oxidation on the contact pad 103. The engagement surface 148 can be a knurled surface. The engagement surface 148 can be serrated. The engagement surface 148 can be crenulated. The engagement surface 148 can be notched. The engagement surface 148 can include a plurality of peaks 148a and valleys 148b alternatingly arranged with each other. For instance, the peaks 148a and valleys 148b can be circumferentially alternatingly arranged with each other. The valleys 148b can extend out with respect to the peaks 148a in the fourth or distal direction. The valleys 148b can be recessed from the conductor first end 142a in the third or proximal direction. In some examples, the peaks 148a have an arcuate profile shape in a plane that extends along the transverse direction. In other examples, the peaks 148a can have a triangular profile shape in a plane that extends along the transverse direction. In some examples, the engagement surface 148 is drilled or cut (e.g., via a laser) to create the valleys 148b. The peaks 148a can increase the contact surface area with the respective electrical signal contact pad. When the peaks 148a bear against the electrical signal contact pad, the peaks 148a can increase the number of points of contact with the electrical signal contact pads with respect to flat engagement surfaces 148 that each defines a single point of contact with the contact pads. For instance, the peaks 148a can define at least two separate points of contacts with the electrical signal contact pad, at least three separate points of contact with the electrical signal contact pad, or at least four separate points of contact with the electrical signal contact pad. The peaks 148a can mechanically wipe or can partially clean unwanted oxidation or debris from the respective electrical signal contact pad.

[0067] The electrical shield 146 and the first electrical conductor 142 can each be configured to bear against or otherwise engage a ground contact pad of the plurality of electrical contact pads 103 of the substrate 104. The first end 146a of the electrical shield 146 can include an engagement surface 150 configured to engage the ground contact pad of the substrate 104. The engagement surface 150 can be configured to remove oxidation from the ground contact pad. The engagement surface 150 can be a knurled surface. The engagement surface 150 can be serrated. The engagement surface 150 can be crenulated.The engagement surface 150 can be notched. The engagement surface 150 can be serrated.The engagement surface 150 can include a plurality of recesses. The engagement surface 150 can include a plurality of peaks 150a and valleys 150b disposed between adjacent ones of the peaks 150a. For instance, the peaks 150a and the valleys 150b can be alternatingly arranged circumferentially about the central axis of the cable assembly. The valleys 150b can extend out with respect to the peaks 150a in the fourth or distal direction. The valleys 150b can be recessed from the peaks 150a, and thus from the first end of the electrical shield 146, in the third or proximal direction. In some examples, the peaks 150a have an arcuate profile shape in a plane that extends along the transverse direction. In other examples, the peaks 150a can have a triangular profile shape in a plane that extends along the transverse direction. In some examples, the engagement surface 150 is drilled or cut (e.g., via a laser) to create the peaks 150a and valleys 150b. The peaks 150a can increase the contact surface area with the respective electrical ground contact pad. When the peaks 150a bear against the ground contact pad, the peaks 150a can increase the number of points of contact with the electrical signal contact pads with respect to flat engagement surfaces 150 that each defines a single point of contact with the contact pads. For instance, the peaks 150a can define at least two separate points of contacts with the electrical ground contact pad, at least three separate points of contact with the electrical ground contact pad, or at least four separate points of contact with the electrical ground contact pad. The peaks 150a can mechanically wipe or can partially clean unwanted oxidation or debris from the respective electrical ground contact pad.

[0068] The first and second connectors 122 and 118 can be secured such that they contact each other or are otherwise secured such that the first at least one connector conductor 142 is in electrical communication with the at least one electrical conductor 126 of the second electrical cable 122 (see Fig. 6). Referring to Fig. 4B, the first connector second end 140 can be configured to couple to the second conductor first end 128. The first connector second end 140 can include a recess 152 configured to receive a portion of the second electrical conductor 126 of the second electrical cable 122. In other examples, a third conductor is positioned in the recess 152 and placed in electrical communication with the second electrical conductor 126 of the second electrical cable 122. The recess 152 can have a width in the lateral direction that is equal to or greater than a width of the second electrical conductor 126. The recess 152 can have a width in a select direction perpendicular to thecentral axis A2 that is less than the width of the second electrical conductor 126 of the second electrical cable 122 such that the second electrical conductor 126 of the second electrical cable 122 is press fit into the recess 152. The recess 152 can be created by removing (e.g., by drilling) a portion of the first electrical conductor 142 of the first cable 118.

[0069] The first and second cables 122 and 118 can be coupled together by the coupler 124. The coupler 124 can be made of an electrically insulative or dielectric material. The coupler 124 can be FEB solid or foamed, PFA solid or foamed, LDPE, PP, PE, ePTFE tape, PTFE, or any suitable alternative electrical isolator. Referring to Fig. 5, the coupler 124 can include an engagement element configured to engage a complementary engagement element of at least one of the first and second cables 118 and 122 so as to removably secure the coupler 124 to the at least one of the first and second cables 118 and 122. The engagement element can be a channel 154 configured to receive a portion of at least one of the first cable 118 and the second electrical cable 122, such that the at least one of the first cable 118 and the second electrical cable 122 defines a press-fit with the coupler 124 in the channel 154. In other examples, the engagement element can be adhesive or a mechanical coupler that fixes the first and second cables 118 and 122 to the coupler 124.

[0070] The coupler 124 can include first and second ends 156 and 158 opposite each other in along a central axis A4 of the coupler 124. It can be said that the central axis A4 extends in a coupler axial direction. The channel 154 can be a through hole that extends along the coupler axial direction from the first end 156 to the second end 158. In other examples, the channel 154 extends from at least one of the first and second ends 156 and 158 toward the other of the first and second ends 156 and 158 but does not fully extend to the other of the first and second ends 156 and 158. The coupler 124 can include a first channel that extends from the first end 156 and a second channel that extends from the second end 158 without extending to the first channel.

[0071] The channel 1 4 can have a width in a direction perpendicular to the coupler axial direction. In some examples, the width is equal to the thickness of at least one of the electrical shield 146 of the first electrical cable 118 and the electrical shield 134 of the second electrical cable 122 such that at least one of the electrical shield 146 and the electrical shield 134 are press fit into the channel 154. In other examples, the width is greater than the thickness of at least one of the electrical shield 146 and the electrical shield 134. The width of the channel 154 and the thicknesses of the electrical shield 146 and the electrical shield134 can be defined by a diameter of the channel and outer diameters of the electrical shield 146 and the electrical shield 134, respectively. The width of the channel 154 defined by the inner surface 160a can be the same along the length of the channel 154 in the coupler axial direction. The width of the channel 154 at the first end 156 can be equal to the width of the channel 154 at the second end 158.

[0072] The coupler 124 can include a sidewall 160 having an inner surface 160a and an outer surface 160b opposite the inner surface 160a and spaced from the inner surface 160a in an outward direction that is perpendicular to the coupler axial direction. The outward direction can be a radially outward direction in some examples. The inner surface 160a can define the channel 154. The inner surface 160a can define a circular cross-section shape in a plane including the outward direction. In other examples, the inner surface 160a can define a non-circular shape. The inner surface 160a can face each of the first cable 118 and the second cable 122. For instance ,in one example, the inner surface 160a can have a first portion that faces the first cable 118, and a second portion that faces the second cable 122. The outer surface and the inner surface of the coupler 124 can surround the central axis of the cable assembly 112.

[0073] The sidewall 160 can include first and second portions 162 and 164. The first portion 162 can have a first sidewall width in the outward direction. The second portion 164 can have a second sidewall width in the outward direction. The second sidewall width can be different from the first sidewall width. The first sidewall width can be greater than the second sidewall width. Thus, the first portion 162 can extend outward with respect to the second portion 160 along a direction perpendicular to the coupler axial direction. The sidewall widths can be defined by respective diameters in some examples. The width of the channel 154 can be consistent along the length of the channel in the coupler axial direction.

[0074] The first and second portions 162 and 164 can each have a height in the coupler axial direction. The height of the first portion 162 can be greater than, less than, or equal to the height of the second portion 164. The junction of the first and second portions 162 and 164 of the sidewall 160 can define a shoulder 170. The shoulder 170 can extend around a perimeter of the coupler 124. In other examples, the shoulder does not extend all the way around the perimeter of the coupler 124. The coupler 124 can define at least one opening 168 that extends therethrough from the inner surface 160a of the coupler 124 to the outer surface 160b of the coupler 124. Any suitable bonding agent can be applied throughthe opening 168 so as to bond either or both of the cables 118 and 122 to the coupler 124, and in particular to the inner surface 160a of the coupler 124. For instance, the bonding agent can be configured as a solder, adhesive, or other suitable bonding agent as desired, and outer surfaces of the coupler 124. This opening 168 could be used to feed solder or adhesive to bond the outer conductors of the cables to the coupler. In one example, it should be appreciated that the coupler 124 does not crimp to either or both of the cables 118 and 122.

[0075] The shoulder 170 of the coupler 124 can be configured to engage a biasing element. As is described below, the biasing element can be configured as a spring, which can be seated against the shoulder 170. Thus, the shoulder 170 can define a spring seat. Referring back to Figs. 2A and 2B, a biasing element 174 can be configured to engage the coupler 124. The biasing element 174 can extend from the housing 120 to the coupler 124. The biasing element 174 can be configured to engage the shoulder 170 of the coupler 124. The biasing element 174 can be configured to exert a biasing force against the shoulder 170. The biasing element 174 can be a spring. The biasing element 174 can be configured to engage the coupler 124 and the housing 120 so as to bias the coupler 124 into engagement with the housing 120. The biasing element 174 can define an opening to receive the second portion 164 of the coupler 124. At least a portion of the second electrical cable 122 can be positioned within the opening defined by the biasing element 174.

[0076] Referring to Fig. 6, the second electrical cable 122 can extend into the channel 154 through the second end 1 8 of the coupler 124. The first end of the second electrical cable 122 can be positioned within the channel 154. The first cable 118 can extend through the first end 156 into the channel 154. Thus, the second end of the first cable 118 can be positioned within the channel 154. The first cable 118 can be fixed to the coupler 124. The first cable 118 can be welded to the coupler 124. In some examples the electrical shield 134 of the first cable 118 can be welded to the coupler 124. Alternatively, the first cable 118 can be fixed to the coupler 124 by a fastener or adhesive. The second electrical cable 122 can be fixed to the coupler 124. The second electrical cable 122 can be welded to the coupler 124. In some examples, the electrical shield 146 of the second electrical cable 122 can be welded to the coupler 124. Alternatively, the second electrical cable 122 can be fixed to the coupler 124 by a fastener or adhesive.

[0077] The second electrical conductor 126 of the second electrical cable 122 can be in electrical communication with the first electrical conductor 142 of the first cable 118when the first and second cables 118 and 122 are coupled together by the coupler 124. In some examples, the conductors 126 and 142 of the first and second cables 118 and 122 are in physical contact with each other when the first cable 118 and second electrical cable 122 are coupled. In other examples, the conductors 126 and 142 are spaced from each other but still electrically coupled when the first cable 118 and second electrical cable 122 are coupled. For example, an intermediate electrical conductor can be in electrical communication with each of the conductors 126 and 142. At least a portion of the second electrical conductor 126 can be received by the recess defined by the first cable 118 when the first and second cables 118 and 122 are coupled to each other, thereby placing the conductors 126 and 142 in contact with each other.

[0078] The outer conductors 134 and 146 of the first and second cables 118 and 122 can be electrically coupled to each other when the first and second cables 118 and 122 are coupled together by the coupler 124. In some examples, the outer conductors 134 and 146 are in physical contact with each other when the first cable 118 and the second electrical cable 122 are coupled. In other examples, the outer conductors 134 and 146 are spaced from each other but still electrically coupled when the first cable 118 and second electrical cable 122 are coupled. For example, the coupler 124 can include an electrical shield that electrically couples to each of the outer conductors 134 and 146 of the first and second cables 118 and 122.

[0079] Referring now to Fig. 7the channel 115 of the housing 120 can be configured to receive the coupler 124 and at least a portion of one or more of the first and second cables 118 and 122. Further details of the housing 120 will now be discussed. The housing 120 can include a first housing portion 120a and a second housing portion 120b. The first housing portion 120a can be positioned adjacent the second housing portion 120b in the first direction. The first housing portion 120a can be configured to contact the second housing portion 120b. Each of the first and second housing portions 120a and 120b can include an opening to receive the coupling member 119. The coupling member 119 can extend through each of the first and second housing portions 120a and 120b. An end surface of the first housing portion 120a can face an end surface of the second housing portion 120b. The end surfaces of the first and second housing portions 120a and 120b can contact each other when the housing 120 is coupled to the substrate 104.

[0080] Referring to Fig. 8, the channel 115 can extend through each of the first and second housing portions 120a and 120b. The channel 115 can include a first channel portion 115a, a second channel portion 115b, and a third channel portion 115c. The first housing portion 120a can define the first and second channel portions 115a and 115b. The second housing portion 120b can include the third channel portion 115c. The first, second, and third channel portions 115a and 115b and 115c can each be configured to receive at least a portion of the cable assembly 112. The second channel portion 115b can be positioned between the first and third channel portions 115a and 1 15c in the transverse direction T. The second channel portion 115b can be adjacent the third opening portion in the first direction. The first channel portion 115a can be adjacent the first channel portion 115a in the first direction.

[0081] Each of the first, second, and third channel portions 115a, 115b and 115c can have a width in the lateral direction A. In some examples, the widths can be defined by respective diameters. The second channel portion 115b can have a greater width than the first channel portion 115a. The second channel portion 115b can have a greater width than the third channel portion 115c. The second channel portion 115b and the third channel portion 115c can have equal widths. As shown at Fig. 9 and described in more detail below, the housing 120 can include a first shoulder 166a configured to engage a portion of the cable assembly 112 as discussed below. The first shoulder 166a can be positioned at the junction of the first and second channel portions 115a and 115b. The first shoulder 166a can define an engagement surface in a plane perpendicular to the first direction.

[0082] The housing 120 can include a second shoulder 166b configured to engage the biasing element 174. The second shoulder 166b can be positioned at the junction of the second and third channel portions 115b and 1 15c. The second shoulder 166b can define an engagement surface in a plane perpendicular to the first direction. The second shoulder 166b can be defined by the end surface of the second housing portion 120b.

[0083] Referring now to Fig. 9, at least a portion of the first cable 118 can be positioned within the channel 115. At least a portion of the second electrical cable 122 can be positioned within the channel 115. The coupler 124 can be positioned within the channel 115. The coupler 124 can be positioned within the channel 115 between the first and second shoulders 166a and 166b. The first end 156 of the coupler 124 can be positioned adjacent the first shoulder 166a. The first end 156 of the coupler 124 can engage the first shoulder 166a. The biasing element 174 can be positioned in the channel 115 between the coupler 124 andthe second shoulder 166b in the fourth direction, and seated against the second shoulder 166b. The cable assembly 112 can engage each of the first and second shoulders 166a and 166b. The cable assembly 112 can be in physical contact with each of the first and second shoulders 166a and 166b at the same time.

[0084] The biasing element 174 can urge the first cable 118 in the first or distal direction, and thus away from the second cable 122. In particular, the biasing element 174 can exert a force on the coupler 124 so as to urge the coupler 124 in the first direction. Thus, the biasing element 174 can exert a force on the coupler 124 to maintain the electrical connection between the first cable 118 and the contact pad 103 of the substrate 104 when the housing 120 is coupled to the substrate 104. The biasing element 174 can bias the coupler 124 into engagement with the first shoulder 166a. The biasing element 174 can apply a force to the coupler 124 to move the coupler 124 into engagement with the first shoulder 166a. The biasing element 174 can exert a force against the coupler 124 and the second shoulder 166b. The biasing element 174 can simultaneously exert a force against the coupler 124 and the second shoulder 166b. Referring to Fig. 9B, when the coupler 124 abuts the first shoulder 166a, the first electrical conductor 142 of the first cable 118 can extend out of the housing 120 in the first direction.

[0085] Referring to Fig. 10, a method of manufacturing a cable assembly 112 can include a step 190 of preparing a first cable 118. Preparing the first connector can include cutting a desired length of the first cable 118. The step 190 can include forming the engagement surface 148 on the first end of the first cable 118. The step 190 can include laser cutting the first end to form the engagement surface 148. The step 190 can include removing a portion of the first end of the first electrical conductor 142 so as to form at least one peak and at least one valley at the first end of the first electrical conductor 142. The step 190 can include removing a portion of the insulator 144 such that the first electrical conductor 142 and the electrical shield 146 extend from the insulator 144 in the first direction The step 190 can include forming an engagement surface on the first end 146a of the electrical shield 146. The step 190 can include forming at least one peak and at least one valley on the first end 146a of the electrical shield 146. Forming the engagement surface can be done by cutting, drilling, ablating, etching, etc.

[0086] The step 190 can include removing a portion of the second end of the first electrical conductor 142 to form the recess 152. Removing the portion of the first electricalconductor 142 can be done by cutting, drilling, ablating, etching, etc. The step 190 can include plating at least a portion of the first cable 118 with a conductive material. The conductive material can be metal. The conductive material can be silver plated copper, bare copper, CuNi alloys, Cu alloys, Ag alloys, Tin, Tin alloys, or any suitable alternative materials.

[0087] The method can include a step 192 of preparing a second electrical cable 122. The step 192 can include cutting the insulator 144 to expose the outer electrical shield 134 of the second electrical cable 122. The step 192 can include cutting the outer electrical shield 134 and the insulator 132 to expose a portion of the second electrical conductor 126. The step 192 can include cutting the outer electrical shield 134 and the insulator 132 such that the second electrical conductor 126 extends from the insulator 132 in the first direction.

[0088] The method can include a step 194 of attaching the first and second conductors to the coupler 124. Coupling the first cable 118 to the coupler 124 can include inserting the second end of the first cable 118 into the channel 154 of the coupler 124. The step 194 can include fixing the first cable 118 to the coupler 124. For example, the first cable 118 can be fixed to the coupler 124 by welding, adhesive, or fastener. Coupling the second electrical cable 122 to the coupler 124 can include inserting the first end of the second electrical cable 122 into the channel 154. The step 194 can include coupling the biasing element 174 to the coupler 124. Coupling the biasing element 174 to the coupler 124 can be performed prior to coupling the second electrical cable 122 to the coupler 124. The step 194 can include fixing the second electrical cable 122 to the coupler 124. For example, the second electrical cable 122 can be fixed to the coupler 124 by welding, adhesive, or fastener.

[0089] The method can include a step 196 of positioning a portion of the first cable 118 within the housing 120. The step 196 can include inserting at least a portion of the cable assembly 112 into the channel 115. The step 196 can include positioning at least a portion of the first cable within the channel such that the first end of the first cable extends from the housing in the first direction. The step 196 can include inserting the coupler 124 into the channel 115. The step 196 can include coupling the second housing portion 120b with the first housing portion 120a such that the coupler 124 is positioned between the first shoulder 166a and the second shoulder 166b. The step 196 can include coupling the second housing portion 120b with the first housing portion 120a such that the biasing element 174 is positioned between the second shoulder 166b and the coupler 124.

[0090] The method can include coupling a plurality of cable assemblies 112 to the housing 120. The method can include coupling the housing 120 to the substrate 104. The method can include coupling the housing 120 to the substrate 104 such that each first cable 118 is in electrical communication with one of the contact pads 103 of the substrate 104. The method can include at least temporarily fixing the housing 120 to the substrate 104.

[0091] While each cable assembly 112 has been described above in accordance with one example, it should be appreciated that the cable assemblies 112 can be constructed in accordance with alternative examples. For instance, referring to Fig. 11, a conductor assembly 212 can include is shown. The conductor assembly 212 defines first and second ends 212a, 212b opposite each other along a central axis A4. The conductor assembly 212 can include the second electrical cable 122 as previously described. The conductor assembly 212 can include first and second couplers 224a and 224b coupled to opposing ends of the second electrical cable 122. The first and second couplers 224a and 224b can each be the same as the coupler 124 as described above.

[0092] The conductor assembly 212 can include first and second first cables 218a and 218b coupled to the couplers 224a and 224b, respectively. The first and second first cables 218a and 218b can each be the same as the first cable 118 as described above. Each of the first and second first cables 218a and 218b can be placed in electrical communication with the second electrical cable 122 as described above with respect to the electrical communication between the first and second cables 118 and 122.

[0093] The conductor assembly 212 can further include first and second biasing elements 274a and 274b coupled to the first and second couplers 224a and 224b, respectively. The first and second biasing elements 274a and 274b can be the same as the biasing element 174 as described above.

[0094] While systems and methods have been described in connection with the various embodiments of the various figures, it will be appreciated by those skilled in the art that changes could be made to the embodiments without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, and it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims.

[0095] It is to be appreciated that certain features of the invention which are, for clarity, described herein in the context of separate embodiments, may also be provided incombination in a single embodiment. That is, unless obviously incompatible or specifically excluded, each individual embodiment is deemed to be combinable with any other embodiment(s) and such a combination is considered to be another embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub -combination. Finally, while an embodiment may be described as part of a series of steps or part of a more general structure, each said step may also be considered an independent embodiment in itself, combinable with others.

[0096] It should be understood that the steps of the exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various embodiments of the present invention. Although the elements in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence.

Claims

What is claimed:

1. An electrical conductor assembly comprising: a first electrical conductor configured to be placed in electrical communication with a substrate; and a coupler configured to couple the first electrical conductor to a second electrical conductor so as to place the first electrical conductor in electrical communication with the second electrical conductor.

2. The electrical conductor assembly of claim 1, wherein the first electrical conductor is separately or removably attached to the coupler and is rigid or non-deflecting or is not movably cantilevered from the coupler.

3. The electrical conductor assembly of claim 1, wherein the first electrical conductor is configured to be placed against the substrate or against an electrically conductive contact member of the substrate.

4. The electrical conductor assembly of claim 3, wherein the contact member comprises an electrical contact pad.

5. The electrical conductor assembly of any of claims 1 to 4, wherein the first electrical conductor defines first and second conductor ends opposite each other along a central axis, wherein the first conductor end is spaced from the second conductor end in a first direction and the second conductor end is spaced from the first conductor end in a second direction opposite the first direction.

6. The electrical conductor assembly of claim 5, wherein the first conductor end includes a plurality of peaks and valleys, the valleys being recessed in the second direction relative to the peaks.

7. The electrical conductor assembly of claim 6, wherein the peaks and valleys are arranged along a plane that is perpendicular to each of the first and second directions.

8. The electrical conductor assembly of any one of claims 6 to 7, wherein the peaks are configured to be placed against an electrical contact member.

9. The electrical conductor assembly of any of claims 1 to 8, further comprising a first electrical cable that includes the first electrical conductor.

10. The electrical conductor assembly of claim 9, wherein the first electrical cable is a first coaxial cable.

11. The electrical conductor assembly of claim 10, wherein the first electrical cable includes an insulative layer disposed about the first electrical conductor.

12. The electrical conductor assembly of claim 9, wherein the insulative layer surrounds the first electrical conductor along a majority of a length of the first electrical conductor.

13. The electrical conductor assembly of any one of claims 11 to 12, wherein the insulative layer includes first and second insulative layer ends opposite each other.

14. The electrical conductor assembly of claim 13, wherein the second insulative layer end is spaced from the second conductor end in the second direction so as to define a recess.

15. The electrical conductor assembly of claim 13, wherein the first insulative layer end is spaced from the first conductor end in the second direction.

16. The electrical conductor assembly of any one of claims 11 to 15, wherein the insulative layer is a dielectric.

17. The electrical conductor assembly of any one of claims 11 tol6, wherein the first electrical cable includes an outer electrical conductor disposed about the insulative layer.

18. The electrical conductor assembly of claim 17, wherein the outer electrical conductor surrounds the insulative layer along a majority of a length of the insulative layer.

19. The electrical conductor assembly of any one of claims 17 to 18, wherein the outer electrical conductor includes first and second outer conductor ends opposite each other.

20. The electrical conductor assembly of claim 19, wherein the outer electrical conductor is configured to be placed in electrical communication with the substrate.

21. The electrical conductor assembly of any one of claims 19 to 20, wherein the outer electrical conductor is configured to be placed against the substrate.

22. The electrical conductor assembly of any one of claims 19 to 21, wherein the outer electrical conductor is configured to be placed against a second electrically conductive contact member of the substrate.

23. The electrical conductor assembly of claim 22, wherein the second electrically conductive contact member comprises an electrical contact pad.

24. The electrical conductor assembly of any one of claims 19 to 23, wherein the first outer electrical conductor end includes a plurality of peaks and valleys, the valleys being recessed in the second direction relative to the peaks.

25. The electrical conductor assembly of any one of claims 19 to 24, wherein the second outer electrical conductor end and the second insulative layer end are coplanar.

26. The electrical conductor assembly of any one of the preceding claims, further comprising the second conductor.

27. The electrical conductor assembly of claim 26, further comprising a second electrical cable that comprises the second electrical conductor.

28. The electrical conductor assembly of claim 27, wherein the second cable is a flexible cable.

29. The electrical conductor assembly of any one of claims 27 to 28, wherein the second cable is a coaxial cable.

30. The electrical conductor assembly of any of claims 27 to 29, wherein the second electrical conductor includes a second conductor first and a second conductor second end opposite the second conductor first end a central axis, wherein the second conductor first end is spaced from the second conductor second end in the first direction and the second conductor second end is spaced from the second conductor first end in the second direction.

31. The electrical conductor assembly of claim 30, wherein the second electrical cable includes an insulative layer disposed about the second electrical conductor.

32. The electrical conductor assembly of claim 31 wherein the insulative layer surrounds the second electrical conductor along a majority of a length of the second electrical conductor along the central axis.

33. The electrical conductor assembly of any one of claims 31 to 32, wherein the insulative layer includes first and second insulative layer ends opposite each other along the central axis.

34. The electrical conductor assembly of claim 33, wherein the second conductor first end is spaced from the first insulative layer end in the first direction such that the second conductor extends from the insulative layer in the first direction.

35. The electrical conductor assembly of any one of claims 31 to 34, wherein the insulative layer is a dielectric.

36. The electrical conductor assembly of any one of claims 31 to 35, wherein the second electrical cable includes an outer electrical conductor disposed about the insulative layer.

37. The electrical conductor assembly of claim 36, wherein the outer electrical conductor surrounds the insulative layer along a majority of a length of the insulative layer along the central axis.

38. The electrical conductor assembly of any one of claims 36 to 37, wherein the outer electrical conductor of the second electrical cable is configured to be placed in electrical communication with the outer electrical conductor of the first electrical cable.

39. The electrical conductor assembly of claim 38, wherein the outer electrical conductor of the second electrical cable is configured to be placed in physical contact with the outer electrical conductor of the first electrical cable.

40. The electrical conductor assembly of any one of claims 27 to 39, wherein the first electrical cable has a first rigidity and the second cable has a second rigidity less than the first rigidity.

41. The electrical conductor assembly of claim 40, wherein first cable has a first bending flexibility so as to change its central axis and the second cable has a second bending flexibility that is greater than the first bending flexibility.

42. The electrical conductor assembly of any one of claims 1 to 39, further comprising a coupler configured to couple the first and second cables together.

43. The electrical conductor assembly of claim 42, wherein the coupler is configured to retain the first electrical cable in physical contact with the second cable.

44. The electrical conductor assembly of any one of claims 42 to 43, wherein the coupler includes a channel configured to receive a portion of at least one of the first and second electrical cables.

45. The electrical conductor assembly of claim 44, wherein the first and second electrical cables contact each other within the channel.

46. The electrical conductor assembly of any one of claims 44 to 45, wherein the first and second electrical conductors contact each other within the channel.

47. The electrical conductor assembly of any one of claims 44 to 46, wherein the first end of the second electrical conductor is positioned within a recess of the first electrical cable when the first and second electrical cables are coupled by the coupler.

48. The electrical conductor assembly of any one of claims 44 to 47, wherein the outer electrical conductor of the second electrical cable is in physical contact with the outer electrical conductor of the first electrical cable within the channel.

49. The electrical conductor assembly of any one of claims 42 to 48, wherein the first electrical cable is fixed to the coupler.

50. The electrical conductor assembly of any one of claims 42 to 49, wherein the second electrical cable is fixed to the coupler.

51. The electrical conductor assembly of any one of claims 42 to 50, wherein each of the first electrical cable and the second electrical cable are fixed to the coupler.

52. The electrical conductor assembly of any of claims 42 to 51, wherein the first electrical cable is welded to the coupler.

53. The electrical conductor assembly of any of claims 42 to 52, wherein the second electrical cable is welded to the coupler.

54. The electrical conductor assembly of any of claims 42 to 53, wherein the coupler includes first and second coupler ends opposite each other along a coupler central axis.

55. The electrical conductor assembly of claim 54, wherein the recess extends from the first coupler end to the second coupler end.

56. The electrical conductor assembly of claim 54, wherein the channel extends from one of the first and second coupler ends toward the other of the first and second coupler ends without extending to the other of the first and second coupler ends.

57. The electrical conductor assembly of any one of claims 44 to 56, wherein the coupler includes a sidewall having an inner surface and an outer surface spaced from the inner surface in an outward direction perpendicular to the coupler central axis.

58. The electrical conductor assembly of claim 57, wherein the inner surface defines the channel.

59. The electrical conductor assembly of any one of claims 57 to 58, wherein the sidewall has a thickness as measured between the inner and outer surfaces.

60. The electrical conductor assembly of claim 59, wherein the coupler includes a first portion having a first sidewall thickness and a second portion having a second sidewall thickness different from the first sidewall thickness.

61. The electrical conductor assembly of claim 60, wherein the first sidewall thickness is greater than the second sidewall thickness.

62. The electrical conductor assembly of any one of claims 60 to 61, wherein the outer surface of the sidewall defines a shoulder at the junction of the first and second portions.

63. The electrical conductor assembly of any one of claims 54 to 62, wherein the channel defines a channel width and the channel width at the first coupler end is equal to the channel width at the second coupler end.

64. The electrical conductor assembly of any one of claims 57 to 63, wherein the coupler includes an opening that extends through the sidewall.

65. The electrical conductor assembly of any one of claims 42 to 64, wherein the coupler is electrically insulative.

66. A communication assembly comprising: the electrical conductor assembly of any of claims 1 to 65; and a housing configured to couple to electrical conductor assembly.

67. The communication assembly of claim 66, wherein the housing is configured to receive at least a portion of the electrical conductor assembly.

68. The communication assembly of any of claims 66 to 67, wherein the housing includes opposing first and second housing ends, the first housing end spaced from the second housing end in the second direction.

69. The communication assembly of claim 68, wherein the housing includes a housing channel configured to receive at least a portion of electrical conductor assembly.

70. The communication assembly of claim 68, wherein the housing includes a housing channel configured to receive at least a portion of the first electrical cable.

71. The communication assembly of any one of claims 69 to 70, wherein the housing channel extends from the first housing end toward the second housing end.

72. The communication assembly of any of claims 70 to 71, wherein the housing channel extends from the first housing end to the second housing end.

73. The communication assembly of any of claims 70 to 72, wherein the housing channel extends through each of the first and second housing ends.

74. The communication assembly of any of claims 70 to 73, wherein the first end of the first conductor extends from the first housing end in the first direction.

75. The communication assembly of any one of claims 70 to 74, wherein the second end of the first electrical cable is positioned within the housing channel.

76. The communication assembly of any one of claims 70 to 75, wherein the first end of the second electrical cable is positioned within the housing channel.

77. The communication assembly of any one of claims 70 to 76, wherein the second end of the second electrical cable is positioned outside of the housing channel.

78. The communication assembly of any one of claims 70 to 77, wherein the coupler is positioned in the housing channel.

79. The communication assembly of any one of claims 70 to 78, wherein the housing channel includes a first channel portion having a first width and a second channel portion having a second width different than the first width.

80. The communication assembly of claim 79, wherein the second width is greater than the first width.

81. The communication assembly of any of claims 79 to 80, wherein the housing includes a first shoulder at the junction of the first and second channel portions.

82. The communication assembly of any of claims 79 to 81, wherein the housing includes a third channel portion having a third width that is different than the second width.

83. The communication assembly of claim 82, wherein the third width is less than the second width.

84. The communication assembly of any of claims 82 to 83, wherein the third width is greater than the first width.

85. The communication assembly of any of claims 82 to 84, wherein the housing includes a second shoulder at the junction of the second and third channel portions.

86. The communication assembly of any of claims 79 to 85, wherein the coupler is positioned in the second channel portion.

87. The communication assembly of claim 86, wherein the first width is less than a maximum width of the coupler.

88. The communication assembly of any of claims 86 to 87, wherein the third width is less than a maximum width of the coupler.

89. The communication assembly of any of claims 86 to 88, wherein the electrical conductor assembly includes a biasing element configured to bias the first end of the first electrical cable away from the housing in the first direction.

90. The communication assembly of claim 89, wherein the biasing element urges the coupler in the first direction.

91. The communication assembly of any of claims 89 to 90, wherein the biasing element urges the coupler into contact with the first shoulder.

92. The communication assembly of any of claims 89 to 91, wherein the biasing element engages the second shoulder and the coupler.

93. The communication assembly of any of claims 89 to 92, wherein the biasing element exerts a biasing force on the coupler shoulder.

94. The communication assembly of any of claims 89 to 93, wherein the biasing element defines an opening to receive at least a portion of the coupler.

95. The communication assembly of claim 94, wherein the second portion of the coupler is positioned within the opening defined by the biasing element.

96. The communication assembly of any of claims 94 to 95, wherein a portion of the second electrical cable is positioned within the opening defined by the biasing element.

97. The communication assembly of any of claims 66 to 96, wherein the housing is configured to couple to the substrate.

98. The communication assembly of claim 97, wherein the housing includes an opening configured to receive a coupling member.

99. The communication assembly of claim 98, further comprising a coupling member positioned within the opening, the coupling member configured to couple the housing to the substrate.

100. The communication assembly of any one of claims 70 to 99, wherein the housing includes a plurality of housing channels, each housing channel configured to receive one of the electrical conductor assemblies of any of claims 1 to 655.

101. A method of manufacturing a conductor assembly comprising: preparing a first electrical cable; preparing a second electrical cable; and electrically coupling the first and second electrical cables to each other with a coupler.

102. The method of claim 101, wherein the first electrical cable is a coaxial cable including first and second ends opposite each other along a central axis, the first end spaced from the second end in a first direction, wherein the first electrical cable includes a first cable inner electrical conductor, a first cable insulative layer, and a first cable outer electrical conductor, and wherein the method includes removing a portion of the first cable insulative layer and the first cable outer electrical conductor such that the first cable inner electrical conductor extends from the first cable insulative layer in the first direction.

103. The method of claim 102, wherein preparing the first electrical cable includes removing a portion of the first electrical cable inner electrical conductor so as to define a recess at the second end of the first electrical cable.

104. The method of any of claims 102 to 103, wherein preparing the first electrical cable includes creating an engagement surface on the first end of the first electrical cable inner electrical conductor.

105. The method of any of claims 102 to 104, wherein creating the engagement surface includes removing a portion of the first end of the first electrical cable inner electrical conductor so as to create at least one peak and at least one valley.

106. The method of any of claims 102 to 105, wherein preparing the first electrical cable includes creating an engagement surface on a first end of the first cable outer electrical conductor.

107. The method of any of claims 102 to 106, wherein creating the engagement surface includes removing a portion of the first end of the first electrical cable outer electrical conductor so as to create at least one peak and at least one valley.

108. The method of any one of claims 101 to 107, wherein the second electrical cable is a coaxial cable first and second ends opposite each other along a central axis, the first end spaced from the second end in a first direction, the second electrical cable including a second cable inner electrical conductor, a second cable insulative layer, and a second cable outer electrical conductor, and wherein the method includes removing a portion of the second electrical cable insulative layer and the second cable outer electrical conductor such that the second cable inner electrical conductor extends from the second cable insulative layer in the first direction.

109. The method of claim 108, wherein the second electrical cable includes a second cable outer insulative layer disposed outside of the second electrical cable outer electrical conductor, and wherein the method includes removing a portion of the second electrical cable outer insulative layer such that the second electrical cable outer electrical conductor extends from the second electrical cable outer insulative layer in the first direction.

110. The method of any of claims 101 to 109, wherein the coupler includes a recess and the electrically coupling step includes positioning a portion of each of the first and second cables within the recess so as to place the first electrical cable inner electrical conductor in electrical communication with the second electrical cable inner electrical conductor.

111. The method of claim 110, wherein the electrically coupling step includes positioning the respective portions of the first and second cables within the recess so as to place the first electrical cable inner electrical conductor in physical contact with the second electrical cable inner electrical conductor.

112. The method of any of claims 110 to 111, wherein the electrically coupling step includes positioning the respective portions of the first and second cables within the recess so as to place the second electrical cable inner electrical conductor within the recess defined by the first electrical cable.

113. The method of any of claims 110 to 112, wherein the electrically coupling step includes positioning the respective portions of each of the first and second cables within the recess so as to place the first electrical cable outer electrical conductor in electrical communication with the second electrical cable outer electrical conductor.

114. The method of claim 113, wherein the electrically coupling step includes positioning the respective portions of the first and second cables within the recess so as to place the first electrical cable outer electrical conductor in physical contact with the second electrical cable outer electrical conductor.

115. The method of any of claims 101 to 114, wherein the method further includes fixing each of the first and second cables to the coupler.

116. The method of any of claims 101 to 114, wherein the method further includes welding each of the first and second cables to the coupler.

117. The method of any one of claims 101 to 116, further comprising positioning a portion of the first electrical cable within a housing such that the first end of the first electrical cable extends from the housing in the first direction.

118. The method of claim 117, wherein the positioning step includes positioning the coupler within the housing.

119. The method of claim 117, wherein the positioning step includes positioning a biasing element within the housing such that the biasing element urges the first electrical cable in the first direction.

120. The method of any one of claims 117 to 118, further comprising coupling the housing to a substrate such that the first end of the first cable bears against the substrate in electrical communication with an electrically conductive contact member of the substrate.

121. The method of claim 120, wherein the first end of the first cable bears against the electrically conductive contact member.

122. The electrical connector assembly of any one of claims 1 to 65 wherein the first electrical conductor is one or more of separate from the coupler, not monolithically attached to the coupler, replaceable on the coupler without also replacing the coupler, and removably attached to the coupler.

123. The electrical connector assembly of any one of claims 1 to 65 and 122 wherein the first electrical conductor is one or more of rigid, non-bending, not cantilevered with respect to the coupler, non-compressible, non-deflectable, and has a longitudinal center axis that is configured to be positioned perpendicular to a major surface of a substrate.

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