Cable assembly for interconnecting card modules in a communication system

• US 8,864,516 B2
• Filed: 02/24/2012
• Issued: 10/21/2014
• Est. Priority Date: 02/24/2012
• Status: Active Grant

• Current Assignee: TE Connectivity Solutions GmbH (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Herring, Michael David, Behziz, Arash
• Primary Examiner(s): Nguyen, Hoa C
• Assistant Examiner(s): Cunningham, Xanthia C
• Application Number:
  US13/404,917
• Publication Number:
  US 20130223036A1
• Time in Patent Office: 970 Days
• Field of Search: None
• US Class Current: 439/502
• CPC Class Codes: H01R 12/724 containing contact members forming a right angle
• CPC Class Codes: H01R 13/6471 by special arrangement of ground and signal conductors, e.g. GSGS [Ground-Signal-Ground-Signal]
• CPC Class Codes: H01R 13/6587 for mounting on PCBs
• CPC Class Codes: H05K 7/1451 with connections between circuit boards or units
• CPC Class Codes: H05K 7/1492 having electrical distribution arrangements, e.g. power supply or data communications

Abstract

A cable assembly including first and second header connectors. The first header connector has mating and loading sides and includes electrical contacts. The mating side is configured to mate with a first module connector. The second header connector has mating and loading sides and includes electrical contacts. The mating side of the second header connector is configured to mate with a second module connector. The cable assembly also has a cable bundle including communication cables that extend between the loading sides of the first and second header connectors and that connect the electrical contacts of the first and second header connectors. The cables are substantially twist-free between the first and second header connectors when the first and second header connectors face in substantially opposite directions and the first and second module connectors have an orthogonal relationship.

Claims

1. A cable assembly comprising:

a first header connector having mating and loading sides and including electrical contacts, the mating side configured to mate with a first module connector;

a second header connector having mating and loading sides and including electrical contacts, the mating side of the second header connector configured to mate with a second module connector; and

a cable bundle including communication cables that extend between the loading sides of the first and second header connectors and that connect the electrical contacts of the first and second header connectors, wherein the cables are substantially twist-free between the first and second header connectors when the first and second header connectors face in substantially opposite directions and when the first and second module connectors have an orthogonal relationship, and wherein the electrical contacts of the first header connector are at least one of shaped differently or spaced apart differently than the electrical contacts of the second header connector.

2. The cable assembly of claim 1, wherein the cables are generally parallel to an axial line that extends between respective geometric centers of the loading sides of the first and second header connectors when the first and second header connectors face in substantially opposite directions, the cables having lengths that do not permit the first header connector to be relatively rotated 90°

about the axial line without damaging at least one of the cables, the first header connector, or the second header connector.

3. The cable assembly of claim 2, wherein:

the first header connector includes contact modules that have the electrical contacts of the first header connector, the electrical contacts of each contact module extending within a corresponding module plane; and

the second header connector includes contact modules that have the electrical contacts of the second header connector, the electrical contacts of each contact module of the second header connector extending within a corresponding module plane, wherein the corresponding module planes of the first header connector and the corresponding module planes of the second header connector extend substantially parallel to one another when the loading sides oppose each other and the cables extend generally parallel to an axial line.

4. The cable assembly of claim 1, wherein the first and second header connectors include first and second mating interfaces, respectively, that are configured to directly engage the first and second module connectors, respectively, the first mating interface including the electrical contacts of the first header connector and the second mating interface including the electrical contacts of the second header connector, wherein the electrical contacts at the first mating interface are at least one of shaped differently or spaced apart differently than the electrical contacts at the second mating interface.

5. The cable assembly of claim 1, wherein the first and second header connectors have respective heights that are measured along a first axis when the mating sides face away from each other in opposite directions and the cables extend generally parallel to one another, the first and second header connectors having respective widths that are measured along a second axis when the mating sides face away from each other in opposite directions and the cables extend generally parallel to one another, the first and second axes being perpendicular to each other, wherein at least one of the heights are different or the widths are different.

6. A cable assembly comprising:

a first header connector comprising electrical contacts and including mating and loading sides, the mating side configured to mate with a first module connector;

a second header connector comprising electrical contacts and including mating and loading sides, the mating side of the second header connector configured to mate with a second module connector; and

a cable bundle having communication cables that extend between the loading sides of the first and second header connectors and connect the electrical contacts of the first and second header connectors, wherein the cables extend generally parallel to an axial line that extends between respective geometric centers of the loading sides of the first and second header connectors, wherein the cables have lengths that do not permit the first header connector to be rotated 90°

about the axial line when the mating sides face in substantially opposite directions without damaging at least one of the cables, the first header connector, or the second header connector.

7. The cable assembly of claim 6, wherein the cables have relative locations with respect to one another, the relative locations being substantially the same at the loading side of the first header connector and at the loading side of the second header connector when the cables extend generally parallel to the axial line.

8. The cable assembly of claim 6, wherein the electrical contacts of the first header connector are at least one of shaped differently or spaced apart differently than the electrical contacts of the second header connector.

9. The cable assembly of claim 6, wherein the cables of said bundle have substantially equal lengths.

10. The cable assembly of claim 6, wherein:

the first header connector includes contact modules that have the electrical contacts of the first header connector, the electrical contacts of each contact module extending within a corresponding module plane; and

the second header connector includes contact modules that have the electrical contacts of the second header connector, the electrical contacts of each contact module of the second header connector extending within a corresponding module plane, wherein the corresponding module planes of the first header connector and the corresponding module planes of the second header connector extend substantially parallel to one another when the cables extend generally parallel to the axial line.

11. A communication system comprising:

a system chassis;

a front card module having a circuit board and a module connector mounted to the circuit board;

a rear card module having a circuit board and a module connector mounted to the circuit board, the front and rear card modules are configured to be held by the system chassis so that the module connector of the front card module substantially opposes the module connector of the rear card module with a gap between the module connectors; and

a cable assembly positioned in the gap and comprising first and second header connectors, the first header connector configured to mate with the module connector of the front card module and the second header connector configured to mate with the module connector of the rear card module, the cable assembly also including a cable bundle having communication cables that extend between and connect the first and second header connectors;

wherein the cables extend across the gap in a substantially twist-free manner when the first and second header connectors are mated to the corresponding module connectors and the circuit boards of the front and rear card modules have an orthogonal relationship relative to each other.

12. The communication system of claim 11, wherein the first and second header connectors include respective loading sides, the cables extending generally parallel to an axial line that extends between respective geometric centers of the loading sides when the front and rear card modules have the orthogonal relationship.

13. The communication system of claim 12, wherein the cables have lengths that do not permit the first header connector to be rotated 90°

about the axial line without damaging at least one of the cables, the first header connector, or the second header connector.

14. The communication system of claim 11, wherein:

the first header connector includes contact modules that have the electrical contacts of the first header connector, the electrical contacts of each contact module extending within a corresponding module plane; and

the second header connector includes contact modules that have the electrical contacts of the second header connector, the electrical contacts of each contact module of the second header connector extending within a corresponding module plane, wherein the corresponding module planes of the first header connector and the corresponding module planes of the second header connector extend substantially parallel to one another when the front and rear card modules have the orthogonal relationship.

15. The communication system of claim 11, wherein the module connector of the first card module and the module connector of the second card module have different mating interfaces.

16. The communication system of claim 11, wherein the cables permit the first and second header connectors to float with respect to the system chassis.

17. The communication system of claim 11, wherein the first and second header connectors have first and second loading sides, respectively, with corresponding geometric centers, the first and second loading sides opposing each other with the cables extending therebetween, wherein the cable assembly has an axial line extending between the corresponding geometric centers, each of the cables having a total twist from the first loading side to the second loading side that is at most 10°

with respect to the axial line.

18. The communication system of claim 11, wherein the first and second header connectors have loading sides that oppose each other with the cables extending therebetween, each of the cables having a first location at the loading side of the first header connector relative to a geometric center of the loading side of the first header connector, each of the cables having a second location at the loading side of the second header connector relative to a geometric center of the loading side of the second header connector, wherein the first and second locations are first and second radial distances away from the corresponding geometric center, wherein a difference between the first and second radial distances is at most 30% of the greater of the first and second radial distances.

19. The communication system of claim 11, wherein the first and second header connectors have loading sides that oppose each other, the cables extending between the loading sides and having respective addresses at the loading side of the first header connector and the loading side of the second header connector, each address representing a spatial location of the corresponding cable relative to spatial locations of other cables at the corresponding loading side, wherein the address for each corresponding cable at the loading side of the first header connector is the same as the address for the corresponding cable at the loading side of the second header connector.

20. The communication system of claim 19, wherein each of the addresses is represented by a row number and a column number along the corresponding loading side.