High speed electrical connector

• US 9,257,778 B2
• Filed: 03/15/2013
• Issued: 02/09/2016
• Est. Priority Date: 04/13/2012
• Status: Active Grant

• Current Assignee: FCI Americas Technology Incorporated (FCI)
• Original Assignee: FCI Americas Technology Incorporated (FCI)
• Inventors: Buck, Jonathan E., Stoner, Stuart C., Johnescu, Douglas M., Smith, Stephen B., Zerebilov, Arkady Y., Ingram, Deborah A., Lord, Hung-Wei, Fulton, Robert Douglas, Minich, Steven E.
• Primary Examiner(s): LE, THANH TAM T
• Application Number:
  US13/836,610
• Publication Number:
  US 20130273781A1
• Time in Patent Office: 1,061 Days
• Field of Search: 439/65, 439/68, 439/79, 439/108, 439/607.01, 439/607.06, 439/607.07, 439/607.08, 439/607.09, 439/607.1, 439/660
• US Class Current: 1/1
• CPC Class Codes: H01R 12/7005 Guiding, mounting, polarizing or locking means; Extractors for printed circuit boards H05K
• CPC Class Codes: H01R 12/737 Printed circuits being substantially perpendicular to each other for printed connections H05K3/366
• CPC Class Codes: H01R 13/516 Means for holding or embracing insulating body, e.g. casing , hoods
• CPC Class Codes: H01R 13/6463 using twisted pairs of wires
• 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 13/6585 Shielding material individually surrounding or interposed between mutually spaced contacts
• CPC Class Codes: H01R 13/6587 for mounting on PCBs

Abstract

Electrical connector assemblies are provided that include electrical connectors having electrical contacts that have receptacle mating ends are provided. The connector housings of the provided electrical connectors include alignment members that are capable of performing staged alignment of components of the electrical connector assemblies. The provided electrical connector assemblies and the electrical connectors provided therein are capable of operating at a data transfer rate of forty gigabits per second with worst case multi-active cross talk that does not exceed a range of about two percent to about four percent.

Claims

1. An electrical connector configured to be mated to a complementary electrical connector along a first direction, the electrical connector comprising:

an electrically insulative connector housing including a divider wall and a plurality of ribs that project out from the divider wall, such that adjacent ones of the ribs define a plurality of pockets;

a plurality of signal contacts supported by the connector housing, each of the plurality of signal contacts defining a mounting end and a receptacle mating end, each receptacle mating end defining a tip that defines a concave surface and a convex surface opposite the concave surface; and

a plurality of ground contacts including a plurality of ground mounting ends and a plurality of ground mating ends;

wherein

     1) the signal contacts are arranged in at least first and second linear arrays, the second linear array disposed immediately adjacent the first linear array along a second direction that is perpendicular to the first direction, such that the concave surfaces of the signal contacts of the first linear array face the concave surfaces of the signal contacts of the second linear array,

     2) immediately adjacent signal contacts along each of the linear arrays defines respective differential signal pairs of adjacent ones of the signal contacts, the signal contacts of each of the differential signal pairs having respective receptacle mating ends, and each linear array includes one of the ground mating ends disposed between immediately adjacent ones of the respective differential signal pairs,

     3) the ground mating ends are taller than each of the respective receptacle mating ends of the respective differential signal pairs along a third direction that is perpendicular to each of the first and second directions,

     4) each of the pockets is sized to receive only a single one of a group that includes the receptacle mating ends and the ground mating ends, and

     5) ones of the ground mating ends of the first linear array are offset along the third direction with respect to all of the ground mating ends of the second linear array.

2. The electrical connector as recited in claim 1, wherein each receptacle mating end defines first and second contact locations and is configured to mate with a complementary mating end that is a mirror image of each receptacle mating end at the two contact locations.

3. The electrical connector as recited in claim 2, wherein each receptacle mating end is elongate along a central axis and defines a stub length measured from the first contact location to a terminating edge of the tip along the central axis, and the stub length is in a range having a lower end of approximately 1 mm and an upper end of approximately 3 mm.

4. The electrical connector as recited in claim 3, wherein the stub length is approximately 1 mm.

5. The electrical connector as recited in claim 3, wherein each of the first contact locations abuts and rides along the complementary mating end a wipe distance until the first contact locations of each of the receptacle mating end and the complementary mating end abuts the second contact location of the other of the receptacle mating end and the complementary mating end, and the wipe distance is in a range having a lower end of approximately 2 mm and an upper end of approximately 5 mm.

6. The electrical connector as recited in claim 1, wherein the concave surfaces of the signal contacts of the first linear array face a first surface of the divider wall, and the concave surfaces of the signal contacts of the second linear array face a second surface of the divider wall that is opposite the first surface along the second direction.

7. The electrical connector as recited in claim 6, wherein the connector housing further defines at least one cover wall that extends from the divider wall along the second direction so as to overlap at least a portion of the tips of the first and second linear arrays along the first direction.

8. The electrical connector as recited in claim 1, wherein each of the signal contacts and the ground mating ends defines respective opposed broadsides and opposed edges connected between the broadsides, and each of the signal contacts and the ground mating ends is oriented such that the respective edges of the ground mating ends and the signal contacts face respective ones of the adjacent ribs that define the respective pocket.

9. The electrical connector as recited in claim 8, wherein the receptacle mating ends and the ground mating ends each extend continuously from one of the respective edges to the other of the respective edges along each of the respective broadsides.

10. The electrical connector as recited in claim 1, wherein the first linear array defines a single electrical widow contact disposed at a first end of the linear array, and the second linear array defines a single widow contact disposed at a second end of the second linear array, the second end opposite the first end, and each of the widow contacts having a respective mating end and a respective mounting end.

11. The electrical connector as recited in claim 10, wherein the ground mating ends includes a ground mating end disposed between the mating ends of each of the widow contacts and one of the differential signal pairs of the respective first and second linear arrays.

12. The electrical connector as recited in claim 11, wherein the single widow contacts are not disposed adjacent any other electrical contacts along the respective linear array, except for the respective ground mating end.

13. The electrical connector as recited in claim 10, wherein the ground mating ends include a ground mating end disposed between first and second ones of the differential signal pairs along at least one of the linear arrays, and an aperture extends through the ground mating end along the second direction.

14. The electrical connector as recited in claim 1, wherein each of the plurality of ground contacts comprises an electrically conductive ground plate, and the electrical connector further comprises a leadframe assembly that includes an electrically insulative leadframe housing, the signal contacts of the first linear array supported by the leadframe housing, and one of the ground plates attached to the leadframe housing, wherein each of the ground plates includes a ground plate body and a plurality of ribs that are carried by the ground plate body, each of the ribs extending to a location between and inline with adjacent differential signal pairs of the first linear array, and each of the ribs aligned with respective ground mating ends and ground mounting ends.

15. The electrical connector as recited in claim 14, wherein a plurality of the mounting ends of the signal contacts and the ground mounting ends define leads having a stem that extends out from the leadframe housing to a distal end, and a hook that extends from the distal end of the stem along a direction that is angularly offset from both the stem and a third direction that is perpendicular to the first and second directions.

16. The electrical connector as recited in claim 14, wherein the signal contacts of the first linear array reside in channels that extend through the leadframe housing, and the leadframe housing defines a plurality of projections that extend beyond the channels and contact the signal contacts so as to resist flexing of the signal contacts as they mate with complementary signal contacts.

17. The electrical connector as recited in claim 14, wherein the leadframe assembly defines leadframe apertures that extend through the leadframe housing at locations aligned with respective ones of the ribs, wherein the leadframe apertures define a length between the ground mating ends and the ground mounting ends that are aligned with the one of the ribs, and the length is at least half a length of the one of the ribs between the aligned ground mating end and the ground mounting end.

18. The electrical connector as recited in claim 14, wherein the ribs are embossed into the ground plate body.

19. The electrical connector as recited in claim 1, wherein the mounting ends are configured to be mounted to a first substrate oriented along a first plane defined by the first and second directions, and the mating ends define a gap between the first linear array and the second linear array, the gap sized to receive a leading end of a second substrate oriented along a second plane that is defined by the first direction and third direction.

20. The electrical connector as recited in claim 1, wherein the ground mating ends of each of the linear arrays are disposed between adjacent ones of the mating ends of the respective differential signal pairs at a mating interface, and the ground mating ends of each of the linear arrays is between adjacent ones of the mounting ends of the respective differential signal pairs at a mounting interface, and the electrical connector defines a constant contact pitch at the mounting interface and a variable contact pitch at the mating interface.

21. The electrical connector as recited in claim 1, wherein the mating ends are oriented substantially perpendicular with respect to the mounting ends.

22. The electrical connector as recited in claim 21, wherein the tip is recessed in the connector housing in a direction opposite the first direction.

23. The electrical connector as recited in claim 1, wherein the mating ends of each differential signal pair along each of the first and second linear arrays are flanked by a respective immediately adjacent ground mating end on opposite sides of the differential signal pair along the linear array.

24. The electrical connector as recited in claim 1, wherein the differential signal pairs are configured to transfer data signals up to 40 Gigabits per second with asynchronous, multi-active, worst-case crosstalk on a victim pair of no more than six percent, while simultaneously maintaining insertion loss within a range of at approximately zero to −

2 dB through 30 GHz.

25. The electrical connector as recited in claim 24, wherein the plurality of ground contacts comprises a respective plurality of electrically conductive ground plates each including a ground plate body, respective ones of the plurality of ground mounting ends that extend from the ground plate body, and respective ones of the plurality of ground mating ends that extend from the ground plate body.

26. The electrical connector as recited in claim 25, wherein each of the ground plates includes a plurality of embossments that are carried by the ground plate body and project out from the ground plate body along the second direction.

27. The electrical connector as recited in claim 1, wherein the plurality of ground contacts comprises individual discrete ground contacts, each including a respective one of the ground mating ends and a respective one of the ground mounting ends.

28. The electrical connector as recited in claim 27, wherein each of the linear arrays includes a plurality of the individual discrete ground contacts.

29. The electrical connector as recited in claim 1, wherein the plurality of ground contacts comprises a respective plurality of electrically conductive ground plates each including a ground plate body, respective ones of the plurality of ground mounting ends that extend from the ground plate body, and respective ones of the plurality of ground mating ends that extend from the ground plate body.

30. The electrical connector as recited in claim 29, wherein a first one of the ground plates is disposed adjacent the signal contacts of the first linear array, and a second one of the ground plates is disposed adjacent the signal contacts of the second linear array.

31. The electrical connector as recited in claim 30, wherein the ground mating ends of the first one of the ground plates are inline with the receptacle mating ends of the first linear array along the third direction, and the ground mating ends of the second one of the ground plates are inline with the receptacle mating ends of the second linear array along the third direction.

32. The electrical connector as recited in claim 31, wherein the ground mounting ends of the first one of the ground plates are inline with the mounting ends of the signal contacts of the first linear array along the first direction, and the ground mounting ends of the second one of the ground plates are inline with the mounting ends of the signal contacts of the second linear array along the first direction.

33. The electrical connector as recited in claim 30, wherein the first one of the ground plates includes a plurality of embossments that are carried by the ground plate body, each of the embossments extending to a location between adjacent differential signal pairs of the first linear array.

34. The electrical connector as recited in claim 30, wherein the ground mating ends are oriented substantially perpendicular with respect to the ground mounting ends, and the receptacle mating ends are oriented substantially perpendicular with respect to the mounting ends of the signal contacts.

35. The electrical connector as recited in claim 34, wherein the differential signal pairs are configured to transfer differential signals between their mating and mounting ends at data transfer rates of 25 Gigabits/sec while producing produce no more than six percent worst-case, multi-active cross talk on a victim differential signal pair.

36. The electrical connector as recited in claim 29, further comprising a plurality of leadframe assemblies that each includes an electrically insulative leadframe housing, ones of the plurality of signal contacts, and one of the ground plates attached to the leadframe housing, wherein the leadframe housing is configured to be supported by the connector housing.

37. The electrical connector as recited in claim 1, wherein some of the ribs that project from the divider wall to define pockets that receive the receptacle mating ends and the ground mating ends of the first linear array are offset along the third direction with respect to all of the ribs that project from the divider wall to define pockets that receive the receptacle mating ends and the ground mating ends of the second linear array.

38. The electrical connector as recited in claim 1, wherein adjacent ones of the ribs that project from the divider wall to define pockets that receive the ground mating ends are spaced a apart from each other a greater distance along the third direction than adjacent ones of the ribs that project from the divider wall to define pockets that receive the receptacle mating ends.

39. An electrical connector configured to be mated to a complementary electrical connector along a first direction, the electrical connector comprising:

an electrically insulative connector housing; and

first and second leadframe assemblies each including a leadframe housing, a plurality of signal contacts supported by the leadframe housing so as to define a plurality of mating ends along a mating interface, and an electrically conductive ground plate attached to the leadframe housing, the ground plate defining a plurality of ground mounting ends extending out from the connector housing substantially along a longitudinal direction, respective ones of the ground mating ends disposed between and aligned with the mating ends of the signal contacts along a transverse direction that is substantially perpendicular to the longitudinal direction,

wherein

     1) the first leadframe assembly defines a first linear array of mating ends, and the second leadframe assembly defines a second linear array of mating ends,

     2) the first leadframe assembly defines a single electrical widow contact disposed at a first end of the first linear array,

     3) the second leadframe assembly defines a single widow contact disposed at a second end of the second linear array, the second end opposite the first end, and

     4) each of the single widow contacts is not disposed adjacent any other electrical contacts, except a single ground mating end along the respective first and second linear arrays.

40. The electrical connector as recited in claim 39, wherein the ground mating ends define a distance along the transverse direction from edge to edge that is greater than a distance defined by each of the mating ends of the signal contacts along the transverse direction from edge to edge.

41. The electrical connector as recited in claim 39, wherein the mating ends of the electrical signal contacts and the ground mating ends are recessed in the connector housing in a second direction opposite the first direction.

42. The electrical connector as recited in claim 39, wherein the housing further comprises at least one divider wall disposed between the first and second leadframe assemblies, such that concave surfaces of the ground mating ends and the mating ends of the electrical signal contacts of the first leadframe assembly face a first surface of the divider wall, and concave surfaces of the ground mating ends and the mating ends of the electrical signal contacts of the second leadframe assembly face a second surface of the divider wall that is opposite the first surface.

43. The electrical connector as recited in claim 42, further comprising a plurality of ribs that project out from the divider wall, such that the divider wall and adjacent ones of the ribs define respective pockets that each receives only a single one of a group that includes the ground mating ends and the mating ends of the electrical signal contacts, wherein the ground mating ends are taller than the signal mating ends along the transverse direction.

44. The electrical connector as recited in claim 39, wherein the ground plate defines an enclosed aperture that extends through each of the ground mating ends along the lateral direction.

45. The electrical connector as recited in claim 39, wherein immediately adjacent signal contacts of each of the first and second leadframe assemblies define differential signal pairs, and the ground plate of each leadframe assembly includes a ground plate body and a plurality of ribs that project out from the ground plate body to a location between and aligned with immediately adjacent differential signal pairs of the respective leadframe assembly.

46. The electrical connector as recited in claim 45, wherein the ribs are embossed into the ground plate body, each of the ribs aligned with respective ones of ground mating ends and ground mounting ends.

47. The electrical connector as recited in claim 46, wherein the leadframe assembly defines leadframe apertures that extend through the leadframe housing at locations aligned with respective ones of the ribs, wherein the leadframe apertures define a length between the ground mating ends and the ground mounting ends that are aligned with the one of the ribs, and the length is at least half a length of the one of the ribs between the aligned ground mating end and the ground mounting end.

48. An electrical connector configured to be mated to a complementary electrical connector along a first direction, the right-angle electrical connector comprising:

an electrically insulative connector housing;

a plurality of signal contacts, each of the plurality of signal contacts defining a mounting end and a mating end, immediately adjacent signal contacts defining respective differential pairs; and

a plurality of ground mating ends aligned with the signal contacts along first and second adjacent linear arrays, such that each differential signal pair along the first linear array is flanked by a respective immediately adjacent one of the ground mating ends on opposite sides of the differential signal pair along the first linear array, and each differential signal pair along the second linear array is flanked by a respective immediately adjacent one of the ground mating ends on opposite sides of the differential signal pair along the second linear array,

wherein the first linear array defines a single electrical widow contact disposed at a first end of the first linear array, and the second linear array defines a single widow contact disposed at a second end of the second linear array, the second end opposite the first end, and each of the widow contacts are single-ended signal contacts having a respective mating end aligned with the ground mating ends of the respective linear array, and a respective mounting end aligned with the ground mounting ends of the respective linear array.

49. The electrical connector as recited in claim 48, wherein the single widow contacts are not disposed adjacent any other electrical contacts along the respective linear array, except for one of the ground mating ends and aligned mounting end.

50. The electrical connector as recited in claim 48, wherein mating ends of the signal contacts and the ground mating ends each define receptacle mating ends having a concave surface and a convex surface opposite the concave surface, and each of the receptacle mating ends are configured to mate with complementary receptacle mating ends of a second electrical connector.

51. The electrical connector as recited in claim 50, further comprising first and second electrically conductive ground plates that each includes a ground plate body, respective ones of the plurality of ground mounting ends that extend from the ground plate body, respective ones of the plurality of ground mating ends that extend from the ground plate body, and a respective plurality of ribs that project from the ground plate body.

52. The electrical connector as recited in claim 51, wherein the ground plate body of the first electrically conductive ground plate is disposed adjacent and spaced from the signal contacts of the first linear array, the ribs of the first electrically conductive ground plate extend between and aligned with adjacent differential signal pairs of the first linear array, the ground plate body of the second electrically conductive ground plate is disposed adjacent and spaced from the signal contacts of the second linear array, and the ribs of the second electrically conductive ground plate extend between and aligned with adjacent differential signal pairs of the second linear array.

53. The electrical connector as recited in claim 52, wherein the differential signal pairs are configured to transfer differential signals between their mating and mounting ends at data transfer rates of 30 Gigabits/sec while producing produce no more than six percent worst-case, multi-active cross talk on a victim differential signal pair.

54. An electrical connector assembly comprising:

a first electrical connector configured to be mounted to a first electrical component, the first electrical connector including;

a first plurality of signal contacts, each of the first plurality of signal contacts defining a mounting end and a receptacle mating end, each receptacle mating end defining a tip that defines a first concave surface and a second convex surface opposite the first concave surface,

an electrically insulative first connector housing supporting the first plurality of signal contacts, such that the first connector housing extends forward from the tips, the first connector housing defining at least one gross alignment member and at least one fine alignment member;

wherein the first plurality of signal contacts is arranged in at least first and second linear arrays of signal contacts, such that the first concave surfaces of the signal contacts of the first linear array faces a direction opposite a direction that the first concave surfaces of the signal contacts of the second linear array face; and

a second electrical connector configured to mate with the first electrical connector and further configured to be mounted to a second electrical component, the second electrical connector including;

a second plurality of signal contacts, each of the second plurality of signal contacts defining a mounting end and a receptacle mating end, each receptacle mating end defining a tip that defines a first concave surface and a second convex surface opposite the first concave surface,

an electrically insulative second connector housing supporting the second plurality of signal contacts, such that the first connector housing extends forward from the tips, the second connector housing defining at least one gross alignment member and at least one fine alignment member;

wherein the second plurality of signal contacts is arranged in at least first and second linear arrays of signal contacts, such that the first concave surfaces of the signal contacts of the first linear array of the second plurality of signal contacts faces the first concave surfaces of the signal contacts of the second linear array of the second plurality of signal contacts,

wherein the gross alignment members of the first and second connector housings are configured to engage each other to place the signal contacts of the first electrical connector in a first stage of alignment with the signal contacts of the second electrical, and the fine alignment members of the first and second connector housings are configured to engage each only other after the gross alignment members have engaged each other to place the signal contacts of the first electrical connector in a second stage of alignment with the signal contacts of the second electrical, the second stage of alignment more precise than the first stage of alignment.

55. The electrical connector assembly of claim 54, wherein the gross alignment members of the first electrical connector comprise beams, and the gross alignment members of the second electrical connector comprises recesses configured to receive the beams so as to engage the gross alignment members of the first electrical connector with the gross alignment members of the second electrical connector.

56. The electrical connector assembly of claim 55, wherein the fine alignment members of the first electrical connector comprise beams, and the fine alignment members of the second electrical connector comprises recesses configured to receive the beams so as to engage the fine alignment members of the first electrical connector with the fine alignment members of the second electrical connector.

57. The electrical connector assembly of claim 55, wherein the fine alignment members of the first electrical connector comprise fine alignment beams, and the second fine alignment members of the second electrical connector comprise arms that are flexible along a third direction that is perpendicular to both the first and the second directions, wherein the arms are configured to ride along the fine alignment beams so as to engage the fine alignment members of the first electrical connector with the fine alignment members of the second electrical connector.