Electrical cable assembly

• US 9,741,465 B2
• Filed: 11/25/2013
• Issued: 08/22/2017
• Est. Priority Date: 12/31/2012
• Status: Active Grant

• Current Assignee: FCI Americas Technology LLC (Amphenol Corporation)
• Original Assignee: FCI Americas Technology LLC (Amphenol Corporation)
• Inventors: Gross, Charles M., Garman, Joshua A.
• Primary Examiner(s): Nguyen, Chau N
• Application Number:
  US14/089,125
• Publication Number:
  US 20140182890A1
• Time in Patent Office: 1,366 Days
• Field of Search: 174115, 174117 F
• CPC Class Codes: H01B 7/00 Insulated conductors or cables characterised by their form
• CPC Class Codes: H01B 7/0861 comprising one or more screens
• CPC Class Codes: H01R 12/53 connecting to cables except for flat or ribbon cables
• CPC Class Codes: H01R 13/6592 the conductive member being a shielded cable
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 43/28 for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

In accordance with an embodiment, an electrical cable can be configured to electrically connect to contact pads that are carried by a substrate. The electrical cable can include at least one, such as a pair, of electrical signal conductors and at least one, for instance a pair, of electrically conductive drain wires. A drain wire in the electrical cable can define a first surface that is configured to face the signal conductors and a second surface that is opposite the first surface. The drain wire can define a width that is greater than 0.12 mm as measured from the first surface to the second surface along a straight line. At least one auxiliary wire can be attached to at least one drain wire. The auxiliary wire can be configured to attach to the substrate.

Claims

1. An electrical cable assembly comprising:

a plurality of electrical cables arranged in an array extending in a first direction, wherein each of the plurality of electrical cables comprises;

an electrical insulator;

a first electrical signal conductor and a second electrical signal conductor, respective portions of each disposed within the insulator, and each of the first and second electrical signal conductors defining a mounting portion that extends from the insulator and defines a diameter along the first direction;

first and second drain wires having respective portions disposed within the insulator and spaced apart from each other along the first direction such that each of the first and second electrical signal conductors is elongate along its respective length and disposed between the first and second drain wires with respect to the first direction, and each of the first and second drain wires define a mounting portion that extends from the electrical insulator and is configured to attach to a substrate; and

first and second electrically conductive auxiliary wires each defining an outer perimeter that is attached to the mounting portion of the first and second drain wires, respectively, such that a straight line along the first direction passes through all of the first and second electrical signal conductors, first and second drain wires, and first and second auxiliary wires wherein a maximum width along the first direction formed by the first or second auxiliary wire attached to a respective first or second drain wire is greater than the diameter.

2. The electrical cable assembly as recited in claim 1, wherein the auxiliary wires are attached to the mounting portion of the respective drain wire via a common pad or an intermediate conductive member.

3. The electrical cable assembly as recited in claim 1, wherein each of the first and second drain wires defines a respective outer perimeter having first and second opposed sides that are spaced from each other along the first direction.

4. The electrical cable assembly as recited in claim 3, wherein the mounting portion defines the first side configured to face the first and second electrical signal conductors, the second side is opposite the first side, and the auxiliary wires are attached to the second side of the respective drain wires.

5. The electrical cable assembly as recited in claim 4, whereineach auxiliary wire defines a first side that is attached to the second side of the one drain wire, and a second side opposite the first side of the auxiliary wire and spaced from the first side of the auxiliary wire an auxiliary distance, and 2) the first and second sides of the mounting portion are spaced from each other a drain distance.

6. The electrical cable assembly as recited in claim 5, wherein the auxiliary wires define a respective third side that is configured to attach to the substrate.

7. The electrical cable assembly as recited in claim 3, wherein the mounting portion defines the first side configured to face the first and second signal conductors, the second side opposite is the first side, and the auxiliary wires are attached to the first side of the respective drain wires.

8. The electrical cable assembly as recited in claim 7, whereineach auxiliary wire defines a first side that is proximate to the first and second signal conductors along the first direction, and a second side that is opposite the first side of the auxiliary wire and attached to the first side of the respective drain wire, the first and second sides of each auxiliary wire spaced from each other an auxiliary distance, and 2) the first and second sides of the mounting portion are spaced from each other a drain distance.

9. The electrical cable assembly as recited in claim 8, wherein the drain distance is substantially equal to the auxiliary distance.

10. The electrical cable assembly as recited in claim 1, wherein the mounting portion is elongate along its length, and each of the auxiliary wires is elongate along its length that is substantially equal to the length of the mounting portion.

11. The electrical cable assembly as recited in claim 1, wherein each of the drain wires is elongate along its length, and each of the auxiliary wires is elongate along its length that is substantially equal to the length of each of the drain wires.

12. The electrical cable assembly as recited in claim 1, wherein only one auxiliary wire is attached to each of the first and second drain wires.

13. The electrical cable assembly as recited in claim 1, the electrical cable assembly further comprising:

the substrate that carries a plurality of signal contact pads and ground contact pads disposed between ones of the signal contact pads, each of the first and second electrical signal conductors mounted to respective signal contact pads and each of the first and second drain wires mounted to respective ground contact pads.

14. The electrical cable assembly as recited in claim 1, wherein the first auxiliary wire is physically adhered to the mounting portion of the first drain wire, and the second auxiliary wire is physically adhered to the mounting portion of the second drain wire.

15. The electrical cable assembly as recited in claim 1, wherein the first and second electrical signal conductors are the only signal conductors disposed between the first and second electrically conductive auxiliary wires along the first direction.

16. A method of fabricating an electrical cable assembly, the cable assembly comprising an array extending in a first direction of a plurality of electrical cables, each electrical cable comprising at least one electrically conductive signal conductor and at least one electrically conductive drain wire, wherein:

a first side of the at least one drain wire faces the at least one electrically conductive signal conductor in an electrical insulator, and a second side of the at least one drain wire is opposite the first side; and

the at least one electrical conductive signal conductor defines a diameter along the first direction;

the method comprising;

causing a mounting portion of the at least one drain wire to extend from the insulator, such that the mounting portion is configured to attach to a substrate; and

attaching an electrically conductive auxiliary wire to the second side of the mounting portion of the at least one drain wire so as to define a width along the first direction that is measured from the first side to a side of the auxiliary wire along a straight line, the width;

greater than 0.2 millimeters (mm), less than 1.5 mm,

greater than a maximum width of the at least one drain wire, and

greater than the diameter defined by the at least one conductor,

wherein the straight line passes through the at least drain wire, the at least one electrically conductive signal conductor, and the auxiliary wire in the electrical cable.

17. The method as recited in claim 16, wherein the at least one drain wire is a first and second drain wire, and the at least one electrically conductive signal conductor is a first and second electrically conductive signal conductor, the method further comprising:

disposing the first and second electrically conductive signal conductors between the first and second electrically conductive drain wires with respect to a first direction,

wherein the first and second sides of each of the first and second drain wires are opposite other with respect to the first direction.

18. The method as recited in claim 17, wherein only one electrically conductive auxiliary wire is attached to each of the first and second drain wires.

19. An electrical cable assembly comprising:

a plurality of electrical cables arranged in an array extending in a first direction, wherein each of the plurality of electrical cables comprises;

an electrical insulator;

a first electrical signal conductor and a second electrical signal conductor, respective portions of each disposed within the insulator and each defining a diameter along the first direction;

first and second drain wires having respective portions disposed within the insulator and spaced apart from each other along the first direction such that each of the first and second electrical signal conductors is disposed between the first and second drain wires with respect to the first direction; and

first and second electrically conductive auxiliary wires contacting the first and second drain wires, respectively, such that conducting structures between the first and second signal conductors of adjacent cables formed by the first or second auxiliary wire and a respective first or second drain wire has a width, along the first direction, greater than a maximum width of the drain wire and greater than the diameter.

20. The electrical cable assembly of claim 19, further comprising a substrate that carries a plurality of signal contact pads and ground contact pads disposed between ones of the signal contact pads, each of the first and second electrical signal conductors is mounted to respective signal contact pads and each of the first and second drain wires is mounted to respective ground contact pads.

21. The electrical cable assembly of claim 20, wherein the auxiliary wires are mounted to the same ground contact pad as a respective drain wire.