High speed electrical connector

[0001] The present application is a continuation application of U.S. patent application Ser. No. 10/255,769, filed on Sep. 25, 2002 now U.S. Pat. No. 6,808,420, which claims priority from U.S. Provisional Patent Application Ser. No. 60/382,886, filed on May 22, 2002, which are incorporated by reference herein in their entirety.

[0002] The present invention generally relates to an electrical connector for transmitting high speed electrical signals in differential pair applications.

[0003] Many board-to-board connector systems have been proposed for interconnecting circuit boards that include traces arranged to convey differential pairs of signals. The differential pairs include complimentary signals such that if one signal in a differential pair switches from 0 V to 1 V, the other signal in the differential pair switches from 1 V to 0 V. Each connector exhibits a characteristic impedance.

[0004] In that past, fluctuations in impedance exhibited by a connector did not degrade signal performance by an appreciable amount when signal/data transmission rates were relatively low (e.g., less than 1 GHz). However, newer systems have been proposed to transmit data signals at speeds approaching and exceeding 2 GHz. In these high speed data transmission systems, even small impedance fluctuations may pose significant problems, such as signal loss, interference, noise, jitter and the like within each connector.

[0005] Further, each trace of the circuit board is attached to a unique signal pin of the connector. Within the connector, signal pins of separate different differential pairs may become electromagnetically coupled to one another. When signal pins of different differential pairs become coupled with one another, the signal pins exhibit cross talk. Cross talk increases the interference, noise, and jitter within the circuit board, connector and system. Increasing the distance between signal pins of separate differential pairs typically decreases the effects of interference, noise and jitter. Increasing the distance between differential pairs typically requires a larger connector. However, electrical and electronic applications today require a large number of differential pairs to be packaged in a small space. Many systems require as small a connector as possible to make efficient use of internal space.

[0006] Thus, a need remains for an electrical connector that exhibits improved signal characteristics in terms of impedance, interference, noise and jitter. Further, a need exists for an electrical connector that may accommodate a high number of signal contacts, while reducing interference, noise and jitter among the signal contacts.

[0007] Certain embodiments of the present invention provide an electrical connector comprising a connector, signal contacts and ground contacts. The connector comprises a connector housing having a mating face configured to join a mating electrical connector. The connector housing includes channels extending therethrough.

[0008] The signal contacts and ground contacts are held in the channels in an array organized into rows. Each row includes ground contacts separated by signal contact pairs. The ground contacts and signal contact pairs are ordered in different first and second patterns, respectively, in adjacent first and second rows in the array. The first and second rows are staggered relative to one another so that the signal contact pairs in the first and second rows are separated from one another by the ground contacts. A first signal contact pair in the first row is shielded from a second signal contact pair in the first row by a first ground contact. The first row is staggered with respect to the second row so that the first signal contact pair is shielded from a third signal contact pair in the second row by the first ground contact.

[0031] The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.

[0032] As shown in FIGS. 1-4, a header connector 10 comprises a dielectric housing 12 including a main wall 14, an upper shroud 15 and a lower shroud 16. The header connector 10 further comprises a plurality of signal contacts 20 and ground contacts 30 that extend through and are secured in the main wall 14. The header connector 10 includes a mating face 17 that interfaces with a mating face 57 of a corresponding receptacle connector 50, shown in FIG. 6. The header connector 10 also includes a board-mounting face 18 that interfaces with a circuit board (not shown) on which the header connector 10 is mounted. The header connector 10 mates with the receptacle connector 50 such that the circuit board on which the header connector 10 mounts is oriented perpendicular to the circuit board, backplane, or other such structure, on which the receptacle connector 50 is mounted or otherwise positioned.

[0033] FIG. 11 illustrates an exemplary signal contact 20, which includes a tail or lead 22 with a compliant section 24 that is configured for press-fit insertion into a plated signal through-hole in the circuit board (not shown). Each of the signal contacts 20 also has a post 26 that is matable with a corresponding contact in the receptacle connector 50. The posts 26 are insertable into respective holes 58 in the mating face 57 of the receptacle connector 50 (FIG. 6).

[0034] FIG. 5 illustrates an exemplary ground contact 30, which includes a tail or lead 32 with a compliant section 34 that is configured for press-fit insertion into a plated ground through-hole in the circuit board, and a blade 36 that is engagable with a corresponding ground shield in the receptacle connector 50. The tail 32 and compliant section 34 are oriented at an angle to the plane of the blade 36 by a bend portion 37. The bend portion 37 is provided along one side edge of the blade 36, such that the tail 32 is offset from a central longitudinal axis 35 of the blade 36. The blades 36 are insertable into respective slots 59 in the mating face of the receptacle connector 50 (FIG. 6). For the sake of simplicity, only one ground contact 30 is shown in FIG. 5. It is to be understood, however, that analogous ground contacts are used with the header connector 10. For example, the ground contacts 30 in adjacent rows (such as rows 41 in FIG. 3) are not merely inverted. Rather, ground contacts 30 in one row 41 may be formed as mirror images of the ground contacts 30 in an adjacent row 41. Preferably, two sets of ground contacts 30 are formed such that one set is a mirror image of the other. However, all of the ground contacts 30 share the same basic features.

[0035] With respect to FIG. 3, the signal and ground contacts 20 and 30 are arranged in an array in the header connector 10. The array includes groups with each group comprising two signal contacts 20 and one ground contact 30. The two signal contacts 20 in each group are associated as a signal contact pair 28, which serves to transmit a pair of differential electrical signals through the header connector 10. One ground contact 30 is associated with each signal contact pair 28. More particularly, along the mating face 17 as shown in FIG. 3, the signal contact posts 26 are arranged in parallel rows 41 which are separated by rows 42 of the ground contact blades 36. That is, adjacent rows of signal contact pairs 28 are separated by an intervening row of ground contact blades 36.

[0036] As shown in FIG. 4, along the board-mounting face 18, the signal contact tails 22 are arranged in parallel rows 43 that also include the ground contact tails 32 due to the ground contact tails 32 being offset from the blades 36 by the bend portions 37 of the ground contacts 30. The ground contact tails 32 intervene between the pairs of signal contact tails 22 within each row 43.

[0037] The signal contact pairs 28 in the array are staggered from row 43 to row 43. More particularly, the pattern of signal and ground contacts 20 and 30, respectively, in any one row along the board-mounting face 18 shown in FIG. 4 is reversed in the next adjacent row. That is, as shown in FIG. 4, for example, the orientation of one row 43 is opposite that of the adjacent row. The rows may be termed odd and even according to their sequence from one side of the header connector 10. All of the odd rows have one pattern of signal and ground contacts 20 and 30, respectively, and all of the even rows have another pattern that is reversed from that in the odd rows. For example, as shown in FIGS. 3 and 4, the pattern of row A is reversed from the pattern of row B. Thus, the signal contact pairs 28 in row A are staggered relative to the signal contact pairs 28 in row B. Along the mating face 17 shown in FIG. 3, the pairs of signal contact posts 26 in any one row are staggered with respect to the pairs of signal contact posts 26 in the next adjacent row. This staggered array of signal and ground contacts 20 and 30 serves to isolate each signal contact pair 28 from neighboring signal contact pairs 28, thereby reducing electrical cross-talk and improving electrical performance.

[0038] FIG. 6 illustrates the receptacle connector 50, which comprises a dielectric housing 52 having a main wall 54, an upper shroud 55 and a lower shroud 56. The receptacle connector 50 holds a plurality of contact modules 60a, 60b, shown in FIGS. 7-10. Each contact module 60a and 60b includes a dielectric molding 62a, 62b that holds signal contacts and a ground contact. The contact modules 60a and 60b are similar to each other, but each has a respective pattern of signal contacts corresponding to the pattern of signal contacts 20 in a respective one of the rows in the header connector 10.

[0039] As shown in FIGS. 9 and 10, each of the modules 60a, 60b has a plurality of signal contacts 70a, 70b each having a receptacle section 72a, 72b at a mating end and a compliant tail section 74a, 74b at a board-mounting end (only two representative compliant sections are shown in the Figures). The receptacle section 72a, 72b comprises dual contact beams 76a, 76b that engage a corresponding signal contact post 26 that is inserted therebetween.

[0040] As shown in FIGS. 7 and 8, each of the modules 60a, 60b includes a ground shield 80a, 80b with ground contact springs 82a, 82b that are engageable with corresponding ground contact blades 36 of the header connector. The ground shields 80a, 80b include compliant tail sections 84a, 84b configured to engage ground through-holes in a circuit board (not shown).

[0041] Each of the modules 60a, 60b has a beam 64a, 64b that is receivable in a track in the upper shroud, a projection 65a, 65b that overlies a support on the upper shroud, and a lug 66a, 66b that is receivable in a groove in the lower shroud. Additionally, the modules 60a, 60b have lower beams 68a, 68b, respectively, that are receivable in a track on the lower shroud. The beams 64a, 64b, 68a, 68b, the projections 65a, 65b and the lugs 66a, 66b serve to stabilize and align the module 60a, 60b in the receptacle housing 52.

[0042] Each of the ground shields 80a, 80b has a first upper barb 86a, 86b, a second upper barb 87a, 87b, and a lower barb 88a, 88b, all of which dig into the dielectric housing 52 as the modules 60a, 60b are inserted into the dielectric housing 52 to secure the modules 60a, 60b in the dielectric housing 52. Each ground shield 80a, 80b also has a resilient latch tab 89a, 89b that extends from a folded portion 90a, 90b. The latch tabs 89a, 89b engage a corresponding ledge of the dielectric housing 52 to prevent the modules 60a, 60b from backing out of the dielectric housing 52.

[0043] FIG. 12 is an isometric view of a header connector 100 according to an alternative embodiment of the present invention. The header connector 100 includes a dielectric housing 112 having a main wall 114, an upper shroud 115 and a lower shroud 116. The header connector 100 further includes a plurality of signal contacts 20 and ground contacts 130 that extend through and are secured in the main wall 114. The header connector 100 also includes a mating face 117 that interfaces with a mating face 157 of a corresponding receptacle connector 150 (shown in FIG. 15). Further, the header connector 100 includes a board-mating face 118 that interfaces with a circuit board (not shown) on which the header connector 100 is mounted. The header connector 100 mates with the receptacle connector 150 such that the circuit board to which the header connector 100 mounts is oriented perpendicular to the circuit board, backplane, or other such structure on which the receptacle connector 150 is mounted or otherwise positioned.

[0044] The signal contacts 20 used with the header connector 100 are the same as those used with the header connector 10. The posts 26 of the signal contacts 20, which are matable with a corresponding contact in the receptacle connector 150, are insertable into respective holes 158 in the mating face 157 of the receptacle connector 150 (as shown in FIG. 15).

[0045] FIG. 13 is an isometric view of a ground contact 130 according to an alternative embodiment of the present invention. Similar to the ground contacts 30, two sets of ground contacts 130 are formed so that one set is a mirror image of the other set. The ground contacts 130 are similar to the ground contacts 30, with some variations. Each ground contact 130 includes a tail 132 formed integrally with a compliant section 134, which in turn is formed integrally with a bend portion 137. The bend portion 137 is formed integrally with a blade 136. The tail 132 is oriented at an angle to the plane of the blade 136. The bend portion 137 is provided along one side edge of the blade 136, such that the tail 132 is offset from a central longitudinal axis 135 of the blade 136. As shown in FIG. 13, the plane of the blade 136 may be perpendicular to the plane of the tail 132 and complaint section 134.

[0046] The blade 136, which is also formed integrally with a housing retained portion 140, includes a leading edge 142 and a rear edge 143. The blade 136 is recessed from the housing retained portion 140 such that the leading edge 142 is offset from a leading edge 145 of the housing retained portion 140. Because the blade 136 is recessed from the housing retained portion 140, the main wall retained portion 140 includes an exposed upper edge 138. Due to the recessed nature of the blade 136 from the leading edge of the housing retained portion 140, the blade 136 is not as wide as the blade 36 of the ground contact 30. Additionally, as shown in FIG. 12, the ground contacts 130 may include a notched upper portion 147 to allow for clearance between internal structures when mated with the receptacle connector 150.

[0047] The signal and ground contacts 20 and 130 are arranged in an array in the header connector 100. The array includes a plurality of associated groups, each comprising two signal contacts 20 and one ground contact 130. The two signal contacts 20 in each associated group are associated as signal contact pairs 28 to transmit a pair of differential electrical signals through the header connector 100. One ground contact 130 within an associated group is associated with each signal contact pair 28.

[0048] FIG. 14 is an isometric view of the mating face 117 of the header connector 100 according to an alternative embodiment of the present invention. The signal contact pairs 28 are staggered relative from row to row with respect to one another. That is, the signal contact pairs 28 in row A are staggered relative to the signal contact pairs 28 is row B. Each signal contact pair 28 in one row, for example, row A, is staggered relative to a signal contact pair 28 in an adjacent row, for example, row B. Further, each signal contact pair 28 in one row, for example, row A, is shielded from a signal contact pair in an adjacent row, for example, row B, by a blade 136 of a ground contact 130. That is, an intervening row of blades 136 of ground contacts 130 is positioned between two rows of signal contact pairs 28, such as rows A and B of signal contact pairs 28. Further, the ground contact tails 132 intervene between signal contact tails 122 of signal contact pairs 28 within each row. Thus, each signal contact pair 28 is shielded from other signal contact pairs 28 by ground contacts 30.

[0049] A comparison of blades 36 and 136 (as shown, for example, in FIGS. 2 and 14, respectively) shows that the recessed nature of the blade 136 from the housing retained portion 140 exhibits a more pronounced staggered effect between ground contacts 136. Further, the recessed nature of the blade 136 requires less material for the blades 136, and also allows for increased space within the header connector 100.

[0050] FIG. 15 is an isometric view of a portion of a receptacle connector 150 according to an alternative embodiment of the present invention. The receptacle connector 150 is similar to the receptacle connector 50 (shown with respect to FIG. 6). The receptacle connector 150 includes a dielectric housing 152 having a main wall 154, an upper shroud 155 and a lower shroud 156. The receptacle connector 150 also includes the mating face 157 having a plurality of holes 158 and slots 159. The holes 158 receive and retain posts 26 of signal contacts 20, while the slots receive and retain blades 136 of ground contacts 130.

[0051] FIG. 16 is a plan view of the mating face 157 of the receptacle connector 150 according to an alternative embodiment of the present invention. The mating face 157 of the receptacle connector 150 is configured to mate with the mating face 117 of the header connector 100. When the receptacle connector 150 is fully mated with the header connector 100, the staggered nature of the associated groups of signal contact pairs 28 and ground contacts 130 with respect to one another shields signal contact pairs 28 in one row from signal contact pairs 28 in an adjacent row.

[0052] FIG. 17 is an isometric view showing one side of a contact module 160a, which is configured to be housed in the receptacle connector 150, according to an alternative embodiment of the present invention. FIG. 18 is an isometric view showing one side of a contact module 160b, which is configured to be housed in the receptacle connector 150, according to an alternative embodiment of the present invention. The contact modules 160a and 160b are similar to each other, but each has a respective pattern of signal contacts corresponding to the pattern of signal contacts 20 in a respective one of the rows in the header connector 100.

[0053] The receptacle connector 150 holds a plurality of contact modules 160a and 160b. Each contact module 160a, 160b includes a dielectric molding 162a, 162b that holds signal contacts and a ground shield. The contact modules 160a, 160b may be assembled by inserting signal contacts 170a, 170b into the dielectric molding 162a, 162b, respectively, and mounting ground shields 180a, 180b onto the opposite sides of the dielectric moldings 162a, 162b, respectively. The ground shields 180a, 180b are mounted onto the dielectric moldings 162a, 162b, respectively, such that an interference fit exists between each ground shield 180a, 180b and its corresponding dielectric molding 162, 162b. Alternatively, the ground shields 180a, 180b may be snapably secured into the dielectric moldings 162a, 162b, respectively.

[0054] FIG. 19 is an isometric view of the contact module 160a from the opposite side of that shown in FIG. 17 according to an alternative embodiment of the present invention. FIG. 20 is an isometric view of the contact module 160b from the opposite side of that shown in FIG. 17 according to an alternative embodiment of the present invention. Each of the contact modules 160a, 160b has a plurality of signal contacts 170a, 170b. Each signal contact 170a, 170b has a receptacle section 172a, 172b at a mating end and a compliant tail section 174a, 174b at a board-mating end. The receptacle sections 172a, 172b include dual contact beams 176a, 176b, respectively, each of which engages a corresponding signal contact post 26 that is inserted therebetween.

[0055] FIG. 21 is an isometric view of a ground shield 180a configured for the contact module 160a according to an alternative embodiment of the present invention. FIG. 22 is an isometric view of a ground shield 180b configured for the contact 160b module according to an alternative embodiment of the present invention. As shown in FIGS. 17 and 18, each of the contact modules 160a, 160b has a ground shield 180a, 180b, respectively. Each ground shield 180a, 180b has ground contact springs 182a, 182b, respectively, which are engageable with corresponding ground contact blades 136 of the header connector 100. Additionally, each ground shield 180a, 180b has a compliant tail section 184a, 184b, respectively, for engaging ground through-holes in a circuit board (not shown). Each ground shield 180a, 180b also has a first upper barb 186a, 186b, a second upper bard 187a, 187b, and a lower barb 188a, 188b, all of which dig into the dielectric housing 152 as the contact module 160a, 160b is inserted into the receptacle housing 150 to secure the contact module 160a, 160b in the receptacle housing 150. Additionally, each ground shield 180a, 180b includes a resilient latch tab 189a, 189b, respectively, which extends from a folded portion 190a, 190b. The latch tabs 189a, 189b engage a corresponding ledge of the receptacle housing 150 to prevent the contact modules 160a, 160b from backing out of the receptacle housing 150. Additionally, the ground shields 180a, 180b include protruding members 185a, 187a and 185b, 187b, respectively, which engage corresponding features within the dielectric moldings 162a, 162b, respectively, so that the ground shields 180a, 180b may be secured within the dielectric moldings.

[0056] Each of the contact modules 160a, 160b have upper beams 164a, 164b and lower beams 168a, 168b that are receivable in corresponding tracks in the upper and lower shrouds 155 and 156, a projection 165a, 165b that may cooperate with a support on the upper shroud 155, and a lug 166a, 166b that is receivable in a groove in the lower shroud 156. The beams 164a, 164b, the projections 165a, 165b and the lugs 166a, 166b serve to stabilize and align the contact modules 160a, 160b in the receptacle housing 150.

[0057] Embodiments of the present invention are not limited to the configurations shown. For example, more or less signal and ground contacts may be used within corresponding header and receptacle connectors. That is, the header connector may include more or less rows of signal contact pairs (and associated ground compliant sections), and the receptacle connector may include a corresponding number of contact modules spaced apart according to the orientation of the rows within the header connector. Additionally, the ground contacts may be configured so that the plane of the blade is not perpendicular to the plane of the compliant section of the ground contact. For example, the ground contact may include a semi-cylindrical blade that partially encircles a signal contact pair. Alternatively, the ground contacts may also include walls that extend perpendicularly from the edges of the blade to complete enclose a signal contact pair.

[0058] Thus, embodiments of the present invention provide an electrical connector that exhibits improved signal characteristics in terms of impedance, interference, noise and jitter. Because differential pairs are shielded from one another both physically and electrically (by ground contacts), the effects of impedance, interference, noise and jitter are diminished. Embodiments of the electrical connector electrical connector may accommodate a high number of signal contacts, while minimizing interference, noise and jitter among the signal contacts, due to the staggered nature of the rows of signal contact pairs and ground contacts within the electrical connector.

[0059] While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.