Abstract:
A cable assembly is provided that includes a wire bundle having individual wires, and first and second connectors provided on first and second ends of said wire bundle. The first and second connectors include first and second circuit boards, respectively. The first and second ends of the wires are terminated on the first and second circuit boards in accordance with different first and second wire management configurations, respectively.

Description:
BACKGROUND OF THE INVENTION 
   This invention relates generally to cable assemblies, and more particularly, to wire management configurations for cable assemblies. 
   Modern electronic devices use cable assemblies to link various electronic components. Conventional cable assemblies typically include a cable having a wire bundle that extend between electrical connectors. In some applications, the electrical connectors include circuit boards that carry and are electrically coupled to various electronic components. The individual wires in the wire bundle are electrically and mechanically coupled at signal contacts on the circuit boards in the respective electrical connectors. The wires may be coupled to the circuit boards as differential pairs. As connectors and the circuit boards therein are reduced in size, less and less room is available for the wires to enter the connectors. Hence, it has become increasingly of interest to arrange the wires in a space efficient manner where the wires enter the rear of the connector. 
   Conventional cable assemblies utilize identical circuit boards in each of the electrical connectors. Hence, the wires in each cable assembly extend between the electrical connectors and are coupled to the same type of circuit board at opposite electrical connectors. However, during assembly, the wires do not readily align with the signal contacts of the opposing circuit boards. Accordingly, the wires at one end of the cable assembly are rearranged until aligning with associated contacts on the opposing circuit board. Rearranging the wires increases the manufacturing time and complexity and increases the envelope of the wires, thereby increasing the overall cost and size of the cable assembly. 
   BRIEF DESCRIPTION OF THE INVENTION 
   In accordance with an embodiment of the present invention, a cable assembly is provided that includes a wire bundle having individual wires that may be arranged in differential pairs, and first and second connectors provided on first and second ends of the wire bundle. The first and second connectors include first and second circuit boards, respectively. The first and second ends of the wires are terminated on the first and second circuit boards in accordance with different first and second wire management configurations, respectively. Optionally, the first and second wire management configurations may be inverse configurations of one another. Optionally, the first and second circuit boards may have wire management ends attached to the first and second ends of the wires, respectively, and opposing ends forming separable interfaces. 
   One example of a wire management configuration may include differential pairs of the wires designated 1 to N, wherein the 1 to N differential pairs of wires may be joined to the first circuit board in a clockwise pattern about the first circuit board, and wherein the 1 to N differential pairs of wires may be joined to the second circuit board in a counter-clockwise pattern about the second circuit board. 
   Another example of a wire management configuration may include first and second circuit boards having contact layouts that include upper inner, upper outer, lower inner, and lower outer positions, wherein the wire bundle has a first differential pair of wires joined to the first circuit board at the upper inner position and to the second circuit board at the lower outer position. 
   Certain embodiments of the present invention may also include the first circuit board having a pair of signal contacts provided on a common side and at a wire management end of the first circuit board, wherein the pair of signal contacts may be interconnected along a pair of traces to a pair of internal signal contacts at a separable interface end of the circuit board, and wherein the pair of interface signal contacts may be located opposite one another on opposite sides of the circuit board. Optionally, the pair of traces may be located on opposite sides of the first circuit board. 
   Certain embodiments of the present invention may also include signal traces on the first circuit board arranged in differential pairs, wherein signal traces of a first differential pair are located on opposite sides of the first circuit board and arranged along a plane extending perpendicularly to the sides of the first circuit board. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a perspective view of a cable assembly formed in accordance with an embodiment of the present invention. 
       FIG. 2  illustrates a top perspective view of a portion of the cable assembly shown in  FIG. 1 . 
       FIG. 3  illustrates a top view of a circuit board used in the cable assembly shown in  FIG. 1 . 
       FIG. 4  illustrates a bottom view of the circuit board shown in  FIG. 3 . 
       FIG. 5  illustrates a top view of another circuit board used in the cable assembly shown in  FIG. 1 . 
       FIG. 6  illustrates a bottom view of the circuit board shown in  FIG. 5 . 
       FIG. 7  illustrates a schematic illustration of a wire management configuration for the circuit board shown in  FIG. 3 . 
       FIG. 8  illustrates a schematic illustration of a wire management configuration for the circuit board shown in  FIG. 5 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  illustrates a perspective view of a cable assembly  100  including a first electrical connector  102 , a second electrical connector  104 , and a cable  106  extending therebetween. The cable  106  includes an insulating cover  108  that circumscribes a wire bundle  110 . The cable  106  has a first end  112  and a second end  114 . The first end  112  is coupled to the first electrical connector  102 , and the second end  114  is coupled to the second electrical connector  104 . The wire bundle  110  includes a plurality of individually shielded wires  116  that may be arranged in differential pairs. Alternatively, the wire bundle may include un-shielded wires or groups of wires. Specifically, the wire bundle  110  includes sixteen wires  116  arranged in eight differential pairs having a helical shape. The wire bundle  110  has six differential pairs extending around the perimeter of the cable  106 , and two differential pairs extending in the center of the cable  106 . Alternatively, the wires  116  could be formed in a different shape, such as, for example, a linear shape. 
   The first electrical connector  102  includes a housing  120  arranged in an upright orientation with an upper shell  122  and a lower shell  124  that extends between an interconnect end  126  and a rear end  128 . The first electrical connector  102  also includes an interconnect cavity  130  located adjacent the interconnect end  126 . The interconnect cavity  130  has a non-uniform envelope that functions as a keying feature to orient the first electrical connector  102  in an upright position with respect to the receptacle. The non-uniform envelope has a trapezoidal shape with a long edge  129  located proximate to the upper shell  122  and extending parallel to a short edge  131  located proximate to the lower shell  124 . A circuit board  132  is operatively positioned in an upright orientation within the interconnect cavity  130 , such that the circuit board  132  can be electrically and mechanically coupled to a receptacle (not shown), or mating connector. The first end  112  of the cable  106  is coupled to the rear end  128  of the first electrical connector  102 . Moreover, the wires  116  extend through the rear end  128  and into the interior portion of the first electrical connector  102  and are electrically coupled to the circuit board  132 , as will be described in detail below. 
   The second electrical connector  104  includes a housing  134  arranged in an upright orientation with an upper shell  136  and a lower shell  138  that extends between an interconnect end  140  and a rear end  142 . The second electrical connector  104  also includes an interconnect cavity  144  located adjacent the interconnect end  130 . The interconnect cavity  144  has a non-uniform envelope that functions as a keying feature to orient the second electrical connector  104  in an upright position with respect to the receptacle. The non-uniform envelope has a trapezoidal shape with a long edge  143  located proximate to the upper shell  136  and extending parallel to a short edge  145  located proximate to the lower shell  138 . A circuit board  146  is operatively positioned in an upright orientation within the interconnect cavity  144 , such that the circuit board  146  can be electrically and mechanically coupled to a receptacle (not shown), or mating connector. The second end  114  of the cable  106  is coupled to the rear end  142  of the second electrical connector  104 . Moreover, the wires  116  extend through the rear end  142  and into the interior portion of the second electrical connector  104  and are electrically coupled to the circuit board  146 , as will be described in detail below. The second circuit board  146  has a different trace arrangement than the first circuit board  132  to facilitate easier routing of the wires  116  between the first and second circuit boards  132  and  146 . 
     FIG. 2  is a perspective view of a portion of the first electrical connector  102  including the lower shell  124  and the circuit board  132 . While the electrical connector shown in  FIG. 2  is described and illustrated in the context of the first electrical connector  102 , it is recognized that the upper and lower shells  122 ,  124 ,  136  and  138  of the first and second electrical connectors  102  and  104  are similar, but receive circuit boards  132  and  146  that have different wire management configurations. As such, like reference numerals will be used to describe like components. The lower shell  124  includes a cavity  148  between the interconnect end  126  and the rear end  128 , and between side walls  150  and  152  extending the length of the housing  120 . The lower shell  124  includes a shelf  154  extending between the side walls  150  and  152  proximate to the interconnect end  126  of the housing  120 . The lower shell  124  also includes keying features  156  extending inwardly from the side walls  150  and  152 . The shelf  154  and the keying features  156  facilitate aligning the circuit board  132  within the housing  120 . 
   The circuit board  132  includes circuit components, shown generally at  158 , that perform signal conditioning upon high speed serial data received from the wires  116 . As shown in  FIG. 2 , the circuit components  158  may be arranged as differential pairs, shown generally at  160 . However, as will be described in detail below, the first circuit board  132  and the second circuit board  146  have different circuit component arrangements to facilitate reducing assembly time of the cable assembly  100 . As shown in  FIG. 2 , the circuit board  132  includes a body  162  having a top signal layer  164 , a bottom signal layer  166 , a top ground layer  168 , and a bottom ground layer  170 , wherein the ground layers each include a horizontal ground plane (not shown). The body  162  also includes a top surface  174 , a bottom surface  176 , a separable interface end  178 , a wire management end  180 . The circuit board  132  has an upright orientation such that the circuit board  132  is located within the housing  120  with the top surface  174  facing the long edge  129  of the interconnect cavity  130  and the bottom surface  176  facing the short edge  131  of the interconnect cavity. Moreover, the separable interface end  178  is located proximate to the interconnect end  126  of the housing  120 . 
   Side edges  182  and  184  extend between the separable interface end  178  and the wire management end  180 . The side edges  182  and  184  include notched out portions  186  that correspond to the keying features  156 . The circuit board  132  is oriented within the cavity  148  such that a portion of the circuit board  132  is contained within the interconnect cavity  130 . Specifically, the circuit board  132  is placed on the shelf  154  and the notched out portions  186  of the circuit board  132  conform to the keying features  156  of the lower shell  124 . As such, the separable interface end  178  is positioned within the interconnect cavity  130  and is oriented to interface with the electrical components of the mating connector (not shown) when the electrical connector  100  and the mating connector are mated. 
     FIG. 3  illustrates a top view of the first circuit board  132 .  FIG. 4  illustrates a bottom view of the first circuit board  132 . As illustrated in  FIGS. 3 and 4 , the first circuit board  132  has a first wire management configuration  188  such that the circuit components  158  are oriented on the first circuit board  132  in a particular pattern. Specifically, the circuit components  158  are electrically and mechanically coupled to the top signal layer  164  on the top surface  174  as shown in  FIG. 3 . Additionally, the circuit components  158  are electrically and mechanically coupled to the bottom signal layer  166  on the bottom surface  176  as shown in  FIG. 4 . Alternatively, the circuit components  158  may have other wire management configurations. 
   The circuit components  158  include a plurality of signal contacts  190 , a plurality of ground contacts  192 , a plurality of interface signal contacts  194 , and a plurality of interface ground contacts  196 . The circuit components  158  are connected to one another by traces  198  extending between the signal contacts  190  and the interface signal contacts  194 , and by a plurality of vias  200  that extend through the circuit board  132  between the top signal layer  164  and the bottom signal layer  166 . 
   The signal contacts  190  and the ground contacts  192  are arranged at the wire management end  180  of the first circuit board  132  such that the wires  116  delivered to the first electrical connector  102  can be coupled directly to the signal contacts  190 . Moreover, the signal contacts  190  are arranged as a differential pair  160  such that two individual signal contacts  190  are placed adjacent one another on a common side of the first circuit board  132 . The adjacent signal contacts  190  are interconnected along a pair of traces  198  to a pair of interface signal contacts  194 . In one embodiment, the interface signal contacts  194  are positioned on opposite sides of the first circuit board  132 , such that one of the interface signal contacts  194  is located on the top signal layer  164  and the other interface signal contact  194  is located on the bottom signal layer  166 . Furthermore, the pair of traces  198  that initially extend from the adjacent signal contacts  190  are partially positioned on opposite sides of the first circuit board  132  such that one of the interface signal contacts  194  is located on the top signal layer  164  and the other interface signal contact  194  is located on the bottom signal layer  166  proximate to the separable interface end  178  of the first circuit board  132 . The traces  198  are transferred or routed to the opposing layer  164  or  166  by the vias  200 . Optionally, the traces  198  may extend along the opposing layers  164  or  166  along a plane that is generally perpendicular to the circuit board plane (not shown). 
   Each differential pair  160  is separated from each other differential pair  160  by a ground contact  192 . This arrangement reduces cross talk between the differential pairs  160 . Optionally, the signals transmitted through the first circuit board  132  may have a single ended arrangement such that each trace  198  carries an independent signal and can function without the need of any other signal having an opposite voltage to balance the electromagnetic fields created by the individual signals. The top and bottom ground layers  168  and  170  provide the single ended coupling of each signal due to the close coupling of the trace  198  to the respective ground layer  168  and  170 . Specifically, the electromagnetic fields of each signal are constrained between the trace  198  and the respective ground layer  168  and  170 . As such, traces  198  can be located in close proximity to other traces  198  and not be located within the primary fields of one another. Therefore coupling and cross talk is limited between the fields. However, two single ended signals may be coupled differentially by sending equal but opposite signals on two separate traces  198 . Furthermore, due to the single ended nature of the signals, the separate signals of the differential pair  160  can be transmitted from any location on the first circuit board  132 . 
     FIG. 5  illustrates a top view of the second circuit board  146  including a top signal layer  202 .  FIG. 6  illustrates a bottom view of the second circuit board  146  including a bottom signal layer  204 . As illustrated in  FIGS. 5 and 6 , the second circuit board  146  has a second wire management configuration  206  such that circuit components  208  are oriented on the second circuit board  146  in a particular pattern. Specifically, the circuit components  208  are electrically and mechanically coupled to the top signal layer  202  as shown in  FIG. 5 . Additionally, the circuit components  208  are electrically and mechanically coupled to the bottom signal layer  204  as shown in  FIG. 4 . Alternatively, the circuit components  208  may have other wire management configurations. 
   The circuit components  208  include a plurality of signal contacts  210  and a plurality of ground contacts  212  positioned on a wire management end  222  of the second circuit board  146 , and a plurality of interface signal contacts  214  and a plurality of interface ground contact  216  positioned on a separable interface end  224  of the second circuit board  146 . The circuit components  208  are connected to one another by traces  218  extending between the signal contacts  210  and the interface signal contacts  214 , and by a plurality of vias  220  that extend through the circuit board  146  between the top signal layer  202  and the bottom signal layer  204 . 
   The signal contacts  210  and the ground contacts  212  are arranged at the wire management end  222  of the second circuit board  146  such that the wires  116  delivered to the second electrical connector  104  can be coupled directly to the signal contacts  210 . Moreover, the signal contacts  210  are arranged differentially such that two individual signal contacts  210  are placed adjacent one another on a common side of the second circuit board  146 . The adjacent signal contacts  210  are interconnected along a pair of traces  218  to a pair of interface signal contacts  214 . In one embodiment, the interface signal contacts  214  are positioned on opposite sides of the second circuit board  146 , such that one of the interface signal contacts  214  is located on the top signal layer  202  and the other interface signal contact  214  is located on the bottom signal layer  204 . Furthermore, the pair of traces  218  that initially extend from the adjacent signal contacts  210  are partially positioned on opposite sides of the second circuit board  146  such that one of the interface signal contacts  214  is located on the top signal layer  202  and the other interface signal contact  214  is located on the bottom signal layer  204  proximate to the separable interface end  224  of the second circuit board  146 . The traces  218  are transferred or routed to the opposing layer  202  or  204  by the vias  220 . Optionally, the traces  218  may extend along the opposing layers  202  or  204  along a plane that is generally perpendicular to the circuit board plane (not shown). 
   Each differential pair  160  is separated from each other differential pair  160  by a ground contact  212 . This arrangement reduces cross talk between the differential pairs  160 . Optionally, the signals transmitted through the second circuit board  146  may have a single ended arrangement such that each trace  198  carries an independent signal and can function without the need of any other signal having an opposite voltage to balance the electromagnetic fields created by the individual signals. 
     FIG. 7  is a schematic illustration of the first wire management configuration  188  showing the wire management end  180  of the first circuit board  132  including the connection of each of the wires  116  and the arrangement of the differential pairs  160 .  FIG. 8  is a schematic illustration of the second wire management configuration  206  showing the wire management end  222  of the second circuit board  146  including the connection of each of the wires  116  and the arrangement of the differential pairs  160 . 
   As illustrated in  FIGS. 7 and 8 , the cable assembly  100  includes sixteen wires  116  and eight differential pairs  160 . The first circuit board  132  has the first wire management configuration  188  and the second circuit board  146  has the second wire management configuration  206 . Specifically, the first wire management configuration  188  and the second wire management configuration  206  are inverse configurations of one another such that the wires  116  extending from the first circuit board  132  readily align with the associated signal contacts  210  and the associated ground contacts  212  of the second circuit board  146 . Moreover, as indicated above, each of the circuit boards  132  and  146  have an upright orientation within the respective housings  120  and  134  (FIG.  1 ). Accordingly, the cable assembly  100  facilitates reducing the need to manipulate and rearrange the wires  116  at the opposite end of the cable  106 . 
   Each of the wires  116  are numbered consecutively from one to sixteen. The wires  116  are coupled to the first and second circuit boards  132  and  146  and arranged as a differential pair  160 . Each differential pair  160  has a ground contact G, such as ground contact  192  ( FIGS. 3 and 4 ) or ground contact  212  ( FIGS. 5 and 6 ), associated therewith. Accordingly, each of the first and second circuit boards  132  and  146  have eight contact layout positions  228 . Specifically, each of the first and second circuit boards  132  and  146  includes a right upper outer position  230 , a right lower outer position  232 , a right upper inner position  234 , a right lower outer position  236 , a left upper inner position  238 , a left lower inner position  240 , a left upper outer position  242 , and a left lower outer position  244  when viewing the wire management end  180  or  222  of the circuit boards  132  and  146 . The sixteen wires  116  are coupled to the first and second circuit boards  132  and  146  in differential pairs  160  in one of the eight contact layout positions  228 . 
   In the exemplary embodiment, the first wire management configuration  188  and the second wire management configuration  206  are inverse configurations of one another such that the differential pairs  160  associated with the first circuit board  132  are transposed with respect to the differential pairs  160  associated with the second circuit board  146 . Specifically, the differential pair  160  coupled to the right upper outer position  230  on the first circuit board  132  is coupled to the left upper outer position  242  on the second circuit board  146  and vice versa. Similarly, the differential pair  160  coupled to the right upper inner position  234  on the first circuit board  132  is coupled to the left upper inner position  238  on the second circuit board  146  and vice versa. Moreover, the differential pair  160  coupled to the right lower outer position  232  on the first circuit board  132  is coupled to the left lower outer position  244  on the second circuit board  146  and vice versa. Similarly, the differential pair  160  coupled to the right lower inner position  236  on the first circuit board  132  is coupled to the left lower inner position  240  on the second circuit board  146  and vice versa. Moreover, the wires associated with each differential pair  160  are inverted on the opposing circuit board  132  or  146 . As such, the differential pairs of wires  116  are joined to the first circuit board  132  in a clockwise pattern (CW) about the first circuit board  132 , while the differential pairs of wires  116  are joined to the second circuit board  146  in a counter-clockwise pattern (CCW) about the second circuit board  146 . Accordingly, the wires  116  are properly aligned between the respective circuit boards  132  and  146 . 
   The above-described embodiments provide a cost effective and reliable means for developing a cable assembly  100 . Specifically, the cable assembly  100  includes a cable  106  extending between two opposing electrical connectors  102  and  104 . The cable  106  houses a wire bundle  110  having a plurality of wires  116  that may be arranged as a differential pair  160 . The wires  116  are electrically and mechanically coupled to circuit boards  132  and  146  in the respective electrical connectors  102  and  104 , and the circuit boards  132  and  146  each have different trace arrangements. Accordingly, the wires  116  in the wire bundle  110  extending from the signal contacts  190  of the first circuit board  132  are aligned in a natural and direct manner with the corresponding signal contacts  210  of the second circuit board  146 . As a result, the assembly time and complexity, and thereby the overall cost of the cable assembly  100 , are reduced, while the mechanical reliability is improved. 
   Exemplary embodiments of a cable assembly  100  are described above in detail. The cable assembly  100  is not limited to the specific embodiments described herein, but rather, components of each cable assembly  100  may be utilized independently and separately from other components described herein. For example, each cable assembly  100  component can also be used in combination with other cable assembly  100  components. 
   While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.