Patent Publication Number: US-9407046-B1

Title: Electrical connector assembly

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to electrical connector assemblies for high speed fiber optical and copper communications. 
     It is known to provide a metal cage with a plurality of ports, whereby transceiver modules are pluggable therein. Several pluggable module designs and standards have been introduced in which a pluggable module plugs into a receptacle which is electronically connected to a host circuit board. For example, a well-known type of transceiver developed by an industry consortium is known as a gigabit interface converter (GBIC) or serial optical converter (SOC) and provides an interface between a computer and a data communication network such as Ethernet or a fiber network. These standards offer a generally robust design which has been well received in industry. 
     It is desirable to increase the operating frequency of the network connections. Electrical connector systems that are used at increased operating speeds present a number of design problems, particularly in applications in which data transmission rates are high, e.g., in the range above 10 Gbps (Gigabits/second). One concern with such systems is reducing electromagnetic interference (EMI) emissions. Another concern is reducing operating temperatures of the transceivers. 
     In conventional designs, thermal cooling is achieved by using a heat sink and/or airflow over the shielding metal cage surrounding the receptacles. However, the thermal cooling provided by conventional designs is proving to be inadequate, particularly for the transceivers in the lower row of a stacked configuration. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, an electrical connector assembly is provided including a cage member having a plurality of walls defining an upper port and a lower port configured to receive pluggable modules therein. The walls define side walls along sides of the upper and lower ports. The walls are manufactured from a metal material and provide electrical shielding for the upper port and the lower port. The walls define a port separator extending between the side walls below at least one of the upper port and the lower port. The port separator has an upper plate and a lower plate extending between the side walls of the cage member. The port separator has a plurality of channel walls extending between the upper plate and the lower plate to divide the port separator into a plurality of channels. The channels are open at a front and a rear of the port separator to direct airflow through the port separator. 
     In a further embodiment, an electrical connector assembly is provided including a cage member having a plurality of walls defining an upper port and a lower port configured to receive pluggable modules therein. The walls define side walls along sides of the upper and lower ports. The walls are manufactured from a metal material and provide electrical shielding for the upper port and the lower port. The walls define a lower port separator extending between the side walls below the lower port. The lower port separator has an upper plate and a lower plate extending between the side walls of the cage member. The lower port separator has a plurality of channel walls extending between the upper plate and the lower plate to divide the lower port separator into a plurality of channels. The channels are open at a front and a rear of the lower port separator to direct airflow through the lower port separator. The walls define an upper port separator extending between the side walls between the upper port and the lower port. The upper port separator has an upper plate and a lower plate extending between the side walls of the cage member. The upper port separator has a plurality of channel walls extending between the upper plate and the lower plate to divide the upper port separator into a plurality of channels. The channels are open at a front and a rear of the upper port separator to direct airflow through the upper port separator. 
     In a further embodiment, an electrical connector assembly is provided including a cage member having a plurality of walls defining an upper port and a lower port configured to receive pluggable modules therein through a front end of the cage member. The walls define side walls along sides of the upper and lower ports. The walls are manufactured from a metal material and provide electrical shielding for the upper port and the lower port. A communication connector is disposed within the cage member at a rear end of the cage member and positioned to mate with the pluggable modules when the pluggable modules are inserted into the upper and lower ports. The walls define a port separator extending between the side walls below at least one of the upper port and the lower port. The port separator has an upper plate and a lower plate extending between the side walls of the cage member. The port separator has a plurality of channel walls extending between the upper plate and the lower plate to divide the port separator into a plurality of channels. The channels are open at the front end and the rear end of the cage member to direct airflow through the cage member. Portions of the channels pass between the communication connector and the corresponding side walls. The walls define port flanks extending between the side walls and the corresponding upper port or the lower port. Each port flank has a plurality of channel walls dividing the port flank into a plurality of channels being open at the front end and the rear end of the cage member to direct airflow through the cage member with portions of the channels passing between the communication connector and the corresponding side walls. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of an electrical connector assembly formed in accordance with an exemplary embodiment. 
         FIG. 2  is a front perspective view of a communication connector of the electrical connector assembly shown in  FIG. 1 . 
         FIG. 3  illustrates an exemplary embodiment of a pluggable module for use with electrical connector assembly shown in  FIG. 1 . 
         FIG. 4  is a partial sectional view of the electrical connector assembly showing a port separator thereof. 
         FIG. 5  is a partial sectional view of the electrical connector assembly showing port flanks thereof. 
         FIG. 6  is a front view of the electrical connector assembly showing the port separators and port flanks. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a front perspective view of an electrical connector assembly  100  formed in accordance with an exemplary embodiment. The electrical connector assembly  100  includes a cage member  102  and a communication connector  104  received in the cage member  102 . Pluggable modules  106  are configured to be loaded into the cage member  102  for mating with the communication connector  104 . The communication connector  104  is intended for placement on a circuit board, such as a motherboard, and is arranged within the cage member  102  for mating engagement with the pluggable modules  106 . 
     The cage member  102  is a shielding, stamped and formed cage member that includes a plurality of shield walls  108  that define multiple ports  110 ,  112  for receipt of the pluggable modules  106 . In the illustrated embodiment, the cage member  102  constitutes a stacked cage member having the ports  110 ,  112  in a stacked configuration. The port  110  defines an upper port positioned above the port  112  and may be referred to hereinafter as upper port  110 . The port  112  defines a lower port positioned below the port  110  and may be referred to hereinafter as lower port  112 . Any number of ports may be provided in alternative embodiments. In the illustrated embodiment, the cage member  102  includes the ports  110 ,  112  arranged in a single column, however, the cage member  102  may include multiple columns of ports  110 ,  112  in alternative embodiments (for example, 2×2, 3×2, 4×2, 4×3, etc.). In other alternative embodiments, the cage member  102  may include a single port or may include ports arranged in a single row (for example, non-stacked). 
     The cage member  102  includes a top wall  114 , a lower wall  116 , a rear wall  118  and side walls  120 ,  122 , which together define the general enclosure or outer perimeter for the cage member  102 . Optionally, at least a portion of the lower wall  116  may be open to allow the communication connector  104  to interface with the circuit board. In an exemplary embodiment, the shield walls  108  may include a plurality of airflow openings or channels to allow airflow therethrough, such as from front to back, back to front and/or side to side. The airflow openings help cool the shield walls  108 , the ports  110 ,  112  and/or the pluggable modules  106 . The airflow openings may have any size and shape. In an exemplary embodiment, the size, shape, spacing and/or positioning of the airflow openings may be selected with consideration to thermal performance, shielding performance (e.g. electromagnetic interference (EMI) shielding), electrical performance, or other design considerations. 
     In an exemplary embodiment, the cage member  102  includes port flanks  124  on opposite sides of the ports  110 ,  112 . The port flanks  124  are positioned between the ports  110 ,  112  and the corresponding side walls  120 ,  122 . The port flanks  124  have openings or channels  126  defined by channel walls  128  that define thermal vents through the cage member  102  to allow airflow entirely through the cage member  102 . The port flanks  124  provide airflow through the cage member  102  for cooling the components of the electrical connector assembly  100 . For example, the airflow through the port flanks  124  may cool the walls  108  defining the port flanks  124  and/or the ports  110 ,  112 , which may transfer heat from the pluggable modules  106  and/or the communication connector  104 . 
     The cage member  102  is subdivided by one or more port separators  130 ,  132 . The port separators  130 ,  132  extend along the ports  110 ,  112  (for example, either above the corresponding port  110 ,  112  or below the corresponding port  110 ,  112 ). In the illustrated embodiment, the cage member  102  includes an upper port separator  130  below the upper port  110  and a lower port separator  132  below the lower port  112 . The upper port separator  130  is positioned between the upper and lower ports  110 ,  112  such that the upper port separator  130  defines a lower portion of the upper port  110  and an upper portion of the lower port  112 . The lower port separator  132  is positioned between the lower port  112  and the circuit board. The port separators  130 ,  132  are open to allow airflow through the cage member  102 . The cage member  102  may include any number of port separators in alternative embodiments, including a single port separator. In various embodiments, a port separator (not shown) may be provided above the upper port  110 . The channels or openings defined by the port separators  130 ,  132  define thermal vents through the cage member  102  to allow airflow entirely through the cage member  102 . The port separators  130 ,  132  provide pathways for airflow through the cage member  102  for cooling the components of the electrical connector assembly  100 , such as by convection. For example, the airflow through the port separators  130 ,  132  may cool the walls  108  defining the port separators  130 ,  132  and/or the ports  110 ,  112 , which may transfer heat from the pluggable modules  106  and/or the communication connector  104 . 
       FIG. 2  is a front perspective view of the communication connector  104 . The communication connector  104  includes a housing  200  defined by an upstanding body portion  202  having sides  204 ,  206 , a lower face  208  configured to be mounted to the motherboard, and a mating face  210 . Upper and lower extension portions  212  and  214  extend from the body portion  202  to define the mating face  210 . A recessed face  216  is defined between the upper and lower extension portions  212 ,  214  at the front face of the body portion  202 . 
     Circuit card receiving slots  220  and  222  extend inwardly from the mating face  210  of each of the respective upper and lower extension portions  212 ,  214 , and extend inwardly to the body portion  202 . The circuit card receiving slots  220 ,  222  are configured to receive a card edge of the pluggable module  106  (shown in  FIG. 3 ). A plurality of contacts  224  are held by the housing  200  and are exposed within the circuit card receiving slots  220 ,  222  for mating with the corresponding pluggable module  106 . The contacts  224  extend from the lower face  208  for termination to the motherboard. For example, the ends of the contacts  224  may constitute pins that are loaded into plated vias of the motherboard. Alternatively, the contacts  224  may be terminated to the motherboard in another manner, such as by surface mounting to the motherboard. 
       FIG. 3  illustrates an exemplary embodiment of the pluggable module  106  for use with electrical connector assembly  100  (shown in  FIG. 1 ). In the illustrated embodiment, the pluggable module  106  constitutes a small form-factor pluggable (SFP) module; however other types of pluggable modules or transceivers may be used in alternative embodiments. The pluggable module  106  includes a metal body or shell  230  holding a circuit card  232  at a mating end  234  thereof for interconnection into one of the slots  220  or  222  (shown in  FIG. 2 ). The pluggable module  106  would further include an electrical interconnection within the module to an interface at end  236 , such as a copper interface in the way of a modular jack, or to a fiber optic connector for further interfacing. The pluggable module  106  may include thermal interface features  238  configured to provide a thermal interface with the cage member  102  (shown in  FIG. 1 ), such as for direct thermal contact or communication with the corresponding port separator  130 ,  132  (shown in  FIG. 1 ). The thermal interface features  238  may be fins extending from the shell  230 . The pluggable module may include a latching feature for securing the pluggable module  106  in the cage member  102 . The latching feature may be releasable for extraction of the pluggable module  106 . Other types of pluggable modules or transceivers may be utilized in alternative embodiments. 
       FIG. 4  is a partial sectional view of the electrical connector assembly  100  taken through the upper port separator  130 ; however the lower port separator  132  may include similar or identical features and like reference numerals may be used to reference like components thereof. The port separator  130  is defined by the walls  108  of the cage member  102 . The port separator  130  extends between a front  134  and a rear  135 . The port separator  130  has an upper plate  136  (shown in  FIG. 6 , the upper plate  136  of the lower port separator  132  is shown in  FIG. 4 ) and a lower plate  138  extending between the side walls  120 ,  122 . The upper and lower plates  136 ,  138  are spaced apart from one another defining an air gap therebetween that allows airflow through the cage member  102  between the front  134  and the rear  135 . The upper and lower plates  136  may define portions of the corresponding ports  110 ,  112 . 
     The port separator  130  has a plurality of channel walls  140  extending between the upper plate  136  and the lower plate  138  to divide the port separator  130  into a plurality of channels  142 . In an exemplary embodiment, the channel walls  140  are oriented vertically; however the channels walls  140  may be oriented at other orientations, including horizontally, in alternative embodiments. In an exemplary embodiment, the channel walls  140  are interior of the walls  108  of the cage member  102 . As such, the channels  142  are interior of the cage member  102 . The channels  142  are open at the front  134  and the rear  135  of the port separator  130  to direct airflow through the port separator  130 . The channel walls  140  divide the air gap of the port separator  130  into the individual channels  142 . Optionally, the channel walls  140  may extend the entire length between the front  134  and the rear  135  of the port separator  130 . Alternatively, any or all of the channel walls  140  may extend only partially between the front  134  and the rear  135 . The channel walls  140  may be recessed inward from the front  134  and/or from the rear  135 . Optionally, the channels  142  may have variable widths  144  along lengths thereof defined between the front  134  and the rear  135  of the port separator  130 . For example, in the illustrated embodiment, portions of the channel walls  140  near the front  134  and near the rear  135  are oriented parallel to the side walls  120 ,  122 , but the channel walls  140  include convergent sections  146  that change spacings  148  between the channel walls  140 . As such, the channels  142  may be wider at the front  134  and narrower at the rear  135 . Other arrangements are possible in alternative embodiments. Having variable width channels  142  may affect flow rate of the airflow in the channels  142 . 
     In an exemplary embodiment, each of the channels  142  has an air inlet  150  and an air outlet  152 . The airflow system may be set up such that the air flows from the front of the cage member  102  to the rear of the cage member  102 . In such embodiments, the air inlets  150  are provided at a front end  154  of the cage member  102  while the air outlets  152  are provided at a rear end  156  of the cage member  102 . However, the airflow system may be set up such that the air flows in the opposite direction from the rear end  156  of the cage member  102  to the front end  154  of the cage member  102 . Optionally, the cage member  102  may have EMI reducers at the air inlet  150  and/or the air outlet  152 . For example, the cage member  102  may include cross members that span across the channels  142  to reduce the size of the openings at the air inlet  150  and/or the air outlet  152 . 
     The communication connector  104  is disposed within the cage member  102  at the rear end  156  of the cage member  102  and positioned to mate with the pluggable modules  106  when the pluggable modules  106  are inserted into the ports  110  (shown in  FIG. 1 ),  112 . In an exemplary embodiment, portions of the channels  142  pass between the communication connector  104  and the corresponding side walls  120 ,  122 . Optionally, multiple channels  142  pass between the communication connector  104  and each side wall  120 ,  122 . Optionally, at least one of the channel walls  140  defines a diverter wall  158  to divert the airflow from a front  226  of the communication connector  104  to the corresponding side  204 ,  206  of the communication connector  104  or vice versa. The diverter walls  158  ensure that the airflow does not flow into the front  226  of the communication connector  104 , which would cause a pressure loss in the airflow. The channel walls  140  transition the airflow from the center of the port separator  130  to the outer sides of the port separator  130  (for example, the small space between the communication connector  104  and the side walls  120 ,  122 ) to allow the airflow to bypass the communication connector  104 . The airflow flows along the sides  204 ,  206  and is expelled at the rear end  156 . The channel walls  140  provide smooth transitions for the airflow to reduce flow resistance. 
     The channel walls  140  have module segments  160  near the front  134  of the port separator  130  and connector segments  162  near the rear  135  of the port separator  130 . The convergent sections  146  may transition between the module segments  160  and the connector segments  162 . The convergent sections  146  may form part of the module segments  160  and/or part of the connector segments  162 . The module segments  160  are generally aligned (for example, aligned front to back) with the pluggable module  106  while the connector segments  162  are generally aligned (for example, aligned front to back) with the communication connector  104 . The spacing  148  between the module segments  160  may be wider than the spacing  148  between the connector segments  162  as the connector segments  162  must pass through the small space between the communication connector  104  and the side walls  120 ,  122 . 
       FIG. 5  is a partial sectional view of the electrical connector assembly  100  taken through the port flanks  124 . The port flanks  124  are defined by the walls  108  of the cage member  102 . The port flanks  124  extend between the front end  154  and the rear end  156 . The port flanks  124  may be positioned above or below the port separators  130 . The port flanks  124  extend along opposite sides  240 ,  242  of the shell  230  of the pluggable module  106 . The channel walls  128  of the port flanks  124  may extend between the upper plate  136  of the lower port separator  132  and the lower plate  138  (shown in  FIG. 6 ) of the upper port separator  130  (shown in  FIG. 6 ) to divide the port flanks  124  into the individual channels  126 . The channels  126  are open at the front end  154  and the rear end  156  to direct airflow through the cage member  102 . Optionally, the channel walls  128  may extend the entire length between the front end  154  and the rear end  156 . Optionally, the channels  126  may have uniform widths along lengths thereof. For example, in the illustrated embodiment, the channel walls  128  are oriented parallel to the side walls  120 ,  122 ; however other orientations are possible in alternative embodiments. 
     The port flanks  124  provide pathways for airflow along the pluggable module  106  and along the communication connector  104 . The airflow is used for heat dissipation from the pluggable module  106  and/or the communication connector  104 . Connector portions of the channels  126  pass between the communication connector  104  and the corresponding side walls  120 ,  122 . Module portions of the channels  126  pass between the pluggable module  106  and the corresponding side walls  120 ,  122 . In an exemplary embodiment, multiple channels  126  pass between the communication connector  104 /pluggable module  106  and each side wall  120 ,  122 . The channel walls  128  are in thermal communication with corresponding plates  136 ,  138  of the port separators  130 ,  132  to dissipate heat from the system as the air flows past the channel walls  128 . 
       FIG. 6  is a front view of the electrical connector assembly  100 . The pluggable modules  106  are shown loaded into the cage member  102 . In an exemplary embodiment, the upper plate  136  of each port separator  130 ,  132  is configured to be in direct thermal contact or communication with the pluggable module  106  associated with the upper port  110  and the lower port  112 , respectively. For example, the port separators  130 ,  132  have thermal interface features  170  that interface with corresponding thermal interface features  238  of the pluggable modules  106 . In the illustrated embodiment, the thermal interface features  170  are fins with grooves defined therebetween that extend from the upper plates  136 . The thermal interface features  238  are received in corresponding grooves such that the fins  170  are in direct thermal engagement with the thermal interface features  238 . The lower plates  138  may be in direct thermal communication with corresponding pluggable modules  106  in other embodiments. Having the various walls and plates in thermal communication with the pluggable modules  106  allows efficient heat dissipation from the pluggable modules  106  as the heat may be transferred into any or all of the walls/plates, which may then be cooled by airflow across the walls/plates. 
     Other arrangements of the port separators  130 ,  132  are possible in alternative embodiments. For example, while the port separators  130 ,  132  are illustrated below the ports  110 ,  112 , respectively, it is possible that the port separators  130 ,  132  are arranged above the ports  110 ,  112 , respectively, in alternative embodiments. Optionally, only one port separator  130  may be provided between the ports  110 ,  112  without the lower port separator  132  in various embodiments. In other various embodiments, three port separators may be provided (for example, one above the upper port  110 , one between the ports  110 ,  112  and one below the lower port  112 ). Other arrangements are possible when other ports are provided. 
     Optionally, in embodiments having multiple columns of ports  110 ,  112  (For example, 2×2, 2×4, etc.), the walls  108  of the cage member  102  may include a single divider wall between such ports  110 ,  112 . The channels  126 ,  142  of the port flanks  124  and port separators  130  are located between the divider wall and the pluggable modules  106 . Optionally, the cage member  102  may include a common upper wall and a common lower wall extending along all of the ports  110 ,  112 . 
     During use, the pluggable modules  106  generate heat. It is desirable to remove the heat generated by the pluggable modules  106  so that the pluggable modules  106  can operate at higher performance levels. The heat generated by the pluggable modules  106  is thermally transferred to the cage member  102 . Airflow along the walls  108  (for example, along the plates  136 ,  138 , along the channel walls  128 , along the channel walls  140 , along the side walls  120 ,  122 , and the like) cools the cage member  102 , allowing more heat transfer from the pluggable modules  106 . The airflow through the cage member  102  may be forced, such as by a fan or other component mounted proximate to the cage member  102 . The airflow helps to reduce the temperature of the pluggable modules  106 . 
     The thermal efficiency of the cage member  102 , and thus the amount of heat transfer from a particular port  110 ,  112 , is at least partially dependent on the amount of airflow through the cage member  102 . Providing the channels  126  and the channels  142  between and around the ports, including the lower port  112 , increases the amount of heat transfer from the pluggable modules  106 . Optionally, the side walls  120 ,  122  may include openings or vents that allow airflow therethrough. The channel walls  128 ,  140  may include openings or vents to allow airflow between the channels  126 ,  142 . 
     Direct heat transfer into the walls  108  of the cage member  102  allows efficient heat transfer from the pluggable module  106 . The channel walls  140  are thermally coupled to the upper plates  136  to draw heat therefrom. Similarly, the channel walls  128  of the port flanks  124  are thermally coupled to the upper plates  136  to draw heat therefrom. The airflow through the channels  142  of the port separators  130 ,  132  and through the channels  126  of the port flanks  124  cools the cage member  102 . The channels  126 ,  142  promote venting and/or cooling of the interior of the chassis where the electrical connector assembly  100  and printed circuit board are located. Optionally, the lower plate  138  of the upper port separator  130  is configured to be in direct thermal contact with the pluggable module  106  associated with the lower port  112  to dissipate heat from the pluggable module  106  in the lower port  112 . The channel walls  140  are thermally coupled to the lower plate  138  to draw heat from the lower plate  138 . 
     In some embodiments, the thermal vents created by the channels  126 ,  142  may encompass at least 50% of the surface area defined by the front end  154  of the cage member  102 . In some embodiments, the thermal vents may encompass at least 75% or more of the surface area. For example, the port separators  130 ,  132  may have a larger width and/or height as compared to the ports  110 ,  112 . 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. 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. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.