Patent ID: 12199386

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description taken in connection with the accompanying figures and examples, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, applications, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the scope of the present disclosure. Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include “at least one” and a plurality. Further, reference to a plurality as used in the specification including the appended claims includes the singular “a,” “an,” “one,” and “the,” and further includes “at least one.” Further still, reference to a particular numerical value in the specification including the appended claims includes at least that particular value, unless the context clearly dictates otherwise.

The term “plurality”, as used herein, means more than one. When a range of values is expressed, another example includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another example. All ranges are inclusive and combinable.

Lossy materials can be used to change the resonance characteristics of a connector, a connector assembly, a cable assembly, or a data communication assembly that includes any one or more of the above. In general, a material's electrical and magnetic properties can be defined by permittivity ε and permeability which are both frequency dependent. Permittivity ε and permeability μ are complex numbers:

ɛ=ɛ′-ɛ″μ=μ′-μ″
where the real part (′) is related to energy storage and the imaginary part (″) is related to energy loss. Lossy materials can be chosen to have specific permittivity ε and permeability Dopants can be added to a base material to alter the permittivity ε and permeability μ. Dopants can alter the magnitudes of the permittivity ε and permeability μ of the lossy materials, and thus can selectively increase or decrease the dampening effect of the lossy materials at a given operating frequency of the electrical signals. Thus, the dopants can alter the frequency dependency of the lossy materials, and can shift or tune the frequency at which the lossy material is configured to provide electrical shielding. For instance, the lossy material can be configured to absorb electromagnetic interference (EMI) during operation of the electrical connector. By tuning the frequency dependency of the lossy material, the lossy material can function best to provide electrical shielding or absorption at a predetermined specific frequency or range of frequencies, while allowing energy of different frequencies to pass.

The lossy material can be electrically lossy. Alternatively or additionally, the lossy material can be magnetically lossy. Electrically lossy materials can have good broad-band performance over wide frequency ranges, are often electrically conductive (for instance can be made from carbon), can be easy to simulate, and are available as off-the-shelf moldable materials that can be used in static control and plating. Magnetically lossy materials can have a tunable frequency performance. Further, magnetically lossy materials can have greater volumetric efficiency than electrically lossy materials. Thus, a reduced quantity of lossy magnetic material than electrically lossy material can provide a similar effect to that of the electrically lossy material. Further, magnetically lossy materials can be electrically conductive or electrically nonconductive. Conventional magnetically lossy materials are available as crude molded parts and are more complex to simulate.FIG.2is a graph that plots permittivity and permeability as a function of frequency for a typical lossy material. Different lossy materials, of course, will have different plots.

Lossy materials are available in many forms. Lossy materials can be injection moldable. For example, the lossy material can be included in an injection moldable resin that acts a binder for the lossy material. The resin with the lossy material can then be injection molded. Lossy materials can also be dispensable such as epoxies and urethanes. If the lossy material is dispensable, then the lossy materials can be applied to a connector after the connector housing is formed, which is typically formed by injection molding. The lossy material can be applied while the injected-molded housing dries, which is usually is a time during which no additional manufacturing steps can be performed until the housing reaches a certain dryness. The connector housing can be dried using ultra-violet light (UV) or using heat. It is also possible to use a two-phase injection molding process in which the first phase uses an injection molding material without a lossy material and the second phase uses an injection molding material with a lossy material. For example, a first phase can form a housing by injection molding using a material without a lossy material, and in a second phase material with a lossy material can be injection molded to the housing.

As an example, the lossy material can include carbon microcoils (CMCs). The CMCs can include various sizes and shapes, and different types of CMCs can be used together. For example, the CMCs can include a spiral shape with a coil diameter on the order of a micron, a fiber diameter of about 0.01 μm-about 1.0 μm, a coil pitch of about 0.1 μm-about 5.0 μm, and an overall length of about 10 μm-about 10 mm. The spirals can be left handed and/or right handed. The CMCs can have a single-helix structure or a double-helix structure. The fibers of the coils can have a flat shape or a round shape. The coils of the CMCs can be three dimensional. Alternatively, the coils of CMCs can be two dimensional, and thus defined in a single plane. The CMCs can be made by any suitable method, including using different catalysts grains to grow the coils.

In some examples, the lossy material can include CMCs embedded in a dielectric material. For example, the CMCs can be included in a silicon rubber structure. The silicon rubber structure can be configured as a sheet. It is appreciated, however, that other dielectric materials can be used, such as LCP (liquid crystal polymer) or glass reinforced LCP. When the CMCs are mixed with the dielectric material, the CMCs can form a L-C-R circuit network, whereby “L” represents an inductor, “C” represents a capacitor, and “R” represents a resistor. The CMCs and the dielectric material can be used to absorb a portion of the magnetic field produced during operation of an electrical connector. A characteristic of the CMCs in the dielectric material, such as at least one or more up to all of concentration, size, shape, and geometry of the CMCs in the dielectric material can be changed to tune the magnetic absorbing characteristics of the lossy material, including the wavelength (frequency) at which the lossy material is configured to absorb the magnetic field. For example, changing the coil diameter or coil length can tune the frequency at which the lossy material absorbs the magnetic field. Alternatively or additionally, changing the dielectric constant (DK) of the dielectric material of the lossy material can change the frequency at which the lossy material absorbs the magnetic field.

In other examples, the lossy material can be configured as a polymer and a plurality of nanoparticles embedded in the polymer. The polymer can be configured as ethylene tetrafluoroethylene (ETFE) in one example, or any suitable alternative polymer. The particles can be iron in one example, or any alternative material suitable for such that the resulting lossy material is configured to absorb magnetic field at a frequency. The iron particles can be present in a range of approximately 20% to approximately 45% by weight, such as approximately 40% by volume, such that the resulting lossy material is electrically nonconductive. However, it is envisioned that the lossy material can alternatively have a sufficient quantity of iron particles such that the lossy material is electrically conductive. The lossy material can further include graphene embedded in the polymer if desired to increase the electrical conductivity of the lossy material. The iron particles can be iron spheres in one example. For instance all particles can be iron. As an alternative to iron, the lossy material can include ceramic particles embedded in polymer at any desired concentration to produce an electrically nonconductive lossy material. At least one of the size, quantity, shape, and composition of the particles embedded in the polymer can be changed so as to tune the frequency at which the lossy material absorbs the magnetic field.

Some electrical connectors include electrically conductive shields to provide electrical shielding between adjacent signal contacts or differential signal pairs. However, such electrically conductive shields typically function by containing electrical fields and directing electrical currents. Thus, such electrically conductive shields are typically ineffective against magnetic fields, can become a source of resonances at some frequencies, and usually work best when grounded. Lossy materials can be electrically conductive or electrically non-conductive. Further, lossy materials function by containing or absorbing fields and by reflecting and/or dissipating energy internally. Thus, lossy materials can provide shielding with respect to magnetic fields. For instance, lossy material can be configured to absorb magnetic fields. Further, the lossy material can be grounded in some examples. In other examples, the lossy material can be ungrounded.

Lossy materials can be applied to different portions or locations of an electrical connector to alter the electrical connector's resonance characteristics. For example, the addition of a lossy material can shift resonant frequency and/or can reduce the resonant peaks as shown inFIGS.3and4. InFIG.3, a hot melt, which has a narrow frequency band, is used as the lossy material (identified as “material” inFIG.3). InFIG.4, a rubberized sheet, which has a wide frequency band, is used as the lossy material (identified as “material” inFIG.4). The lossy material can shift the resonant frequency to a frequency that is out of the desired operating frequency range of the electrical connector.

In some examples, and in all examples described herein, the lossy material can be an epoxy. For instance, the epoxy can be an electrically conductive epoxy. Further, the lossy material can be applied to different locations of an electrical connector. In some examples, the lossy material can be dispensed using computer numerical control (CNC). Thus, the application of the lossy material can be easily and quickly customized, thereby applying the epoxy at predetermined locations of the electrical connector, or components configured to be included in the electrical connector, including one or more of a connector housing, one or more electrical contacts, and a leadframe housing.

Referring now toFIG.5, an electrical connector20can include an electrically insulative connector housing22and a plurality of electrical contacts24that are supported by the connector housing22. In one example, the electrical contacts24can be press-fit or otherwise mechanically attached to the connector housing22. Alternatively, the electrical contacts24can be insert molded in the connector housing22. Each of the electrical contacts24can include a contact body that defines a mating end26and a mounting end28opposite the mating end26. Each of the contact bodies, and thus the electrical contacts24can further include an intermediate portion27that extends from the mating end26to the mounting end28. Thus, the mounting end28can extend from a first end of the intermediate portion27, and the mating end26can extend from a second end of the intermediate portion27opposite the first end. The contact bodies, and thus the electrical contacts24, can further define a tip29that defines a distal end of contact body. The tip29can extend out from the mating end26, such that the mating end26is disposed between the intermediate portion of the contact and the tip29. The mounting ends28can be configured to be mounted to a first electrical device, which can be configured as a substrate. The substrate, in turn, can be configured as a printed circuit board in some examples. Thus, the connector housing22can define a mounting interface23that is configured to face the underlying substrate when the electrical connector20is mounted to the underlying substrate.

The mating ends26can be configured to mate with respective electrical contacts of a second electrical connector when the electrical connector20is mated with the second electrical connector. In particular, the electrical connector20can mate with the second electrical connector along a mating direction. The mating ends26can define a separable interface with the respective electrical contacts of the second electrical connector. Thus, the electrical connector20can unmate from the second electrical connector along an unmating direction that is opposite the mating direction. Both the mating direction and the unmating direction can be oriented along a longitudinal direction L.

The electrical contacts24can be arranged along a row32, which can be oriented along a lateral direction A that is perpendicular with respect to the longitudinal direction L. The connector housing22can include divider walls30disposed between the mating ends26of adjacent pairs of electrical contacts24. The pairs of electrical contacts24can define differential signal pairs in one example. Alternatively, the electrical signal contacts can be single ended. In this regard, the divider walls30can be disposed between adjacent electrical contacts24, or disposed between any number of adjacent electrical contacts24as desired. Thus, it can be said that the divider walls30can be disposed between at least first and second electrical contacts24of the electrical connector20. The electrical contacts24can be configured as signal contacts. Alternatively, one or more of the electrical contacts24can be configured as ground contacts. Alternatively still, the electrical connector20can be devoid of ground contacts. The connector housing22can further extend along a transverse direction T that is perpendicular with respect to each of the longitudinal direction and the lateral direction A. In some examples, the electrical contacts24can be arranged in multiple rows32that are spaced from each other along the transverse direction T that is perpendicular with respect to each of the longitudinal direction and the lateral direction A.

The connector housing22can define a mating interface25that is typically either received in or received by a complementary mating interface of the second electrical connector when the electrical connector20is mated with the second electrical connector. In this regard, an electrical connector assembly can include the electrical connector20, which can be referred to as a first electrical connector, and the second electrical connector. The electrical connector20can be mounted to the underlying substrate so as to define a data communication assembly. When the electrical connector is mounted to the underlying substrate and mated with the second electrical connector, the electrical connector20can place the substrate and the second electrical connector in data communication with each other. Thus, the electrical contacts24can transmit signals between the substrate and the second electrical connector at an operating frequency.

The mating ends26and mounting ends28can be disposed opposite each other along the longitudinal direction L and oriented along the longitudinal direction L. Thus, the electrical contacts24can be referred to as vertical contacts, and the electrical connector20can be referred to as a vertical electrical connector. Alternatively, the mating ends26and mounting ends28can be oriented perpendicular to each other, such that the electrical contacts24define right-angle contacts, and the electrical connector20can be referred to as a right-angle electrical connector as described in more detail below with respect toFIGS.8A-9F.

As illustrated inFIG.5, the electrical connector20can include a lossy material64that is tuned to absorb magnetic field substantially at the operating frequency of the electrical connector20. The word “substantially” with respect to frequency includes the stated frequency along with frequencies within five GHz above the stated frequency and five GHz below the stated frequency (+/−5 GHz). In one example, the connector housing22can include the lossy material64. In particular, the connector housing22can include a housing body31and the lossy material64carried by the housing body31. In particular, the lossy material64can be embedded in the housing body31. Alternatively or additionally, the lossy material64can be disposed on an outer surface of the housing body31. The lossy material64can be magnetically absorbing. In one example, the lossy material64can be electrically conductive. For instance, the lossy material64can have an electrical conductivity greater than 1 Siemens per meter up to substantially 6.1 times 10{circumflex over ( )}7. Alternatively, the lossy material64can be electrically nonconductive. For instance, the lossy material64can have an electrical conductivity that ranges from 1 Siemens per meter to substantially 1 times 10{circumflex over ( )}−17.

The housing body31of the connector housing22can be electrically insulative, can support the electrical contacts24, and can define the mounting interface23and the mating interface25. The housing body31, and thus the connector housing22, can support the electrical contacts directly. Alternatively, as will be described in more detail below, the housing body31, and thus the connector housing22, can support the electrical contacts indirectly. For instance, the housing body31can support at least one leadframe assembly that, in turn, includes at least some or all of the electrical contacts24.

For instance, as illustrated inFIG.5, the lossy material64can be disposed on at least one of the divider walls, including a plurality up to an entirety of the divider walls30. In one example, the lossy material64can be embedded in the at least one divider wall30. Thus, the lossy material64can be disposed between adjacent pairs of electrical contacts24in the manner described above. The lossy material64can be configured as an insert, or a coating one example. Alternatively, the lossy material64can be insert molded in the divider walls30. The lossy material64can be oriented along the longitudinal direction L and the transverse direction T. The lossy material64can have a largest dimension in the longitudinal direction L. The longitudinal direction L can be oriented perpendicular to the mounting interface23of the connector housing22. It should be appreciated, of course, that the lossy material64can be sized and shaped in any suitable alternative manner as desired. Alternatively, connector housing22can have at least one void defined therein, and the lossy material64can be inserted into the at least one void. The at least one void can be a single void or a plurality of voids as desired. Alternatively or additionally, the lossy material64can be applied to one or both outer surfaces of the divider walls30that face a respective one of the electrical contacts24.

The lossy material64can be aligned with at least a portion of the electrical contacts24along the lateral direction A. Thus, a straight line that passes through the at least a portion of the electrical contacts24also passes through the lossy material64. The at least a portion of the electrical contacts24can include the mating ends26. Alternatively or additionally, the at least a portion of the electrical contacts24can include the tips29. Thus, the lossy material64can be disposed at the tips29. In one example, the lossy material64can be disposed only at the tips29. Alternatively or additionally still, the at least a portion of the electrical contacts24can include at least a portion of the intermediate portion27, such as an entirety of the intermediate portion27. The lossy material64can be disposed at the tips of the signal contacts. Alternatively or additionally, the lossy material64can be disposed at the tips of the ground contacts. The lossy material can span a majority of the height of the divider walls30along the longitudinal direction L. The lossy material at each of the divider walls30can be aligned with each other along the lateral direction A.

Referring now toFIG.6, the lossy material64can alternatively or additionally be applied to the connector housing22at other locations of the connector housing. For instance, the lossy material64can be disposed on one or both of the mounting interface23and the mating interface25. In particular, the lossy material64can have a longest dimension that is parallel to the mounting interface23. Thus, the lossy material64can have a longest dimension that is parallel to the underlying substrate when the electrical connector20is mounted to the underlying substrate. mounting interface23. The lossy material64can be configured as a plate that is oriented in the lateral direction A and the transverse direction T. In one example, the lossy material64can be embedded in one or both of the mounting interface23and the mating interface25. For instance, the lossy material64can be insert molded in one or both of the mounting interface23and the mating interface25. Alternatively, the lossy material64can be molded so as to define the connector housing22. Thus an entirety of the connector housing22can comprise the lossy material64. Alternatively, the lossy material64can be applied to an external surface of one or both of the mounting interface23and the mating interface25.

For instance, referring now toFIG.7, the lossy material64can be disposed on the mounting interface23of the connector housing22. In particular, the lossy material64can be applied to an outer surface of the connector housing22at the mounting interface23. Thus, the lossy material64can be on a surface of the connector housing22that is configured to face the underlying substrate when the electrical connector20is mounted to the underlying substrate. Accordingly, the lossy material64can face the substrate when the electrical connector20is mounted to the substrate. For instance, as described above, the electrical contacts24can be arranged in first and second rows32that are each oriented along the lateral direction A, and are spaced from each other along the transverse direction T. The lossy material64can be disposed on the outer surface of the connector housing at a location between the rows32. In one example, the lossy material64can be disposed equidistantly between the rows32. Further, the lossy material64can be disposed equidistantly between the mounting ends28of the electrical contacts24.

Referring now toFIGS.8A-9Fgenerally, the electrical connector20can be configured as a right-angle connector. In particular, the mating ends26and the mounting ends28can be oriented substantially perpendicular to each other. In one example, the mating ends26can be oriented along the longitudinal direction L, and the mounting ends28can be oriented along the transverse direction T. For instance, the mating ends26can extend out from the connector housing22along the longitudinal direction L, and the mounting ends28can extend out from the connector housing22along the transverse direction T.

The electrical contacts24can be supported by the connector housing22indirectly. In particular, the electrical connector20can include at least one leadframe assembly50that includes a leadframe housing52and a respective plurality of the electrical contacts24supported by the leadframe housing52. The at least one leadframe housings52, and thus the at least one leadframe assembly50, can be supported by the connector housing22. In one example, the electrical connector20can include first and second leadframe assemblies50aand50b. Each of the first and second leadframe assemblies50aand50bcan include respective first and second pluralities of the electrical contacts24supported by the respective leadframe housing52. The electrical contacts24of each leadframe assembly50can be aligned along a respective row32that is oriented along the lateral direction A as described above.

The leadframe assemblies50aand50bcan be spaced from each other along the transverse direction T. Thus, the first and second leadframe housings52of the first and second leadframe assemblies50aand50b, respectively, can be spaced from each other along the transverse direction T. Each of the leadframe housings52can define an inner surface53that faces the other of the leadframe housings, and an outer surface55opposite the inner surface53along the transverse direction T. Further, the rows32can be spaced from each other along the transverse direction T. In one example, the electrical contacts24can be insert molded in the respective leadframe housing52. Alternatively, the electrical contacts24can be stitched into the respective leadframe housing. While the electrical connector20is shown including first and second leadframe assemblies50aand50b, it should be appreciated that the electrical connector can include any number of leadframe assemblies as desired.

The electrical contacts24can include a plurality of electrical signal contacts54and a plurality of ground contacts56. For instance, adjacent ones of the electrical signal contacts54along the row32can define a differential signal pair. The electrical contacts24can further include a plurality of electrical ground contacts56. The electrical ground contacts56can be disposed between adjacent differential signal pairs along the row32. Thus, each leadframe assembly50can include a plurality of signal contacts54and a plurality of ground contacts56in one example. It should be appreciated that the electrical signal contacts54can alternatively be single ended. Further, the electrical ground contacts56can be disposed at any alternative suitable locations as desired.

Referring now also toFIGS.8B-8C, the rows32can be arranged such that the mounting ends28of the electrical contacts52are configured to be mounted to a first electrical device58. The first electrical device58can be a first substrate60, which can be configured as a first printed circuit board. When the first substrate60is received between the mating ends of each row32, the mating ends26can establish an electrical connection with opposed surfaces of the first substrate60. The first substrate60can belong to an electrical connector, such as a QSFP connector in one example. Thus the first electrical device58can be configured as a QSFP connector. It should be appreciated, of course, that the first electrical device58can be alternatively configured in any suitable manner as desired.

Referring now also toFIGS.8B-8C, the rows32can be arranged such that the mounting ends28of the electrical contacts52are configured to be mounted to a first electrical device58. The first electrical device58can be a first substrate60, which can be configured as a first printed circuit board. Thus, the mounting ends28are configured to establish an electrical connection with the first substrate60. The first substrate60can belong to an electrical connector, such as a QSFP connector in one example. Thus the first electrical device58can be configured as a QSFP connector. It should be appreciated, of course, that the first electrical device58can be alternatively configured in any suitable manner as desired.

Referring now also toFIGS.8B-8C, the rows32can be arranged such that the mating ends26of the electrical contacts52of the rows32are spaced from each other so as to receive a second electrical device62. The second electrical device62can be a second substrate63, which can be configured as a second printed circuit board. When the second substrate63is received between the mating ends26of each row32, the mating ends26can establish an electrical connection with opposed surfaces of the second substrate63. The second substrate63can belong to an electrical connector, such as a QSFP connector in one example. Thus the second electrical device62can be configured as a QSFP connector. It should be appreciated, of course, that the second electrical device62can be alternatively configured in any suitable manner as desired.

A data communication assembly66can include the electrical connector20and the first and second electrical devices58and62as described above. Thus, when the electrical connector is mounted to the first electrical device58and mated to the second electrical device62, the first and second electrical devices58can be placed in electrical communication with each other.

In one example, the electrical connector20shown inFIG.8A-8Ccan be configured as a UECS-2 electrical connector commercially available from Samtec, having a place of business in New Albany, Indiana, USA. However, the electrical connector20can further include the lossy material64as will now be described.

Referring now toFIGS.9A-9E, one or both of the leadframe housings52up to all of the leadframe housings of the electrical connector can include the lossy material64. For instance, one or both of the leadframe housings52can define at least one void68that is configured to receive the lossy material64. The at least one void68can define a single void or a plurality of voids as desired. The void68can extend into any suitable surface of the leadframe housing52as desired.

For instance, the void68can extend into the outer surface55toward the inner surface53. In one example, the void68can terminate in the leadframe housing52without extending through the inner surface53along the transverse direction. Further, the void68can terminate along the lateral direction A without extending through either of the lateral side walls of the leadframe housing52that are opposite each other along the lateral direction A. Thus, the void can be configured as a pocket in one example. For instance, the pocket can be open only to the outer surface55in one example. Alternatively, the void68can extend through the inner surface53along the transverse direction T. It should therefore be appreciated that the void68can alternatively define a through hole that is open to more than one different surface of the leadframe housing52. For instance, the through hole can be open to both the inner surface53and the outer surface55of the leadframe housing52. Alternatively or additionally, the void68can extend through one or both of the lateral side walls of the leadframe housing52. Further still, the void68can terminate without extending through either front or rear walls of the leadframe housing52that are opposite each other along the longitudinal direction L. Alternatively, the void68can extend through one or both of the front and rear walls of the leadframe housing52.

The lossy material64can be disposed in the void68. Thus, the lossy material64can be disposed between the mating ends26and the mounting ends28with respect to the longitudinal direction L. The void68can be defined by a base70that is defined by the leadframe housing52. The base70can define a plurality of raised regions72. In one example, the electrical contacts52can extend through the raised regions. The lossy material can be substantially flush with the at least one surface of the leadframe housing52that defines the opening to the void68. For instance, the lossy material can be substantially flush with the outer surface55of the leadframe housing52in one example. The term “substantially,” “approximately,” and derivatives thereof, and words of similar import, when used to described sizes, shapes, spatial relationships, distances, directions, and other similar parameters includes the stated parameter in addition to a range up to 10% more and up to 10% less than the stated parameter, including 5% more and 5% less, including 3% more and 3% less, including 1% more and 1% less. However, with respect to a stated frequency, the term “substantially,” “approximately,” and derivatives thereof, and words of similar import includes the stated frequency in addition to a range up to 5 GHz more than the stated frequency and up to 5 GHz less than the stated frequency.

With continuing reference toFIGS.8A-9F, the leadframe housing52can include an insert57that projects forward along the mating direction and is configured to be disposed between electrical signal conductors of a respective differential pair. In particular, the insert57can contact each of the electrical signal contacts at a location adjacent a concavity and a convexity of the electrical contacts. In one example, the insert57can include a forward extending web, and a button at a distal end of the web. The button and the web can be disposed between adjacent electrical contacts24, and the button can be in abutment with the adjacent electrical contacts24. Because the insert can be part of the leadframe housing52, it can be insert molded electrically insulative material monolithic with a remainder of the leadframe housing52. The insert57can control impedance of the differential signal pairs based on its dielectric constant. Thus, the dielectric constant of the leadframe housing52, and thus of the insert57, can be selected to provide a desired impedance. In one example, the insert57can further include a lossy material disposed thereon or in a void therein. As illustrated inFIG.9F, the electrical contacts24can deflect when mated with a complementary electrical connector. The inserts57can remain between the respective adjacent electrical contacts24and in abutment with the respective adjacent electrical contacts24as the electrical contacts24deflect.

As illustrated inFIG.10, it is recognized that instead of or in addition to disposing the lossy material to one or more portions of the electrical connector20, the connector housing22can be made from a lossy material64. Thus, an entirety of the connector housing22can comprise the lossy material64. While certain examples of electrical connectors including the lossy material64have been described, it is recognized that any suitable alternative electrical connector as electrical

While the lossy material64can be disposed on the housing body31as described above, it should be appreciated that the electrical connector can include lossy material64at other locations. For instance, referring now toFIGS.11A-11B, at least one electrical contact24of an electrical connector can include lossy material64that is disposed on the contact body. For instance, a plurality of electrical contacts24up to all of the electrical contacts24of the electrical connector can include the lossy material. In one example, the at least one electrical contact24can be configured as a ground contact of the electrical connector. Thus, the at least one electrical contact24can include a plurality of the ground contacts up to all of the ground contacts of the electrical connector. Alternatively or additionally, the at least one electrical contact24can be configured as a signal contact of the electrical connector. Thus, the at least one electrical contact24can include a plurality of the signal contacts up to all of the signal contacts of the electrical connector. In one example, the lossy material64can be disposed on the mating end26of the contact body. Alternatively or additionally, the lossy material64can be disposed on the tip29of the contact body. As shown inFIGS.11A-11B, the lossy material64can be disposed on the respective tips29of both the at least one electrical contact24of the electrical connector and on respective tips29of a complementary electrical contact24′ of a complementary electrical connector. The electrical contacts24can mate with the complementary electrical contacts24′ when the first and second electrical connectors are mated with each other at their respective mating ends26.

In particular, the mating ends26of the electrical contact24and the complementary electrical contact24′ can define respective wiping surfaces34that are configured to wipe against each other as the electrical contacts24and24′ are mated with each other. As illustrated inFIG.11A, the wiping surfaces34can be aligned with each other along the longitudinal direction L when the respective electrical connectors are aligned to be mated with each other in the mating direction. Next, as illustrated inFIG.11B, the electrical contacts24and24′ can be brought toward each other along respective mating directions, thereby causing the wiping surfaces34to ride along each other while in abutment with each other. The wiping surfaces34ride along each other until the electrical contacts24and24′ are mated with each other. The mating ends of the electrical contacts24and24′ can deflect away from each other as they mate. In particular, the electrical contacts24and24′ can be elastically resilient. Thus, as the bent wiping surfaces34ride along each other, the abutment of the wiping surfaces34can cause the mating ends26of the electrical contacts24and24′ to deflect away from each other along the transverse direction T.

The tips29can constructed to flare away from the wiping surfaces34as they extend in a direction away from their respective intermediate portion27. For instance, the tips29can extend away from respective portions of the electrical contact24that define the wiping surfaces34. Thus, the tips29of the electrical contacts24and24′ can be offset from each other along the transverse direction T when the electrical contacts24and24′ are aligned to be mated with each other. As a result, the tips29of the electrical contacts24and24′ can move past each other without contacting each other. The lossy material64can be disposed on respective first surfaces36of the electrical contacts24and24′ that are opposite the wiping surfaces34. In particular, the lossy material64can be disposed on the first surface36at the mating end26. Further, the lossy material64can be disposed on the first surface36and not the second surface38at the mating end26. Similarly, the lossy material64can be disposed on the first surface36at the tip29. In one example, the lossy material64can be disposed on the first surface36at the tip29and not at the second surface38. Alternatively, as described in more detail below with respect toFIG.14D, the lossy material64can be disposed on the first surface36and the second surface38at the tip29. Further, the lossy material can be disposed on edges42that extend between the first and second surfaces36and38, which can define broadsides40of the electrical contact24. In one example, the first and second surfaces36and38can be opposite each other along the transverse direction T. The broadsides40of the electrical contact24extend between and up to the edges42along a plane that is oriented normal to the electrical contact. The plane can also be said to extend along the transverse direction T and the lateral direction A. The edges42can be opposite each other along the lateral direction A. The broadsides40can define a length that is greater than the length of the edges42in the plane. In another example, the broadsides40can be opposite each other along the lateral direction A, and the edges42can be opposite each other along the transverse direction T.

With continuing reference toFIGS.11A-11B, the first surface36can define a concavity44, and the second surface38can define a convexity46that is opposite and aligned with the concavity44. The convexities46of the electrical contacts24and24′ can ride along each other when the electrical connectors24and24′ are mated with each other. Thus, at least a portion of the convexity46of each electrical contact can define at least a portion of the wiping surface36. The concavity44and the convexity46of each electrical contact can be opposite each other along the direction along which the first and second surfaces36and38are opposite each other. Thus, when the first and second surfaces36and38are opposite each other along the transverse direction T, the concavity44and the convexity46can be opposite and aligned with each other along the transverse direction T. When the first and second surfaces36and38are opposite each other along the lateral direction A, the concavity44and the convexity46can be opposite and aligned with each other along the lateral direction A. In one example, the lossy material64can extend along the first surface36between the concavity44and the distalmost end48of the electrical contact. Further the lossy material64can extend along a portion of the concavity44less than an entirety of the concavity44, as illustrated at electrical contact24. Alternatively, the lossy material64can be disposed only distal of the concavity44as illustrated at the electrical contact24′.

It has been found that the lossy material64disposed at the tips29of the electrical contacts can reduce a phenomenon known as a stub effect. In particular, the tips29can become a quarter-wave resonator during operation. The lossy material64disposed at the tip29can absorb at least a portion of the resulting magnetic field emitted from the tip29. As illustrated atFIG.5, the convexities46of adjacent electrical contacts24that define a differential signal pair can face each other. Accordingly, the concavities44of electrical contacts24of adjacent differential pairs can face each other. Thus, because the lossy material64is disposed on the concavities44, the lossy material64can be disposed between adjacent differential signal pairs.

It should be appreciated that the lossy material64can be disposed only at the tips29in one example. Alternatively, the lossy material64can be disposed at other locations of the first surface36of the electrical contacts. For instance, the lossy material64can alternatively or additionally be disposed at the mating end26as described above. Alternatively or additionally still, the lossy material64can be disposed at the base35of the electrical contact24as described below with reference toFIGS.14A-14D.

Referring now toFIGS.5-11Bgenerally, the lossy material can be tuned to dampen the resonant frequency of the tips29or any other suitable frequency. The lossy material64of the electrical contacts of a differential signal pair can be tuned to absorb magnetic fields at first and second different frequencies. In particular, first and second different types of lossy material tuned to absorb magnetic fields at the first and second different frequencies, respectively, can be disposed on first and second signal contacts, respectively, or a differential signal pair. For example, the first type of lossy material configured to absorb frequencies of substantially 10 GHz can be disposed on a first electrical contact24of the differential signal pair. The second type of lossy material capable of absorbing frequencies of substantially 15 GHz can be disposed on a second electrical contact24of the differential signal pair. While the first frequency can be 10 GHz, and the second frequency can be 15 GHz in one example, it is recognized that the first and second frequencies can be selected as desired to reduce unwanted resonance frequencies.

The lossy material64can define any suitable volume, size, and shape as desired. Further, the lossy material64can be disposed at any suitable location of the electrical contacts24. The volume, size, shape, and location of the lossy material64can be determined through testing or computer simulations. In some instances, the volume, size, shape, and location can result in manufacturing tradeoffs. The contact with the lossy material can be included any suitable electrical connector. Lossy material can be applied to the signal contacts of the electrical connector that transport, i.e., transmit and/or receive, electrical signals. In some electrical connectors, lossy material can be applied only to the signal contacts.

In one example the lossy material64can be a dispensed material such as an epoxy. Alternatively, the lossy material64can be a stamped material. With a dispensed material, the lossy material can be applied after the electrical contact24is formed or housing body31, for example, by stamping from a metal sheet. For instance, thin sheets of uncured epoxy can be die cut and applied to a contact through pick and place or other automated process, and then cured after initial attachment to the electrical contact24or housing body31. When attaching the lossy material64to the electrical contacts24, the lossy material64can be applied to the electrical contacts24in a contact reel and a reel-to-reel stage. It should be appreciated, of course, that the lossy material64can be fabricated using any suitable alternative fabrication method.

It is therefore appreciated that the lossy material64can be disposed on or in the housing body31, defined by the connector housing22, included in a leadframe assembly, carried by an electrical contact, or a combination of one or more of the above. Further, while the leadframe assemblies can define differential signal pairs along the respective row as described above, it is further recognized that leadframe assemblies can define differential signal pairs along columns that are oriented perpendicular to the rows.

For instance, referring toFIGS.12A-12B, an electrical connector can include a connector housing that supports a plurality of leadframe assemblies74constructed in accordance with another example. For instance, the leadframe assembly can include a leadframe housing76and a respective plurality of the electrical contacts24supported by the leadframe housing76. The electrical contacts24can be right-angle contacts, whereby the mating ends26are oriented along the longitudinal direction L, and the mounting ends28are oriented along the transverse direction T. The mating ends26of the electrical contacts24of each leadframe assembly74can be aligned along a respective column that is oriented along the transverse direction T, and thus perpendicular to the row. The mounting ends28of the electrical contacts of each leadframe assembly74can be aligned along the longitudinal direction L, or mating direction. Adjacent signal contacts of each leadframe assembly74define respective differential signal pairs. The leadframe assemblies74can further include a plurality of ground contacts, such that at least one ground contact is disposed between adjacent differential signal pairs. Alternatively, the leadframe assemblies74can be devoid of ground contacts. A plurality of leadframe assemblies74can be supported by the connector housing, such that the leadframe assemblies74are arranged along the row that is oriented along the lateral direction A.

Each of the leadframe housings76can define opposed side surfaces73and75that are opposite each other along the lateral direction A. As illustrated inFIGS.12A-12B, the leadframe assemblies74can include a plurality of voids78that are configured to receive lossy material64. For instance, the voids78can extend in at least one or both of the side surfaces73and75. The voids78can terminate in the leadframe housing76without extending to the electrical contacts24that are supported by the leadframe housing76. Thus, the voids78can be configured as pockets. Further, at least a portion of the voids78can be aligned with respective ones of the electrical contacts24that are supported by the leadframe housing76. For instance, the voids78can define a plurality of front voids78athat are aligned along the lateral direction with a portion of at least some of the electrical contacts that are oriented along the longitudinal direction L. Thus, the front plurality of voids78acan be elongate along the longitudinal direction L, and in alignment with respective ones of the electrical contacts52supported by the leadframe housing76. The front voids78acan further be aligned with each other along the transverse direction T. As illustrated inFIG.12B, lossy material64can be disposed in the front voids78a, and thus aligned with respective ones of the electrical contacts along the lateral direction A.

The voids78can further include rear voids78b. Respective portions of the rear voids78bcan be aligned along the lateral direction A with a bent portion of at least some of the respective electrical contacts24that are bent as they extend between the mating end26and the mounting end28. oriented along the longitudinal direction L. Thus, the rear voids78bcan be elongate along the longitudinal direction L. The rear voids78bcan further be aligned with each other along the transverse direction T. Certain ones of the rear voids78bcan have different lengths along the longitudinal direction L that are different than other ones of the rear voids78bin some examples.

As described above, the voids78can be configured to receive lossy material64as illustrated inFIG.12B. In particular, as is the case with the other voids described herein, the voids78can be substantially filled with the lossy material64. Further, the lossy material64can be substantially flush with the at least one of the side surfaces73and75of the leadframe housing76that defines an opening to the voids. In this regard, it should be appreciated that the lossy material64can be disposed between columns of electrical contacts along a row, whereby the electrical contacts define differential signal pairs along a direction that is perpendicular to the row. It is recognized that the lossy material64disposed in the front voids78acan be tuned to attenuate substantially first frequency, and the lossy material, and the lossy material64in the rear voids78bcan be configured to attenuate substantially second frequency different than the first frequency. The first frequency can be higher than the second frequency. Alternatively, the second frequency can be higher than the first frequency. Alternatively, the first and second frequencies can be substantially equal to each other.

Referring now toFIGS.13A-13B, first and second leadframe assemblies74aand74bcan be positioned adjacent each other in the connector housing. The voids78are positioned at different locations inFIGS.13A-13Bwith respect to the voids inFIGS.12A-12Bto illustrated that the voids78can be disposed at any suitable location as desired. For instance, the leadframe housings76can include lower voids78cthat are disposed proximate the mounting interface, whereas the front voids78acan be disposed proximate the mating interface. Thus, the lower voids78ccan be elongate along the transverse direction T. Further, the lower voids78ccan be aligned along the lateral direction A with portions of respective ones of the electrical contacts24that are supported by the leadframe housing76, the portions oriented along the transverse direction T. The first side surface73of the leadframe housing76of the first leadframe assembly74acan face the second side surface75of the leadframe housing76of the second leadframe assembly74balong the lateral direction A.

In one example, the voids78in the first side surface73of the first leadframe assembly74acan be aligned with the voids78in the second side surface75of the second leadframe assembly74balong the lateral direction A. Thus, when the lossy material64is disposed in the voids78, the lossy material64carried by the leadframe housing76of the first leadframe assembly74acan face the lossy material64carried by the leadframe housing76of the second leadframe assembly74b. In some examples, the lossy material64carried by the leadframe housing76of the first leadframe assembly74acan be aligned in its entirety with the lossy material64carried by the leadframe housing76of the second leadframe assembly74b. For instance, the lossy material64carried by the leadframe housing76of the first leadframe assembly74acan abut the lossy material64carried by the leadframe housing76of the second leadframe assembly74b. Alternatively, the lossy material64carried by the leadframe housing76of the first leadframe assembly74acan be spaced from the lossy material64carried by the leadframe housing76of the second leadframe assembly74balong the lateral direction A.

Referring now toFIGS.14A-16Cgenerally, an electrical connector in another example can be configured as an edge card connector80. In this regard, it should be appreciated that any suitably constructed electrical connector can include the lossy material64in any manner described herein. Further, the placement of the lossy material80described in accordance with any examples herein can be incorporated into any other examples unless otherwise indicated.

Referring now toFIGS.14A-14Din particular, the edge card connector80can include an electrically insulative connector housing82including a housing body83and a plurality of electrical contacts84supported by the housing body83, and thus the connector housing82. The electrical contacts84can include electrical signal contacts86. The electrical contacts84can further include electrical ground contacts88. In one example, the edge card connector80can include a plurality of leadframe assemblies112that each includes a leadframe housing114and respective ones of the electrical contacts84supported by the leadframe housing114. Thus, the electrical contacts84can be supported by the respective leadframe housing114that, in turn, is supported by the housing body83, and thus the connector housing82. In this regard, it can be said that the electrical contacts84are indirectly supported by the housing body83, and thus the connector housing82. Alternatively, the edge card connector80can be devoid of the leadframe assemblies112, such that the electrical contacts84can be supported directly by the connector housing82.

The electrical contacts84can define respective mounting ends28that are configured to mount to a first complementary electrical component in the manner described above. The electrical contacts84can further include mating ends26that are configured to mate with a second complementary electrical device in the manner described above. The connector housing can define a mounting interface100and a mating interface102of the type described above. The edge card connector80can be configured as a vertical connector whereby the mounting ends28and the mating ends are oriented substantially parallel to each other. Alternatively, the edge card connector80can be configured as a right-angle connector whereby the mounting ends28and the mating ends are oriented substantially perpendicular to each other. The electrical contacts84can each define the wiping surface34, the first and second surfaces36and38that define broadsides40, can define the respective edges42, the concavity44, the convexity46, and the tip29as described above with respect to the electrical contacts24of the electrical connector20.

In one example, the electrical contacts84can be spaced from each other along at least one row97that can be oriented along the longitudinal direction L. The mounting ends28and the mating ends can be opposite each other along the longitudinal direction L. While the edge card connector80is shown as including one row of electrical contacts84, it should be appreciated that the edge card connector80can include multiple rows of electrical contacts spaced from each other along the transverse direction T.

The mounting ends28can be configured to be mounted to a first electrical device such as a first substrate as described above. The mating ends26can be configured to mate with a second electrical device, such as a card that can be received by the mating ends26so as to place the edge card connector80in electrical communication with the second electrical device. Thus, the edge card connector80can place the first and second electrical devices in electrical communication with each other in the manner described above. AlthoughFIGS.14A-16Cshow examples of the edge card connector80and portions thereof, it should be appreciated that any suitable electrical connector can be used.

In one example, the housing body83, and thus the connector housing82, can include a base104and a wall106that extends out from the base104along the longitudinal direction L. The wall106can define the mating interface102of the edge card connector80. The housing body83can further include a plurality of divider walls108that define respective cavities110. The cavities110can, in turn, receive the mating end26of at least one of the electrical contacts84. The divider walls108can be spaced from each other along the lateral direction A, and can extend from the wall106along the transverse direction T. The wall106, and thus the connector housing82, can further include lateral outer side walls109that are opposite each other, and cooperate with laterally outermost ones of the divider walls108so as to define the laterally outermost cavities110. The cavities110can include ground cavities and signal cavities. The ground cavities can receive at least one ground contact88. In one example, the laterally outermost cavities can be ground cavities. The signal cavities can receive at least one signal contact86. For instance, the signal cavities can receive respective pairs of signal contacts86that define differential signal pairs. The ground cavities can be disposed between adjacent signal cavities, such that the ground contact88received therein can be disposed between adjacent differential signal pairs along the row. The signal contacts86and the ground contacts88can be aligned with each other along the lateral direction A as described above.

The electrical connector can include at least one leadframe assembly112that is supported by the connector housing82. For instance, the at least one leadframe assembly112can be supported by the base104. In one example, the edge card connector80includes first and second leadframe assemblies112, but it should be appreciated that the electrical connector80can include any number of leadframe assemblies as desired. Each of the leadframe assemblies112can include a leadframe housing114and respective ones of the plurality of electrical contacts84supported by the leadframe housing114in the manner described above. The electrical contacts84can be insert molded in the leadframe housing114, or can be stitched into the leadframe housing114as desired. When the leadframe assemblies112are supported by the connector housing80, the respective ones of the electrical contacts84can be spaced from each other and aligned with each other along the lateral direction A. Further, the leadframe assemblies112can be disposed adjacent each other along the lateral direction A. Thus, the electrical contacts84of a first one of the leadframe assemblies112can be aligned with the electrical contacts of a second one of the leadframe assemblies112along the lateral direction A.

Each of the leadframe assemblies112can include at least a pair of signal contacts86disposed adjacent each other. The adjacent signal contacts86can define a differential signal pair. Alternatively, the signal contacts86can be single ended. Each of the leadframe assemblies112can further include at least one ground contact88positioned adjacent the differential signal pair. For instance, each of the leadframe assemblies112can include a pair of ground contacts88disposed such that the differential signal pair is disposed between the ground contacts88along the lateral direction. Thus, when the leadframe assemblies112are positioned adjacent each other, the card edge connector80can include a pair of ground contacts disposed between adjacent differential signal pairs along the lateral direction (S-S-G-G-S-S, wherein “G” represents a ground contact and S represents a signal contact). It should be appreciated that the electrical contacts of all electrical connectors described herein can define this this or any alternative contact pattern of electrical signals as described. For instance, the contact pattern can include G-S-G-S or S-S-G-S-S as examples. Alternatively, the edge card connector80can be devoid of ground contacts if desired. The edge card connector80can include the insert57of the type described above with respect toFIGS.8A-9F.

As will now be described with respect toFIGS.14A-16C, the edge card connector80can include the lossy material64at any one or more of a number of suitable locations. For instance, as is the case with the electrical connector20described above, the lossy material64can be carried by at least one or more up to all of the housing body, one or more of the signal contacts, one or more of the ground contacts, and the leadframe housing. The lossy material84can be magnetically absorbing and electrically non-conductive in the manner described above, in one example.

Referring now toFIGS.14A-14Din particular, the lossy material64can be disposed on the tip29of at least one electrical contact84of the electrical contacts84. For example, the lossy material64can be configured as a cap113that is disposed on the respective tip29of the at least one electrical contact84. In one example, the lossy material64can be molded onto the electrical contact. Alternatively, the tip29can be press-fit into an opening of the cap defined by the lossy material. Alternatively still, the lossy material64can be adhesively attached to the electrical contact24. Alternatively still, the lossy material64can be sprayed onto the electrical contact24. Alternatively still, the electrical contact24can be dipped into a liquid bath of the lossy material64. The lossy material64can be disposed on the first surface36that is opposite the wiping surface34. The lossy material64can further be disposed on the second surface38that define the wiping surface34. In particular, the lossy material64can be disposed distal of the wiping surface34. Thus, the lossy material can be disposed on the broadsides40of the at least one electrical contact84. Alternatively or additionally, the lossy material64can further be disposed on one or both of the edges42. In one example, the lossy material64can be disposed on the distal-most surface of the at least one electrical contact84.

The lossy material64can surround at least three sides of at least a portion up to an entirety of the tip29along a plane that is oriented normal to the tip. The plane can alternatively be oriented along the lateral direction A and the transverse direction T. The three sides can be defined by one or both of the broadsides40and the edges38. The broadsides40and edges38can similarly be defined along a plane that is oriented along the lateral direction A and the transverse direction T. Alternatively, the lossy material64can surround all four sides of the at least one electrical contact84, including both broadsides40and both edges38. However, other arrangements are also possible. For example, the lossy material64can be positioned along one, two, three or four sides of the at least one electrical contact84. Further, the lossy material64can encapsulate the tip29, as it can be disposed on an entirety of the distal-most surface of the electrical contact84. By placing the lossy material64at the tip29, distal with respect to the wiping surface34of the at least one electrical contact84, the lossy material64, in addition to reducing the stub effect discussed above, does not mechanically interfere with the mating of the at least one electrical contact84to a complementary electrical contact.

Alternatively or additionally, the lossy material64can be disposed on a base35of the at least one electrical contact84. The base35of the electrical contacts can be supported by, aligned with or disposed in the leadframe housing114. The base35can be included in the intermediate portion of the electrical contact. The mounting end28can extend out from the base35along the transverse direction toward the complementary first electrical device. In one example, the lossy material64can extend along both the broadsides40and the edges42of at least a portion of the base35. In this regard, the lossy material64be configured as a collar115that can at least partially or entirely surround the electrical contacts at the base35or any suitable alternative location. Thus, the lossy material64can surround the base35in a plane that is oriented normal to the base35. The lossy material64that is disposed on the base35can be localized only at the base35, and thus does not extend along the transverse direction to a location that is not disposed in the leadframe housing114. Alternatively, the lossy material64that is disposed on the base35can further extend outside the leadframe housing114. It should be appreciated, however, that the lossy material64can be disposed at any suitable position of the at least one electrical contact84up to an entirety of the at least one electrical contact84as desired. When the electrical contacts24are supported directly by a connector housing, the lossy material64at the base35can be localized to a location, and thus does not extend to a location that outside the connector housing. Alternatively, the lossy material64that is disposed on the base35can further extend outside the connector housing.

In one example, the at least one electrical contact84that includes the lossy material64can be defined by at least one ground contact88. For instance, the at least one electrical contact84can be defined by a plurality of ground contacts88. In particular, the at least one electrical contact84can be defined by all of the ground contacts88. By placing lossy material64on the ground contacts84instead of the signal contacts86, there is less attenuation of the desired signal frequency. Alternatively or additionally, the at least one electrical contact84can be defined by at least one signal contact86. For instance, the at least one electrical contact84can be defined by a plurality of signal contacts86. In particular, the at least one electrical contact84can be defined by all of the signal contacts86. Placing lossy material at the base35of the ground or signal contacts can help absorb unwanted frequencies near the mounting interface100, as it is recognized that substrate footprints can be electrically noisy.

The lossy material64can have attenuation properties that can be tuned to attenuate a select frequency, within a range of plus or minus 5 GHz in the manner described above. For instance, the lossy material64can be configured to attenuate a resonant frequency of the electrical connector and all connectors disclosed herein without attenuating frequencies substantially outside of the resonant frequency (for instance, outside of plus or minus 5 GHz of the resonant frequency). It should be appreciated, of course, that the lossy material64can be configured to attenuate other frequencies as desired. The lossy material64can further be tuned to attenuate a band of frequencies broader than 10 GHz. The broader band of frequencies can range up to substantially 50 GHz, such as substantially 40 GHz, for instance, substantially 30 GHz, and in one example substantially 20 GHz. Further, the lossy material64can be disposed at different locations of the electrical connector and all connectors disclosed herein, for instance as illustrated atFIGS.14A-16C. Thus, the lossy material can be tuned to attenuate different frequencies at different locations of the electrical connector and all electrical connectors disclosed herein. The attenuated frequencies different can be any frequency disclosed herein.

Referring now toFIG.15, the connector housing82can include the lossy material64. For instance, the connector housing82can define at least one void68that extends at least into or through the housing body83, that contains the lossy material64. The at least one void can include a plurality of voids68. Alternatively or additionally, the lossy material64can be disposed on an outer surface of the housing body83. The voids68can be aligned with the tips29of the ground contacts88along the lateral direction A. In this regard, it should be appreciated that the tips29of the signal contacts86can be offset with respect to the tips29of the ground contacts88in the mating direction. Thus, the voids68and the lossy material64can be offset from the tips29of the signal contacts86along the longitudinal direction. Thus, a straight line oriented along the lateral direction A that passes the voids68, and thus the lossy material64, can also pass through the tips29of the ground contacts88but does not pass through the tips29of the signal contacts86. Alternatively, the tips29of the signal contacts86can be aligned with the tips29of the ground contacts88along the lateral direction A. The voids68can extend through at least one or more up to all of the divider walls108and the outer side walls109.

Referring now toFIGS.16A-16C, the electrical connector can include an attenuation wall116that can be made of the lossy material64, or can define pockets that include the lossy material64. The attenuation wall116can be aligned with the tips29of either or both the electrical signal contacts86and the electrical ground contacts88along the transverse direction T. For instance, the attenuation wall116can face the first surface36of the ground contacts88that is opposite the wiping surface34of the ground contacts88. Because the mating ends of some of the signal contacts86can be mirror images of others of the signal contacts86, the attenuation wall116can face the first surface36of some of the signal contacts86and the second surface38of others of the signal contacts86. In one example, the attenuation wall116can be localized, and thus does not extend past the concavities44and convexities46of the electrical contacts84toward the mounting ends28in this example. The attenuation wall116can include a back wall107, and divider walls108and lateral outer side walls109of the type described above with respect to the connector housing82that extend from the back wall107so as to define the respective cavities110. At least one or more up to all of the divider walls108and lateral outer side walls109can be aligned with the tips29of the signal contacts86and ground contacts88along the lateral direction A. Thus, a portion of the attenuation wall116can further be aligned with the tips29of the signal contacts86and ground contacts88along the lateral direction A. The attenuation wall116can be separate from the housing body83, or can be supported by the housing body83as desired.

Referring now toFIGS.17-18, a data communication assembly can be configured as an electrical cable assembly120in one example. The electrical cable assembly120can include at least one electrical cable122such as a plurality of electrical cables122, and a complementary electrical device124. The electrical cables122can be mounted to respective electrical contacts that can be configured as electrical contact pads of the electrical device124. In one example, the electrical device124can be defined by a substrate125, which can be configured as a printed circuit board. It will be appreciated from the description below, however, that the electrical device124can be alternatively configured as any suitable electrical device. For instance, the electrical device can be configured as an electrical connector.

The electrical cables122can be twinaxial cables that include first and second electrical signal conductors128surrounded by a common outer electrically insulative jacket130. The first and second electrical signal conductors128can be disposed in a respective inner electrical insulator and thus electrically insulated from each other inside the outer electrically insulative jacket130. Further, the first and second electrical signal conductors128can define differential signal pairs in one example. The twinaxial cables can further define an electrical shield129that is disposed between the inner electrical insulators127and the outer electrically insulative jacket130. Alternatively, the electrical cables122can be configured as coaxial cables that include a single electrical conductor surrounded by an outer electrically insulative jacket. Exposed portions of the electrical shields129can extend out from the outer electrical insulative jacket130along the longitudinal direction L, and can terminate at respective ground contact pads131of the substrate125. Exposed portions of the electrical signal conductors128can extend out with respect to the electrical shields129along the longitudinal direction L, and can be mounted onto respective electrical contact pads133of the substrate125. The exposed signal conductors128can be aligned with each other along the lateral direction A.

The cable assembly120can include lossy material64. For instance, as illustrated inFIG.17, the electrically nonconductive lossy material64can cover the exposed portions of one or more up to all of the electrical signal conductors128. Thus, the electrically nonconductive lossy material64can be disposed on the substrate125, and can cover the electrical contact pads93and at least a portion up to a substantial entirety the exposed portions of the respective electrical signal conductors128. Alternatively or additionally, the lossy material64can be disposed between adjacent pairs of first and second electrical signal conductors128. The lossy material64can be spaced from the exposed portions of the electrical signal conductors128and the respective contact pads123, and can thus be electrically conductive or electrically nonconductive. Alternatively, the lossy material64can contact one or more of the exposed portions of the electrical conductors88and/or the electrical contact pads123, in which case it can be desirable for the lossy material64to be electrically nonconductive. In one example, the lossy material64can be arranged in strips that are disposed between respective pairs of first and second electrical signal conductors128along the lateral direction A. Further, the strips can be aligned with the exposed portions of the electrical signal conductors128along the lateral direction.

The electrical cables122can be configured as at least one cable ribbon89mounted onto at least one surface of the substrate125. In particular, the substrate125can define first and second opposed surfaces134aand134bthat are opposite each other along the transverse direction T. A first one of the cable ribbons129can be mounted to the first surface134a, and a second one of the cable ribbons129can be mounted to the second surface134a. As illustrated inFIG.18, the lossy material64can alternatively or additionally be disposed on one or both of the first and second surfaces134aand134bso as to be positioned between the substrate125and the cable ribbon129that is mounted to the respective one or both of the first and second surfaces134aand134b. For instance, the lossy material64can be elongated along the lateral direction A, and can span at least a portion up to an entirety of the width of the respective at least one cable ribbon129along the lateral direction A. Without being bound by theory, it is believed that the lossy material illustrated inFIGS.17-18can reduce crosstalk during operation of the electrical cable assembly120.

Referring now toFIGS.19A-20B, and as described above, the electrical cable assembly120in one example can include the at least one electrical cable122such as a plurality of electrical cables122, and the complementary electrical device124. The complementary electrical device124can be configured as an electrical connector140, which can also be referred to as a cable connector.

The electrical connector140can include an electrically insulative connector housing142and a plurality of electrical contacts144that are supported by the connector housing142. In one example, the electrical contacts144can be press-fit or otherwise mechanically attached to the connector housing142. Alternatively, the electrical contacts144can be insert molded in the connector housing142. Alternatively still, the electrical contacts144can be supported by at respective at least one leadframe housing of a leadframe assembly, that is in turn supported by the connector housing142in the manner described above. Each of the electrical contacts144can define a mating end146and a mounting end148opposite the mating end146. The mounting ends148can be configured to be mounted to a first electrical device, which can be configured as the at least one electrical cable such as a plurality of electrical cables122.

The electrical contacts144can include electrical signal contacts167and ground contacts168. Adjacent ones of the electrical signal contacts167along a respective row152can define differential signal pairs. The electrical contacts144can include at least one or more ground contacts168between differential signal pairs along the row152. The mating ends146of the electrical contacts144can be configured to mate with respective electrical contacts of a second electrical connector when the electrical connector140is mated with the second electrical connector.

The mating ends146can be configured to mate with respective electrical contacts of a second electrical connector when the electrical connector140is mated with the second electrical connector. In particular, the electrical connector140can mate with the second electrical connector along a mating direction. The mating ends146can define a separable interface with the respective electrical contacts of the second electrical connector. Thus, the electrical connector140can unmate from the second electrical connector along an unmating direction that is opposite the mating direction. Both the mating direction and the unmating direction can be oriented along a longitudinal direction L. The mounting ends148can be configured to be mounted to a first electrical device, which can be configured as the at least one electrical cable122such as a plurality of electrical cables122.

The electrical cables122can be mounted to the electrical connector140at a cable termination interface. In one example, the mounting ends148of the signal contacts167can be configured to be mounted to respective ones of the first and second signal conductors128of the electrical cables122. The mounting ends148of the ground contacts168can be configured to be mounted to respective electrical shields of the electrical cables122, or to drain wires if present. In one example, the lossy material64can be disposed adjacent the cable termination interface. In one example illustrated inFIGS.9A-9B, the lossy material64can be configured as a strain relief member that is configured to provide strain relief to the signal conductors128of the electrical cables122. The lossy material64can cover at least a portion of an overall length of the exposed portion of the electrical shield129along with at least a portion of the ground contact168to which the exposed portion of the electrical shield is mounted. In this regard, the lossy material can secure the outer insulative jacket130to the connector housing. Thus, the lossy material can provide strain relief to the at least one electrical contact. Accordingly, if a tensile force is applied to one or more of the electrical cables122, the tensile force will be absorbed by the lossy material64, rather than the connection between the electrical signal conductors128and the electrical signal contacts167. In one example, the lossy material64can be molded onto the exposed portion of the electrical shield129and the at least a portion of the ground contact168to which the exposed portion of the electrical shield is mounted. If desired, the lossy material64can alternatively or additionally be configured as described above with respect toFIGS.17-18.

Referring now toFIGS.20A-20B, the lossy material64can surround one or both of the outer insulative jacket130, the exposed portion of the electrical shield, and the exposed portions of the electrical signal conductors128as desired. In particular, the lossy material64can be configured as a protective cover154that is configured to be mounted onto the electrical connector. The protective cover154can have an upper wall155, and a pair of opposed side walls156that extend down from the upper wall155toward the electrical connector140when the cover154is mounted to the electrical connector140. The side walls156can be opposite each other along the lateral direction A. The cover154can further include a divider wall157that extends down from the upper wall155between the side walls156. For instance, the divider wall157can be equidistantly spaced from the side walls156with respect to the lateral direction A. The divider wall157can extend along a portion up to an entirety of an overall length of the cover154along the longitudinal direction L. The cover154can define at least a pair of cavities158that extend from the divider wall177to the opposed side walls156, respectively.

During operation, the electrical connector140can include the cover154mounted thereon, such that the cover154cooperates with a portion of the electrical connector to surround one or more up to all of a portion of the outer electrical insulative jacket130, the exposed portion of the electrical shield, and at least a portion up to an entirety of of the exposed portion of the electrical signal conductors128of one or more of the electrical cables122. For instance, one or more up to all of a portion of the outer electrical insulative jacket130, the exposed portion of the electrical shield, and at least a portion of the exposed portion of the electrical signal conductors128of a first one of the electrical cables122can be disposed in a first one of the cavities158, and one or more up to all of a portion of the outer electrical insulative jacket130, the exposed portion of the electrical shield, and at least a portion up to an entirety of the exposed portion of the electrical signal conductors128of a second one of the electrical cables122can be disposed in a second one of the cavities158. The divider wall177can be disposed between adjacent cables122mounted to the electrical connector. The cover154can be mechanically rigid, and thus configured to provide a mechanical barrier that protects the cable termination interface.

Referring now toFIGS.21A-24in general, it is further recognized that near-end cross-talk (NEXT) can be reduced by applying the lossy material to one or more surfaces of an ungrounded electrically conductive substrate of an electrical shield that is disposed between adjacent rows of signal contacts. For instance, the lossy material can be configured to absorb electromagnetic interference that is generated during operation of the electrical connector. It has been found that NEXT can be reduced when the electrically conductive substrate, and thus the electrical shield, is ungrounded (meaning that the no portion of the electrical shield including the electrically conductive substrate is in contact with any electrically grounds of the electrical connector or any grounded electrically conductive structures mated with or mounted to the electrical connector). Further, it has been found that NEXT can be reduced when the electrically conductive substrate, and thus the electrical shield, is not mechanically connected to any other electrically conductive structures of the electrical connector. Of course, it is appreciated that the electrically conductive substrate can alternatively be grounded if desired. However, the ability to reduce NEXT with an ungrounded electrical shield is a surprising result, as ungrounded electrical shields in an electrical connector typically act as antennas that tend to degrade signal integrity, including cross-talk, at data frequencies greater than 5 GHz.

Referring now toFIGS.21A-21B, an electrical connector assembly220can include a first electrical connector222and a second electrical connector224that is configured to be mated to the first electrical connector222along the longitudinal direction L, which can define a mating direction. Each of the first and second electrical connectors222and224can be configured to be mounted to respective first and second electrical devices. For instance, the first electrical connector222can be mounted to at least one electrical cable226so as to place the first electrical connector222in electrical communication with the at least one electrical cable226. In this regard, the first electrical connector222can be referred to as a cable connector. The second electrical connector224can be configured to be mounted to an underlying substrate228that can be configured as a printed circuit board (PCB). When the first and second electrical connectors222and224are mounted to the at least one electrical cable226and the substrate228, respectively, the first and second electrical connectors222and224place the at least one electrical cable226and the substrate228in electrical communication with each other. Thus, the electrical connector assembly220can further include that at least one electrical cable226and the substrate228.

Referring also toFIG.22, the first electrical connector222can include a first electrically insulative connector housing230, and a plurality of first electrical contacts232supported by the connector housing230. The electrical contacts32can be arranged in a first plurality of rows234. The rows234can be oriented along a lateral direction A that is perpendicular to the longitudinal direction L, and can also be referred to as a row direction. Further, adjacent rows234can be spaced from each other along a transverse direction T that is perpendicular to the lateral direction A and the longitudinal direction L.

Each of the electrical contacts232can define a mating end236and a mounting end238opposite the mating end. The mounting ends238can be configured to be mounted to the first electrical device. The mating ends236can be configured to mate with respective electrical contacts240of the second electrical connector224when the first and second electrical connectors222and224are mated with each other. The mating ends236and mounting ends238can be disposed opposite each other along the longitudinal direction L and oriented along the longitudinal direction L. Thus, the electrical contacts232can be referred to as vertical contacts, and the first electrical connector222can be referred to as a vertical electrical connector. Alternatively, the mating ends236and mounting ends238can be oriented perpendicular to each other, such that the electrical contacts232define right-angle contacts, and the first electrical connector222can be referred to as a right-angle electrical connector.

As described above, the first electrical connector222can be mounted to a plurality of electrical cables226so as to define a cable connector. The electrical cables226can each include at least one electrical signal conductor242, and an electrical insulator244that surrounds the signal conductor242. The electrical cables226can each further include an electrical ground. In one example, the electrical ground can be configured as an electrical shield that at least partially or entirely surrounds the electrical insulator244, and thus the at least one signal conductor242. Accordingly, it can be said that the at least one signal conductor242, and thus the electrical cable226, can be electrically shielded. In one example, the electrical cables226can be configured as twinaxial cables that each includes a pair of signal conductors242surrounded by the electrical insulator244. The pair of signal conductors242of each of the electrical cables226can be arranged along a common one of the rows234, or along the lateral direction A. Alternatively, the electrical cables226can be configured as coaxial cables, whereby the at least one electrical signal conductor242defines only a single electrical signal conductor. Adjacent ones of the electrical signal conductors242along the respective rows234can define a differential signal pair. Alternatively, the electrical signal conductors242can be single ended. A plurality of electrical cables can be disposed adjacent each other along each of the rows234as desired.

The electrical contacts232can include electrical signal contacts247and electrical ground contacts248. Alternatively, the electrical contacts232can define an open pinfield, and not assigned as ground contacts or signal contacts prior to use. The mounting ends238of the electrical ground contacts248can be configured to contact the electrical ground of the electrical cables226, respectively. Further, the electrical ground contacts248can be electrically commoned to each other. That is, the electrical ground contacts248can all be in electrical communication with each other. In one example, the electrical ground contacts248of each row can be defined by a single monolithic electrically conductive structure. The electrically conductive structure can be metallic. The mounting ends238of the electrical signal contacts247can be configured to contact a respective one of the electrical signal conductors242of the electrical cables226. The mating ends236of the electrical ground contacts248can be disposed between adjacent ones of the mating ends236of the electrical signal contacts247. For instance, at least one mating end236of the electrical ground contacts248can be disposed between adjacent pairs of the mating ends236of the electrical signal contacts247along each of the respective rows234. In one example, a pair of mating ends236of the electrical ground contacts248can be disposed between adjacent pairs of the mating ends236of the electrical signal contacts247along each of the respective rows234. Thus, the electrical contacts232can be arranged in a repeating S-S-G-G configuration along the respective row, where “S” designates one or more up to all of a mating end236, a mounting end238, and a body of an electrical signal contact247, and “G” designates one or more up to all of a mating end236, a mounting end238, and a body of an electrical ground contact248. The body of the electrical signal contact247and the electrical ground contact248, respectively, can extend from the respective mating end236to the respective mounting end238. Alternatively, the electrical contacts232can be arranged in a repeating S-S-G configuration along the respective row. In this regard, it should be appreciated, of course, that the electrical contacts232can be arranged in any suitable alternative configuration of signal contacts and ground contacts as desired. Further, the mating ends236of the electrical ground contacts248can be aligned with the mating ends236of the electrical signal contacts247along the respective rows234. Similarly, the mounting ends238of the electrical ground contacts248can be aligned with the mounting ends of the electrical signal contacts247along the respective rows234.

The second electrical connector224includes a second electrically insulative connector housing250and a plurality of second electrical contacts240supported by the second connector housing250. The electrical contacts232of the first electrical connector222can be insert molded in the first connector housing230. Alternatively, electrical contacts232of the first electrical connector222can be stitched into the first connector housing230. Similarly, the electrical contacts240of the second electrical connector224can be insert molded in the second connector housing250. Alternatively, electrical contacts240of the second electrical connector224can be stitched into the second connector housing250.

The electrical contacts240can be arranged in a second plurality of rows252. The rows252can be oriented along the lateral direction A. Further, adjacent rows252can be spaced from each other along the transverse direction T. Thus, the rows234and252can be oriented parallel to each other.

Each of the electrical contacts240of the second electrical connector224can define a mating end254and a mounting end256opposite the mating end. The mounting ends256can be configured to be mounted to the substrate228, thereby placing the second electrical connector224in electrical communication with the substrate228. The mating ends254can be configured to mate with the mating ends236of respective ones of the electrical contacts232of the first electrical connector222when the first and second electrical connectors222and224are mated with each other. The mating ends254and mounting ends256can be disposed opposite each other along the longitudinal direction L and oriented along the longitudinal direction L. Thus, the electrical contacts240can be referred to as vertical contacts, and the second electrical connector224can be referred to as a vertical electrical connector. Alternatively, the mating ends254and mounting ends256can be oriented perpendicular to each other, such that the electrical contacts240define right-angle contacts, and the second electrical connector224can be referred to as a right-angle electrical connector.

Referring now toFIGS.21A-23C, the first electrical connector222can include at least one first electrical shield258that is configured to reduce near-end crosstalk in the first electrical connector222. Further, the electrical shield258can be configured to reduce near-end crosstalk in the electrical connector assembly220. Similarly, the second electrical connector can include at least one second electrical shield260that is configured to reduce near-end crosstalk in the second electrical connector224. Further, the second electrical shield260can be configured to reduce near-end crosstalk in the electrical connector assembly220. The first electrical shield258will now be described, followed by a description of the second electrical shield260.

The first electrical shield258can include an electrically conducive substrate262that is supported by the connector housing230. In one example, the electrically conductive substrate262can be configured as a plate. In another example, the electrically conductive substrate262can define a mesh. For instance, the electrically conductive substrate262can comprise a plurality of electrically conductive fibers. The fibers can be woven so as to define the mesh. It is appreciated that the mesh can define a plurality of openings. The openings can be defined by the interstices of the fibers. Alternatively, it is recognized that openings extending through the substrate262can be alternatively defined. For instance, a plurality of openings can be defined in a nonwoven substrate or plate. In one example, the electrically conductive substrate262can be metallic. Thus, the plate or fibers can be metallic. For instance, the electrically conductive substrate262can be made from copper, which can be pure copper or a copper alloy. It should be appreciated, of course, that the electrically conductive substrate262can be made from and comprise any suitable alternative material as desired. The electrical shield260, and thus the electrically conductive substrate262, can be disposed between first and second signal contacts247so as to provide electrical shielding therebetween. For instance, the electrical shield260, and thus the electrically conductive substrate262, can be disposed between first and second adjacent rows of the plurality of rows234of electrical contacts, and can provide electrical shielding between the signal contacts247of the first row and the signal contacts247of the second row.

In one example, the electrically conductive substrate262, and thus the electrical shield258, can be ungrounded. Accordingly, the electrical shield258, and thus the electrically conductive substrate262, is not in contact with any electrically conductive structures that, in turn, are in contact with any of the ground contacts248. Further, in one example, the electrical connector222can be configured such that no portion of the electrical shield258, and thus the electrically conductive substrate262, is in contact with any grounded electrically conductive structures of the electrical connector222and of any electrically conductive structures that are mated with or mounted to the electrical connector222. Alternatively, in some examples, the electrically conductive substrate262can be in electrical communication with the electrical ground contacts248if desired. The electrically conductive substrate262can be planar along a plane defined by the longitudinal direction L and the lateral direction A. Further, the electrically conductive substrate262can be equidistantly positioned between the first and second rows234with respect to the transverse direction T. It should be appreciated, of course, that the electrically conductive substrate can define any suitable shape as desired. While the electrical shield258is described as being between the first and second rows, it is recognized that the electrical connector222can include a plurality of electrical shields disposed between respective different adjacent ones of the plurality of rows234.

The electrical shield258can further include a lossy material64disposed on at least a portion up of the electrically conductive substrate262. For instance, as described in more detail below, the lossy material64can be disposed on a majority of the electrically conductive substrate262. In one example, the lossy material64can be disposed on an entirety of the electrically conductive substrate262. The lossy material64can be electrically conductive in one example. In another example, the lossy material64can be electrically nonconductive. In one example, the lossy material64can be provided as commercially available by Ecosorb® having a place of business in Houston, TX For instance, the lossy material64can be Ecosorb® GDS. Alternatively, the lossy material64can be Ecosorb® LS-30. In another example, the lossy material can be HM2000 commercially available from Arc Technologies, Inc having a place of business in Massachusetts. In one example, the lossy material64can be a broadband lossy material. Thus, the lossy material64of the first electrical connector222of the electrical connector assembly220can be devoid of CMC that can be configured to tune the absorbing frequency of the lossy material64as described above.

The electrically conductive substrate262can define a first side263aand a second side263bopposite the first side263aalong the transverse direction T. The first side263acan face the first row234, and the second side263bcan face the second row234. The electrically conductive substrate262can further define at least one edge that extends from the first side263ato the second side263b. For instance, the electrically conductive substrate262can define a first edge265aand a second edge265bthat is opposite the first edge265aalong the longitudinal direction L. For instance, the first edge265acan be spaced from the second edge265bin the mating direction. Thus, the first edge265acan be disposed adjacent a mating interface of the first electrical connector222. Further, the first edge265acan face the second electrical connector224. The second edge265bcan be disposed adjacent a mounting interface of the first electrical connector222. The mounting interface of the first electrical connector222can face away from the second electrical connector when the first electrical connector is configured as a vertical connector. The electrically conductive substrate262can define side edges265cthat are opposite each other along the lateral direction A, and extend from the first edge265ato the second edge265b, and from the first side263ato the second side263b.

In one example, the lossy material64can be disposed on at least one of the first side,263a, the second side263b, and the at least one edge of the electrically conductive substrate262. For instance, the lossy material64can be disposed on at least one of the first and second sides263aand263b. For instance, the lossy material64can be disposed on a respective entirety of at least one of the first and second sides263aand263b. In one example, the lossy material64can be disposed on each of the first and second sides263aand263b. The lossy material64can extend from the first edge265ato the second edge265b, and from and to the opposed side edges265c. Alternatively or additionally, the lossy material64can be impregnated in the electrically conductive substrate262in the manner described above.

Thus, the lossy material64can extend continuously between a plurality of the electrical contacts232of the first row and a plurality of the electrical contacts232of the second row. In one example, the lossy material64can extend continuously between all signal contacts247electrical of the first row234and all signal contacts247of the second row234. For instance, the lossy material64can extend continuously between all electrical contacts232of the first row234and all electrical contacts232of the second row234. Thus, it will be appreciated that the electrical shield258, including the substrate262and the lossy material64, can extend to a position aligned along the transverse direction T with the mounting ends238of the electrical signal contacts247of each of the first and second rows. The mounting location can be referred to as a location at the mounting ends238of the signal contacts247that contact, or are mounted to, the signal conductors242of the electrical cables226. Further, the electrical shield258, including the substrate262and the lossy material64, can extend to a position aligned along the transverse direction T with the mating locations of the electrical signal contacts247of each of the first and second rows. The mating locations can be referred to as locations in the first electrical connector222at the mating ends236of the signal contacts247that contact, or are mated with, the signal contacts of the second electrical connector224.

The electrically conductive substrate262can have a thickness from the first side263ato the second side263balong the transverse direction T. The lossy material64disposed on the first side263acan also have a thickness along the transverse direction. The thickness of the lossy material64disposed on the first side263acan be greater than, less than, or substantially equal to the thickness of the electrically conductive substrate262. In one example, the thickness of the lossy material64disposed on the first side263acan be within substantially 50% of the thickness of the electrically conductive substrate262. Similarly, the lossy material64disposed on the second side263bcan also have a thickness along the transverse direction. The thickness of the lossy material64disposed on the second side263bcan be greater than, less than, or substantially equal to the thickness of the electrically conductive substrate262. In one example, the thickness of the lossy material64disposed on the second side263bcan be within substantially 50% of the thickness of the electrically conductive substrate262.

In one example, the thickness of the electrical shield258can range from substantially 5 microns to substantially 1000 microns, such as from substantially 5 microns to substantially 500 microns. For instance, the thickness of the electrical shield258can range from substantially 10 microns to substantially 500 microns, such as from substantially 50 microns to substantially 300 microns. The thickness of the electrically conductive substrate can range from substantially 5 microns to substantially 1000 microns, such as from substantially 5 microns to substantially 500 microns. For instance, the thickness of the substrate262can range from substantially 10 microns to substantially 500 microns, such as from substantially 50 microns to substantially 300 microns. It should be appreciated, of course, that the thickness of the electrical conductive substrate262and the lossy material disposed on each of the first and second sides263aand263bcan vary as desired. For instance, it is recognized that the material or materials used for the lossy material64can result in different thicknesses.

In some examples, the lossy material64can be disposed on one or both of the edges265aand265b. Alternatively or additionally, the lossy material64can be disposed on one or both of the side edges265c. Thus, it will be appreciated that the electrically conductive substrate262can be encapsulated by the lossy material64as desired.

It should be appreciated that a method can include the step of supporting the electrical shield258by the first connector housing230. For instance, in one example, the lossy material64can be applied to the electrically conductive substrate262in suitable any manner desired. For instance, the lossy material64can be applied to the electrically conductive substrate in any manner described above with respect to the electrical contact, the connector housing, and the leadframe housing. Thus, the lossy material can define a coating on an outer side of the substrate262. Alternatively, for instance, the first substrate262defines a plurality of openings therethrough, for instance when the first substrate262is a mesh, the first substrate262can be impregnated with the lossy material64. Thus, the thickness of the electrical shield258can be less than the sum of the individual thickness of the lossy material and the individual thickness of the substrate26. Next, the electrical shield258can be insert molded in the first connector housing230. Alternatively, the electrical shield258can be fastened to the connector housing230in any manner as desired. Alternatively, the electrically conductive substrate262can be first supported by the first connector housing230. For instance, the electrically conductive substrate262can be insert molded in the first connector housing. Alternatively, the electrically conductive substrate262can be fastened to the connector housing230in any manner as desired. Next, the lossy material64can be applied to the exposed portions of the electrically conductive substrate262as described above.

A portion of the electrical shield258can be cantilevered in the mating direction. For instance, the connector housing230can define a cantilevered portion231, and a portion of the electrical shield258can be supported by the cantilevered portion. For instance, a first portion of the cantilevered portion231can be in contact with the lossy material64that is disposed on the first side263aof the electrically conductive substrate262, and a second portion of the cantilevered portion231can be in contact with the lossy material64that is disposed on the second side263bof the electrically conductive substrate262. The cantilevered portion231can define a plug that is received in a corresponding receptacle251defined by the second connector housing250of the second electrical connector224so as to mate the first and second electrical connectors222and224to each other. Alternatively, the second electrical connector224can define the plug, and the first electrical connector222can define the receptacle.

With continuing reference toFIGS.21A-23C, the second electrical shield260can include a second electrically conducive substrate266that is supported by the second connector housing250. Thus, the electrically conductive substrate262can be referred to as a first electrically conductive substrate. The second electrically conductive substrate266can be constructed as described above with respect to the electrically conductive substrate262. Thus, for example, the substrate266can be configured as a plate. Alternatively, the substrate266can have openings. For instance, the substrate266can be configured as a mesh. The electrical shield260, and thus the electrically conductive substrate266, can be disposed between first and second electrical contacts240so as to provide electrical shielding therebetween. For instance, the second electrical shield260, and thus the electrically conductive substrate266, can be disposed between adjacent rows of the plurality of second rows252of electrical contacts240. The electrical contacts240can include electrical signal contacts268and electrical ground contacts270. The mating ends254of the electrical signal contacts268can be configured to mate with respective ones of the mating ends236of the electrical signal contacts247of the first electrical connector222. The mounting ends256of the electrical ground contacts270can be mounted to the substrate228. Similarly, the mating ends254of the electrical ground contacts270can be configured to mate with respective ones of the mating ends236of the electrical ground contacts270of the first electrical connector222. The mounting ends256of the electrical ground contacts270can be mounted to the substrate228.

The second electrical shield260can provide electrical shielding between the signal contacts268of the first row and the signal contacts268of the second row. In one example, the electrically conductive substrate266is metallic. For instance, the electrically conductive substrate266can be made from copper, which can be pure copper or a copper alloy. It should be appreciated, of course, that the electrically conductive substrate266can be made from any suitable alternative material as desired.

In one example, the second electrically conductive substrate266, and thus the second electrical shield260, can be ungrounded. Accordingly, the second electrical shield260, and thus the electrically conductive substrate266, is not in contact with any electrically conductive structures that, in turn, are in contact with any of the ground contacts270. Further, in one example, the electrical connector224can be configured such that no portion of the second electrical shield260, and thus the electrically conductive substrate266, is in contact with any grounded electrically conductive structures of the electrical connector224and of any electrically conductive structures that are mated with or mounted to the electrical connector224. Alternatively, in some examples, the electrically conductive substrate266can be in electrical communication with the electrical ground contacts270if desired. The electrically conductive substrate266can be planar along a plane defined by the longitudinal direction L and the lateral direction A. Further, the electrically conductive substrate266can be equidistantly positioned between the first and second rows252with respect to the transverse direction T. It should be appreciated, of course, that the electrically conductive substrate266can define any suitable shape as desired. While the second electrical shield260is described as being disposed between the first and second rows252, it is recognized that the electrical connector222can include a plurality of electrical shields disposed between respective different adjacent ones of the plurality of rows252.

The second electrical shield260can further include a lossy material272disposed on at least a portion up of the electrically conductive substrate266. The lossy material272can be as described above with respect to the lossy material64. Thus, the lossy material272can be referred to as a second lossy material to the extent that it is included in the second electrical shield260, but it can be the same material as the lossy material64, which can be referred to as a first lossy material to the extent that it is included in the first electrical shield258. The lossy material272For instance, as described in more detail below, the lossy material272can be disposed on a majority of the electrically conductive substrate266. In one example, the lossy material272can be disposed on an entirety of the electrically conductive substrate266. The lossy material272can be electrically conductive in one example. In another example, the lossy material272can be electrically nonconductive. In one example, the lossy material272can be provide as commercially available by Ecosorb® having a place of business in Houston, TX. In this regard, the lossy material272can be the same material as the lossy material64of the first electrical shield258.

The second electrically conductive substrate266can define a first side267aand a second side267bopposite the first side267aalong the transverse direction T. The first side267acan face the first row252, and the second side267bcan face the second row252. The second electrically conductive substrate266can further define at least one edge that extends from the first side267ato the second side267b. For instance, the electrically conductive substrate266can define a first edge269aand a second edge269bthat is opposite the first edge269aalong the longitudinal direction L. For instance, the first edge269acan be spaced from the second edge269bin the mating direction. Thus, the first edge269acan be disposed adjacent a mating interface of the first electrical connector222. Further, the first edge269acan face the first electrical connector222. The second edge269bcan be disposed adjacent a mounting interface of the second electrical connector224. Thus, the second edge269bcan face the substrate228. The second electrically conductive substrate266can define side edges that are opposite each other along the lateral direction A, and extend from the first edge269ato the second edge269b, and from the first side267ato the second side267b.

In one example, the lossy material272can be disposed on at least one of the first side267a, the second side267b, and the at least one edge of the electrically conductive substrate266. For instance, the lossy material272can be disposed on at least one of the first and second sides267aand267b. For instance, the lossy material272can be disposed on a respective entirety of at least one of the first and second sides267aand267b. In one example, the lossy material272can be disposed on each of the first and second sides267aand267b. The lossy material272can extend from the first edge269ato the second edge269b, and from and to the opposed side edges. Alternatively or additionally, the lossy material272can be impregnated in the second electrically conductive substrate266in the manner described above.

Thus, the lossy material272can extend continuously between a plurality of the electrical contacts240of the first row252and a plurality of the electrical contacts240of the second row252. In one example, the lossy material272can extend continuously between all signal contacts268electrical of the first row262and all signal contacts268of the second row262. For instance, the lossy material272can extend continuously between all electrical contacts240of the first row262and all electrical contacts240of the second row252. Thus, it will be appreciated that the second electrical shield260, including the substrate266and the lossy material272, can extend to a position aligned along the transverse direction T with the mounting ends256of the electrical signal contacts268of each of the first and second rows252. The mounting location can be referred to as a location at the mounting ends256of the signal contacts268that contact, or are mounted to, solder balls that, in turn, are mounted to the substrate228. The second electrical shield260can extend out from a mounting end of the connector housing250toward the substrate228to a location that is spaced from the substrate228along the longitudinal direction L so as to define a gap that extends from the second electrical shield260to the substrate228. For instance, the gap can extend from the second edge269bto the substrate28. In one example, the gap can be less than substantially 0.5 mm. For instance, the gap can be less than substantially 0.3 mm. In one example, the gap can be substantially 0.1 mm. The mounting end of the connector housing250can face the substrate228when the second electrical connector224is mounted to the substrate228. It can be desirable to minimize the gaps, and all gaps disclosed herein, in order to enhance the effective shielding of the electrical shields258and260. It can further be desirable to eliminate the gaps.

Further, the second electrical shield260, including the substrate266and the lossy material272, can extend to a position aligned along the transverse direction T with the mating locations of the electrical signal contacts268of each of the first and second rows252. The mating locations can be referred to as locations in the second electrical connector24at the mating ends254of the signal contacts268that contact, or are mated with, the signal contacts247of the first electrical connector222.

The electrically conductive substrate266can have a thickness from the first side267ato the second side267balong the transverse direction T. The lossy material272disposed on the first side267acan also have a thickness along the transverse direction. The thickness of the lossy material272disposed on the first side267acan be greater than, less than, or substantially equal to the thickness of the electrically conductive substrate266. In one example, the thickness of the lossy material272disposed on the first side267acan be within substantially 50% of the thickness of the electrically conductive substrate266. Similarly, the lossy material272disposed on the second side267bcan also have a thickness along the transverse direction. The thickness of the lossy material272disposed on the second side267bcan be greater than, less than, or substantially equal to the thickness of the electrically conductive substrate266. In one example, the thickness of the lossy material272disposed on the second side267bcan be within substantially 50% of the thickness of the electrically conductive substrate266.

In one example, the thickness of the second electrical shield260can range from substantially 5 microns to substantially 1000 microns, such as from substantially 5 microns to substantially 500 microns. For instance, the thickness of the second electrical shield260can range from substantially 10 microns to substantially 500 microns, such as substantially 50 microns to substantially 300 microns. Thus, it should be appreciated that the second electrical shield260can have substantially the same thickness as the first electrical shield258. Further, the lossy material272can have the same thickness as the lossy material64. The thickness of the second electrically conductive substrate266can range from substantially 5 microns to substantially 1000 microns, such as from substantially 5 microns to substantially 500 microns. For instance, the thickness of the substrate266can range from substantially 10 microns to substantially 500 microns, such as substantially 50 microns to substantially 300 microns. It should be appreciated, of course, that the thickness of the electrically conductive substrate266and the lossy material272disposed on each of the first and second sides267aand267bcan vary as desired

In some examples, the lossy material272can be disposed on one or both of the edges267aand267b. Alternatively or additionally, the lossy material272can be disposed on one or both of the side edges. Thus, it will be appreciated that the electrically conductive substrate262can be encapsulated by the lossy material272as desired.

It should be appreciated that a method can include the step of supporting the second electrical shield260by the second connector housing250. For instance, in one example, the lossy material272can be applied to the electrically conductive substrate266as described above with respect to the application of the lossy material64to the electrically conductive substrate262. Next, the second electrical shield260can be insert molded in the second connector housing250. Alternatively, the second electrical shield260can be fastened to the connector housing250in any manner as desired. Alternatively, the electrically conductive substrate266can be first supported by the second connector housing250. For instance, the electrically conductive substrate266can be insert molded in the second connector housing250. Alternatively, the electrically conductive substrate266can be fastened to the connector housing250in any manner as desired. Next, the lossy material272can be applied to the exposed portions of the electrically conductive substrate266as described above.

Referring now toFIGS.21B and23A-23C, and as described above, the first and second electrical connectors222and224are configured to be mated with each other. Further, in one example, the first and second electrical shields258and260can be aligned with each other along the longitudinal direction L. Further, the electrical connector assembly220can define a gap that extends from the first electrical shield258to the second electrical shield260along the longitudinal direction L. In particular, the first electrical shield258can extend to a mounting end of the connector housing230along the longitudinal direction L. The mounting end of the connector housing230can face the second electrical connector224when the first and second electrical connectors222and224are mated with each other. Alternatively, the first electrical shield258can be inwardly recessed with respect to the mounting end of the connector housing30along the longitudinal direction L. The mounting end of the connector housing230can be aligned with the first electrical shield258, and in particular with the first edge265a, along the longitudinal direction L. Further, the second electrical shield260can extend to a mating end of the second connector housing250, in particular at a region of the mating end that is aligned with the second electrical shield260along the longitudinal direction L.

When the first and second electrical connectors222and224are mated with each other, the mating ends of the respective first and second connector housings230and250can abut each other. Because the first electrical shield258can be recessed from the mating end of the first housing230, and the second electrical shield260extends to the mating end of the second housing250, the electrical connector assembly220can define a gap that extends from the first electrical shield258to the second electrical shield258along the longitudinal direction. Alternatively, the first electrical shield258can extend to the mating end of the first housing230, and the second electrical shield260can be recessed from the mating end of the second housing250. Alternatively still, each of the first electrical shield258and the second electrical shield260can be recessed from the mating end of the first housing230and the mating end of the second housing250, respectively. In one example, the gap can be less than substantially 0.5 mm. For instance, the gap can be less than substantially 0.3 mm.

In one example, each of the first and second electrical connectors222and224can be configured to transmit signals along the respective electrical signal contact at data transfer speeds of 256 gigabits per second with no more than 4% worst-case asynchronous multiactive crosstalk at a rise time that ranges from substantially 5 picoseconds to substantially 240 picoseconds. For instance, each of the first and second electrical connectors222and224can be configured to transmit signals along the respective electrical signal contact at data transfer speeds of 256 gigabits per second with no more than 5% worst-case asynchronous multiactive crosstalk at a rise time that ranges from substantially 5 picoseconds to substantially 240 picoseconds. In another example, each of the first and second electrical connectors222and224can be configured to transmit signals along the respective electrical signal contact at data transfer speeds of 256 gigabits per second with no more than 5% worst-case asynchronous multiactive crosstalk at a rise time that ranges from substantially 5 picoseconds to substantially 240 picoseconds.

In one example, the first and second electrical shields258and260can be aligned with each other along the longitudinal direction. For instance, the first and second electrical shields258and260can be coplanar with each other along a plane that is defined by the longitudinal direction L and the lateral direction A. Thus, the first and second electrically conductive substrates262and266can be aligned with each other along the longitudinal direction L. Further, the first and second electrical shields258and260can be coplanar with each other along a plane that is defined by the longitudinal direction L and the lateral direction A. Additionally, the lossy material64disposed on the first side263aof the first electrically conductive substrate262can be aligned with the lossy material272disposed on the first side267aof the second electrically conductive substrate266. For instance, the lossy material64disposed on the first side263aof the first electrically conductive substrate262can be coplanar with the lossy material272disposed on the first side267aalong a plane that is defined by the longitudinal direction L and the lateral direction A. Further still, the lossy material64disposed on the second side263bof the first electrically conductive substrate262can be aligned with the lossy material272disposed on the second side267bof the second electrically conductive substrate266. For instance, the lossy material64disposed on the second side263bof the first electrically conductive substrate262can be coplanar with the lossy material272disposed on the second side267balong a plane that is defined by the longitudinal direction L and the lateral direction A.

Referring now toFIG.24, in another example, at least respective portions of the first and second shields258and260can overlap each other along the transverse direction T. In particular, the first and second electrically conductive substrates262and266can be offset with respect to each other along the transverse direction T. Further, the first electrically conductive substrate262can extend out from the connector housing230toward the second electrical connector224. Further, a portion of the first substrate262can be received by the second connector housing250. Alternatively or additionally, the second electrically conductive substrate266can extend out from the connector housing250toward the first electrical connector222. Further, a portion of the second substrate266can be received by the first connector housing220.

Thus, a portion of the first substrate262can overlap a portion of the second substrate266, such that a straight line oriented along the transverse direction T can pass through each of the first substrate262and the second substrate266. In one example, a portion of the first side263aof the first substrate262and the second side267bof the second substrate266can face each other along the transverse direction T. The first and second substrates262and266can overlap each other any suitable distance along the longitudinal direction L as desired. For instance, the first and second substrates262and266can overlap each other up to substantially 2.5 mm along the longitudinal direction L in one example. For instance, the first and second substrates262and266can overlap each other up to substantially 1 mm along the longitudinal direction L. In another example, the first and second substrates262and266can overlap each other substantially 0.5 mm along the longitudinal direction L.

Further still, the first electrically conductive substrate262can overlap the lossy material272that is disposed on one or both of the first and second sides267aand267bof the second electrically conductive substrate266at a first region of overlap. Further, the first side263aof the first electrically conductive substrate262can abut the lossy material272that is disposed on the second side267bof the second electrically conductive substrate266. Thus, the lossy material that is disposed on the second side267bof the second electrically conductive substrate266can be disposed between the first and second electrically conductive substrates262and266at the first region of overlap.

Similarly, the second electrically conductive substrate266can overlap the lossy material64that is disposed on one or both of the first and second sides263aand263bof the first electrically conductive substrate262at a second region of overlap. Further, the second side267bof the second electrically conductive substrate266can abut the lossy material64that is disposed on the first side263aof the first electrically conductive substrate262. Thus, the lossy material64that is disposed on the first side263aof the first electrically conductive substrate262can be disposed between the first and second electrically conductive substrates262and266at the second region of overlap. In one example, the first region of overlap and the second region of overlap can have substantially equal distances along the longitudinal direction L. The distances can range from greater than 0 mm to substantially 1.5 mm. For instance, the distances can range from greater than 0 mm to substantially 1 mm. In particular, the distances can range from greater than 0 mm to substantially 0.5 mm. In one specific example, the distances can be substantially 0.25 mm.

Further, the lossy material64disposed on the first side263aof the first electrically conductive substrate262can be aligned with the lossy material272disposed on the second side267bof the second electrically conductive substrate266along the longitudinal direction L. Further still, the lossy material64disposed on the first side263aof the first electrically conductive substrate262can abut the lossy material272disposed on the second side267bof the second electrically conductive substrate266. Alternatively, a gap can extend along the longitudinal direction L from the lossy material64disposed on the first side263aof the first electrically conductive substrate262to the lossy material272disposed on the second side267bof the second electrically conductive substrate266. Otherwise stated, the lossy material64and272that is disposed on the sides263aand267b, of the respective first and second substrates262and266, that face each other is aligned with each other along the mating direction.

Referring now toFIGS.26A and27A-27Dat least a portion of the first and second shields258and260can have aligned portions that are aligned with each other along the longitudinal direction L, and jogged portions that are offset from each other along the longitudinal direction L. For instance, the first and second substrates262and266can have aligned portions that are aligned with each other along the longitudinal direction L, and jogged portions that are offset from each other. The jogged portions can overlap each other along the transverse direction T. Thus, a straight line oriented along the transverse direction T can intersect the jogged portion of each of the first and second substrates262and266.

As shown inFIGS.26A and27A-27D, either or both of the first and second electrical shields258and260as described above, for instance of respective first and second electrical connectors22and24of an electrical connector assembly20, can be jogged. Either or both of the first and second electrical connectors22and24can be board connectors configured to mount to a respective substrate such as a printed circuit board. Alternatively or additionally, either or both of the first and second electrical connectors22and24can be electrical cable connectors configured to be mounted to respective electrical cables.

Referring now toFIGS.27B-27Din particular, each of the first and second electrical shields258and260can define respective first and second substrates262and262. However, the electrical shields258and260can be alternative constructed as described herein. The substrates262and266can be configured as first and second plates that can be electrically conductive. Either or both of the first and second electrical shields can be jogged.

For instance, referring in particular toFIGS.27B-27C, the first electrical shield258can define a respective first portion271aand a respective second portion271bthat is offset with respect to the respective first portion271aalong the transverse direction T. Thus, the first substrate262can define a respective first portion273aand a respective second portion273bthat is offset with respect to the respective first portion273aalong the transverse direction T. It can therefore be said that when the first electrical shield258is disposed between first and second rows of electrical contacts of the first electrical connector22, the first electrical shield258is jogged toward the first row and away from the second row.

The second portions271band273bcan be defined by distal portions of the first electrical shield258and first substrate262, respectively. Thus, the second portions271band273bcan be spaced from the first portions271aand273a, respectively, along the mating direction along which the first electrical connector22mates with the second electrical connector24. The first portions271aand273acan be longer than the second portions271band273b, respectively, along the mating direction. Thus, as will be described in more detail below, the second electrical shield260of the second electrical connector24can better nest in the jogged second portion271bof the first electrical shield258. The transverse direction T is oriented perpendicular to a direction of elongation of the first electrical shield258and the first substrate262, which can be either or both of the longitudinal direction L and the lateral direction A.

The first and second portions271a,273a,271b, and273bcan be substantially planar. That is, at least a portion of the respective outer sides of the first and second portions can be substantially planar, for instance along the lateral direction A and the longitudinal direction L. Thus, the first portion271aof the electrical shield258can extend parallel to the second portion271bof the electrical shield. Similarly, the first portion273aof the first substrate262can extend parallel to the second portion273bof the first substrate262. The first electrical shield258can define a first jogged transition region275that extends from the first portion271ato the second portion271b. Thus, the first substrate262can define a jogged region277that extends from the first portion273ato the second portion273b.

The first electrically conductive substrate262, and thus the first electrical shield258, can define the first side263athat faces the first row, the second side263bthat is opposite the first side263aand faces the second row. The second portions271band273bcan be offset, or jogged, with respect to the first portions271aand273aalong a first direction that is from the first side263ato the second side263b. The first electrically conductive substrate262, and thus the first electrical shield258, further defines at least one edge263cthat extends from the first side263ato the second side263balong the transverse direction. In one example, the first electrical shield258can define an EMI absorber is disposed on at least one of the first side263a, the second side263b, and the at least one edge263c. In one example, the EMI absorber can be configured as lossy material64. However, as is described below, the first electrical shield258can have any suitable alternative configuration suitable to absorb EMI at a predetermined frequency within +/−5 GHz. As described herein, the predetermined frequency can be tunable by varying at least one characteristic of the first electrical shield258.

With continuing reference toFIGS.27B-27C, the second electrical shield260can similarly define a respective first portion281aand a respective second portion281bthat is offset with respect to the respective first portion281aalong the transverse direction T. Thus, the second substrate266can define a respective first portion283aand a respective second portion283bthat is offset with respect to the respective first portion283aalong the transverse direction T. The transverse direction T is oriented perpendicular to a direction of elongation of the second electrical shield260and the second substrate266, which can be either or both of the longitudinal direction L and the lateral direction A. It can therefore be said that when the second electrical shield260is disposed between first and second rows of electrical contacts of the second electrical connector24, the second electrical shield260is jogged toward the first row and away from the second row.

The second portions281band283bcan be defined by distal portions of the second electrical shield260and first substrate266, respectively. Thus, the second portions281band283bcan be spaced from the first portions281aand283a, respectively, along the mating direction along which the first electrical connector22mates with the second electrical connector24. The first portions281aand283acan be longer than the second portions281band283b, respectively, along the mating direction. The mating direction of the second electrical connector24can be opposite the mating end of the first electrical connector22. Thus, as will be described in more detail below, the second portion281bof the second electrical shield260can nest in the jogged second portion271bof the first electrical shield258. However, an entirety of the second electrical shield260can be spaced from the first electrical shield258. Alternatively, the first and second electrical shields258and260can contact each other.

The first and second portions281a,283a,281b, and283bcan be substantially planar. That is, at least a portion of the respective outer sides of the first and second portions can be substantially planar, for instance along the lateral direction A and the longitudinal direction L. Thus, the first portion281aof the second electrical shield260can extend parallel to the second portion281bof the second electrical shield260. Similarly, the first portion283aof the second substrate266can extend parallel to the second portion283bof the second substrate266. The second electrical shield260can define a second jogged transition region285that extends from the first portion281ato the second portion281b. Thus, the second substrate266can define a jogged region287that extends from the first portion283ato the second portion283b.

The first electrically conductive substrate262, and thus the first electrical shield258, can define the first side267athat faces the first row of electrical contacts of the second electrical connector24, the second side267bthat is opposite the first side263aand faces the second row. The first sides263aand267acan face the same direction, and the second sides263band267bcan face the same direction. The second portions281band283bcan be offset, or jogged, with respect to the first portions281aand283aalong a second direction that is from the second side267bto the first side267a. Thus, the first and second directions can be oriented along the transverse direction, and can further be opposite each other. The second electrically conductive substrate266, and thus the second electrical shield260, further defines at least one edge273cthat extends from the first side267ato the second side267balong the transverse direction T. In one example, the second electrical shield260can define an EMI absorber is disposed on at least one of the first side267a, the second side267b, and the at least one edge267c. In one example, the EMI absorber can be configured as lossy material272. However, as is described below, the second electrical shield260can have any suitable alternative configuration suitable to absorb EMI at a predetermined frequency within +/−5 GHz. As described herein, the predetermined frequency can be tunable by varying at least one characteristic of the second electrical shield260.

The first side263aof the first substrate262can face the second surface267bof the second substrate266at the distal ends of the first and second substrates262and266, or at the second portions271band281bof the first and second electrical shields258and260, respectively. Further, the first electrical shield258and the second electrical shield60can be devoid of lossy material at the first and second sides263aand267balong at least some up to all of the second portions271band281b, respectively. Accordingly, an air gap can extend from the first side263aof the first substrate262to the second side267bof the second substrate266at the respective second portions271band281b, respectively.

At least a portion of the second electrical shield260can be substantially coplanar with the first portion271aof the first electrical shield258when the first and second electrical connectors22and24are mated to each other. For instance, the first portion281aof the second electrical shield260can be coplanar with the first portion271aof the first electrical shield258. Further, when the first and second electrical connectors22and24are mated with each other, a portion less than an entirety of the lossy material272that is disposed on the first side267aof the second substrate266at the first portion281aof the second electrical shield258can be aligned along the mating direction with lossy material64on the first side263aof the first substrate262at the second portion of the first electrical shield. Additionally, a portion of the lossy material272less than an entirety of lossy material272that is disposed on the second side278bof the second substrate266at the first portion281aof the second electrical shield260can be aligned along the mating direction with lossy material62that is on the second side264bof the first substrate262at the second portion281bof the first electrical shield260. Further still, the second substrate266at the first portion281aof the second electrical shield260can be coplanar with the first substrate262at the first portion271aof the first electrical shield258when the first and second electrical connectors are mated to each other.

The second portions271band281bof the first and second electrical shields258and260can overlap each other along the second direction at a region of overlap. Thus, a straight line that extends along the transverse direction can extend through each of the second portions271band281b. In particular, a portion of the second side263aof the first substrate262can face a portion of the first side267aof the second substrate266at the second portion281bof the second electrical shield260along the second direction. The first and second electrical shields258and260can be devoid of lossy material between the portion of the second side263bof the first substrate258and the portion of the first side267aof the second substrate260. Accordingly, an air gap can extend from the portion of the second side263bof the first substrate258to the portion of the first side267aof the second substrate260. The first electrical shield258can include lossy material64at the first side263aof the first substrate262that is opposite the portion of the second side263bof the first substrate262and aligned with the portion of the second side263bof the first substrate262in the first direction. Similarly, the second electrical shield260can include lossy material272at the second side267bof the second substrate266that is opposite the portion of the first side267aof the second substrate266and aligned with the portion of the first side267aof the second substrate266in the second direction.

Referring now toFIG.27D, it is recognized that one of the first and second electrical shields258and260can be jogged as described above, and the other of the first and second shields258and260is not jogged in one example. Thus, an entirety of the other of the first and second shields258and260can be substantially planar along the longitudinal direction L and the lateral direction A. In one example, the first electrical shield258is jogged and the second electrical shield260is not jogged. Thus, a substantial entirety of the second electrical shield260can be substantially coplanar with the first portion271aof the first electrical shield258when the first and second electrical connectors22and24are mated to each other. Further, the lossy material272disposed on the first side267aof the second substrate266can be substantially fully aligned with the lossy material64that is disposed on the first side263aof the first substrate262at the first portion271aof the first electrical shield258. Similarly, the lossy material272disposed on the second side267bof the second substrate266can be substantially fully aligned with the lossy material64disposed on the second side263bof the first electrically conductive substrate262at the first portion271aof the first electrical shield258.

Thus, the first and second electrical shields258and260can define a region of overlap whereby the first and second electrical shields258and260are aligned along the transverse direction T, such that a straight line oriented along the transverse direction T passes through each of the first and second electrical shields258and260. In particular, the straight line can pass through the second portion271bof the first electrical shield258. In the region of overlap, a portion of the first side263aof the second substrate266faces a portion of the second side267bof the first substrate62. The portion of the second side267bis disposed at the second portion271bof the first electrical shield. The first and second electrical shields258and260can be devoid of lossy material between the portion of the first side267aof the second substrate260and the portion of the second side263bof the first substrate258. Thus, an air gap can extend from the portion of the first side267aof the second substrate260to the portion of the second side263bof the first substrate258. The first electrical shield258can include lossy material64at the first side263aof the first substrate262that is opposite the portion of the second side263bof the first substrate262and aligned with the portion of the second side263bof the first substrate262in the first direction. The second electrical shield260can include lossy material272at the second side267bof the second substrate260that is opposite the portion of the first side267aof the second substrate260and aligned with the portion of the first side267aof the second substrate260in the second direction.

Referring now toFIG.26B, the NEXT of the electrical connector assembly220illustrated inFIG.26Ais reduced with respect to an otherwise identical electrical connector assembly, but without the first and second electrical shields258and260, respectively. For instance, NEXT of the electrical connector assembly220without the first and second electrical shields258and260reaches −60 dB (decibels) at approximately 3 GHz operating frequency. NEXT of the electrical connector assembly220with the first and second electrical shields258and60reaches −60 dB (decibels) at approximately 26 GHz operating frequency. Thus, the first and second electrical shields258and260can allow the operating frequency to at least double with respect to the operating frequency without the first and second electrical shields while remaining below −60 dB. For instance, the operating frequency can triple. In one example, the operating frequency can be 5 times greater with the first and second electrical shields258and260with respect to the operating frequency without the first and second electrical shields. For instance, the operating frequency can be up to approximately 8 times greater with the first and second electrical shields258and260with respect to the operating frequency without the first and second electrical shields.

Referring now toFIG.26C, the FEXT of the electrical connector assembly220illustrated inFIG.26Ais reduced with respect to an otherwise identical electrical connector assembly, but without the first and second electrical shields258and260, respectively. For instance, FEXT of the electrical connector assembly220without the first and second electrical shields258and260reaches −60 dB (decibels) at approximately 5 GHz operating frequency. FEXT of the electrical connector assembly220with the first and second electrical shields258and260reaches −60 dB (decibels) at approximately 26 GHz operating frequency. Thus, the first and second electrical shields258and260can allow the operating frequency to at least double with respect to the operating frequency without the first and second electrical shields while remaining below −60 dB. For instance, the operating frequency can triple. In one example, the operating frequency can be approximately 5 times greater with the first and second electrical shields258and260with respect to the operating frequency without the first and second electrical shields.

Referring now toFIGS.27E-27F, the NEXT of the electrical connector assembly220illustrated inFIGS.27A-27Cis reduced with respect to an otherwise identical electrical connector assembly, but without the first and second electrical shields258and260, respectively. For instance, NEXT of the electrical connector assembly220without the first and second electrical shields258and260reaches −40 dB (decibels) at approximately 11 GHz operating frequency. NEXT of the electrical connector assembly20with the first and second electrical shields258and260reaches −40 dB (decibels) at approximately 55 GHz operating frequency. Thus, the first and second electrical shields258and260can allow the operating frequency to at least double with respect to the operating frequency without the first and second electrical shields while remaining below −40 dB. For instance, the operating frequency can triple. In one example, the operating frequency can be approximately 5 times greater with the first and second electrical shields258and260with respect to the operating frequency without the first and second electrical shields.

Referring now toFIGS.27G-27H, the FEXT of the electrical connector assembly220illustrated inFIGS.27A-27Cis reduced with respect to an otherwise identical electrical connector assembly, but without the first and second electrical shields258and260, respectively. For instance, FEXT of the electrical connector assembly220without the first and second electrical shields58and60reaches −40 dB (decibels) at approximately 11 GHz operating frequency. FEXT of the electrical connector assembly220with the first and second electrical shields258and260reaches −40 dB (decibels) at approximately 65 GHz operating frequency. Thus, the first and second electrical shields258and260can allow the operating frequency to at least double with respect to the operating frequency without the first and second electrical shields while remaining below −40 dB. For instance, the operating frequency can triple. In one example, the operating frequency can be approximately 5 times greater with the first and second electrical shields258and260with respect to the operating frequency without the first and second electrical shields.

Referring now toFIG.28, and as described above, either or both of the first and second electrical shields258and260can be constructed in accordance with any suitable alternative embodiment. For instance, while either or both of the first and second electrically conductive substrates262and266can comprise metallic plates that are homogenous and unitary in one example, the first and second substrates262and266can be alternatively constructed. For instance, either or both of the first and second substrates262and266can be configured as a hybrid structure that includes layers of different materials.

For instance, either or both of the first and second substrates262and266can include a respective electrically nonconductive layer289that defines a first outer side290aand a second outer side290bopposite the first outer side290a. The first and second outer sides290aand290bcan be opposite each other along the transverse direction T as described above. Either or both of the first and second substrates262and266can further include a first electrically conductive layer292disposed on the first outer side290a, and a second electrically conductive layer294disposed on the second outer side290b. The first and second electrically conductive layers292and294can define respective inner sides that face the electrically nonconductive layer289, and outer sides opposite the inner sides. The outer sides of the electrically conductive layers292and294can define respective outer sides of the one or both of the first and second substrates262and266. The electrical shield258or260can further include a lossy material64or272that is disposed on each of the outer sides of the first and second electrically conductive layers292and294.

The electrically nonconductive layer289can be configured as any suitable electrical insulator. For instance, the electrically nonconductive layer289can be configured as a plastic. In one example, the electrically nonconductive layer289can be an epoxy. In another example, the electrically nonconductive layer can be configured as glass. Thus, it is appreciated that the electrically nonconductive layer289can be made of any suitable electrically nonconductive material as desired. The electrically conductive layers292and294can be configured as any suitable electrically conductive material. For instance, the electrically conductive layers292and294can be configured as electrically conductive ink. The electrically conductive ink can be printed onto the outer sides of the electrically nonconductive layer289. In one example, the electrically conductive ink can be a silver ink. However, the electrically conductive ink can be made from any suitable alternative material as desired.

As described above, the resulting electrical shield can be configured to absorb an electromagnetic interference frequency within +/−5 GHz. Further, the interference frequency that is absorbed can be tuned in any manner described above. In this regard, the lossy material64or272can be constructed in accordance with any example described herein.

Referring now toFIG.29A, either or both of the first and second electrical shields258and260can be constructed in accordance with still another alternative embodiment. For instance, either or both of the first and second substrates262and266can be configured as a hybrid structure that includes layers of different materials. In particular, either or both of the first and second substrates262and266can include a respective inner electrically conductive layer291that defines a first outer side293aand a second outer side293bopposite the first outer side293a. The first and second outer sides293aand293bcan be opposite each other along the transverse direction T as described above. Either or both of the first and second substrates262and266can further include a first electrically conductive layer296disposed on the first outer side293a, and a second electrically conductive layer298disposed on the second outer side293b. The first and second electrically conductive layers292and294can define respective inner sides that face the electrically nonconductive layer289, and outer sides opposite the inner sides. Thus, the electrically conductive layer291can be disposed between the first and second electrically conductive layers292and294. The outer sides of the electrically conductive layers292and294can define respective first outer sides263aor267a, respectively, and second outer sides263bor267b, respectively, of the first or second substrates262and266. The electrical shield258or260can further include a lossy material64or272that is disposed on each of the outer sides of the first and second electrically conductive layers292and294. The lossy material64or272can be constructed in accordance with any example described herein.

The electrically conductive layer291can be configured as any suitable electrically conductive material, such as an electrically conductive adhesive in some examples. In one example, the electrically conductive adhesive can be pressure-sensitive adhesive (PSA). Thus, the electrically conductive layer s292and294can be pressure bonded to the electrically conductive layer291. The electrically conductive layers292and294can be configured as any suitable electrically conductive material. For instance, each of the electrically conductive layers292and294can be configured as electrically conductive coating, which can be any electrically conductive metal such as a silver, or any suitable electrically conductive material. The electrically conductive coatings. The electrically conductive coatings can extend along respective inner sides of the lossy material64or272.

The inner electrically conductive layer291can be thicker along the transverse direction T than each of the electrically conductive layers292and294. Further, each of the first and second layers of lossy material64or272can be thicker than each of the electrically conductive layers292and294along the transverse direction T. In one example, the inner electrically conductive layer291can have a thickness in a range from approximately 10 micrometers to approximately 50 micrometers. For instance, the thickness of the inner electrically conductive layer291can be approximately 30 micrometers. Each of the first and second electrically conductive layers292and294can have a thickness along the transverse direction T that is in a range from approximately 1 micrometer to approximately 5 micrometers. For instance, the thickness of each of the first and second electrically conductive layers can be approximately 2 micrometers. Each of the first and second layers of lossy material62or272can have a thickness along the transverse direction T that is in a range from approximately 100 micrometers to approximately 400 micrometers. For instance, the thickness of each of the first and second layers62or272of lossy material can be approximately 250 micrometers. It should be appreciated that these thicknesses are described by way of example, and that other thicknesses are envisioned.

As described above, the resulting electrical shield258or260can be configured to absorb an electromagnetic interference frequency within +/−5 GHz. Further, the interference frequency that is absorbed can be tuned in any manner described above.

The electrical shield258or260can be fabricated in accordance with any suitable method as desired. In one example, referring toFIGS.29B-29G, the method can begin by providing a layer of lossy material64or272atFIG.29B. Next, atFIG.29C, the layer of lossy material64or272can be cut and separated into first and second layers of lossy material64or272. Next atFIG.29D, the first and second electrically conductive layers296and298can be applied to, for instance coated onto, the respective inner sides of the first and second layers of lossy material64or272. Next, atFIG.29E, the material of the inner electrically conductive layer291can be applied, for instance sprayed, to one or both of the inner sides of the first and second electrically conductive layers296and298. Next, atFIG.29F, the first and second electrically conductive layers296and298can then be brought toward each other, with the inner electrically conductive layer291therebetween. Because the inner electrically conductive layer291can be a pressure-sensitive adhesive, the first and second electrically conductive layers296and298can be pressure-bonded to each other. Finally, atFIG.29G, the resulting structure can be cut as desired to produce the final electrically conductive shields258or260having desired dimensions along the lateral and longitudinal directions.

Alternatively, as illustrated inFIGS.29B and30A, the layer of lossy material64or272can be cut as desired to produce the desired final dimensions of the resulting electrical shields258or260along the lateral and longitudinal directions. Next, atFIG.30B, the electrically conductive material that defines first and second electrically conductive layers296and298can be applied to, for instance coated onto, the inner side of the lossy material64or272. Next, atFIG.30C, the material of the inner electrically conductive layer291can be applied, for instance sprayed, onto the inner side of at least one of the first and second electrically conductive layers296and298. The first and second electrically conductive layers can then be bonded to each other in the manner described above with respect toFIG.29G.

It should be appreciated that either of the methods described with respect toFIGS.20B-29G and30A-3Ccan also be used to fabricate the electrical shields258or260shown atFIG.28, whereby the inner electrically conductive layer291would be replaced by the electrically nonconductive layer289, which can be an epoxy as described above. Further, the first and second electrically conductive layers292and294replace the first and second electrically conductive layers296and298, respectively. The epoxy can be applied to the first and second electrically conductive layers292and294using any known suitable technique. Alternatively, the first and second electrically conductive layers292and294can be applied to glass in any suitable manner, when the inner electrically conductive layer289defines a glass.

Referring now toFIGS.31A-31D, either or both of the electrical shields258or260can be fabricated without lossy material. In particular, and as described above with respect toFIG.28, the electrical shields258or260can include a respective substrate262or266that includes the inner electrical insulator, or electrically nonconductive layer289described above, and the first electrically conductive layer292described above disposed on the first outer side of the electrically nonconductive layer289, and the second electrically conductive layer294described above disposed on the second outer side of the electrically nonconductive layer289. The first and second sides of the electrical insulator289can be planar and parallel to each other. As described above, the inner electrically nonconductive layer289and the first and second electrically conductive layers292and294can combine to define the respective substrate262or266. However, instead of including a lossy material, either or both of the first and second electrically conductive layers292and294can be patterned on the inner electrically nonconductive layer289so as to define the electrical shield258or260. In this regard, the respective outer sides of the first and second electrically conductive layers292and294can define the outer surfaces of the respective shield258or260. Accordingly, in the electrical connectors22and24described above, the respective substrate can be replaced with the electrically nonconductive layer289, and the first and second lossy material can be replaced by the first and second patterned electrically conductive layers292and294, respectively.

The first and second electrically conductive layers292and294can be patterned as desired. For instance, the first and second electrically conductive layers292and294can coat the opposed surfaces of the electrically nonconductive layer289, and then can be patterned using a masking and etching process. Alternatively, the first and second electrically conductive layers292and294can be patterned onto the respective outer surfaces of the electrically nonconductive layer289. The pattern of the first and second electrically conductive layers292and294can be tuned to determine the frequency of electromagnetic interference which the electrical shield258and260is configured to shield, +/−5 GHz as described above. In this regard, the first electrically conductive layer292can be patterned so as to define a first frequency at which the electrical shield is configured to shield the electromagnetic interference at the first side of the electrical shield. The second electrically conductive layer292can be patterned so as to define a second frequency at which the electrical shield is configured to shield the electromagnetic interference at the second side of the electrical shield. In some examples, the first and second electrically conductive layers292and294are identically patterned so as to define a common pattern, such that the first frequency is substantially equal to the second frequency. Alternatively, the first electrically conductive layer292can define a different pattern than the second electrically conductive layer294, such that the first and second sides of the electrical shield are configured to shield electromagnetic interference substantially at first and second different frequencies, within.

As illustrated inFIG.31B, the pattern defined by either or both of the first and second electrically conductive layers292and294can be a grid with a plurality of interconnected links. The grid can define a plurality of openings that extend through the respective electrically conductive layer along the transverse direction. The openings can be the same size and shape along an entirety of the respective first and second electrically conductive layer. Further, the openings can have a first dimension and a second dimension, wherein the first dimension is greater than the second dimension. The first and second dimensions can be oriented perpendicular to each other. The first dimension can oriented along the longitudinal direction and the second dimension can be oriented along the lateral direction. Alternatively, the second dimension can oriented along the longitudinal direction and the first dimension can be oriented along the lateral direction. Alternatively still, each of the first and second dimensions can be angled with respect to each of the lateral direction and the longitudinal direction. Alternatively still, the openings defined by the respective electrically conductive layer can have different sizes and/or shapes along the respective side of the inner electrically insulative layer289. While the openings can define the same size and shape in one example, it should be appreciated that the openings can alternatively have different sizes and/or shapes as desired. It is recognized that the sizes and shapes of the openings can determine the frequency at which the electrical shield is configured to shield electromagnetic interference between electrical contacts of an electrical connector.

Referring now toFIG.31C, in another example, the pattern can be defined by a plurality of geometric shapes disposed on the electrical insulator. The geometric shapes can define the same size and shape. Alternatively, the geometric shapes can be different along the side of the electrically insulative layer289. At least some up to all of the geometric shapes can be spaced from all other geometric shapes on the respective side of the electrically insulative layer289. The shapes can be squares, rectangles, triangles, other polygons, or any regular geometric shapes. Alternatively, the shapes can define irregular geometric shapes. Further, the geometric shapes can be spaced from each other at the same distances or at varying distances across the side of the electrically insulative layer289.

Alternatively still, referring toFIG.31D, the pattern can be configured such that the electrically conductive layer defines a plurality of rings. The rings can be concentric with each other, or non-concentric. In some examples, the rings can be discontinuous so as to define ring segments that are spaced from each other. The ring segments can be spaced from each other radially and/or circumferentially. Radially spaced rings can be spaced from each other in their respective entireties in one example. Alternatively, the electrically conductive layer can join two or more radially spaced rings to each other. It should be appreciated that the patterns illustrated inFIGS.31B-Dare presented by way of example only, and that other patterns are envisioned. It is further appreciated that the shielding frequency of the resulting electrical shield can be tuned based on the pattern of the electrically conductive layer, which can be a metallic layer as described above.

It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the appended claims.