ELECTRICAL SHIELD CONNECTOR

Abstract

 An electrical shield connector (172) configured to be attached to an end of a shielded cable (100) having a conductive wire (102) and a shield conductor (124) longitudinally surrounding the conductive wire (102). The shield connector (172) includes a connection portion that is configured for connection with a corresponding mating electrical shield connector (174) and a cable attachment portion (180) that is configured to longitudinally receive an end of the shield conductor (124). The connection portion defines a shroud surrounding an electrical terminal (160) attached to the conductive wire (102). The cable attachment portion (180) and/or crimp wings (176) projecting therefrom define a projection (244) that is configured to contact and indent the shield conductor (124), thereby mechanically and electrically connecting the shield connector (172) to the shield conductor (124). The cable attachment portion (180) may also define a knurled pattern (246) in an interior surface of the cable attachment portion (180), such as a knurled pattern (246) having a number of rhomboid-shaped indentations.

Description

TECHNICAL FIELD OF INVENTION

[0001] The invention relates to an electrical shield connector, particularly an electrical shield connector that is configured to be attached to an end of a shielded wire cable.

BACKGROUND OF THE INVENTION

[0002] The increase in digital data processor speeds has led to an increase in data transfer speeds. Transmission media used to connect electronic components to the digital data processors must be constructed to efficiently transmit the high speed digital signals between the various components. Wired media, such as fiber optic cable, coaxial cable, or twisted pair cable may be suitable in applications where the components being connected are in fixed locations and are relatively close proximity, e.g. separated by less than 100 meters. Fiber optic cable provides a transmission medium that can support data rates of up to nearly 100 Gigabits per second (Gb/s) and is practically immune to electromagnetic interference. Coaxial cable supports data transfer rates up to 10 Gb/s as digital data and has good immunity to electromagnetic interference. Twisted pair cable can support data rates above 5 Gb/s, although these cables typically require multiple twisted pairs within the cable dedicated to transmit or receive lines. The conductors of the twisted pair cables offer good resistance to electromagnetic interference which can be improved by including shielding for the twisted pairs within the cable.

[0003] Data transfer protocols such as Universal Serial Bus (USB) 3.0 and High Definition Multimedia Interface (HDMI) 1.4 require data transfer rates at or above 5 Gb/s. Both fiber optic and twisted pair cables are capable of transmitting data at these transfer rates, however, fiber optic cables are fragile (requiring field service) and significantly more expensive than twisted pair, making them less attractive for cost sensitive applications that do not require the high data transfer rates and electromagnetic interference immunity.

[0004] Infotainment systems and other electronic systems in automobiles and trucks are beginning to require cables capable of carrying high data rate signals. Automotive grade cables must not only be able to meet environmental requirements (e.g. vibration, thermal age, moisture resistance, and EMC), they must also be flexible enough to be routed in a vehicle wiring harness and have a low mass to help meet vehicle fuel economy requirements. Therefore, there is a need for a wire cable with a high data transfer rate that has low mass and is flexible enough to be packaged within a vehicle wiring harness, while meeting cost targets that cannot currently be met by fiber optic cable. Although the particular application given for this wire cable is automotive, such a wire cable would also likely find other applications, such as aerospace, industrial control, or other data communications.

[0005] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.

BRIEF SUMMARY OF THE INVENTION

[0006] In accordance with an embodiment of this invention, an electrical shield connector configured to be attached to an end of a shielded wire cable having a conductive wire cable and a shield conductor longitudinally surrounding the conductive wire cable that is separated from the conductive wire cable by an inner insulator, the shielded wire cable further having an insulative jacket at least partially surrounding the shield conductor is provided. The electrical shield connector includes a connection portion configured for connection with a corresponding mating electrical shield connector and a cable attachment portion configured to longitudinally receive an end of the shield conductor. The cable attachment portion defines a first projection configured to contact and indent the shield conductor.

[0007] The cable attachment portion may define a conductor crimp wing that is configured for attachment to the end of the shield conductor and the conductor crimp wing may define a second projection configured to contact and indent the shield conductor. The cable attachment portion may define a plurality of conductor crimp wings and each conductor crimp wing in the plurality of conductor crimp wings may define a second projection configured to contact and indent the shield conductor.

[0008] The cable attachment portion defines a knurl pattern in an interior surface of the cable attachment portion. This knurl pattern includes a plurality of indentations, wherein each indentation in the plurality of indentations has a rhomboid shape, wherein a first pair of opposing inner corners define a generally longitudinal minor distance therebetween and a second pair of opposing inner corners different from said first pair of opposing inner corners define a major distance therebetween, and wherein the generally longitudinal minor distance is less than the major distance. The cable attachment portion may further include an insulator crimp wing configured for attachment to an end of the insulative jacket. The insulator crimp wing may define a prong having a pointed end that is configured to penetrate the insulative jacket and the end of the prong is configured to not penetrate the inner insulator.

[0009] The connection portion may define a shroud configured to longitudinally surround an electrical terminal attached to the conductive wire cable. The shroud defines an embossment proximate a location of a connection between the electrical terminal and the conductive wire cable, wherein the embossment increases a distance between the connection and the shroud. The electrical shield connector is configured to be disposed within a cavity of an electrical connector body and wherein the electrical shield connector defines a triangular lock tang including a first free edge extending from the electrical shield connector and defining an acute angle relative to a longitudinal axis of the electrical shield connector, and a second free edge also extending from the electrical shield connector, substantially perpendicular to the longitudinal axis and configured to engage a lock edge within the cavity of the electrical connector body, thereby inhibiting removal of the electrical shield connector from the cavity, and wherein the first free edge and the second free edge protrude from the electrical shield connector.

[0010] Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0011] The present invention will now be described, by way of example with reference to the accompanying drawings, in which:

Fig. 1 is a perspective cut away drawing of a wire cable of a wire cable assembly having stranded conductors in accordance with a first embodiment;

Fig. 2 is a cross section drawing of the wire cable of Fig. 1 in accordance with the first embodiment;

Fig. 3 is a partial cut away drawing of the wire cable illustrating the twist lay length of the wire cable of Fig. 1 in accordance with a second embodiment;

Fig. 4 is a perspective cut away drawing of a wire cable of a wire cable assembly having solid conductors in accordance with a third embodiment;

Fig. 5 is a cross section drawing of the wire cable of Fig. 4 in accordance with the third embodiment;

Fig. 6 is a perspective cut away drawing of a wire cable of a wire cable assembly having a solid drain wire in accordance with a fourth embodiment;

Fig. 7 is a cross section drawing of the wire cable of Fig. 6 in accordance with the fourth embodiment;

Fig. 8 is a cross section drawing of a wire cable in accordance with a fifth embodiment;

Fig. 9 is a chart illustrating the signal rise time and desired cable impedance of several high speed digital transmission standards;

Fig. 10 is a chart illustrating various performance characteristics of the wire cable of Figs. 1 to 7 in accordance with several embodiments; and

Fig. 11 is a graph of the differential insertion loss versus signal frequency of the wire cable of Figs. 1 to 7 in accordance with several embodiments;

Fig. 12 is an exploded perspective view of a wire cable assembly in accordance with a sixth embodiment;

Fig. 13 is an exploded perspective view of a subset of the components of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 14 is a perspective view of the receptacle and plug terminals of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 15 is a perspective view of the receptacle terminals of the wire cable assembly of Fig. 12 contained in a carrier strip in accordance with the sixth embodiment;

Fig. 16 is a perspective view of the receptacle terminals assembly of Fig. 15 encased within a receptacle terminal holder in accordance with the sixth embodiment;

Fig. 17 is a perspective view of the receptacle terminals assembly of Fig. 16 including a receptacle terminal cover in accordance with the sixth embodiment;

Fig. 18 is a perspective assembly view of the wire cable assembly of Fig. 13 in accordance with the sixth embodiment;

Fig. 19 is a perspective view of the plug terminals of the wire cable assembly of Fig. 12 contained in a carrier strip in accordance with the sixth embodiment;

Fig. 20 is a perspective view of the plug terminals assembly of Fig. 19 encased within a plug terminal holder in accordance with the sixth embodiment;

Fig. 21 is a perspective view of a plug connector shield half of the wire cable assembly of Fig. 13 in accordance with the sixth embodiment;

Fig. 22 is a perspective view of another plug connector shield half of the wire cable assembly of Fig. 13 in accordance with the sixth embodiment;

Fig. 23 is a perspective view of a receptacle connector shield half of the wire cable assembly of Fig. 13 in accordance with the sixth embodiment;

Fig. 24 is a perspective view of another receptacle connector shield half of the wire cable assembly of Fig. 13 in accordance with the sixth embodiment;

Fig. 25 is a perspective view of the receptacle connector shield assembly of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 26 is a cross sectional view of the receptacle connector body of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 27 is a perspective view of the plug connector shield assembly of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 28 is a perspective view of the receptacle connector body of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 29 is a perspective view of the plug connector body of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 30 is a cross sectional view of the plug connector of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 31 is a perspective view of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 32 is an alternative perspective view of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 33 is a cross sectional view of the wire cable assembly of Fig. 12 in accordance with the sixth embodiment;

Fig. 34 is a perspective cut away drawing of a wire cable of a wire cable assembly having stranded conductors in accordance with a seventh embodiment;

Fig. 35 is a cross section drawing of the wire cable of Fig. 34 in accordance with the seventh embodiment;

Fig. 36 is a perspective cut away drawing of a wire cable of a wire cable assembly having solid conductors in accordance with an eighth embodiment;

Fig. 37 is a cross section drawing of the wire cable of Fig. 36 in accordance with the eighth embodiment;

Fig. 38 is a perspective view of a connector shield having contact bumps and a knurled contact pattern in accordance with the ninth embodiment;

Fig. 39 is a cross section view of the contact bump of Fig. 38 in accordance with the ninth embodiment;

Fig. 40 is a top view of the connector shield of Fig. 38 and a cable assembly in accordance with the ninth embodiment;

Fig. 41 is a perspective top view of the connector shield of Fig. 38 and a cable assembly in accordance with the ninth embodiment;

Fig. 42 is a perspective bottom view of the connector shield of Fig. 38 and a cable assembly in accordance with the ninth embodiment;

Fig. 43 is a cross section view of the connector shield of Fig. 38 and a cable assembly in accordance with the ninth embodiment;

Fig. 44 is a diagram of the indentations in the knurled pattern contact pattern of Fig. 38 in accordance with the ninth embodiment;

Fig. 45 is a top view of the receptacle connector shield of the wire cable assembly of Fig. 38 in accordance with the ninth embodiment;

Fig. 46 is a perspective view of the receptacle connector shield of the wire cable assembly of Fig. 38 in accordance with the ninth embodiment;

Fig. 47 is a top view of the plug connector of the wire cable assembly of Fig. 12 in accordance with one embodiment;

Fig. 48 is a side view of the plug connector of the wire cable assembly of Fig. 38 in accordance with the ninth embodiment; and

Fig. 49 is a chart comparing cable to shield resistance for the connector shield of Fig. 13 in accordance with the sixth embodiment to the connector shield of Fig. 38 in accordance with the ninth embodiment.

DETAILED DESCRIPTION OF THE INVENTION

[0012] Presented herein is a wire cable assembly that is capable of carrying digital signals at rates up to 5 Gigabits per second (Gb/s) (5 billion bits per second) to support both USB 3.0 and HDMI 1.4 performance specifications. The wire cable assembly includes a wire cable having a pair of conductors (wire pair) and a conductive sheet and braided conductor to isolate the wire pair from electromagnetic interference and determine the characteristic impedance of the cable. The wire pair is encased within dielectric belting to maintain transmission line characteristics and provide a consistent radial distance between the wire pair and the shield. The belting also sustains a consistent twist lay length between the wire pair if they are twisted. The consistent radial distance between the wire pair and the shield and the consistent twist lay length provides a wire cable with controlled impedance. The wire cable assembly may also include an electrical receptacle connector having a mirrored pair of receptacle terminals connected to the wire pair and an electrical plug connector having a mirrored pair of plug terminals connected to the wire pair. The receptacle and plug terminals each have a generally rectangular cross section and when the first and second electrical connectors are mated, the major widths of the receptacle terminals are substantially perpendicular to the major widths of the plug terminals and the contact points between the receptacle and plug terminals are external to the receptacle and plug terminals. Both the receptacle and plug connectors include a shield that longitudinally surrounds the receptacle or plug terminals and is connected to the braided conductor of the wire cable. The wire cable assembly may also include an insulative connector body that contains the receptacle or plug terminals and shield.

[0013] Figs. 1 and 2 illustrate a non-limiting example of a wire cable 100a used in the wire cable assembly. The wire cable 100a includes a central pair of conductors comprising a first inner conductor, hereinafter referred to as the first conductor 102a and a second inner conductor, hereinafter referred to as the second conductor 104a. The first and second conductors 102a, 104a are formed of a conductive material with superior conductivity, such as non-plated copper or silver plated copper. As used herein, copper refers to elemental copper or a copper-based alloy. Further, as used herein, silver refers to elemental silver or a silver-based alloy. The design, construction, and sources of copper and silver plated copper conductors are well known to those skilled in the art. In the example shown in Figs. 1 and 2, the first and second conductors 102a, 104a of wire cable 100a may each consist of seven wire strands 106. Each of the wire strands 106 of the first and second conductors 102a, 104a may be characterized as having a diameter of 0.12 millimeters (mm). The first and second conductors 102a, 104a may be characterized as having an overall diameter of about 0.321 millimeters (mm), which is generally equivalent to 28 American Wire Gauge (AWG) stranded wire. Alternatively, the first and second conductors 102a, 104a may be formed of stranded wire having a smaller diameter, resulting in a smaller overall diameter equivalent to 30 AWG or 32 AWG.

[0014] As shown in Fig 2, the central pair of first and second conductors 102a, 104a is longitudinally twisted over a lay length L, for example once every 15.24 mm. Twisting the first and second conductors 102a, 104a provides the benefit of reducing low frequency electromagnetic interference of the signal carried by the central pair. However, the inventors have discovered that satisfactory signal transmission performance may also be provided by a wire cable wherein the first and second conductors 102a, 104a are not twisted about one about the other. Not twisting the first and second conductors 102a, 104a may provide the benefit of reducing manufacturing cost of the wire cable by eliminating the twisting process.

[0015] Referring once more to Figs. 1 and 2, each of the first and second conductors 102a, 104a are enclosed within a respective first dielectric insulator and a second dielectric insulator, hereafter referred to as the first and second insulators 108, 110. The first and second insulators 108, 110 are bonded together. The first and second insulators 108, 110 run the entire length of the wire cable 100a, except for portions that are removed at the ends of the cable in order to terminate the wire cable 100a. The first and second insulators 108, 110 are formed of a flexible dielectric material, such as polypropylene. The first and second insulators 108, 110 may be characterized as having a thickness of about 0.85 mm.

[0016] Bonding the first insulator 108 to the second insulators 110 helps to maintain the spacing between the first and second conductors 102a, 104a. It may also keep a consistent twist lay length (see Fig. 3) between the first and second conductors 102a, 104a consistent when the first and second conductors 102a, 104a are twisted. The methods required to manufacture a pair of conductors with bonded insulators are well known to those skilled in the art.

[0017] The first and second conductors 102a, 104a and the first and second insulators 108, 110 are completely enclosed within a third dielectric insulator, hereafter referred to as the belting 112, except for portions that are removed at the ends of the cable in order to terminate the wire cable 100a. The first and second insulators 108, 110 and the belting 112 together form a dielectric structure 113.

[0018] The belting 112 is formed of a flexible dielectric material, such as polyethylene. As illustrated in Fig. 2, the belting may be characterized as having a diameter D of 2.22 mm. A release agent 114, such as a talc-based powder, may be applied to an outer surface of the bonded first and second insulators 108, 110 in order to facilitate removal of the belting 112 from the first and second insulators 108, 110 when ends of the first and second insulators 108, 110 are stripped from the first and second conductors 102a, 104a to form terminations of the wire cable 100a.

[0019] The belting 112 is completely enclosed within a conductive sheet, hereafter referred to as the inner shield 116, except for portions that may be removed at the ends of the cable in order to terminate the wire cable 100a. The inner shield 116 is longitudinally wrapped in a single layer about the belting 112, so that it forms a single seam 118 that runs generally parallel to the central pair of first and second conductors 102a, 104a. The inner shield 116 is not spirally wrapped or helically wrapped about the belting 112. The seam edges of the inner shield 116 may overlap, so that the inner shield 116 covers at least 100 percent of an outer surface of the belting 112. The inner shield 116 is formed of a flexible conductive material, such as aluminized biaxially oriented PET film. Biaxially oriented polyethylene terephthalate film is commonly known by the trade name MYLAR and the aluminized biaxially oriented PET film will hereafter be referred to as aluminized MYLAR film. The aluminized MYLAR film has a conductive aluminum coating applied to only one of the major surfaces; the other major surface is non-aluminized and therefore nonconductive. The design, construction, and sources for single-sided aluminized MYLAR films are well known to those skilled in the art. The non-aluminized surface of the inner shield 116 is in contact with an outer surface of the belting 112. The inner shield 116 may be characterized as having a thickness of less than or equal to 0.04 mm.

[0020] The belting 112 provides the advantage of maintaining transmission line characteristics and providing a consistent radial distance between the first and second conductor 102a, 104a and the inner shield 116. The belting 112 further provides an advantage of keeping the twist lay length between the first and second conductors 102a, 104a consistent. Shielded twisted pair cables found in the prior art typically only have air as a dielectric between the twisted pair and the shield. Both the distance between first and second conductors 102a, 104a and the inner shield 116 and the effective twist lay length of the first and second conductors 102a, 104a affect the wire cable impedance. Therefore a wire cable with more consistent radial distance between the first and second conductors 102a, 104a and the inner shield 116 provides more consistent impedance. A consistent twist lay length of the first and second conductors 102a, 104a also provides controlled impedance.

[0021] Alternatively, a wire cable may be envisioned incorporating a single dielectric structure encasing the first and second insulators to maintain a consistent lateral distance between the first and second insulators and a consistent radial distance between the first and second insulators and the inner shield. The dielectric structure may also keep the twist lay length of the first and second conductors consistent.

[0022] As shown in Figs. 1 and 2, the wire cable 100a additionally includes a ground conductor, hereafter referred to as the drain wire 120a that is disposed outside of the inner shield 116. The drain wire 120a extends generally parallel to the first and second conductors 102a, 104a and is in intimate contact or at least in electrical communication with the aluminized outer surface of the inner shield 116. In the example of Figs. 1 and 2, the drain wire 120a of wire cable 100a may consist of seven wire strands 122. Each of the wire strands 122 of the drain wire 120a may be characterized as having a diameter of 0.12 mm, which is generally equivalent to 28 AWG stranded wire. Alternatively, the drain wire 120a may be formed of stranded wire having a smaller gauge, such as 30 AWG or 32 AWG. The drain wire 120a is formed of a conductive wire, such as an unplated copper wire or a tin plated copper wire. The design, construction, and sources of copper and tin plated copper conductors are well known to those skilled in the art.

[0023] As illustrated in Figs. 1 and 2, the wire cable 100a further includes a braided wire conductor, hereafter referred to as the outer shield 124, enclosing the inner shield 116 and the drain wire 120a, except for portions that may be removed at the ends of the cable in order to terminate the wire cable 100a. The outer shield 124 is formed of a plurality of woven conductors, such as copper or tin plated copper. As used herein, tin refers to elemental tin or a tin-based alloy. The design, construction, and sources of braided conductors used to provide such an outer shield are well known to those skilled in the art. The outer shield 124 is in intimate contact or at least in electrical communication with both the inner shield 116 and the drain wire 120a. The wires forming the outer shield 124 may be in contact with at least 65 percent of an outer surface of the inner shield 116. The outer shield 124 may be characterized as having a thickness less than or equal to 0.30 mm.

[0024] The wire cable 100a shown in Figs. 1 and 2 further includes an outer dielectric insulator, hereafter referred to as the jacket 126. The jacket 126 encloses the outer shield 124, except for portions that may be removed at the ends of the cable in order to terminate the wire cable 100a. The jacket 126 forms an outer insulation layer that provides both electrical insulation and environmental protection for the wire cable 100a. The jacket 126 is formed of a flexible dielectric material, such as polyvinyl chloride (PVC). The jacket 126 may be characterized as having a thickness of about 0.2 mm.

[0025] The wire cable 100a is constructed so that the inner shield 116 is tight to the belting 112, the outer shield 124 is tight to the drain wire 120a and the inner shield 116, and the jacket 126 is tight to the outer shield 124 so that the formation of air gaps between these elements is minimized or compacted. This provides the wire cable 100a with controlled magnetic permeability.

[0026] The wire cable 100a may be characterized as having a characteristic impedance of 95 Ohms.

[0027] Figs. 4 and 5 illustrate another non-limiting example of a wire cable 100b for transmitting electrical digital data signals. The wire cable 100b illustrated in Figs 4 and 5 is identical in construction to the wire cable 100a shown in Figs. 1 and 2, with the exception that the first and second conductors 102b, 104b each comprise a solid wire conductor, such as a bare (non-plated) copper wire or silver plated copper wire having a diameter of about 0.321 millimeters (mm), which is generally equivalent to 28 AWG solid wire. Alternatively, the first and second conductors 102b, 104b may be formed of a solid wire having a smaller gauge, such as 30 AWG or 32 AWG. The wire cable 100b may be characterized as having an impedance of 95 ± 10 ohms.

[0028] Figs. 6 and 7 illustrate another non-limiting example of a wire cable 100c for transmitting electrical digital data signals. The wire cable 100c illustrated in Figs 6 and 7 is identical in construction to the wire cable 100b shown in Figs. 4 and 5, with the exception that the drain wire 120b comprises a solid wire conductor, such as an unplated copper conductor, tin plated copper conductor, or silver plated copper conductor having a cross section of about 0.321 mm², which is generally equivalent to 28 AWG solid wire. Alternatively, the drain wire 120b may be formed of solid wire having a smaller gauge, such as 30 AWG or 32 AWG. The wire cable 100c may be characterized as having an impedance of 95 ± 10 ohms.

[0029] Fig. 8 illustrates yet another non-limiting example of a wire cable 100d for transmitting electrical digital data signals. The wire cable 100d illustrated in Figs 5 is similar to the construction to the wire cables 100a, 100b, 100c shown in Figs. 1 - 7, however, wire cable 100d includes multiple pairs of first and second conductors 102b, 104b. The belting 112 also eliminates the need for a spacer to maintain separation of the wire pairs as seen in the prior art for wire cables having multiple wire pair conductors. The example illustrated in Fig. 8 includes solid wire conductors 102b, 104b, and 120b. However, alternative embodiments may include stranded wires 102a, 104a, and 120a.

[0030] Fig. 9 illustrates the requirements for signal rise time (in picoseconds (ps)) and differential impedance (in Ohms (Ω)) for the USB 3.0 and HDMI 1.4 performance specifications. Fig. 9 also illustrates the combined requirements for a wire cable capable of simultaneously meeting both USB 3.0 and HDMI 1.4 standards. The wire cable 100a - 100f is expected to meet the combined USB 3.0 and HDMI 1.4 signal rise time and differential impedance requirements shown in Fig. 9.

[0031] Fig. 10 illustrates the differential impedances that are expected for the wire cables 100a - 100f over a signal frequency range of 0 to 7500 MHz (7.5 GHz).

[0032] Fig. 11 illustrates the insertion losses that are expected for wire cable 100a - 100f with a length of 7 m over the signal frequency range of 0 to 7500 MHz (7.5 GHz).

[0033] Therefore, as shown in Figs. 10 and 11, the wire cable 100a - 100f having a length of up to 7 meters are expected to be capable of transmitting digital data at a speed of up to 5 Gigabits per second with an insertion loss of less than 25 dB.

[0034] As illustrated in the non-limiting example of Fig. 12, the wire cable assembly also includes an electrical connector. The connector may be a receptacle connector 128 or a plug connector 130 configured to accept the receptacle connector 128.

[0035] As illustrated in Fig. 13, the receptacle connector 128 include two terminals, a first receptacle terminal 132 connected to a first inner conductor 102 and a second receptacle terminal 134 connected to a second inner conductor (not shown due to drawing perspective) of the wire cable 100. As shown in Fig. 14, the first receptacle terminal 132 includes a first cantilever beam portion 136 that has a generally rectangular cross section and defines a convex first contact point 138 that depends from the first cantilever beam portion 136 near the free end of the first cantilever beam portion 136. The second receptacle terminal 134 also includes a similar second cantilever beam portion 140 having a generally rectangular cross section and defining a convex second contact point 142 depending from the second cantilever beam portion 140 near the free end of the second cantilever beam portion 140. The first and second receptacle terminals 132, 134 each comprise a conductor attachment portion 144 that is configured to receive the end of an inner conductor of the wire cable 100 and provide a surface for attaching the first and second inner conductors 102, 104 to the first and second receptacle terminals 132, 134. As shown in Fig. 14, the conductor attachment portion 144 defines an L shape. The first and second receptacle terminals 132, 134 form a mirrored terminal pair that has bilateral symmetry about the longitudinal axis A and are substantially parallel to the longitudinal axis A and each other. As used herein, substantially parallel means that the first and second receptacle terminals and the longitudinal axis A are ± 5° of absolutely parallel to each other. In the illustrated embodiment, the distance between the first cantilever beam portion 136 and the second cantilever beam portion 140 is 2.85 mm, center to center.

[0036] As illustrated in Fig. 15, the first and second receptacle terminals 132, 134 are formed from a sheet of conductive material by a stamping process that cuts out and bends the sheet to form the first and second receptacle terminals 132, 134. The stamping process also forms a carrier strip 146 to which the first and second receptacle terminals 132, 134 are attached. The first and second receptacle terminals 132, 134 are formed using a fine blanking process that provides a shear cut of at least 80% or greater through the stock thickness. This provides a smoother surface on the minor edges of the cantilever beam portions and the contact point that reduces connection abrasion between the receptacle connector 128 and the plug connector 130. The conductor attachment portion 144 is then bent to the L shape in a subsequent forming operation.

[0037] As illustrated in Fig. 16, first and second receptacle terminals 132, 134 remain attached to the carrier strip 146 for an insert molding process that forms a receptacle terminal holder 148 that partially encases the first and second receptacle terminal 132, 134. The receptacle terminal holder 148 maintains the spatial relationship between the first and second receptacle terminals 132, 134 after they are separated from the carrier strip 146. The receptacle terminal holder 148 also defines a pair of wire guide channels 150 that help to maintain a consistent separation between the first and second inner conductors 102, 104 as they transition from the wire cable 100 to the conductor attachment portions 144 of the first and second receptacle terminals 132, 134. The receptacle terminal holder 148 is formed of a dielectric material, such as a liquid crystal polymer. This material offers performance advantages over other engineering plastics, such as polyamide or polybutylene terephthalate, for molding, processing, and electrical dielectric characteristics.

[0038] As illustrated in Fig. 17, a portion of the carrier strip 146 is removed and a receptacle terminal cover 152 is then attached to the receptacle terminal holder 148. The receptacle terminal cover 152 is configured to protect the first and second receptacle terminals 132, 134 from bending while the receptacle connector 128 is being handled and when the plug connector 130 is being connected or disconnected with the receptacle connector 128. The receptacle terminal cover 152 defines a pair of grooves 154 that allow the first and second cantilever beam portions 136, 140 to flex when the plug connector 130 is connected to the receptacle connector 128. The receptacle terminal cover 152 may also be formed of same liquid crystal polymer material as the receptacle terminal holder 148, although other dielectric materials may alternatively be used. The receptacle terminal holder 148 defines an elongate slot 156 that mated to an elongate post 158 defined by the receptacle terminal holder 148. The receptacle terminal cover 152 is joined to the receptacle terminal holder 148 by ultrasonically welding the post 158 within the slot 156. Alternatively, other means of joining the receptacle terminal holder 148 to the receptacle terminal cover 152 may be employed.

[0039] The remainder of the carrier strip 146 is removed from the first and second receptacle terminals 132, 134 prior to attaching the first and second inner conductors 102, 104 to the first and second receptacle terminals 132, 134.

[0040] As illustrated in Fig. 18, the first and second inner conductors 102, 104 are attached to the conductor attachment portions 144 of the first and second receptacle terminals 132, 134 using an ultrasonic welding process. Sonically welding the conductors to the terminals allows better control of the mass of the joint between the conductor and the terminal than other joining processes such as soldering and therefore provides better control over the capacitance associated with the joint between the conductor and the terminal. It also avoids environmental issues caused by using solder.

[0041] Returning again to Fig. 13, the plug connector 130 also includes two terminals, a first plug terminal 160 connected to a first inner conductor 102 and a second plug terminal 162 connected to a second inner conductor (not shown) of the wire cable 100. As shown in Fig. 14, the first plug terminal 160 includes a first elongate planar portion 164 that has a generally rectangular cross section. The second plug terminal 162 also includes a similar second elongate planar portion 166. The planar portions of the plug terminals are configured to receive and contact the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134. The free ends of the planar portions have a beveled shape to allow the mating first and second receptacle terminals 132, 134 to ride up and over free ends of the first and second planar portions 164, 166 when the plug connector 130 and receptacle connector 128 are mated. The first and second plug terminals 160, 162 each comprise an conductor attachment portion 144 similar to the conductor attachment portions 144 of the first and second receptacle terminals 132, 134 that are configured to receive the ends of the first and second inner conductors 102, 104 and provide a surface for attaching the first and second inner conductors 102, 104 to the first and second plug terminals 160, 162. As shown in Fig. 14, the conductor attachment portion 144 defines an L shape. The first and second plug terminals 160, 162 form a mirrored terminal pair that has bilateral symmetry about the longitudinal axis A and are substantially parallel to the longitudinal axis A and each other. As used herein, substantially parallel means that the first and second plug terminals and the longitudinal axis A are ± 5° of absolutely parallel to each other. In the illustrated embodiment, the distance between the first planar portion and the second planar portion is 2.85 mm, center to center. The inventors have observed through data obtained from computer simulation that the mirrored parallel receptacle terminals and plug terminals have a strong effect on the high speed electrical properties, such as impedance and insertion loss, of the wire cable assembly.

[0042] As illustrated in Fig. 19, the plug terminals are formed from a sheet of conductive material by a stamping process that cuts out and bends the sheet to form the plug terminals. The stamping process also forms a carrier strip 168 to which the plug terminals are attached. The conductor attachment portion 144 is then bent to the L shape in a subsequent forming operation.

[0043] As illustrated in Fig. 20, the plug terminals remain attached to the carrier strip 168 for an insert molding process that forms a plug terminal holder 170 that partially encases the first and second plug terminals 160, 162. The plug terminal holder 170 maintains the spatial relationship between the first and second plug terminals 160, 162 after they are separated from the carrier strip 168. The plug terminal holder 170, similarly to the receptacle terminal holder 148, defines a pair of wire guide channels 150 that help to maintain a consistent separation between the first and second inner conductors 102, 104 as they transition from the wire cable 100 to the conductor attachment portions 144 of the first and second receptacle terminals 132, 134. The plug terminal holder 170 is formed of a dielectric material, such as a liquid crystal polymer.

[0044] The carrier strip 168 is removed from the plug terminals prior to attaching the first and second inner conductors 102, 104 to first and second plug terminals 160, 162.

[0045] As illustrated in Fig. 18, the first and second inner conductors 102, 104 of the wire cable 100 are attached to the conductor attachment portions 144 of the first and second plug terminals 160, 162 using an ultrasonic welding process.

[0046] As illustrated in Figs. 13 and 14, the first and second plug terminals 160, 162 and the first and second receptacle terminals 132, 134 are oriented in the plug and receptacle connectors 130, 128 so that when the plug and receptacle connectors 130, 128 are mated, the major widths of the first and second receptacle terminals 132, 134 are substantially perpendicular to the major widths of the first and second plug terminals 160, 162. As used herein, substantially perpendicular means that the major widths are ± 5° of absolutely perpendicular. The inventors have observed that this orientation between the first and second plug terminals 160, 162 and the first and second receptacle terminals 132, 134 has strong effect on insertion loss. Also, when the plug and receptacle connectors 130, 128 are mated, the first and second receptacle terminals 132, 134 overlap the first and second plug terminals 160, 162. The plug and receptacle connectors 130, 128 are configured so that only the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134 contacts the planar blade portion of the first and second plug terminals 160, 162 and the contact area defined between the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 is less than the area overlapped between the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162. Therefore, the contact area, sometimes referred to as the wipe distance, is determined by the area of the first and second contact points 138, 142 and not by the overlap between the terminals. Therefore, the receptacle and plug terminals provide the benefit of a consistent contact area as long as the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134 are fully engaged with the first and second plug terminals 160, 162. Because both the plug and receptacle terminals are a mirrored pair, a first contact area between the first receptacle terminal 132 and the first plug terminal 160 and a second contact area between the second receptacle terminal 134 and the second plug terminal 162 are substantially equal. As used herein, substantially equal means that the contact area difference between the first contact area and the second contact area is less than 0.1 mm². The inventors have observed through data obtained from computer simulation that the contact area between the plug and receptacle terminals and the difference between the first contact area and the second contact area have a strong impact on insertion loss of the wire cable assembly.

[0047] The first and second plug terminals 160, 162 are not received within the first and second receptacle terminals 132, 134, therefore the first contact area is on the exterior of the first plug terminal 160 and the second contact area is on the exterior of the second plug terminal 162 when the plug connector 130 is mated to the receptacle connector 128.

[0048] The first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 may be formed from a sheet of copper-based material. The first and second cantilever beam portions 136, 140 and the first and second planar portions 164, 166 may be selectively plated using copper/nickel/silver based plating. The terminals may be plated to a 5 skin thickness. The first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 are configured so that the receptacle connector 128 and plug connector 130 exhibit a low insertion normal force of about 1 Newton (100 grams). The low normal force provides the benefit of reducing abrasion of the plating during connection/disconnection cycles.

[0049] As illustrated in Fig. 13, the plug connector 130 includes a receeptacle shield 174 that is attached to the outer shield 124 of the wire cable 100. The receeptacle shield 174 is separated from and longitudinally surrounds the first and second plug terminals 160, 162 and plug terminal holder 170. The receptacle connector 128 also includes a receptacle shield 174 that is attached to the outer shield 124 of the wire cable 100 that is separated from and longitudinally surrounds the first and second receptacle terminals 132, 134, receptacle terminal holder 148 and receptacle terminal cover 152. The receptacle shield 174 and the receeptacle shield 174 are configured to slidingly contact one another and when mated, provide electrical continuity between the outer shields of the attached wire cables 100 and electromagnetic shielding to the plug and receptacle connectors 130, 128.

[0050] As shown in Figs. 13, 21 and 22, the receeptacle shield 174 is made of two parts. The first receeptacle shield 174a illustrated in Fig. 21 includes two pairs of crimping wings, conductor crimp wings 176 and insulator crimp wings 178, adjacent a cable attachment portion 180 configured to receive the wire cable 100. The conductor crimp wings 176 are bypass-type crimp wings that are offset and configured to surround the exposed outer shield 124 of the wire cable 100 when the conductor crimp wings 176 are crimped to the wire cable 110. The drain wire 120a is electrically coupled to the first receeptacle shield 174a when the first receeptacle shield 174a is crimped to the outer shield 124 because the drain wire 120a of the wire cable 100 is sandwiched between the outer shield 124 and the inner shield 116 of the wire cable 110. This provides the benefit of coupling the receeptacle shield 174 to the drain wire 120 without having to orient the drain wire 120 in relation to the shield before crimping.

[0051] The insulation crimp wings are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the receeptacle shield 174 is crimped to the wire cable 110. Each of the insulation crimp wings further include a prong 182 having a pointed end that is configured to penetrate at least the outer insulator of the wire cable 100. The prongs 182 inhibit the receeptacle shield 174 from being separated from the wire cable 100 when a force is applied between the receeptacle shield 174 and the wire cable 100. The prongs 182 also inhibit the receeptacle shield 174 from rotating about the longitudinal axis A of the wire cable 100. The prongs 182 may also penetrate the outer shield 124, inner shield 116, or belting 112 of the wire cable 100 but should not penetrate the first and second insulators 108, 110. While the illustrated example includes two prongs 182, alternative embodiments of the invention may be envisioned using only a single prong 182 define by the first receeptacle shield 174a.

[0052] The first receeptacle shield 174a defines an embossed portion 184 that is proximate to the connection between the conductor attachment portions 144 of the plug terminals and the first and second inner conductors 102, 104. The embossed portion 184 increases the distance between the conductor attachment portions 144 and the first receeptacle shield 174a, thus decreasing the capacitive coupling between them.

[0053] The first receeptacle shield 174a further defines a plurality of protrusions 218 or bumps 186 that are configured to interface with a corresponding plurality of holes 188 defined in the second receeptacle shield 174b as shown in Fig. 22. The bumps 186 are configured to snap into the holes 188, thus mechanically securing and electrically connecting the second receeptacle shield 174b to the first receeptacle shield 174a.

[0054] As shown in Figs. 13, 23 and 24, the receptacle shield 174 is similarly made of two parts. The first receptacle shield 174a, illustrated in Fig. 23, includes two pairs of crimping wings, conductor crimp wings 176 and insulator crimp wings 178, adjacent a cable attachment portion 180 configured to receive the wire cable 110. The conductor crimp wings 176 are bypass-type crimp wings that are offset and configured to surround the exposed outer shield 124 of the wire cable 100 when the conductor crimp wings 176 are crimped to the wire cable 100.

[0055] The insulation crimp wings are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the receeptacle shield 174 is crimped to the wire cable 100. The insulation crimp wings further include a prong 182 having a pointed end that is configured to penetrate at least the outer insulator of the wire cable 100. The prongs 182 may also penetrate the outer shield 124, inner shield 116, or belting of the wire cable 100. While the illustrated example includes two prongs 182, alternative embodiments of the invention may be envisioned using only a single prong 182.

[0056] The first receptacle shield 174a defines a plurality of protrusions 218 or bumps 186 that are configured to interface with a corresponding plurality of holes 188 defined in the second receptacle shield 174b securing the second receptacle shield 174 to the first receptacle shield 174a. The first receptacle shield 174a may not define an embossed portion proximate the connection between the conductor attachment portions 144 of the first and second receptacle terminals 132, 134 and the first and second inner conductors 102, 104 because the distance between the connection and the receptacle shield 174 is larger to accommodate insertion of the receeptacle shield 174 within the receptacle shield 174.

[0057] While the exterior of the receeptacle shield 174 of the illustrated example is configured to slideably engage the interior of the receptacle shield 174, alternative embodiments may be envisioned wherein the exterior of the receptacle shield 174 slideably engages the interior of the receeptacle shield 174.

[0058] The receptacle shield 174 and the receeptacle shield 174 may be formed from a sheet of copper-based material. The receptacle shield 174 and the receeptacle shield 174 may be plated using copper/nickel/silver or tin based plating. The first and second receptacle shield 174a, 174b and the first and second receeptacle shield 174a, 172b may be formed by stamping processes well known to those skilled in the art.

[0059] While the examples of the plug connector and receptacle connector illustrated herein are connected to a wire cable, other embodiments of the plug connector and receptacle connector may be envisioned that are connected to conductive traces on a circuit board.

[0060] According to a non-limiting example of the first receptacle shield 174A shown in Figs. 38-48, the cable attachment portion 180 may include a projection 244 having a hemispherical shape, hereinafter referred to as a contact bump 244 that projects from the cable attachment portion 180 and toward the exposed outer shield 124. The contact bump 244 is configured to improve the electrical and mechanical connection between the receptacle shield 174 and the wire cable 100 by locally increasing the clamping force between the cable attachment portion 180 and the outer shield 124 as the outer shield 124 is compressed between the contact bump 244 and the belting 112. As shown in Figs. 38, 41, and 42, the floor 181 of the cable attachment portion 180 may define a contact bump 244 and/or one or both of the conductor crimp wings 176 may define a contact bump 244. As shown in Figs. 41 and 42, the contact bumps 244 may be located so that the contact bumps 244 on the conductor crimp wings 176 are positioned opposite the contact bump 244 in the floor 181 of the cable attachment portion 180. The hemispherical shape of the contact bump 244 illustrated in Fig. 39 is selected so that the contact bump 244 does not penetrate the outer shield 124 or the inner shield 116 as shown in Fig. 43. This is desirable because penetration of the shields 116, 124 by a portion of the receptacle shield 174 could cause a localized change in capacitance between the first and second inner conductors 102, 104 and the receptacle shield 174 that could negatively impact the performance of the cable assembly. While the projection or contact bump 244 shown in the illustrated embodiments of Figs. 38-48 has a hemispherical shape, other embodiments may be envisioned with projections having ellipsoid, ovoid, other shapes that will deform but will not penetrate the outer shield 124 or the inner shield 116.

[0061] The contact bump 244 may be formed by an embossing or punching process and may be formed when the other features of the receptacle shield 174 are formed.

[0062] As also illustrated in Fig. 38, the interior of the floor 181 of the cable attachment portion 180 and the interior of the conductor crimp wings 176 may define a knurled pattern 246 that includes a plurality of rhomboid indentations 248 that are configured to improve electrical connectivity and mechanical retention between the first receptacle shield 174A and the outer shield 124 of the wire cable 100. Each indentation has two sets of opposing corners 250, 252. A first set of opposing corners 250 is aligned generally along the longitudinal axis A of the receptacle shield 174 and define a minor distance while a second set of opposing corners 252 is aligned generally along a lateral axis of the receptacle shield 174 that is perpendicular to the longitudinal axis A. A minor line 254 defined between the first set of opposing corners 250 is substantially parallel to the longitudinal axis A and a major line 256 defined between the second set of opposing corners 252 is substantially perpendicular to the longitudinal axis A. As used herein, substantially parallel means that the minor line 254 between the first set of opposing corners 250 is ± 5° of absolutely parallel with the longitudinal axis A and substantially perpendicular means that the major line 256 between the second set of opposing corners 252 is ± 5° of absolutely perpendicular with the longitudinal axis A. The length X2 of the major line 256 is greater than the length X1 of the minor line 254, such that the angle α defined by the first set of opposing corners 250 is greater than the angle β defined by the second set of opposing corners 252.. Such rhomboid indentations 248 are described in U.S. Patent No. 8,485,853, the entire disclosure of which is hereby incorporated by reference. The knurl pattern may also be embossed into the contact bumps 244.

[0063] While the examples illustrated in Figs. 38-43 show a receptacle shield 174, the contact bump 244 and knurled pattern 246 shown could also be incorporated into the receptacle shield 174 and provide similar benefits.

[0064] Fig. 49 shows the results of shield to cable resistance tests for the connector shield having the contact bumps 244 and knurled pattern 246 as shown in Fig. 38 compared to a connector shield lacking these features as shown in Fig. 13. Testing performed under various conditions by the inventors has revealed that the connector shield having the contact bumps 244 and knurled pattern 246 as shown in Fig. 38 has beneficially lowered shield to cable resistance compared to the connector shield lacking these features as shown in Fig. 13.

[0065] To meet the requirements of application in an automotive environment, such as vibration and disconnect resistance, the wire cable assembly 100 may further include a receptacle connector body 190 and a plug connector body 192 as illustrated in Fig. 12. The receptacle connector body 190 and the plug connector body 192 are formed of a dielectric material, such as a polyester material.

[0066] Returning again to Fig. 12, the plug connector body 192 defines a cavity 194 that receives the plug connector 130. The plug connector body 192 also defines a shroud configured to accept the receptacle connector body 190. The plug connector body 192 further defines a low profile latching mechanism with a locking arm 196 configured to secure the plug connector body 192 to the receptacle connector body 190 when the receptacle and plug connector bodies 190, 192 are fully mated. The receptacle connector body 190 similarly defines a cavity 198 that receives the receptacle connector 128. The receptacle connector body 190 defines a lock tab 200 that is engaged by the locking arm 196 to secure the plug connector body 192 to the receptacle connector body 190 when the receptacle and plug connector bodies 190, 192 are fully mated. The wire cable assembly 100 also includes connector position assurance devices 202 that hold the plug connector 130 and the receptacle connector 128 within their respective connector body cavities 194, 198.

[0067] As illustrated in Fig. 25, the first receptacle shield 174a defines a triangular lock tang 204 that protrudes from the first receptacle shield 174a and is configured to secure the receptacle connector 128 within the cavity 198 of the receptacle connector body 190. The lock tang 204 includes a fixed edge (not shown) that is attached to the first receptacle shield 174a, a leading edge 206 extends from the fixed edge and defines an acute angle relative to a longitudinal axis A-of the receptacle shield 174a, and a trailing edge 208 that also extends from the fixed edge is substantially perpendicular to the longitudinal axis A. The leading edge 206 and the trailing edge 208 protrude from the first receptacle shield 174a. As illustrated in Fig. 26, the cavity 198 of the receptacle connector body 190 includes a narrow portion 210 and a wide portion 212. When the receptacle connector 128 is initially inserted into the narrow portion 210, the leading edge 206 of the lock tang 204 contacts a top wall 214 of the narrow portion 210 and compresses the lock tang 204, allowing the receptacle connector 128 to pass through the narrow portion 210 of the cavity 198. When the lock tang 204 enters the wide portion 212 of the cavity 198, the lock tang 204 returns to its uncompressed shape. The trailing edge 208 of the lock tang 204 then contacts a back wall 216 of the wide portion 212 of the cavity 198, inhibiting the receptacle connector 128 from passing back through the narrow portion 210 of the receptacle connector body cavity 198. The lock tang 204 may be compressed so that the receptacle connector 128 may be removed from the cavity 198 by inserting a pick tool in the front of the wide portion 212 of the cavity 198.

[0068] As shown in Fig. 27, the first plug shield 172a defines a similar lock tang 204 configured to secure the plug connector 130 within the cavity 194 of the plug connector body 192. The cavity 194 of the plug connector body 192 includes similar wide and narrow portions that have similar top walls and back walls. The lock tangs 204 may be formed during the stamping process of forming the first plug shield 172a and the first receptacle shield 174a.

[0069] Referring once again to Figs. 12 and 13, the second receptacle shield 174b also includes a pair of protrusions 218 configured to interface with a pair of grooves 220 defined in the side walls of the cavity 194 to align and orient the plug connector 130 within the cavity 194 of the plug connector body 192. The second plug shield 172b similarly defines a pair of protrusions 218 configured to interface with a pair of grooves (not shown due to drawing perspective) defined in the side walls of the cavity 198 to align and orient the receptacle connector 128 within the cavity 198 of the receptacle connector body 190.

[0070] While the examples of the receptacle and plug connector bodies 190, 192 illustrated in Fig. 12 include only a single cavity, other embodiments of the connector bodies may be envisioned that include a plurality of cavities so that the connector bodies include multiple receptacle and plug connectors 128, 130 or alternatively contain other connector types in addition to the receptacle and plug connectors 128, 130.

[0071] As illustrated in Fig. 28, the receptacle connector body 190 defines the lock tab 200 that extends outwardly from the receptacle connector body 190.

[0072] As illustrated in Fig. 29, the plug connector body 192 includes a longitudinally extending locking arm 196. A free end 222 of the locking arm 196 defines an inwardly extending lock nib 224 that is configured to engage the lock tab 200 of the receptacle connector body 190. The free end 222 of the locking arm 196 also defines an outwardly extending stop 226. The locking arm 196 is integrally connected to the socket connector body by a resilient U-shaped strap 228 that is configured to impose a hold-down force 230 on the free end 222 of the locking arm 196 when the locking arm 196 is pivoted from a state of rest. The plug connector body 192 further includes a transverse hold down beam 232 integrally that is connected to the plug connector body 192 between fixed ends and configured to engage the stop 226 when a longitudinal separating force 234 applied between the receptacle connector body 190 and the plug connector body 192 exceeds a first threshold. Without subscribing to any particular theory of operation, when the separating force 234 is applied, the front portion 236 of the U-shaped strap 228 is displaced by the separating force 234 until the stop 226 on the free end 222 of the locking arm 196 contacts the hold down beam 232. This contact between the stop 226 and the hold down beam 232 increases the hold-down force 230 on the lock nib 224, thereby maintaining engagement of the lock nib 224 with the lock tab 200, thus inhibiting separation of the plug connector body 192 from the receptacle connector body 190.

[0073] The plug connector body 192 further comprises a shoulder 238 that is generally coplanar with the U-shaped strap 228 and is configured to engage the U-shaped strap 228. Without subscribing to any particular theory of operation, when the separating longitudinal force applied between the receptacle connector body 190 and the plug connector body 192 exceeds a second threshold, the front portion 236 of the U-shaped strap 228 is displaced until the front portion 236 contacts the face of the shoulder 238 and thereby increases the hold-down force 230 on the lock nib 224 to maintain the engagement of the lock nib 224 with the lock tab 200. The separating force 234 at the second threshold is greater than the separating force 234 at the first threshold. Because the stop 226 and the U-shaped strap 228 help to increase the hold-down force 230, it is possible to provide a connector body having a low-profile locking mechanism that is capable of resisting a separating force using a polyester material that can meet automotive standards.

[0074] The locking arm 196 also includes a depressible handle 240 that is disposed rearward of the U-shaped strap 228. The lock nib 224 is moveable outwardly away from the lock tab 200 by depressing the handle to enable disengagement of the lock nib 224 with the lock tab 200. As illustrated in Fig. 30, the locking arm 196 further includes an inwardly extending fulcrum 242 disposed between the lock nib 224 and the depressible handle 240.

[0075] The inventors have discovered that a wire cable assembly that does not include a drain wire, such as wire cable assembly 100e illustrated in Figs. 34 and 35 and wire cable assembly 100f illustrated in Figs. 36 and 37 is capable of meeting the performance characteristics shown in Figs. 9 through 11. Elimination of the drain wire connection allows for improved shielding and controlled impedance. The consistency of the original cable shield construction is maintained throughout the connection, thereby improving repeatability and reliability of the system. Elimination of the drain wire connection allows for higher data transfer speeds. Present drain wire connections that are implemented inside of the shield may cause transmission line imbalance of the data pair, limiting the upper data rate.

[0076] As illustrated in Figs. 34 and 35, wire cable assembly 100e includes first and second conductors 102a, 104a that consist of seven wire strands 106. Each of the wire strands 106 of the first and second conductors 102a, 104a may be characterized as having a diameter of 0.12 millimeters (mm). The first and second conductors 102a, 104a may be characterized as having an overall diameter of about 0.321 millimeters (mm), which is generally equivalent to 28 American Wire Gauge (AWG) stranded wire. Alternatively, the first and second conductors 102a, 104a may be formed of stranded wire having a smaller diameter, resulting in a smaller overall diameter equivalent to 30 AWG or 32 AWG. The construction of wire cable assembly 100e is basically identical to the construction of wire cable assembly 100a with the exception of the drain wire 120.

[0077] As illustrated in Figs. 36 and 37, wire cable assembly 100f includes first and second conductors 102b, 104b that each comprise a solid wire conductor, such as a bare (non-plated) copper wire or silver plated copper wire having a diameter of about 0.321 millimeters (mm), which is generally equivalent to 28 AWG solid wire. Alternatively, the first and second conductors 102b, 104b may be formed of a solid wire having a smaller gauge, such as 30 AWG or 32 AWG. The construction of wire cable assembly 100f is basically identical to the construction of wire cable assembly 100b with the exception of the drain wire 120.

[0078] Accordingly, electrical shield connector is provided. A contact bump in the attachment portion and/or crimp wings of the electrical shield connector is configured to improve electrical contact and eliminate the use of ferrules on the end of the outer shield, thereby beneficially reducing the parts required and manufacturing process steps to install the ferrules. The contact bump is also configured to increase the mechanical retention force of the electrical shield connector to the outer shield without penetrating the outer or inner shields. This provides the benefit of increased retention force without a change in capacitance between the inner conductors and the electrical shield connector that could negatively impact the data transmission performance of the wire cable assembly.

Claims

1. An electrical shield connector (172) configured to be attached to an end of a shielded wire cable (100) having a conductive wire (102) cable and a shield conductor (124) longitudinally surrounding the conductive wire (102) cable that is separated from the conductive wire (102) cable by an inner insulator (113), said shielded wire cable (100) further having an insulative jacket (126) at least partially surrounding the shield conductor (124), said electrical shield connector (172) comprising:

a connection portion configured for connection with a corresponding mating electrical shield connector (174); and

a cable attachment portion (180) configured to longitudinally receive an end of the shield conductor (124), wherein the cable attachment portion (180) defines a first projection (244) configured to contact and indent the shield conductor (124).

2. The electrical shield connector (172) according to claim 1, wherein the first projection (244) is characterized as having a hemispherical shape.

3. The electrical shield connector (172) according to one of the preceding claims, wherein the cable attachment portion (180) defines a conductor crimp wing (176) configured for attachment to the end of the shield conductor (124) and wherein the conductor crimp wing (176) defines a second projection (244) configured to contact and indent the shield conductor (124).

4. The electrical shield connector (172) according to claim 3, wherein the second projection (244) is characterized as having a hemispherical shape.

5. The electrical shield connector (172) according to one of the preceding claims, wherein the cable attachment portion (180) defines a plurality of conductor crimp wings (176) and each conductor crimp wing (176) in the plurality of conductor crimp wings (176) defines a second projection (244) configured to contact and indent the shield conductor (124).

6. The electrical shield connector (172) according to one of the claims 3-5, wherein the second projection (244) is positioned opposite the first projection (244) when the conductor crimp wing (176) is crimped to the shield conductor (124).

7. The electrical shield connector (172) according to one of the preceding claims, wherein the cable attachment portion (180) defines a knurled pattern (246) in an interior surface of the cable attachment portion (180).

8. The electrical shield connector (172) according to claim 7, wherein the knurled pattern (246) includes a plurality of indentations (248), wherein each indentation in the plurality of indentations (248) has a rhomboid shape, wherein a first pair of opposing inner corners (250) define a generally longitudinal minor distance (254) therebetween and a second pair of opposing inner corners (252) different from said first pair of opposing inner corners (250) define a major distance (256) therebetween, and wherein the generally longitudinal minor distance (254) is less than the major distance (256).

9. The electrical shield connector (172) according to one of the preceding claims, wherein the cable attachment portion (180) further has an insulator crimp wing (178) configured for attachment to an end of the insulative jacket (126), wherein the insulator crimp wing (178) defines a prong (182) having a pointed end that is configured to penetrate the insulative jacket (126), wherein the end of the prong (182) is configured to not penetrate the inner insulator (113).

10. The electrical shield connector (172) according to one of the preceding claims, wherein the connection portion defines a shroud configured to longitudinally surround an electrical terminal (160) attached to the conductive wire (102).

11. The electrical shield connector (172) according to claim 10, wherein the shroud defines an embossed portion (184) proximate a location of a connection between the electrical terminal (160) and the conductive wire (102), wherein the embossed portion (184) increases a distance between the connection and the shroud.

12. The electrical shield connector (172) according to one of the preceding claims, wherein the electrical shield connector (172) is configured to be disposed within a cavity (194) of an electrical connector body (192) and wherein the electrical shield connector (172) defines a triangular lock tang (204) including a first free edge (206) extending from the electrical shield connector (172) and defining an acute angle relative to a longitudinal axis (A) of the electrical shield connector (172), and a second free edge (208) also extending from the electrical shield connector (172), substantially perpendicular to the longitudinal axis (A) and configured to engage a lock edge (216) within the cavity (194) of the electrical connector body (192), thereby inhibiting removal of the electrical shield connector (172) from the cavity (194), and wherein the first free edge (206) and the second free edge (208) protrude from the electrical shield connector (172).

Drawing