TW202418663A - Electrical connector apparatus and method - Google Patents

Abstract

An electrical connector apparatus and method is described herein. The electrical connector may include a plug connector. The electrical connector may include a mating interface. The mating interface may include a plurality of plates. The electrical connector may include a substrate. The electrical connector may include a cable connector. The electrical connector may have at least a density of at least 213 differential pairs per square inch, including 256 differential pairs per square inch. The electrical connector may include at least one internal and/or external locking mechanism.

Description

Electrical connector apparatus and method

The present embodiments generally relate to an electrical connector apparatus/assembly, and specific embodiments are shown with respect to an electrical connector.

Typical connectors intended to operate at 112G/224G may require a larger width die package substrate to accommodate. However, increasing the size of the die package substrate may increase insertion loss and/or make the die package substrate more susceptible to curling, warping and/or loss of coplanarity during reflow. Therefore, there is a need to improve the size of the die package substrate, reduce the width of the connector, minimize coplanarity issues and/or minimize insertion loss.

The present invention is concerned with overcoming or at least improving the shortcomings of the prior art. Brief description of other technical features

The entire text of U.S. Patent Nos. 7,927,144; 3,587,028; 11,539,169; 4,571,014; 4,720,770; 6,435,913; 6,506,076; 6,981,898; and 4,632,476 and U.S. Publication Nos. US20200212631; US20200280145; US20220368084; US20090203259; US20050215120; and US20210265785 are hereby incorporated by reference.

Cross-reference to previous applications

This application claims priority to U.S. Provisional Patent Application No. 63/403,561 filed on September 2, 2022, U.S. Provisional Patent Application No. 63/481,702 filed on January 26, 2023, and U.S. Provisional Patent Application No. 63/511,451 filed on June 30, 2023, the entire text of which is hereby incorporated by reference into this document.

The embodiments may be further understood with reference to the various figures. Referring to the accompanying figures, one embodiment provides one or more electrical connector assemblies 20. The assembly 20 may include at least one or more electrical connectors 30. In some embodiments, the electrical connectors may include a width of about 12.5 mm, an operation of about 224 Gbps, and/or a package size of about 75 mm. The number of pairs may be 64 pairs in less than half an inch or a density greater than 256 pairs per square inch. In some embodiments, an electrical connector may be sized and shaped such that a plurality of electrical connectors may be mounted on a single side of a die package substrate no larger than approximately 75 mm×75 mm to approximately 85 mm×85 mm, the plurality of electrical connectors may collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit approximately 224 Gbps Pam4 signals at a bandwidth of approximately 56 GHz to approximately 70 GHz with a FEXT (far end crosstalk) no greater than approximately -40 dB. In various embodiments, an electrical connector may be sized and shaped such that a plurality of electrical connectors may be mounted on a single side of a die package substrate of no greater than approximately 75 mm×75 mm to approximately 85 mm×85 mm, the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit approximately 224 Gbps Pam4 signals at a bandwidth of approximately 56 GHz to approximately 70 GHz with a NEXT (near-end crosstalk) of no more than approximately -50 dB. In some embodiments, a die package substrate having sides each no greater than about 75 mm to 110 mm includes about 80 mm±5 mm, 91 mm±5 mm, 95 mm±5 mm, 100 mm±5 mm, and 105 mm±5 mm, a plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit about 224 Gbit/sec PAM-4 signals at a bandwidth of about 56 GHz to about 70 GHz, with a FEXT no greater than about -40 dB.

Now referring to the accompanying drawings, Figures 1 to 4B illustrate an exemplary embodiment of an electrical connector assembly 20 according to one aspect of the present invention. The electrical connector assembly 20 includes an electrical connector 30 and/or a plurality of cable connectors 40 configured to mate with the electrical connector 30. The electrical connector 30 may include or be connected to a circuit substrate 50, such as, for example, a die package substrate 50a, a printed circuit board 50b. As shown in one embodiment, the connector 30 may be positioned/mounted on a single side of the circuit substrate 50 (e.g., 50a, 50b). However, in some embodiments, the connector 30 may be positioned on both sides. Referring to Figures 5 and 6, the electrical connector 30 may include a mating interface or a cable head organizer 60 (e.g., an egg rack mating interface or a shield). The mating interface 60 may include a plurality of interlocking plates 62 defining a plurality of cavities 63. The connector 30 may include or be configured to mate with one or more cable connectors 40. Each cavity 63 is sized to receive or mate to a cable connector 40. The electrical connector 30 may include one or more plug connectors 70. The electrical connector 30 or the plug connector 70 further includes one or more electrical contacts 71 and/or one or more grounding contact elements 72. Each electrical contact 71 is positioned within a cavity 63, electrically insulated from the interlocking plates 62, and configured to mate with one of the contacts 42 (e.g., a socket) of the cable connector 40. The contacts 42 may be non-compression type contacts, such as beam to beam or beam to blade versus beam to pad. A plastic or dielectric mesh and optional button may be positioned between two adjacent contacts 42 as described in U.S. Patent No. 10,439,330, the entirety of which is hereby incorporated by reference. The contacts 42 may be conductive. The contacts for each differential signal pair may be spaced about 0.3 mm to about 0.4 mm, including about 0.3 mm, about 0.35 mm, about 0.4 mm, and all lengths therebetween. The differential pair-to-pair spacing may be about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, or about 1.8 mm, and all lengths therebetween. The row-to-row spacing of the differential signal pairs may be about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, or about 1.8 mm. In an array of differential signal pairs, some rows may be unevenly spaced, such as about 1.3 mm for some rows and about 1.7 mm centerline-to-centerline spacing between other adjacent rows. Each of the ground contact elements 72 may be electrically grounded and configured to mate with at least one board 62 (e.g., directly, indirectly, a first board, a second board). The plug connector 70 (e.g., ground contact element, electrical contact) may be soldered to the circuit substrate 50 (e.g., 50a, 50b). In some embodiments as shown in FIG. 7, a 1024-pair solution may be used. In other embodiments as shown in FIG. 8, a 1192 or 1280-pair solution may be used.

In some embodiments, at least one of the interlocking plates 62 (e.g., the first plate) can be conductive and provide a ground connection between the cable connector 40 and the circuit substrate 50 or a portion thereof. In general, the interlocking plates 62 can be conductive or insulating. As shown in FIGS. 9 and 10 , at least one interlocking plate 62 includes a terminal 64 spaced from the circuit substrate 50 and a mating end 65 for electrically contacting a conductive outer shield element 43 of the cable connector 40. To reciprocally reduce/control impedance, a spacing or distance D from the circuit substrate 50 (e.g., package 50a, 50b) to the terminal 64 of the plate 62/shield 43 can be reduced by a length L of the plate 62 or cavity 63. The remainder of the length or distance D from the circuit substrate to the terminal 64 can be a source of at least one crosstalk. The plate 62 defining the cavity 63 covers or overlaps about 85% to 95% of the length of the cable connector 40 to the package or substrate 50 to minimize the distance D. As shown in one embodiment in FIG. 9 , the plate 62 defining the cavity 63 covers/overlaps about 90% of the length L of the cable connector 40 to the package to reduce crosstalk, and the remainder or distance D can be about 10% of the length L of the cable connector 40 to the substrate. An example of an impedance profile of the cable to the package is shown in FIG. 11 , showing a TDR signal simulated with 92 Ω +/- 5 Ω at 6 ps (20% to 80% rise time).

In some embodiments, the terminal 64 of the plate 62 or cavity 63 may be spaced apart from the package/substrate 50 (e.g., a predetermined distance D). The terminal 64 or plate 62 may be adjacent to/positioned/matched with the ground contact element 72 of the plug connector at a distance D. The contact element 72 or a portion thereof may space the plate 62 or a portion thereof (e.g., the terminal 64) from the substrate 50 at a distance D. In one embodiment shown, the ground contact element 72 extends/protrudes from the circuit substrate 50 (e.g., 50a, 50b). The ground contact element 72 may include one or more arms/blades. For example, the ground contact element may include at least one arm, at least two arms, at least three arms, at least four arms, or four or more arms. When mating to a mating interface (e.g., board(s), the increase in the number of arm(s) can increase the contact area/width. As shown in one embodiment, the ground contact element 72 can include two arms 72a, 72b (e.g., at least two laterally offset cantilever beams) extending upward and away from each other to define a slot 73 to receive the terminal 64 of the board(s) 62 (e.g., the first board). The two arms can branch from the remaining portion of the ground contact element or body. The two arms 72a can be offset from each other by a distance along the length or plane of the slot 73 that receives the board(s) 62. Although the arms may not overlap or cross along the length of the slot, it should be understood that in some embodiments, a portion of the arms can overlap. One or more portions (e.g., arms) of the slot or ground contact element 72 may define a stop or vertical stop mechanism for limiting further axial travel of the plate 62 within the slot or toward the circuit substrate. The stop may position the mating interface, plate, or cavity at a distance D. Additionally, the first and second arms 72a, 72b may be mirror images of each other relative to the plane of the slot 73. The first arm 72a engages the interior of one cavity/plate and the second arm 72b engages the interior of an adjacent cavity/plate. In one embodiment shown, the two ground contact elements 72 may engage adjacent and parallel plates 62 (e.g., a first plate) and not engage an adjacent second plate defining a cavity 63 that receives the cable connector 40. However, in some embodiments, one or more ground contact elements 72 may engage one or more second plates and/or be combined with one or more first plates. In one embodiment shown, each arm 72a, 72b may be spring loaded or biased to push toward the slot 73 or through the engagement plate 62. In addition, each arm or the free distal end of the arm may be opened/bent away from the slot or through the engagement plate. As shown in one embodiment, the arm 72 may be surrounded by air or free space without contacting a plastic or insulating member. There is no plastic between the mating end of the ground contact element 72 and the mating end of the signal contact 71. The mating ends of 71 and 72 may not be constrained or surrounded by (several) plastic or insulating members. Arm 72 (e.g., mating end) may be suspended above, protruding and/or extending (e.g., not inside the plastic) of the plug connector 70 at the base of the arm. In addition, there may be no plastic or insulating material along a line extending between the mating end of arm 72b and an adjacent mating end of arm 72b. An example of S parameters for a shielded return path or ground contact element is shown in FIG. 12. The simulated embodiment shown in FIG. 12 was performed at 92 Ω +/- 5 Ω at 6 ps (20% to 80% rise time). In some embodiments, the (several) contacts may include one or more solder balls/solder blocks 74. In one embodiment shown, the ground contact element 72 includes at least one solder mass 74. It should be understood that the ground contact element 72 may include one or more solder masses. For example, at least one solder mass, at least two solder masses, or at least three solder masses. In some embodiments, two or more solder masses may be adjacent to each other (e.g., linearly aligned). In some embodiments, the welding of the contact piece may be one or more elongated pads of multiple lengths. In some embodiments, the electrical/signal contact 71 may be perpendicular to the ground contact element 72.

In a preferred embodiment, the interlocking plate 62 is a metal plate formed by any suitable method, such as, for example, metal stamping. In other embodiments, the interlocking plate 62 is formed by other means, including molding and/or machining of polymer materials, molding and/or machining of metals, or construction of a metal frame overmolded with a polymer material. In some embodiments, a plastic frame/base may be electroplated.

In some embodiments, the interlocking/interconnecting plates 62 include a plurality of first plates 62a and a plurality of second plates 62b, as shown in FIGS. 5 and 6. The plate(s) 62 may include one or more grooves 66 and/or one or more slots 67. The grooves (if used) may interlock with the slots (if used) to define the cavity 63. The first plate 62a may include a plurality of first slots 67a aligned with the plurality of first grooves 66a. The second plate 62b may include a plurality of second slots 67b aligned with the plurality of second grooves 66b. By interlocking the first slots 67a with the second grooves 66b and the second slots 67b with the first grooves 66a, the second plate 62b is laterally positioned and interconnected relative to the first plate 62a so that when assembled, the plurality of first plates and the second plates define a plurality of cavities 63. The slot/recess closures 66, 67 or mating interface 60 provide a fully enclosed or 360 degree shield/circumference around one of the one or more cable connectors 40. The 360° shield or plate reduces crosstalk between the cable connectors within the cavity. This can prevent or reduce gaps/holes/paths in the cavity wall to reduce crosstalk. The walls of the slot/recess joints may abut or overlap the edges of the opposing slot/recess joints to reduce the gap. As shown in FIG. 13 , the plurality of electrical connectors can transmit about 70 GHz signals with FEXT (far end crosstalk) not exceeding about -40 dB. The simulation embodiment shown in FIG. 13 was performed at 92 Ω +/- 5 Ω at 6 ps (20% to 80% rise time).

In some embodiments, the mating interface 60 may include a housing 68. If used, the housing 68 may include a plurality of grooves 69 positioned in the inner periphery. The groove(s) 69 may maintain the spacing of the cavity 63/plate 62 and/or provide rigidity to the one or more plates 62. The grooves 69 may receive the ends of the first plate 62a and the second plate 62b.

In some embodiments, the electrical connector 30 may include one or more gaps/spaces 32 between the cable connectors 40 to reduce crosstalk. In some embodiments, greater space or distance between rows can reduce the NEXT of the PKG. In one embodiment shown, the gaps 32 can be defined by one or more rows of cavities 63 defined by a plurality of plates 62 that do not contain cable connectors 40. The absence of one or more rows of cable connectors 40 or gaps 32 within an array of cable connectors 40 can reduce crosstalk between the cable connectors 40. As shown in one embodiment, the one or more rows/gaps 32 without cable connectors 40 can be defined by a plurality of smaller cavities (e.g., smaller through openings) or (several) closer spacer plates. Smaller rows or gaps 32 (if used) can be defined by at least two adjacent and parallel plates (e.g., first plate 62a and/or second plate 62b) spaced a distance less than the remaining parallel plates. Grooves 66 and slots 67 can be positioned on respective plates 62 to define gap(s) 32 of a variety of row-to-row spacings/distances D. Although not shown, the intersecting plates 62 of both the first plate and the second plate can be spaced a smaller distance (e.g., row-to-row) to define a smaller row. In addition, as shown in FIG. 14, a plurality of electrical connectors can transmit approximately 70 GHz signals with NEXT (near end crosstalk) not exceeding approximately -50 dB. The simulation embodiment shown in FIG. 14 was performed at 92 Ω +/- 5 Ω at 6 ps (20% to 80% rise time).

In some embodiments, the assembly/connector or a portion thereof (e.g., a mating interface, a plug connector, and/or a cable connector) may be a 224 Gbps Pam4 signal at 6 ps and 20% to 80% rise time at 92 Ω +/-5 Ω, as simulated in one embodiment. In some embodiments, the bandwidth may be approximately 70 GHz to 50 GHz. In some embodiments, the bandwidth may be approximately 56 GHz. In various embodiments, the FEXT may be approximately -30 dB to approximately -45 dB. For example, less than or equal to -30 dB, less than or equal to -35 dB, less than or equal to -40 dB, and/or less than or equal to -45 dB. In some embodiments, the insertion loss may be between approximately 0 dB and approximately -5 dB. For example, between 0 dB and -1 dB, between -1 dB and -2 dB, between -2 dB and -3 dB, between -3 dB and -4 dB, and/or between -4 dB and -5 dB. The bandwidth may be about 50 GHz to about 80 GHz. For example, 50 GHz, 55 GHz, 60 GHz, 65 GHz, 70 GHz, 75 GHz, and/or 80 GHz. In various embodiments, NEXT may be about -40 dB to about -60 dB. For example, less than or equal to -40 dB, less than or equal to -45 dB, less than or equal to -50 dB, less than or equal to -55 dB, and/or less than or equal to -60 dB. In some embodiments, the insertion loss may be between about 0 dB and about -5 dB. For example, between 0 dB and -1 dB, between -1 dB and -2 dB, between -2 dB and -3 dB, between -3 dB and -4 dB, and/or between -4 dB and -5 dB. The bandwidth may be about 50 GHz to about 70 GHz. For example, 50 GHz, 55 GHz, 60 GHz, 65 GHz, and/or 70 GHz.

In some embodiments, the assembly 20 or electrical connector 30 may include an elbow/cable organizer 80 for one or more cables 90. In some embodiments, the elbow/cable organizer 80 may include a strain relief 81. If used, the strain relief 81 may be a hot melt. As shown in Figures 3A and 15, the elbow organizer 80 can be used with a vertical cable 90a or a right angle cable 90b. The overall height of the electrical connector 30 or assembly 20 can be less than 15 mm. The right angle cable 90b with the elbow organizer 80 can define a height of approximately 15 mm. The vertical cable 90a with the elbow organizer 80 can define a height of approximately 10 mm.

In some embodiments, one or more cables 90 may be connected to one or more cable connectors 40. Although the cable 90 is shown as a twisted pair cable in one embodiment shown, it should be understood that a variety of cables may be used and still be within the scope of the present invention. For example, a coaxial cable may be used in some embodiments. The cable 90 may include a shield, such as a wrap shield or an extrusion shield or any type of ground, reference or EMI shield. The shield may be peeled off about one of the exposed surfaces of the central electrical insulator, may be partially peeled off, but is not limited to a length greater than 0 mm to about 1 mm to 2 mm, or 0 mm, or 2 mm or more, or 0 mm to 0.5 mm. Either of the connectors may include electrically conductive or electrically lossy magnetically absorbent material.

In some embodiments, the assembly 20 or electrical connector may include one or more retaining brackets 95. As shown in Figures 16A and 16B, one example of a retaining bracket 95 may be one or more spring fingers. If used, the retaining device can ensure mating components and/or allow maintenance. Another example of the retaining bracket may be a latch.

In some embodiments, the circuit substrate 50 may have a routing density that determines the density. For example, as shown in FIG. 17, the PKG or die substrate package may start with a 350 um pitch to minimize FEXT and reduce the pitch to 200 um as a routing path. A BGA pitch of 0.35 may determine the routing density (e.g., 224 Gbps). There may be a PCB embodiment with 64 pairs of blocks. The PCB version may be approximately 5 mm wider and deeper than the die substrate package, as shown in FIG. 15. In addition, an embodiment of a PKG to PCB embodiment is shown in FIG. 18. The designs are shown as rotated for vertical routing. The PKG may be 2 layers and the PCB may be 4/8 layers.

In some embodiments, the electrical connector assembly may include a lower RA height option. For example, the cable organizer may be less than 8 mm, with compatibility. As shown in Figures 19A-19C, the configuration may be a stacked flex 98 in a sandwich configuration. An example as shown may be four 3-layer flex films stacked and one welded to the connector. The flex 98 may be converted to one or more cables to obtain longer lengths.

In some embodiments, the electrical connector assembly 20, the electrical connector 30, the mating interface 60, 160, the substrate 50 and/or the plug connector 70, 170 may include one or more locking mechanisms 82 or portions thereof that couple the mating interface 160 to the plug connector 170. In one embodiment shown in FIGS. 20-23 , the locking mechanism 82 may be an intermediate or internal locking mechanism that is spaced from or positioned inwardly from or within the outer periphery (e.g., housing, wall) of the electrical connector 30/connector 170/mating interface 160. The locking mechanism 82 may include one or more latches, clips, or friction locks 82a (e.g., intermediate, internal). One or more clips 82a are shown as being inside or inside/inside the plug connector 170, the mating interface 160, and/or the electrical connector 30 (e.g., the outer perimeter). Although the clips 82a are shown as being inside the electrical/plug connector 30, 170, and/or the mating interface 160, it should be understood that in some embodiments, external clips (e.g., located on the outer perimeter, on the wall) can be used in combination with (several) internal clip/locking mechanisms. The one or more clips 82a protrude upward from the inside of the gap at the bottom and/or outer perimeter of the plug connector 170 and/or the substrate 50. The clips may project upwardly from a middle or inner wall 82ab extending between or within an outer peripheral wall (e.g., opposing wall) of the mating interface 160 (e.g., base, grounding member) or the plug connector 170. In one embodiment shown, two spaced apart clips 82a may be spring loaded in a lateral direction (e.g., opposing direction, inwardly toward opposing sides of the inner panel 82b) to the plane of the clips 82a and/or the inner wall 82ab. The clips 82a apply frictional force to the locking mechanism 82 of the mating interface 160 or a portion thereof (e.g., inner panel 82b, detent 82ba) to reduce or prevent axial separation between the mating interface 160 and the plug connector 170. The locking mechanism 82 of the mating interface 160, or a portion thereof, may be one or more sockets/detents 82ba and/or an inner panel 82b that releasably engage one or more clips 82a. When assembled, the clip 82a engages the inner panel 82b of the mating interface 160, or a portion thereof (e.g., an upper notch/detent/socket 82ba). The clip 82a of the plug connector 170 interferes with the axial separation of the mating interface 160 or the inner/middle panel 82b. The inner panel 82b may be positioned in the gap 32 between the cable connector 40 and/or the cavity 32 (e.g., a row of cable connectors). The inner panel 82b may include one or more notches/detents 82ba in its upper edge. If two notches 82ba are used, the notches may be spaced apart from one another along the length of the panel 82b. One or more portions of the locking mechanism 82 may be reversed between the mating interface 160 and the plug connector 170. For example, it should be understood that in some embodiments, the mating interface 160 may include a clip and the plug connector 170 may include an inner panel.

In one embodiment shown in FIGS. 20-25 , the mating interface 160 may include a plurality of interlocking plates 62 defining a cavity 63 that receives at least one row R1 of at least one or more cable connectors 40. The interlocking plates 62 may include at least two third plates/opposite/parallel plates 62c that are interconnected by one or more fourth plates/parallel plates 62d transverse to the third plates. The fourth plate 62d may define opposing end plates at opposing ends of the row of cavities or third plates 62c. Each row R1 may include a third and fourth plate. The mating interface 160 may include a plurality of rows R1 defined by a third and fourth plate. The cavity 63 may have a through opening (e.g., an open top and an open bottom) defined by the third and fourth plates 62c, 62d. In some embodiments, the third plate 62c may include one or more through apertures 62ca that receive one or more protrusions 62da extending from the outer periphery (e.g., opposite ends/sides) of the fourth plate 62d when assembled. As shown in one embodiment in Figures 24, 25, and 25B, the third plate(s) 62c may include one or more through apertures or elongated slots 62ca (e.g., in a direction between the mating end 65 toward the terminal 64). As shown in Figures 24, 25, and 25A, each fourth plate 62d may include one or more protrusions or elongated protrusions 62da on the opposite sides/edges that engage the corresponding elongated slots 62ca of the opposite third plate 62c. The mating end 65 of one or more of the third plate 62c and/or the fourth plate 62d may include a plurality of curved edges for mating or contouring with one or more cables 90 or cable connectors 40. If used, the other of the opposite/parallel third plate 62c may be longer than and extend beyond the curved edges, as shown in Figures 24 and 25. In some embodiments, solder paste may be used adjacent to the aperture/protrusion nipple. The cavity defined by the third and fourth plates 62c, 62d may receive the cable connector 40. The end plate or fourth plate 62d may be spaced inwardly from the opposite end of the third plate or row R1 to define a recess 200b. The groove 200b may include a bottom opening of the tongue member 200a for receiving or inserting the remaining portion of the mating interface 160 (e.g., base, ground member). The third/fourth plates 62c, 62d (e.g., ground, metal) may be stamped and/or plated. In some embodiments, the plates 62 may be solder paste printed, solder plated, and/or laser welded together. The cavity or third and/or fourth plates may be assembled with one or more heat blades, with one or more cable connectors 40 therein. When assembled, the cavities of a row R1 defined by the third and fourth plates 62c, 62d are positioned adjacent to the cavities of one or more rows R1. The adjacent third plates 62c of the adjacent cavities/rows R1 may be positioned parallel to and/or in contact with each other, as shown in Figures 20, 20A, and 21. As shown in one embodiment in FIG. 20 , the locking mechanism 82 or portions thereof, the inner wall 82ab, the gap 32, the inner panel 82b, the notch 82ba and/or the clip 82a can separate two adjacent rows R1 from each other.

In some embodiments, the mating interface 160 may include a plate (e.g., a third plate, a fourth plate, etc.), a socket base 160a, and/or a grounding member 160b. In some embodiments, the socket base 160a may be, but is not limited to, molded plastic, and/or the grounding member 160b may be, but is not limited to, stamped metal (e.g., conductive). In some embodiments, the base 160a or the mating interface 160 may include one or more internal panels 82b and/or (several) locking mechanisms 82 or portions thereof. The base 160a may include a housing 68 having one (several) outer peripheral walls 68a defining a through opening 68b. The inner panel 82b may extend inside or inside the outer perimeter and between opposing walls of the outer peripheral wall 68a and/or intersect the through opening 68b. The grounding member 160b may include an outer peripheral wall 68c defining a through opening 68d. The outer peripheral wall 68c of the grounding member 160b may include a channel 68e (e.g., an inverted U-shaped channel). The grounding member outer peripheral wall 68c may mate with the base outer peripheral wall 68a. The channel 68e or grounding member wall 68c may receive the upper edge of the base outer peripheral wall 68a. The mating interface 160 may include one or more tongue-and-groove engagement portions 200. The opposing wall 68c of the grounding member 160b may include one or more tongue-shaped members or mating surfaces 200a adjacent to the opposing wall of the base 160a. The tongue-shaped member 200a is positioned along at least one wall of the base 160a/grounding member 160b and may be spaced apart from each adjacent tongue-shaped member 200a along the wall(s) by a slot 68f (e.g., vertically, longitudinally). Although not shown, the width of the slot 68f may increase from the free distal end of the tongue toward the proximal end or upper edge of the grounding member. For example, the slot may include an upper slot portion that is larger than a lower slot portion. The tongue-shaped member may be internal to the outer peripheral wall 68a and mate/engage with one or more grooves 200b of one or more rows R1/opposite ends of the third and/or fourth plates 62c, 62d of the mating interface. Although not shown, the tongue-shaped member or portions thereof may be spaced inwardly from the inner surface of the base wall 68a. The plates 62c, 62b may contact one or more walls 68c (eg, opposing walls, one wall, two walls, three walls, etc.) and/or adjacent plates/rows (eg, 62c, 62b) of the grounding member 160b.

In some embodiments, the plates 62c, 62d defining the cavities 63 of one or more rows R1 may engage the grounding member 160b and/or the base 160a by one or more latches. In one embodiment shown in FIGS. 20-24 , the latches may be one or more tongue-and-groove engagements 200 between the plates 62 (e.g., the third and fourth plates) and the grounding member 160b and/or the base 160a. It should be understood that a variety of engagements or latches may be used between the plates 62 and the grounding member 160b. One or more opposing tongues 200a of the base/grounding member engage or are received by opposing grooves 200b or ends of the cavities 63 of one or more rows R1 defined by the third and fourth plates, and/or position the third plates 62d of the adjacent rows R1 to contact each other when assembled. If used, the tongue 200a and/or groove 200b adjacent to the opposing wall of the grounding member 160b may be adjacent to the opposing end of the inner panel 82b. The end of the third plate 62c or groove 200b (e.g., a portion of row R1) may extend between the tongue 200a or a portion thereof (e.g., the slot 68f) and/or the base wall 68a to slidably engage the tongue-and-groove engagement therebetween. In some embodiments, a latch locking mechanism 300 may be used to axially lock the tongue-and-groove engagement 200 or a mating interface portion therebetween. In one embodiment shown in FIGS. 20-25 , the latching locking mechanism 300 may be a releasable engagement between the ground member 160 b and the plates 62 (e.g., 62 c, 62 d) and/or the row(s) R1. As more clearly shown in FIG. 20A , the one or more third plates 62 c may include one or more protrusions 300 a proximate opposite ends of and protruding outwardly from the one or more rows R1 that releasably mate with one or more protrusions 300 b in the slot 68 f extending distally or laterally from the adjacent tongue 200 a therebetween. If used, the protrusion(s) 300 b may narrow a portion of the slot 68 f between the adjacent tongues 200 a. If used, the latch locking mechanism 300 (e.g., protrusions 300a, 300b, openings, etc.) may engage after axial engagement/travel (e.g., sliding) for a distance when engaging the tongue-and-groove engagement portion 200. For example, relative sliding between the tongue-and-groove engagement portions results in engagement (e.g., axial) of one or more protrusions 300a of the array of cavities/plates of the mating interface of the cable connector 40 with one or more protrusions 300b of the grounding member and/or base of the mating interface. Additionally, when the mating interface 160 is assembled to the plug connector 170, the clips 82a (if used) may extend upwardly between the interior panel 82b and the adjacent third plate 62c of the row(s) of cavities/connectors R1 on one or both sides of the interior panel. If two clips 82a are used as shown in one embodiment, the clips may extend along or mate with opposite sides of the interior panel 82b of the base 160a.

In some embodiments, the electrical connector 30 and/or the cable connector 40 may include a shield for a differential signal pair (e.g., 60, 160), while the plug connector 70, 170 does not provide a shield for a differential signal pair. As shown in FIG. 1, FIG. 21, and FIG. 26, the plug connector 70, 170 lacks its own separate circumferential shield or egg-cage shield (e.g., crosstalk). Only the electrical connector 30 and/or the cable connector 40 includes a circumferential egg-cage shield (e.g., crosstalk) or a mating interface 60, 160 for a differential signal pair.

In some embodiments, the electrical connector assembly 20, electrical connector 30, mating interface 60, 160, substrate 50 and/or plug connector 70, 170 may include one or more locking mechanisms 182 or portions thereof that couple the mating interface 160 to the plug connector 170 (e.g., housing, substrate). In one embodiment shown in FIGS. 26-29 , the locking mechanism 182 may be an external locking mechanism positioned within the outer periphery (e.g., housing, wall) of the electrical connector 30/connector 170/mating interface 160. The locking mechanism 182 may include one or more latches or clips 182a (e.g., external). One or more clips 182a are shown as being external (e.g., on the outer periphery) of the plug connector 170, the mating interface 160, and/or the electrical connector 30. Although the clips 182a are shown as being external to the electrical/plug connector 30, 170, and/or the mating interface 160, it should be understood that in some embodiments, internal clips (e.g., located on the outer periphery, on the wall) may be used in combination with (several) external clip/locking mechanisms. The one or more clips 182a protrude downwardly from the bottom of the mating interface 160 or are included in the housing 168 of the electrical connector 30. The clips 182a may protrude downwardly from one or more outer walls 168a (e.g., opposite) to releasably engage the plug connector 170 (e.g., housing 178, outer wall 178a, receptacle 179). One or more receptacles 179 within the housing 178 and/or outer wall 178a of the plug connector 170 may releasably receive the one or more clips 182a. The receptacles 179 may protrude from or engage the die package substrate 50 (e.g., 50a, 50b). In one embodiment shown, two spaced apart clips 182a may be spring loaded in a direction transverse to the plane of the clips 182a (e.g., opposite directions, inward toward the connector). The clip 182a may include one or more protrusions 182b that releasably engage one or more apertures 179a of the socket 179 or housing 178. It should be understood that the clip 182a and socket 179 may be reversed and still be within the scope of the present invention.

In some embodiments, the plug connector 170 (e.g., housing) and/or the circuit substrate 50 may include one or more reinforcements 180. The reinforcements 180 may support one or more portions of the plug connectors 70, 170. As shown in one embodiment in FIGS. 26 to 29, one or more reinforcements 180 may be attached to the board side of the circuit substrate 50 and/or one or more portions (e.g., bottom 178b, outer wall 178a) of the housing 178. One reinforcement may be engaged with three outer walls 178a in some embodiments as shown, or with a single outer wall or the entire periphery of the outer wall in some embodiments. The embodiment shown includes two opposing reinforcements. The reinforcement may include one or more upwardly protruding members/tabs 181 that engage the housing 178 (e.g., wall). The tab 181 may include one or more posts 181a received in the socket 177 of the housing 178 and/or one or more posts 181b having an aperture 181ba that receives an offset tab 178c of the housing 178. In some embodiments, the reinforcement may support the bottom/baseboard wall 178b or an outer perimeter or edge of the housing 178. The reinforcement or portions thereof may be made of a conductive material, a non-conductive material, or both. In some embodiments, the reinforcement may be stainless steel. It should be understood that the reinforcement may have a variety of shapes, sizes, quantities, locations, and configurations and still be within the scope of the present invention.

In some embodiments, the assembly 20, the cable connector 40, and/or the mating interface 60, 160 may include one or more retaining members 190. The one or more retaining members 190 may align or maintain engagement (e.g., conductive, non-conductive) between one or more portions of the mating interface 160. In some embodiments, the retaining member 190 may retain and/or align (e.g., horizontally, vertically) the plate 62, the cavity 63, the egg crate shield, or the mating interface, or portions thereof. In some embodiments, the retaining member 190 may retain and/or align (e.g., horizontally, vertically) the egg crate shield, the cavity 63, the plate 62, and the housing 168. In one embodiment shown in FIGS. 26-29 , the retaining member 190 may be one or more elongated members or rods 191 (e.g., horizontal) that engage one or more elongated slots/apertures 192 of the housing 168 (e.g., wall(s)) and/or one or more slots/apertures 193 of the plate 62/cavity 63/egg crate shield. The retaining member or portions thereof may be made of a conductive material, non-conductive material, or both. It should be understood that the retaining members/mechanisms may have a variety of shapes, sizes, quantities, locations, and configurations and still be within the scope of the present invention.

In some embodiments, one or more ends 65 of one or more plates 62 may electrically contact a conductive outer shield element 43 of a cable connector 40. As shown in FIGS. 24, 25, and 25A, the mating end 65 of one or more of the third plates 62c and/or the second plates 62d may include a plurality of curved edges for mating or contouring with one or more cables 90 or cable connectors 40 (e.g., outer shield element 43). In some embodiments, the mating end 65 may directly contact the outer shield element 43. As shown in FIGS. 26-29, the mating end 65 of one or more of the third plates 62c may include a plurality of flat edges for mating or contouring with one or more cables 90 or cable connectors 40 (e.g., outer shield element 43) or portions thereof. Additionally, in some embodiments, the mating interface 160 and/or the connector 30 may include an epoxy 65a at one or more conductive nipples. For example, as shown in one embodiment in FIGS. 26-29 , an epoxy 65a (e.g., conductive) may be used between a planar-shaped mating end 65 or one or more portions of the plate(s) 62 (e.g., the mating end) and the outer shielding element 43.

In some embodiments, FIG. 30 and FIG. 31 illustrate the differential FD Next power sum and the differential FD FEXT power sum of one embodiment of the electrical connector shown in FIG. 26 to FIG. 29. As shown in FIG. 30, a plurality of electrical connectors can transmit approximately 70 GHz signals, where NEXT (near-end crosstalk) does not exceed approximately -50 dB. The simulation embodiment shown in FIG. 30 is the total power sum (the industry standard sum of all noise sources). In addition, as shown in FIG. 31, a plurality of electrical connectors can transmit approximately 70 GHz signals, where FEXT (far-end crosstalk) does not exceed approximately -30 dB. The simulation embodiment shown in FIG. 31 is the total power sum (the industry standard sum of all noise sources).

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate and/or a cable connector) may include at least 257 differential pairs per square inch, at least 256 to 264 differential pairs per square inch, at least 139 to 263 differential pairs per square inch, at least 138 to 145 differential pairs per square inch and/or at least 88 to 137 differential pairs per square inch.

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate and/or a cable connector) may include at least 257 single-ended pins per square inch, at least 256 to 264 single-ended pins per square inch, at least 139 to 263 single-ended pins per square inch, at least 138 to 145 single-ended pins per square inch and/or at least 88 to 137 single-ended pins per square inch.

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate and/or a cable connector) may include at least 127 differential pairs per linear inch, at least 128 differential pairs per linear inch and/or at least 129 differential pairs per linear inch.

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include conductors of about 30 AWG, 31 AWG, 32 AWG, 33 AWG, 34 AWG, 35 AWG, and/or 36 AWG. A range of such conductors may be, but is not limited to, about 30 AWG to about 36 AWG, about 30 AWG to about 34 AWG, and about 32 AWG to about 36 AWG. About 33 AWG and/or about 34 AWG are also contemplated.

In some embodiments, the assembly/connector 20, 30 or portions thereof (e.g., the mating interface, plug connector, circuit substrate, and/or cable connector) may include approximately 92 ohms +/- 9 ohms, or +/- 5% and/or +/- 10%.

In some embodiments, the assembly/connector 20, 30 or portions thereof (eg, a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include an IL to XT distance exceeding about 55 dB at about 25 GHz.

In some embodiments, the assembly/connector 20, 30 or portions thereof (eg, a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include an IL to XT distance exceeding about 40 dB at about 60 GHz.

In some embodiments, the assembly/connector 20, 30 or portions thereof (eg, a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include a bandwidth of 60 GHz.

In some embodiments, the assembly/connector 20, 30 or portions thereof (eg, a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include an edge-coupled connector without skew (a perfectly symmetrical path in the connector).

In some embodiments, the assembly/connector 20, 30 or portions thereof (eg, a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include a cable, a mezzanine, and/or a card edge connector.

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include a single track trace in a die package substrate.

In some embodiments, the assembly/connector 20, 30 or a portion thereof (e.g., a mating interface, a plug connector, a circuit substrate, and/or a cable connector) may include a SMT/BGA/surface mount. In some embodiments, a through-hole mount may be used. The plug connector and the cable connector may be separable from each other, such as being repeatedly separable and reconnectable. The plug connector may be a vertical connector carried by a major surface of a die package substrate. The vertical connector may be configured to receive the cable connector in a direction perpendicular to the major surface of a die package substrate.

In some implementations, the ASIC may lack screw hole(s) and/or through hole(s).

In some embodiments, one or more connectors may carry at least 64 differential signal pairs per connector. One example is eight rows of conductors, each row having eight differential signal pairs. Other examples are four rows of conductors or six rows of conductors. Four row embodiments may also have eight differential signal pairs per row. Six row embodiments may also have eight differential signal pairs per row. Two row embodiments may also have eight differential signal pairs per row. All embodiments may also have more than eight differential signal pairs per row or less than eight differential signal pairs per row but at least one signal pair. For an approximately 90 mm×90 mm die package substrate, the differential signal pair density may be approximately 320 differential signal pairs, approximately 640 differential signal pairs, approximately 960 differential signal pairs, approximately 1280 differential signal pairs, or more than one differential signal pair and at least approximately 840 differential signal pairs, or more than one differential signal pair and at least approximately 769 differential signal pairs, or some other number of differential signal pairs. In other words, at least twenty-eight rows of eight differential signal pairs per row of connectors may fit around the outer periphery of the approximately 90 mm×approximately 90 mm die package substrate. At least thirteen rows, at least fourteen rows, at least fifteen rows, at least sixteen rows, at least seventeen rows, at least eighteen rows, and/or at least nineteen rows of eight differential signal pairs per row of connectors may fit around the outer periphery of the approximately 90 mm×approximately 90 mm die package substrate. A die or keep-out area of any die package substrate may be about 40 mm by about 40 mm. In other words, at least four or at least five electrical connectors each having at least eight rows of at least eight differential signal pairs per row may be assembled along a side of an approximately 90 mm by approximately 90 mm die package substrate. Each electrical connector having eight differential signal pairs in eight rows may have a mating footprint of about 13 mm by about 13 mm, about 13.7 mm by about 13.7 mm, about 14 mm by about 14 mm, about 15 mm by about 15 mm, etc.

For example, in some embodiments of the present invention, an electrical connector may be sized and shaped such that a plurality of the electrical connectors fit on a single side of a die package substrate of no greater than approximately 75 mm×75 mm to approximately 85 mm×85 mm, the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and/or the plurality of electrical connectors transmit approximately 224 Gbps Pam4 signals at a bandwidth of approximately 56 GHz to approximately 70 GHz with a FEXT (Far End Crosstalk) of no more than approximately -40 dB.

In some embodiments, an electrical connector may be sized and shaped such that a plurality of electrical connectors fit on a single side of a die package substrate of no greater than approximately 75 mm×75 mm to approximately 85 mm×85 mm, the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and/or the plurality of electrical connectors transmit approximately 224 Gbps Pam4 signals at a bandwidth of approximately 56 GHz to approximately 70 GHz with a NEXT (near-end crosstalk) of no more than approximately -50 dB.

Additionally, in some embodiments, the plurality of electrical connectors may transmit signals at approximately 60 GHz with a FEXT no greater than approximately -45 dB. In various embodiments, the plurality of electrical connectors may transmit signals at approximately 50 GHz with a NEXT no greater than approximately -45 dB. In some embodiments, each electrical connector in the plurality of electrical connectors may include an egg-crate mating interface. In various embodiments, the electrical connector may be configured to mate with a cable connector.

In some embodiments, an electrical connector can include a mating interface having a plurality of interconnect plates defining a plurality of cavities therein.

Additionally, in some embodiments, the connector may include a plurality of cable connectors mated within the plurality of cavities. In various embodiments, each of the plurality of plates may include a plurality of slots aligned with the plurality of grooves. In some embodiments, the plurality of plates may define a circumference of a first cavity of the plurality of cavities without any gaps therein. In various embodiments, the plurality of plates may define a row of cavities without any of the plurality of cable connectors. In some embodiments, the plurality of plates may extend to approximately 90% of the length of the cable connector up to a substrate. In various embodiments, the electrical connector may include a substrate and a ground contact element that positions the plurality of plates at a distance from the substrate. In some embodiments, the electrical connector may include a die package substrate that is no larger than about 75 mm×75 mm to about 85 mm×85 mm, the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and/or the plurality of electrical connectors transmit about 224 Gbps Pam4 signals at a bandwidth of about 56 GHz to about 70 GHz with a FEXT (far end crosstalk) no greater than about -40 dB or a NEXT (near end crosstalk) no greater than about -50 dB. In various embodiments, the plurality of electrical connectors may transmit signals at about 60 GHz with a FEXT no greater than about -45 dB. In some embodiments, the plurality of electrical connectors may transmit signals at about 50 GHz with a NEXT no greater than about -45 dB.

Additionally, in some embodiments, an electrical connector configured to attach to a die package may include a density of at least 256 differential pairs per square inch.

In various embodiments, the electrical connector can transmit about 224 Gbps Pam4 signals with crosstalk no greater than about -40 dB. In some embodiments, the connector can transmit at a bandwidth of about 56 GHz to about 70 GHz.

In addition, in some embodiments, an electrical connector may include a mating interface. In various embodiments, the connector may include a plug connector having at least one ground contact element configured to mate with the mating interface.

In some embodiments, the ground contact element may include at least one arm that mates with the mating interface. In various embodiments, the ground contact element may include at least two arms that mate with the mating interface. In some embodiments, the ground contact element may include at least three arms that mate with the mating interface. In various embodiments, the ground contact element may include at least four arms that mate with the mating interface. In some embodiments, the ground contact element includes four or more arms that mate with the mating interface. In various embodiments, the ground contact element may include at least one solder mass. In some embodiments, the ground contact element may include at least two solder masses that are adjacent to each other. In various embodiments, the ground contact element may include at least three solder masses that are adjacent to each other.

In some embodiments, an electrical connector may include at least one of a mating interface, a plug connector, and/or a cable connector. In various embodiments, the connector may include a 224 Gbps Pam4 signal at 6 ps and a 20% to 80% rise time.

In some embodiments, the connector may include at least one of FEXT and/or insertion loss. In various embodiments, the FEXT may be less than or equal to -30 dB. In some embodiments, the FEXT may be less than or equal to -35 dB. In various embodiments, the FEXT may be less than or equal to -40 dB. In some embodiments, the FEXT may be less than or equal to -45 dB. In various embodiments, the insertion loss may be between 0 dB and -1 dB. In some embodiments, the insertion loss may be between -1 dB and -2 dB. In various embodiments, the insertion loss may be between -2 dB and -3 dB. In some embodiments, the insertion loss may be between -3 dB and -4 dB. In various embodiments, the insertion loss may be between -4 dB and -5 dB. In some embodiments, the connector may be at 50 GHz, 55 GHz, 60 GHz, 65 GHz, 70 GHz, 75 GHz, and/or 80 GHz.

In various embodiments, the electrical connector may include at least one of NEXT and/or insertion loss. In some embodiments, the NEXT may be less than or equal to -40 dB. In various embodiments, the NEXT may be less than or equal to -45 dB. In various embodiments, the NEXT may be less than or equal to -50 dB. In some embodiments, the NEXT may be less than or equal to -55 dB. In various embodiments, the NEXT may be less than or equal to -60 dB. In some embodiments, the insertion loss may be between 0 dB and -1 dB. In various embodiments, the insertion loss may be between -1 dB and -2 dB. In some embodiments, the insertion loss may be between -2 dB and -3 dB. In some embodiments, the insertion loss may be between -3 dB and -4 dB. In various embodiments, the insertion loss may be between -4 dB and -5 dB. In some embodiments, the connector may be at 50 GHz, 55 GHz, 60 GHz, 65 GHz, and/or 70 GHz.

In addition, in some embodiments, an electrical connector may include an outer periphery. In various embodiments, the connector may include a locking mechanism, which is positioned within the outer periphery of the electrical connector.

In some embodiments, the electrical connector may include a mating interface and a plug connector, wherein the locking mechanism may be positioned within an outer periphery of at least one of the mating interface and/or the plug connector. In various embodiments, the locking mechanism may include at least one clip. In some embodiments, the locking mechanism may include at least two clips. In various embodiments, the locking mechanism may include at least one notch. In some embodiments, the locking mechanism may include at least two notches. In various embodiments, the locking mechanism may be positioned within at least one gap between adjacent rows of cavities. In some embodiments, the electrical connector may include a plurality of cable connectors, wherein the locking mechanism may be positioned between adjacent cable connectors of the plurality of cable connectors. In various embodiments, the electrical connector may include a plurality of cavities, wherein the locking mechanism may be positioned between adjacent cavities of the plurality of cavities. In some embodiments, the locking mechanism may be spaced internally from one or more walls of the outer periphery of the electrical connector. In various embodiments, the connector may be configured to attach to a die package having a density of at least 256 differential pairs per square inch.

In some embodiments, an electrical connector may include a plurality of differential signal pairs. In various embodiments, the electrical connector may include a plurality of ground contact elements, each ground contact element configured to receive a respective portion of an egg-crate shield of a mating connector, wherein the electrical connector lacks an egg-crate crosstalk shield, is sized and shaped so that the plurality of electrical connectors are each respectively mounted on a single side of a die package substrate having sides each no larger than about 75 mm to 96 mm (including about 80 mm ± 5 mm and 91 mm ± 5 mm), the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit about 224 Gbit/sec PAM-4 signals at a bandwidth of about 56 GHz to about 70 GHz, wherein the FEXT does not exceed about -40 dB.

Additionally, in some embodiments, the electrical connector further comprises a first housing carrying the differential signal pairs, and at least two or more of the plurality of ground contacts each define at least two laterally offset cantilever beams, wherein each of the at least two laterally offset cantilever beams has a respective free end. In various embodiments, the differential signal pairs are surface mounted to the die package substrate. In some embodiments, the differential signal pairs may each include a first and a second stamped and formed conductor. In some embodiments, the electrical connector may further comprise a conductive or non-conductive magnetically absorbing material or an electrically lossy material. In various embodiments, the plurality of differential signal pairs are electrically connected, physically connected, or both to corresponding respective pads on the die package substrate.

In some embodiments, an electrical connector may include a mating interface having a housing and a plurality of plates defining a plurality of cavities in the housing. In various embodiments, the electrical connector may include at least one retaining member that retains at least one of the plurality of plates therebetween and/or holds the plurality of plates together with the housing.

Additionally, in some embodiments, at least one retaining member can retain the plurality of panels therebetween. In various embodiments, at least one retaining member can retain the plurality of panels with the housing. In some embodiments, at least one retaining member can both retain the plurality of panels therebetween and retain the plurality of panels with the housing. In various embodiments, at least one retaining member can be an elongated member incorporating one or more slots. In some embodiments, at least one retaining member can be conductive or non-conductive.

In some embodiments, an electrical connector may include an outer periphery. In various embodiments, the electrical connector may include a locking mechanism positioned in the outer periphery of the electrical connector.

Additionally, in some embodiments, the electrical connector may include a mating interface and a plug connector, wherein the locking mechanism may be positioned within an outer periphery of at least one of the mating interface and/or the plug connector. In various embodiments, the locking mechanism may include at least one clip. In some embodiments, the locking mechanism may include at least two clips. In various embodiments, the locking mechanism may include at least one socket that releasably engages at least one clip. In some embodiments, the electrical connector may include another locking mechanism positioned within the outer periphery.

In some embodiments, an electrical connector may include a plug connector having a housing. In various embodiments, the electrical connector may include at least one reinforcing member coupled to the housing.

Additionally, in some embodiments, at least one reinforcement member may be attached to a side of a die package substrate. In various embodiments, the electrical connector may include at least two of the reinforcement members spaced apart from each other in a horizontal plane. In some embodiments, at least one reinforcement member may be conductive or non-conductive. In various embodiments, at least one reinforcement member may include at least one protruding tab.

Additionally, in some embodiments, an electrical connector may include a component for accessing at least 513, at least 600, at least 700, at least 800, at least 900, at least 1000 and/or at least 1024 differential signal pairs from a side of an approximately 75 mm to approximately 95 mm die package substrate having a keep-out area of at least approximately 40 ^mm2 .

Additionally, in some embodiments, an electrical connector may include a component for accessing at least 513, at least 600, at least 700, at least 800, at least 900, at least 1000 and/or at least 1024 differential signal pairs from a side of a 75 mm to 95 mm die package substrate.

Additionally, in some embodiments, an electrical connector may include a component for accessing at least 513, at least 600, at least 700, at least 800, at least 900, at least 1000 and/or at least 1024 differential signal pairs from a side of a die package substrate of any size disclosed herein, the die package substrate having a keep-out area of at least about 40 ^mm2 .

Additionally, in some embodiments, an electrical connector may include a component for obtaining at least 513, at least 600, at least 700, at least 800, at least 900, at least 1000 and/or at least 1024 differential signal pairs from a side of a die package substrate of any size disclosed herein.

Although several embodiments have been described and illustrated herein, a person of ordinary skill will readily conceive of a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more advantages described herein, and each of these variations and/or modifications is considered to be within the scope of the embodiments described herein. More generally, a person skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary, and that actual parameters, dimensions, materials, and/or configurations will depend on the specific application or applications for which their use is taught. A person skilled in the art will recognize or be able to ascertain, using no more than routine experimentation, many equivalents to the specific embodiments described herein. Therefore, it should be understood that the foregoing embodiments are presented by way of example only and within the scope of the attached invention application and its equivalents, the embodiments may be practiced in ways other than as specifically described and claimed. The embodiments of the present invention are related to each individual feature, system, object, material and/or method described herein. In addition, if two or more of these features, systems, objects, materials and/or methods are not mutually inconsistent, any combination of these features, systems, objects, materials and/or methods is included in the scope of the present invention.

As defined and used herein, all definitions should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

As used herein in the specification and patent application, the indefinite articles "a" and "an" should be understood to mean "at least one" unless explicitly indicated otherwise.

As used herein in the specification and the scope of the invention, the phrase "and/or" should be understood to mean "either or both" of the elements so connected, that is, elements that exist in conjunction in some cases and separately in other cases. Multiple elements listed with "and/or" should be interpreted in the same manner, that is, "one or more" of the elements so connected. Other elements may also be present in addition to the elements specifically identified by the "and/or" clause, whether related or unrelated to the specifically identified elements, as the case may be. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising," a reference to "A and/or B" may refer to only A in one embodiment (including elements other than B, as the case may be); to only B in another embodiment (including elements other than A, as the case may be); to both A and B in yet another embodiment (including other elements, as the case may be); etc.

As used herein in the specification and the claims, "or" should be understood to have the same meaning as "and/or" as defined above. For example, when isolating items in a list, "or" or "and/or" should be interpreted as inclusive, i.e., including at least one, but also including more than one of a plurality or series of elements, and including additional unlisted items as appropriate. Only terms that clearly indicate the contrary, such as "only one of..." or "exactly one of..." or "consisting of..." when used in the claims will refer to exactly one element of a plurality or series of elements. In general, as used herein, the term "or" should be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceding exclusive terms such as "either," "one of," "only one of," or "exactly one of." When used in the context of an invention claim, "consisting essentially of" shall have its ordinary meaning as used in the art of patent law.

As used herein in the specification and the scope of the invention, the phrase "at least one" in relation to a list of one or more elements should be understood to mean an element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed in the list of elements and not excluding any combination of elements in the list of elements. This definition also allows for the presence of elements other than the elements specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to the specifically identified elements, as the case may be. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently "at least one of A and/or B") may refer to at least one, optionally including more than one A, and no B (and optionally including elements other than B) in one embodiment; at least one, optionally including more than one B, and no A (and optionally including elements other than A) in another embodiment; at least one, optionally including more than one A and at least one, optionally including more than one B (and optionally including other elements) in yet another embodiment; etc.

It should also be understood that, in any method claimed herein that includes more than one step or action, the order of the steps or actions of the method is not necessarily limited to the order in which the steps or actions of the method are described, unless explicitly indicated to the contrary.

In the scope of the invention application and the above description, all transitional phrases (such as "include", "comprising", "carrying", "having", "containing", "involving", "having", "consisting of" and the like) shall be understood as open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in Section 2111.03 of the Manual of Patent Examining Procedure of the United States Patent Office.

It should be understood that the application of the embodiments is not limited to the structural details and component configurations described in the description or shown in the drawings. The present invention is capable of other embodiments and can be practiced or implemented in various ways. Unless otherwise limited, the terms "connected", "coupled", "in communication with", and "mounted" and their variations are used extensively herein and cover direct and indirect connections, couplings, and mountings. In addition, the terms "connected" and "coupled" and their variations are not limited to physical or mechanical connections or couplings.

The foregoing description of several embodiments of the present invention has been presented for purposes of illustration. This is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously, many modifications and variations are possible in light of the above teachings.

20: electrical connector assembly 30: electrical connector 32: gap/space 40: cable connector 42: contact 43: conductive outer shielding element/shielding element 50: circuit substrate/package 50a: die package substrate 50b: printed circuit board 60: mating interface or cable head organizer 62: interlocking plate/interconnecting plate 62a: first plate 62b: second plate 62c: third plate/opposite/parallel plate 62ca: through hole or elongated slot 62d: fourth plate/parallel plate/plate 62da: protrusion 63: cavity 64: terminal 65: mating end 65a: epoxy resin 66: slot/groove joint 66a: first groove 66b: second groove 67: slot/groove joint 67a: first slot 67b: second slot 68: housing 68a: base peripheral wall 68b: through opening 68c: grounding member peripheral wall 68d: through opening 68e: channel 68f: slot 69: groove 70: plug connector 71: electrical contact/signal contact 72: grounding contact element 72a: first arm 72b: second arm 73: slot 74: solder ball/solder block 80: elbow/cable organizer 81: strain relief 82: locking mechanism 82a: latch, clip or friction lock 82ab: center or inner wall 82b: inner panel 82ba: upper notch/detent/socket 90: cable 90a: vertical cable 90b: right-angle cable 95: retaining bracket 98: stacking flexibility 160: mating interface 160a: socket base 160b: grounding member 168: housing 168a: outer wall 170: plug connector 177: socket 178: housing 178a: outer wall 178b: bottom/base wall 178c: offset tab 179: socket 179a: aperture 180: reinforcement 181: upwardly projecting member/tab 181a: support 181b: support 181ba: aperture 182: locking mechanism 182a: latch or clip 182b: projection 190: retaining member 191: elongated member or rod 192: elongated slot/aperture 193: slot/aperture 200: tongue-and-groove engagement 200a: tongue-shaped member or mating surface/tongue 200b: groove 300: latch locking mechanism 300a: projection 300b: projection D: spacing or distance L: length R1: row

In the drawings, like reference numerals generally refer to the same parts throughout the different views. Furthermore, the drawings are not necessarily drawn to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

FIG. 1 is a perspective view of an embodiment of an electrical connector assembly of an embodiment of an electrical connector.

FIG. 2 is an exploded view of the electrical connector assembly of FIG. 1 .

FIG. 3A is a perspective view of one of the plurality of electrical connectors of FIG. 1 .

FIG. 3B is a side view of a vertical cable of FIG. 3A .

FIG. 3C is a side view of the right angle cable of FIG. 3A .

FIG. 4A is a perspective view of the right angle cable and electrical connector of FIG. 3A .

FIG. 4B is a perspective view of the right-angle cable of FIG. 4A .

FIG. 5 is a perspective view of an embodiment of a mating interface of the electrical connector of FIG. 1 .

FIG. 6 is an exploded view of the mating interface of FIG. 5 .

FIG. 7 is a perspective view showing a 1024-pair electrical connector assembly.

FIG. 8 is a perspective view of the electrical connector assembly of the pair 1192 and/or 1280.

FIG. 9 is a perspective view of an electrical connector that surrounds a cable connector and/or a mating interface or board that is spaced a distance from a substrate.

FIG. 10 is a perspective view of an electrical connector with the mating surface cut away.

FIG. 11 is a graph showing the impedance profile of the cable to package in one embodiment.

FIG. 12 is a graph illustrating the effects of shielding return path transitions according to one embodiment.

FIG. 13 is a graph showing the differential FD NEXT power sum according to one embodiment.

FIG. 14 is a graph showing the differential FD FEXT power sum of one embodiment.

FIG. 15 shows a PKG and PCB implementation example of 64 pairs of blocks.

16A and 16B illustrate an embodiment of a retaining bracket.

Figure 17 shows a portion of the PKG substrate layout.

FIG. 18 is an example of a PKG on a PCB, the design being rotated for vertical routing.

19A to 19C are views showing an embodiment of a sandwich having a height less than 8 mm.

FIG. 20 is another embodiment of an electrical connector in which a portion of the cable connector is removed to illustrate a locking mechanism.

FIG. 20A is an enlarged cross-sectional view of the latch locking mechanism of FIG. 20 showing engagement between portions of the mating interface.

FIG. 21 is an exploded view of FIG. 20 .

FIG. 22 is a perspective view showing a mating interface of an assembled socket base and a grounding member.

FIG. 22A is an enlarged perspective view of FIG. 22 .

FIG. 23 is an exploded view of FIG. 22 .

FIG. 24 is a perspective view of a row of cavities of a mating interface that receives one or more connectors.

FIG. 25 is an exploded view of FIG. 24 .

FIG. 25A and FIG. 25B are enlarged perspective views of FIG. 25 .

FIG. 26 is another embodiment of an electrical connector in which a portion of a cable connector is removed to illustrate a mating interface and a portion of a plug connector is cut away.

27 is a perspective view of the electrical connector of FIG. 26 with a portion of the housing of the mating interface cut away and a portion of the housing of the plug connector removed to illustrate an embodiment of a reinforcement member and a retaining member.

28 is a perspective view of the electrical connector of FIG. 26 with the mating interface and the cable connector and the plug connector disassembled and a portion of the housing of the mating interface removed.

29 is an exploded view of a row of cavities of the mating interface of FIG. 26 that receives a partial row of connectors or a plurality of connectors.

FIG. 30 is a graph illustrating the differential FD NEXT power sum of an embodiment shown in FIG. 26 .

FIG. 31 is a graph illustrating the differential FD FEXT power sum of an embodiment shown in FIG. 26 .

20:Electrical connector assembly

30:Electrical connector

32: Gap/Space

40: Cable connector

50: Circuit board/package

50a: Chip packaging substrate

60: Mating interface or cable head organizer

62: Interlocking board/interconnecting board

62a: First board

62b: Second board

63: Cavity

64:Terminal

65:Mating end

70: Plug connector

72: Ground contact element

72a: First arm

72b: Second arm

73: Slot

74: Solder ball/solder block

90: Cable

D: Spacing or distance

Claims (83)

An electrical connector is sized and shaped so that a plurality of the electrical connectors fit on a single side of a die package substrate of no greater than about 75 mm×75 mm to about 85 mm×85 mm, the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit about 224 Gbps Pam4 signals at a bandwidth of about 56 GHz to about 70 GHz with a FEXT (Far End Crosstalk) of no more than about -40 dB. An electrical connector is sized and shaped so that a plurality of the electrical connectors fit on a single side of a die package substrate of no greater than about 75 mm×75 mm to about 85 mm×85 mm, the plurality of electrical connectors collectively carrying at least 1024 differential signal pairs, and the plurality of electrical connectors transmit about 224 Gbps Pam4 signals at a bandwidth of about 56 GHz to about 70 GHz with a NEXT (near end crosstalk) of no more than about -50 dB. An electrical connector as in any one of claims 1 and 2, wherein the plurality of electrical connectors transmit signals at approximately 60 GHz with a FEXT no greater than approximately -45 dB. An electrical connector as in any one of claims 1 to 2, wherein the plurality of electrical connectors transmit signals at approximately 50 GHz with a NEXT of no more than approximately -45 dB. An electrical connector as in any one of claims 1 to 2, wherein each of the plurality of electrical connectors comprises an egg-cage mating interface. An electrical connector as in any one of claims 1 to 2, wherein the electrical connector is configured to mate with a cable connector. An electrical connector comprising: A mating interface having a plurality of interconnect plates defining a plurality of cavities therein. The electrical connector of claim 7 further comprises a plurality of cable connectors, wherein the plurality of cable connectors are fitted into the plurality of cavities. An electrical connector as in any one of claims 7 to 8, wherein each of the plurality of plates includes a plurality of slots aligned with the plurality of grooves. An electrical connector as in any one of claims 7 to 8, wherein the plurality of plates define a circumference of a first cavity of the plurality of cavities without any gaps therein. An electrical connector as in claim 8, wherein the plurality of plates define a row of cavities without any of the plurality of cable connectors. An electrical connector as claimed in claim 8, wherein the plurality of plates extend to approximately 90% of the length of the cable connector of a substrate. An electrical connector as in any one of claims 7 to 8, further comprising a substrate and a ground contact element, which positions the plurality of plates at a distance from the substrate. An electrical connector as in any one of claims 7 to 8, further comprising a die package substrate no larger than about 75 mm×75 mm to about 85 mm×85 mm, a plurality of electrical connectors collectively carrying at least 1024 differential signal pairs, and the plurality of electrical connectors transmitting about 224 Gbps Pam4 signals at a bandwidth of about 56 GHz to about 70 GHz, wherein the FEXT (far-end crosstalk) does not exceed about -40 dB or the NEXT (near-end crosstalk) does not exceed about -50 dB. An electrical connector as in claim 14, wherein the plurality of electrical connectors transmit signals at approximately 60 GHz with a FEXT no greater than approximately -45 dB. An electrical connector as in claim 14, wherein the plurality of electrical connectors transmit signals at approximately 50 GHz with a NEXT of no more than approximately -45 dB. An electrical connector configured to attach to a die package, comprising: A density of at least 256 differential pairs per square inch. An electrical connector as claimed in claim 17, which transmits approximately 224 Gbps Pam4 signals with crosstalk no greater than approximately -40 dB. An electrical connector as in any of claims 17 and 18, transmitting at a bandwidth of about 56 GHz to about 70 GHz. An electrical connector comprising: a mating interface; and a plug connector having at least one ground contact element configured to mate with the mating interface. An electrical connector as claimed in claim 20, wherein the ground contact element includes at least one arm that mates with the mating interface. An electrical connector as in any of claims 20 and 21, wherein the ground contact element includes at least two arms that mate with the mating interface. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises at least three arms mating with the mating interface. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises at least four arms mating with the mating interface. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises four or more arms that mate with the mating interface. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises at least one solder block. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises at least two solder blocks adjacent to each other. An electrical connector as in any one of claims 20 to 21, wherein the ground contact element comprises at least three solder blocks adjacent to each other. An electrical connector comprising: At least one of a mating interface, a plug connector and/or a cable connector; and A 224 Gbps Pam4 signal with 6 ps and a 20% to 80% rise time. An electrical connector as in claim 29, further comprising at least one of FEXT and/or insertion loss. An electrical connector as claimed in claim 30, wherein the FEXT is less than or equal to -30 dB. An electrical connector as in any of claims 30 to 31, wherein the FEXT is less than or equal to -35 dB. An electrical connector as in any of claims 30 to 31, wherein the FEXT is less than or equal to -40 dB. An electrical connector as in any of claims 30 to 31, wherein the FEXT is less than or equal to -45 dB. An electrical connector as in any one of claims 30 to 31, wherein the insertion loss is between 0 dB and -1 dB. An electrical connector as in any one of claims 30 to 31, wherein the insertion loss is between -1 dB and -2 dB. An electrical connector as in any one of claims 30 to 31, wherein the insertion loss is between -2 dB and -3 dB. An electrical connector as in any one of claims 30 to 31, wherein the insertion loss is between -3 dB and -4 dB. An electrical connector as in any one of claims 30 to 31, wherein the insertion loss is between -4 dB and -5 dB. An electrical connector as in any one of claims 30 to 31 at 50 GHz. An electrical connector as claimed in any one of claims 30 to 31 at 55 GHz. An electrical connector as claimed in any one of claims 30 to 31 at 60 GHz. An electrical connector as claimed in any one of claims 30 to 31 at 65 GHz. An electrical connector as in any one of claims 30 to 31 at 70 GHz. An electrical connector as claimed in any one of claims 30 to 31 at 75 GHz. An electrical connector as in any one of claims 30 to 31 at 80 GHz. An electrical connector as in claim 29, further comprising at least one of NEXT and/or insertion loss. An electrical connector as claimed in claim 47, wherein the NEXT is less than or equal to -40 dB. An electrical connector as in any of claims 47 to 48, wherein the NEXT is less than or equal to -45 dB. An electrical connector as in any one of claims 47 to 48, wherein the NEXT is less than or equal to -50 dB. An electrical connector as in any of claims 47 to 48, wherein the NEXT is less than or equal to -55 dB. An electrical connector as in any of claims 47 to 48, wherein the NEXT is less than or equal to -60 dB. An electrical connector as in any one of claims 47 to 48, wherein the insertion loss is between 0 dB and -1 dB. An electrical connector as in any of claims 47 to 48, wherein the insertion loss is between -1 dB and -2 dB. An electrical connector as in any one of claims 47 to 48, wherein the insertion loss is between -2 dB and -3 dB. An electrical connector as in any of claims 47 to 48, wherein the insertion loss is between -3 dB and -4 dB. An electrical connector as in any of claims 47 to 48, wherein the insertion loss is between -4 dB and -5 dB. An electrical connector as in any one of claims 47 to 48, operating at 50 GHz. An electrical connector as claimed in any one of claims 47 to 48, operating at 55 GHz. An electrical connector as in any of claims 47 to 48, operating at 60 GHz. An electrical connector as claimed in any one of claims 47 to 48, operating at 65 GHz. An electrical connector as in any of claims 47 to 48, operating at 70 GHz. An electrical connector comprising: an outer periphery; and a locking mechanism positioned within the outer periphery of the electrical connector. The electrical connector of claim 63 further comprises a mating interface and a plug connector, wherein the locking mechanism is positioned within an outer periphery of at least one of the mating interface and/or the plug connector. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism comprises at least one clip. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism comprises at least two clips. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism includes at least one notch. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism comprises at least two notches. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism is positioned in at least one gap between adjacent rows of cavities. An electrical connector as in any one of claims 63 to 64, further comprising a plurality of cable connectors, wherein the locking mechanism is positioned between adjacent cable connectors of the plurality of cable connectors. An electrical connector as in any one of claims 63 to 64, further comprising a plurality of cavities, wherein the locking mechanism is positioned between adjacent cavities of the plurality of cavities. An electrical connector as in any of claims 63 to 64, wherein the locking mechanism is internally separated from one or more walls of the outer periphery of the electrical connector. An electrical connector as in any of claims 63-64, configured to attach to a die package having a density of at least 256 differential pairs per square inch. An electrical connector comprising: a plurality of differential signal pairs; and a plurality of ground contact elements, each ground contact element configured to receive a respective portion of an egg-crate shield of a mating connector, wherein the electrical connector lacks an egg-crate crosstalk shield, is sized and shaped so that the plurality of electrical connectors are each respectively mounted on a single side of a die package substrate having sides each no greater than about 75 mm to 96 mm (including about 80 mm ± 5 mm and 91 mm ± 5 mm), the plurality of electrical connectors collectively carry at least 1024 differential signal pairs, and the plurality of electrical connectors transmit about 224 Gbit/sec PAM-4 signals at a bandwidth of about 56 GHz to about 70 GHz, wherein the FEXT does not exceed about -40 dB. An electrical connector as in claim 74, wherein the electrical connector further comprises a first housing for carrying the differential signal pairs, and at least two or more of the plurality of ground contacts each define at least two laterally offset cantilevered beams, wherein each of the at least two laterally offset cantilevered beams has a respective free end. An electrical connector as in any of claims 74 and 75, wherein the differential signal pairs are surface mounted to the die package substrate. An electrical connector as in any of claims 74 to 75, wherein the differential signal pairs each include first and second stamped and formed conductors. An electrical connector as in any one of claims 74 to 75, further comprising a conductive or non-conductive magnetically absorbing material or an electrically lossy material. An electrical connector as in any of claims 74 to 75, wherein the plurality of differential signal pairs are electrically connected, physically connected, or both, to corresponding respective pads on the die package substrate. An electrical connector includes: a component for obtaining at least 800 differential signal pairs from one side of a 75 mm to 95 mm die package substrate having at least a 40 ^mm2 keep-out area. An electrical connector comprising: A component for obtaining at least 800 differential signal pairs from one side of a 75 mm to 95 mm die package substrate. An electrical connector includes: a component for obtaining at least 800 differential signal pairs from one side of a die package substrate of any size disclosed herein, the die package substrate having at least a 40 ^mm2 keep-out area. An electrical connector comprising: A component for obtaining at least 800 differential signal pairs from one side of a die package substrate of any size disclosed herein.