High speed, high density interconnect system for differential and single-ende d transmission systems on backplane / motherboards

(54) (56) (57)

OMBUD AWAPATENT AB

NAME Coupling system

CALLED PUBLICATIONS:

WO Al 0 024 092

SUMMARY:

An interconnection system comprises spacers which are arranged side by side in a row, which spacers have cable sections located therein. Each cable section has at least one central conductor and an outer conductive shield. Each cable sect in one has one end exposed in one plane and a second end exposed in a second plane. Electrically conductive contacts are located inside apertures in pairs of the switches in such a way that they have one end which creates electrical contact with one of the cable sections and another end extending through its respective aperture in its respective switch.

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The numbers in parentheses indicate the INID code.

525 544

SUMMARY

An interconnection system comprises spacers which are arranged adjacent to one another in a row, which spacers have cable sections placed therein. Each cable section has at least one central conductor and an outer conductive shield. All cable sections have one breath exposed in a first plane and a second breath exposed in a second plane. Electrically conductive contacts are located inside openings in pairs of the switches in such a way that they have one end which makes electrical contact with one of the cable sect in one ma and another end extending through its respective opening in its respective switch.

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Background of the invention

Field of the Invention

The present invention relates generally to electrical interconnection systems and more particularly to a tightly packed high-speed interconnection system for differential and asymmetric transmission applications.

Description of relevant technology

Backplane systems consist of a complex circuit board, which is referred to as the backplane or motherboard, and a number of smaller circuit boards, which are referred to as daughter boards, which are connected to the backplane. Each of the daughter boards may comprise a circuit, which is referred to as the driver / receiver. The driver / receiver sends and receives signals from driver circuits / receivers on other daughter boards. A signal path is created between the driver / receiver on a first daughter card and a driver / receiver on a second daughter card. The signal path comprises an electrical connector connecting the first daughter board to the backplane, a second electrical connector connecting the second daughter board to the backplane, the second daughter board having a driver circuit / receiver receiving the transmitted signal. The various drives / receivers used today can transmit signals at data rates between 5-10 Gb / s and higher. The limiting factor (data transfer rate) of the signal path is the electrical connectors that connect each daughter board to the backplane. Thus, in the art, there is a need for a high-speed electronic connector capable of handling the required high-speed data transmission.

525 544 to receive signals such as the signal strength transmitted

Furthermore, the receivers are capable of having only 5% of the original of the drive circuit. This decrease in signal strength increases the importance of minimizing crosstalk between signal paths to avoid signal degradation or errors being introduced in digital data streams. With tightly packed high speed electrical connectors, it is even more important to eliminate or reduce the overhearing. Thus, in the art, there is a need for a high-speed electrical connector capable of handling high-speed signals and reducing inter-signal transduction.

There are different types of electrical connectors. One type is a connector with through holes that can either be a resilient pin or a through hole. Backplane systems have typically used connectors which consist of multiple contacts having pins, which are inserted into the through-hole included in the circuit boards to be connected. The pins may be resiliently fit or they may be soldered in place. These require a relatively large diameter hole in the circuit board to receive the pins of the connector. The larger the hole, the greater the probability of defects from the plating and the greater the capacitance, which reduces the signal speed that can be adjusted with these connectors. For example, plated through holes may not be properly plated and thus pins inserted from the electrical connector may create open short circuits, etc. A plated through hole creates a capacitive effect, which reduces the data rate that can be transmitted through the pin and hole. Furthermore, many connector-type connectors are made of pressed parts having varying geometries, which increase signal reflection and decrease signal speed. Thus, it is advantageous to reduce the diameter of plated through hole sizes using a compressor connector. · Ϊ · :: ι '/ υ

525 544 sion mounting type, which is dependent on a spring contacting a contact plate on a circuit board.

Many of these problems can be solved by using a compression mounting type electrical connector. This type of connector overcomes many of the shortcomings of the through-hole connector type, but compression mount type connectors need bulky and expensive hardware to be able to attach the compression mount type connector to the circuit board. Close contact must be maintained between the compression mount type contacts and the circuit board surface without the use of additional fasteners such as screw jacks.

Furthermore, regardless of the type of electrical connector, the electrical connector must be capable of being switched on and off at least 250 times and perhaps more than 1000 times. If the contacts wear out, the contact resistance will increase. Contact wear can be done through metal to metal either through a point or a line. For example, a certain area can be repeatedly rubbed when the connector is turned on / off, and the contact tends to wear through the metal rubbing movement, which can also create wear. Some compression mounting type connectors also use dendrite connectors on flexible circuits. One difficulty with dendrite contacts is that these contacts tend to wear out and are only good for half a dozen switching cycles, and the dendrites begin to flatten out and the majority of contact points are lost, thereby reducing reliability. Thus, there is a need for a compression mounting type connector that eliminates or reduces contact wear.

Another problem with known electrical connectors is that impedance changes along the signal path decrease the potential signal speed. A need exists for an electrical connector in which the impedance can be controlled to a particular value and in which the particular value remains relatively constant along the entire signal path.

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In summary, electrical connectors used to electrically connect circuit boards, such as back panels, are afflicted with multiple defect daughter boards, including poor shielding resulting in electrical interference, changes in impedance and inability to connect and unplug many times without damaging the electrical connector. These shortcomings limit the data rate that can be transmitted through the connector. Thus, there is a need for a tightly packed electrical connector that greatly overcomes the aforementioned problems.

Summary of the Invention

It is an object of the present invention to provide an electrical interconnection system capable of transmitting signals at data rates between 5-10 Gb / s or more.

It is a further object of the present invention to provide an electrical connector having a differential pair which has a constant impedance along the signal path and which is capable of transmitting signals at 5-10 Gb / s or more.

It is a further object of the present invention to provide a coaxial cable type connector having a constant impedance along the signal path and capable of transmitting signals at data rates between 5-10 Gb / s or more.

It is a further object of the present invention to provide an electrical connector in which intersection between the signal paths of adjacent two-axis cables or adjacent coaxial cables within the electrical connector is reduced and / or eliminated.

It is a further object of the present invention to provide a compression type electrical connector using a conductive spring design.

The present invention relates to a tightly packed electrical connector which can provide 40 or more twin-axis connectors per linear inch in short-circuit.

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of 25 mm or less. In a typical electronic system package, the distance from the center line to the center line of adjacent parallel daughter boards (20 mm) is. A two-axis cable is a coaxial cable that includes two inner conducting wires instead of one. The two inner conducting lines provide two physical channels. Coaxial cable is called coaxial because it includes a physical channel that conveys the signal, which channel is surrounded (after a layer of insulation) by another concentric physical channel, both of which extend along the same axis. The outer channel serves as soil.

These and other objects of the present invention can be accomplished by providing an interconnecting system comprising: a plurality of spacers arranged to be adjacent to each other in a row having two ends, each spacer comprising at least one depression provided to allow a cable section is placed therein when said spacer is positioned adjacent to another of said plurality of spacers; a plurality of cable sections each located within respective recesses of said plurality of spacers, each cable section having a first and a second end and at least one central conductor and an outer conductive shield, said recesses of said plurality of spacers being arranged in such a way that all said first ends of said plurality of cable sections are left exposed in a first plane and that all said second ends of said plurality of cable sections are left exposed in a second plane; a pair of end portions each arranged to be positioned adjacent to each of said two ends of said row of plurality of spacers; first and second intermediaries each arranged to be positioned adjacent said first and second planes, each intermediary having an opening for each central conductor of said plurality of cable sections and at least one opening for each outer conductive shielding of said plurality of cable sections; and one

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525 544 plurality of electrically conductive contacts, each electrically conductive contact having a first and a second end and being arranged to be located in one of said apertures of said first and second intermediaries, said first end of each of said plurality of electrically conductive contacts creates electrical contact with one of said plurality of cable sections, and wherein said second end of each of said plurality of electrically conductive contacts extends through its respective aperture in its respective intermediary past a plane of said intermediary.

These and other objects of the present invention may also be accomplished by providing a method of manufacturing an interconnection system, which method comprises: placing a plurality of spacers adjacent to each other in a row having two ends; arranging each spacer so that it includes at least one recess to allow a cable section to be placed therein when said spacer is positioned adjacent to another of said plurality of spacers; positioning each of a plurality of cable sections within respective recesses of said plurality of spacers, each cable section having a first and a second end and at least one central conductor and an outer conductive shield; arranging said recesses of said plurality of spacers in such a manner that all said first ends of said plurality of cable sections are left exposed in a first plane, and that all said second ends of said plurality of cable sections are left exposed in a second plane; positioning each of a pair of end portions adjacent to each of said two ends of said row of plurality of spacers; positioning each of said first and second intermediates adjacent said first and second planes, each intermediary having an opening for each central conductor of said plurality of cable sections and at least one opening for each outer conductive shielding of said plurality of cable sections; and to

525 544 ·· « · • · ·· ·&lt;

Place each of a plurality of electrically conductive contacts, each electrically conductive contact having a first and a second end, in one of said respective openings of said first and second intermediaries. , wherein said first end of each of said plurality of electrically conductive contacts establishes electrical contact with a respective of said plurality of cable sections, and wherein said second end of each of said plurality of electrically conductive contacts extends through its respective aperture in its respective intermediary past a plane of said intermediary.

In addition, these and other objects of the present invention may be accomplished by providing an interconnecting system comprising: a plurality of spacers disposed adjacent to one another in a row; a plurality of cable sections, each of said plurality of cable sections having at least one central conductor and an outer conductive shield, and each of said cable sections being located within at least one of said plurality of spacers, and all said plurality of cable sections having an end which is exposed in a first plane and a second end exposed in a second plane; a pair of intermediaries having apertures located therein, said intermediary pairs being located on respective faces of said plurality of spacers; and electrically conductive contacts each located within and respectively of said apertures in said pair of switches in such a way that they have one end making electrical contact with one of said cable sections and another end extending through its respective aperture in its respective apertures. intermediary.

Finally, these and other objects of the present invention can be accomplished by providing a method of manufacturing an interconnecting system, which method comprises: arranging a plurality of spacers adjacent to one another in a row; positioning each of a plurality of cable sections within at least one of

525 544

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said plurality of spacers, each of said plurality of cable sections having at least one central conductor and an outer conductive shield and all said plurality of cable sections having an end exposed in a first plane and a second end exposed in a second plane; positioning a pair of intermediaries on respective faces of said plurality of spacers, each intermediary of said pair of intermediaries having apertures located therein; and positioning electrically conductive contacts within each of said openings in said pair of switches, in such a way that they have one end which makes electrical contact with one of said cable sections and another end extending through its respective opening in its respective switch.

In the present invention, each of said electrically conductive contacts may comprise a spring contact located within a high cap, wherein an exposed end of said spring contact comprises said first end of said respective electrically conductive contact and a closed end of said high cap comprises said second end. of said electrically conductive contact and each high cap may comprise a shoulder portion in a plane perpendicular to an axis thereof.

Furthermore, each of said electrically conductive contacts of the present invention may comprise a semi-rigid spring contact of one piece having a first and a second end, said first end of said spring contact comprising said first end of said respective electrically conductive contact and said second end. said spring contact includes said second end of said electrically conductive contact. Each spring contact includes a shoulder portion in a plane perpendicular to an axis thereof and each cable section may comprise two central conductors.

Finally, in the present invention, each intermediary may have two openings for each outer conductive shielding of said plurality of cable sections, and a respective

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Still other advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, in which embodiments of the present invention are shown and described, simply by way of illustration. As will be appreciated, the invention can be applied in other and different embodiments, and its many details can be modified in various respects, all without departing from the spirit and scope of the present invention. Thus, the drawings and description of the invention are considered to be illustrative in nature but not limiting.

Brief description of the drawings

The present invention is exemplary but not limiting in the figures of the accompanying drawings, in which elements having the same reference numerals consistently represent similar elements and in which:

Fig. 1A is a perspective view of an electrical connector according to an embodiment according to the invention shown in the parent application, which connector is mounted on a daughter board and a backplane with an upper housing omitted for clarity.

Fig. 1B is the same view as in Fig. 1A with the upper cover shown.

Fig. 2 is a perspective view of the electrical connector according to an embodiment according to the invention shown in the parent application, with a semi-fixed twinax coupled to only the rear panel switch and with the back panel and upper cover omitted for clarity.

Fig. 3 is a bottom perspective view of Fig. 2.

Fig. 4 is the same view as in Fig. 2 with the back panel switch omitted for clarity.

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Fig. 5 is the same view as in Fig. 4 with some of the spring contacts omitted for clarity.

Fig. 6 is the same view as in Fig. 5 with additional spring contacts omitted for clarity.

Fig. 7 is a bottom perspective view with the spring contacts omitted for clarity.

Fig. 8 is a perspective view of the daughter board and back panel comprising circuit board designs.

Fig. 9 shows a back panel, middle panel and daughter board 10 in an actual application.

Fig. 10 is an exploded view of a second embodiment of an electrical connector according to the principles of the invention shown in the parent application.

Fig. 11 is an enlarged exploded view of the cable housing intermediaries.

Fig. 12 is an enlarged view of a front side of the switching cable housing shown in Fig. 10.

Fig. 13A is a perspective view of the electrical connector according to the parent application, which is mounted on a daughter board with the daughter card switching slide in a retracted position and the rear panel switching slide in an extended position.

Fig. 13B is a cross-sectional view of the spring contacts held by the Mylar layer, the figure illustrating one end of the spring contacts inside the mediation slide when the mediation slide is in an extended position.

Fig. 13C is a cross-sectional view, similar to that of Fig. 13B, showing one end of the spring contacts extending past the mediation slide when the mediation slide is in a retracted position;

Fig. 14 is an exploded view of an exemplary embodiment of an electrical connector according to the principle of the present invention.

Fig. 15 is a view of a partially mounted connector according to the principles of the present invention.

Fig. 16 is a view of the portions of the connectors according to the principles of the present invention.

525 544 • · • · · • ···· &lt;

Fig. 17 is a view of the connector according to the principles of the present invention prior to connecting the intermediaries.

Fig. 18 is a view of one connector of the connector in Fig. 14.

Fig. 19 is a view of the mediator of Fig. 18 with a set of high hats inserted therein.

Fig. 20 is a view of the intermediary of Fig. 19 with a set of spring contacts, respectively, arranged against in one set of high hats.

Fig. 21 is a view of the intermediary of Fig. 20 with one end of a simple two-axis cable provided with a set of spring contacts and high caps.

Fig. 21A is a close-up view of a portion of the up position of Fig. 21 with some elements omitted for clarity.

Fig. 22 is a view corresponding to Fig. 21 but with all twine axle cables provided with their respective spring contacts and high caps.

Fig. 23 is a view of the connector of Fig. 22 after encapsulation.

Fig. 24 is a view of the connector of Fig. 23 after connecting the intermediaries.

Detailed description of the invention

The interconnecting device of the present invention provides a unique double-axial (two-axial) shielded coax structure having constant impedance from the interface of the daughter board to the interface of the backplane. The coaxial structure produces constant impedance of 65 ohms asymmetric impedance, 50 ohms odd mode impedance and 100 ohms differential impedance. Preferably, the present invention provides a controlled impedance connector of the ability to change the characteristic impedance of the electrical connector by changing the dielectric thickness and dielectric constant. This allows ordinary connectors to be made

525 544

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at different impedance values ​​in the range of 35 ohms to 150 ohms or higher.

An asymmetric interconnection path uses a data transfer conductor. A differential interconnection path uses two conductors to transmit the same data. The advantage of a differential interconnection path relative to an asymmetric interconnection path is that the transmission rate increases and that problems with interference immunity and electromagnetic interference decrease.

Using the twinax design of the present invention, the interconnection design described herein provides the best known realization for transmitting differential data using copper conductors. This is also true for the asymmetric version. The asymmetric configuration uses a coaxial conductor to transmit data. This makes it possible to transmit analog (RF) or digital data with signal deterioration comparable to that of a coaxial cable.

Figures 1A and 1B, to which reference is first made, show an interconnection system for a densely packed high-speed interconnection path. Fig. 1A shows the electrical connector with the upper cover omitted to facilitate explanation. The connector 18 is used to electrically connect a daughter board 20 to a back panel 22. As shown in Fig. 1B, the connector 18 includes a daughter board connector 30, a back panel connector 32, an upper cover 34 which bridges semi-fixed twinex or coaxial cables. the upper cover 34 is preferably injection molded, for example, by PBT (polybutylene terephthalate). Only two twinax cables 40, 42 are shown to facilitate illustration, as shown in Figures 1A and 1B, but it should be understood that 80 pairs of twinax or more can be used in the electrical connector. This embodiment uses twinax cables which are bent to a desired shape. A more solid construction, which is molded in a single piece, can also be used. For cables 40, 42 it is central

525 The 544 copper conductor, the dielectric material can be Teflon ™ and the outer cable sheath can be a braid. Preferably, the differential impedance between the center conductors is about 100 ohms. When using standard formulas, the impedance can be easily adjusted, for example, by varying the distance between the center conductors and the dielectric constant. In Fig. 1A, the upper cover 34 is omitted for clarity. In Figures 1A and 1B, spring contact devices 50, 52, 60, 62 are shown, when positioned within the intermediaries 30 and 32, respectively, and surround the ends of the twinax cables 40, 42 to protect the twinax cables and check the impedance of the connector.

The spring contacts and its use are explained in U.S. Patent No. 4,998,306, issued January 29, 1991, entitled LOW-LOSS ELECTRICAL INTERCONNECTS, U.S. Patent No. 5,886,590, issued March 23, 1999, entitled MICROSTRIP TO COAX VERTICAL LAUNCHER USING FUZZ BOTTON AND SOLDERLESS INTERCONNECTS, U.S. Patent No. 6,039,580, issued March 21, 2000, entitled RF CONNECTOR HAVING A COMPLIANT CONTACT, U.S. Patent No. 4,924,918, issued May 15, 1990, entitled MACHINE FOR MANUFACTURING BUTTON CONNECTOR AND METHOD THEREFOR, and U.S. Patent No. 5,007,843, issued April 16, 1991, entitled HIGH-DENSITY CONTACT AREA ELECTRICAL CONNECTORS, which are to be considered part of the present application. Although the present invention described herein is described with respect to the type of spring contacts shown, it should be understood that they are an illustrative type of conductive element or contacts, and that other types of electrically conductive elements or springs may be used with the present invention. The conductive element provides high reliability, multiple contact points and is randomly compressed into a mold which provides multiple electronic contact points to a coupling surface.

The conductive element may have different, suitable shapes. For example, the conductive element may comprise a pin of

525 544

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clock bracelet type or POGO type, ie at least one spring loaded pin which can be pressed together. In a further alternative, the conductive member may comprise a bellows device which comprises a plurality of deformable folds which are compressible. A further suitable conductive element comprises a conductor formed into a plug-shaped, compressible mesh. Alternatively, the conductive element may comprise belleville springs or an element comprising an elastomer provided with conductive particles. Preferably, the conductive element is plated with gold to insure low, stable RF losses in favorable or unfavorable environments.

The conductive member may comprise a simple member described above or other types suitable for providing at least one resilient end, or alternatively may comprise more than one member, in which case at least one of the members has at least one resilient end.

Although a rectangular connector 18 is illustrated, it should be understood that other designs, such as straight designs between parallel circuit boards, are possible. Although the use of the present invention is discussed with reference to daughter boards and rear panels, this is only done for convenience, and it should be understood that the electrical connector discussed below is useful for coupling all types of circuit boards, as well as other high speed applications.

As shown in Figures 1A and 1B, connector 18 would be mounted by interconnecting intermediary 30 and rear panel intermediary 32. As shown in Figure 1B, connector 18 is mounted as follows. First, the twinax cables 40, 42 are formed. All spring contacts are installed in the switches 30 and 32. The twinax cables 40, 42 are then installed in the switches 30, 32. The assembly is then injection molded to create the top cover 34, which makes the entire electrical connector 18 stable, the top cover 34 is preferably PBT. The electrical connector 18 can then

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Connected to the daughter board 20 using fasteners such as screws, rivets, compression supports and the like.

The spring contacts 50, 52, 60 and 62 can be made of a simple gold-plated, thin wire which is pressed into a very small shape. The resulting object is a spring mass having spring behavior and exhibiting superior electrical signal conduction from high current DC to microwave frequencies. The typical size for such a spring contact is 0.01 inch in diameter * per 0.060 in length. The signal switching spring contacts preferably have the same outer diameter as the signal switching center cable. The ground contact spring contacts do not have to have the same diameter or length as the signal transmitting spring contacts. The spring contacts 50, 52, 60 and 62 utilize in the illustrative embodiments and are preferably each formed from a strand of metal wire, each strand being padded together to create a desired cylindrical shaped knob of material having a density between 20% and 30%. %. Each padding wire-coupled spring contact fits snugly into openings of the daughter board switch 30 and the rear panel switch 32, shown in Figures 1A and 1B. The spring contacts 50, 52, 60 and 62 of padding wire receive electrical contact at multiple points when pressed against the contact area. Connectors of this type have significant advantages over other types of connectors and provide connections with high integrity and reliability. In contrast to other types of couplings, this mechanical coupling element has very few associated variables that can affect the quality of the coupling. The only significant variables are the size of the clutch member and the compressive force used to effect the clutch, both of which can be properly controlled by controlling the volume in which the spring contacts are placed. Alternatively, in high vibration environments, the spring contacts can be secured in place using a conductive epoxy.

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The spring contacts shown in the illustrative embodiments can be made using nickel or copper alloy threads such as beryllium and copper, silver and copper or phosphorus and bronze. The compression of the padded wires of the spring contacts is substantially elastic in such a way that the spring contacts return to their original form when the compression force of the twinax cables is removed. The wire is randomly compressed into a cylindrical shape, and the wire has some spring constant associated with the same to provide elasticity when pressure is applied. Preferably, this allows the electrical connector 18 to be turned on and off as many times as needed. In the above described embodiments, the wiring wire coupling elements 50, 52, 60, 62 may contain the components manufactured by Technical Wire Products, Inc. Of Piscataway, New Jersey, under the Fuzz Button ™ brand.

In Fig. 2, now referred to, the twinax cables 40, 42 are inserted into the rear panel switcher 32. Fig. 2 differs from Fig. 1 in that two twinax cables 40, 42 are shown instead of one. It is important to note that the central conductors 120, 122 are not shielded from each other. However, it is important to shield the twinax pairs from each other, as shown in Figure 2.

As shown in Figure 2, the rear panel switch 32 has two opposing U-shaped openings 100 and 102, each having an outer U-shaped peripheral wall 110 and 112, an inner U-shaped peripheral wall 117, 118 and a straight wall 114. 116. Walls 114 and 116 are facing each other as shown in Fig. 2. A plurality of spring contacts 200, 202, 204 and 206, respectively, are inserted into the U-shaped openings, each having a half U-shape, as shown. in Figure 2. For example, each of the spring contacts 200 and 202 has a half U-shape, and when placed together, a U is formed which partially surrounds the twinax cable 40. It should be appreciated that other shielding 525 544

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can be used to replace the spring contacts.

The Twinax cable 40 has two central conductors 120, 122 surrounded by, for example, sheathing of Teflon ™ 124. Preferably, the signal-transmitting spring contacts 300306 (see Fig. 3) have the same outer diameters as the two central conductors 120, 122. The sheath of Teflon ™ 124 can are covered by an electrically conductive copper layer or by a solid, or semi-solid, outer casing 128, which is made of copper and aluminum or is a tin-filled braid.

The envelope 128 can be formed using a plating process. The fixed outer casing 128 is removed, as shown in Fig. 2, to a certain length E, thereby releasing the jacket of Teflon ™ 124. The casing of Teflon ™ 124 is removed from the central conductor to a length F. This removal is made symmetrical in both ends of the two-axis cables 40 and 42. The spring contacts 200, 202, 204, 206 are in electrical contact with the bearing 128 in such a way as to provide a shield.

Referring now to Fig. 3, a bottom view of Fig. 2 is shown. The spring contacts mounted inside the switch 32 are stacked on one another in a half U configuration through the thickness of the switch 32 to surround and shield the central twinax conductors 120 and 120, respectively. 122 of the twinax cables 40, 42. A plurality of vertically extending cylindrical spring contacts 210, 212 and 214 are also shown which are located between the walls 114, 116. The spring contacts 210 and 214 extend through the thickness of the intermediary 32 and are used to shield the twinax cables 40, 42 from one another. It should be appreciated that there is a full 360 ° shielding for the twinax cables 40, 42 at the removed portions of the coaxial cables 40, 42 extending through the mediator 32, as shown in Fig. 3. As shown in Figure 3, four spring contacts 300, 302, 304 and 306 are in contact with the exposed portions of the central conductors 120 and 122 of the twinax cables 40 and 42.

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Fig. 4 is an illustration similar to that of Figs. 2 and 3, in which the daughter card switcher 32 has been omitted for clarity. There are four bars with semi-U-shaped spring contacts 200, 222, 224, 226, 228; 202, 232, 234, 236, 238; and 204, 242, 244, 246, 248, 206, 252, 254, 256 and 258 (not shown), as is evident in Fig. 4. These four bars together with the vertically extending spring contacts form a full 360 ° shield around the twinax cables 40 and 42. It is anticipated that the top and bottom spring contacts will be used. However, it is possible to use structures other than spring contacts to electrically connect the top and bottom spring contacts. For example, a pressed and shaped metal component (not shown) can be used to electrically connect the top and bottom spring contacts.

Fig. 5 is similar to Fig. 4 except that the spring contacts 200, 222, 224, 226 and 228 have been omitted to show the spring contacts 306 and 304 in contact with the central conductors 122 and 120 respectively.

As shown in Fig. 6, the spring contacts 300 and 302 and also 304 and 306 (not shown) contact the exposed portions of the central signal transmitters 120, 122. These spring contacts 300-306 are the signal transmitting spring contacts. It is important that the signal switching spring contacts have substantially the same diameter as the twinax central conductors 120 and 122 to maintain constant impedance. It will also be appreciated that other types of spring contacts may be used in the present invention. For example, conductive textiles can be used. Compression springs can also be used. The conductive fabrics can be injected into the connector and replace the spring contacts.

Referring now to Figure 7, a bottom perspective view of the electrical connector 18. As shown in Figure 7, a central portion 701 is created between the straight wall 114 and the bottom of the outer U-shaped wall.

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110th The central portion 701 includes through holes 700 and 702 which receive vertically extending spring contacts 300 and 302. A wall 704 is created centrally in the U-shaped region to create a first semi-U5 shaped opening 710 and a second U-shaped opening. 712, which respectively receive the spring contacts 206, 252, 254, 256 and 258 and 204, 242, 244, 246 and 248. It will be appreciated that it may be a two-part structure and that the center support structure may be a separate member constructed of a Teflon ™ dielectric. Metal-plated plastic components can also be used.

A plurality of electrically nonconductive patterns 402 and 404 are found on the daughter board 20 and the back panel 22, respectively, as shown in Figure 8. The pattern 402 has an electrically conductive region 410 having approximately an 8-figure configuration. The patterns can be created by using known photolithographic techniques. A first non-conductive region 412 and a second non-conductive region 414 are spaced apart and are located within an outer periphery 420 of pattern 402. The first non-conductive region 412 has two regions 430, 432 which include conductive contact plates 440, 442. The second non-conductive region 414 has two regions 434 and 436 which include conductive contact plates 444 and 446.

openings 430, 432, 434 and 436 receive the central conductors 120 and 122 of the twinax cables 40 and 42 extending from the intermediary 30 in such a way that the spring contacts 300, 302, 304 and 306 are respectively contacted with the conductive contact plates 440 , 442, 444 also

446th In Fig. 4, now referred to again, the spring contacts 228, 238, 248 and 258 will be in electrical contact with the electrically conductive region 410. In this way, the spring contacts provide a shielding path to ground. The electrically conductive area 410 is connected to the ground plane on the daughter board and on the back plane.

The inner surface of the openings 430, 432, 434 and 436 is electrically conductive and is coupled to the signal paths so that

525 544 • · · • · · · • ···· · t • · * • ·. The spring contacts 306, 304, 302 and 300 are in electrical contact therewith, when the intermediary 30 is used to connect the daughter board 20 and the back panel 22. The spring contacts are mounted in the intermediary 32. The spring contacts 300, 302, 304 and 306 are preferably compressed. when the daughter board and the back panel are connected, providing a normal force on the signal line and on the cable. The spring contacts 300, 302, 304 and 306 and 228, 238, 248 and 258 will be compressed against the card 20 and maintain normal forces with respect to the daughter card pattern 402. The pattern 404 on the back panel 22 is similar to the pattern 402 and need not be described in more detail herein. . The pattern 404 includes an electrically conductive portion 458 and a first non-conductive region 460 and a second non-conductive region 462. Preferably, the electrical connector 18 can be switched on and off multiple times without impairing the signal contacts 300, 302.

Referring now to Figure 9, a rear panel 700 is shown which is connected to a daughter board 710. Such a device is also useful in center plane connectors such as center plane connector 600, as shown in Figure 9 and is connected to a daughter board 610.

Figure 10, now referred to, shows an electrical connector 1000. It should be noted at the outset that the electrical conductors 1020, 1022 and 1024 have the same electrical properties as the electrical conductors 40 and 42 discussed above. As shown in Fig. 10, an electrical conductor 1024 has the shortest path and an electrical conductor 1020 has the longest path. For example, in Fig. 11, to which reference is now made, the conductor 1020 has a downwardly extending straight portion 1020 ', an angular portion 1020' 'and a horizontally extending, straight portion 1020' ''. The straight portions 1020 'and 1020' 'facilitate installation of the ends of the conductor 1020 into the cable housing 35 intermediaries 1030 and 1032, as described below. For ease of explanation, only the housing of conductors 1020, 1022 and 1024 is explained, although other sets of

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Figures 11-13C illustrate conductors having the same casing, further details of the aforementioned device are shown.

Reference is now made to Fig. 10. The electrical connector 1000 includes opposite guide segments 1002 and 1004 mounted on opposite ends of the electrical connector 1000, which is discussed in detail below. The control segments 1002 and 1004 and the cable housings 1006-1014 can either be created by individually pressed parts, as shown, and assembled, or can be created as an overpressured assembly, previously described with reference to Fig. 1B. Between the control segments 1002, 1004 are a plurality of sets of electrical conductors. The conductors 1020, 1022 and 1024 used herein form a vertical set of conductors. As shown in Fig. 10, there are four horizontal sets of three vertically stacked electrical conductors, creating a vertical and horizontal array of twinax cable conductors, although it should be understood that any number of electrical conductors may be used. For example, there may be eight sets of conductors instead of four sets of conductors. Alternatively, there may be two-conductor stacks or four or five conductors depending on the application rather than a three-conductor stack.

Each of the electrical conductors 1020, 1022 and 1024 is retained by the cable housings 1006 and 1008, and the other electrical conductors are retained by the respective cable housings 1008-1014. As shown in Fig. 10, the cable housing 1006 is specially adapted to be coupled to the control segment 1002 by using horizontal pins 1006 ', 1006 and 1006' which are connected to the corresponding holes 1002 ', 1002 and 1002' in the control segment 1002. The casings 1006, 1008 each comprise recesses 1007, 1009 and 1011 and 1013, 1015 and 1017. Each cable housing comprises a bulge and a hole. For example, there is a bulge 1023 and a hole

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1025 in the cable housing 1008 for connection with the cable housing 1006.

As shown in Fig. 10, the electrical connector 1000 is a rectangular (i.e., 90 degrees) electrical connector, although other designs, such as a straight connector, may be provided.

The electrical connector 1000 includes a central twinax or coaxial portion 1001, which includes all of the copper wire conductors 1020, 1022 and 1024 and all interconnected cable housings 1006-1012 and the control segments 1002 and 1004. As shown in Fig. 10, there is a front rectangular surface 1026 and a lower rectangular surface 1028 to mounted central assembly 1001. Opposite ends of conductors 1020, 1022 and 1024 extend slightly past surfaces 1026 and 1028, respectively, and expose outer cable jacket 128 of each of the twinax conductors 1020 and 1024. Central conductors 120 and 122 extend slightly past dielectric 124 and outer cable sheath 128 of the twinax conductors 1020 and 1024.

A rectangular mediator 1030 has a front surface 1030 'and a rear surface 1030. The mediator 1030 (i.e., the surface 1030') is coupled to the front surface 1026 of the assembly 1001. A second rectangular mediator 1032 has a front surface 1032 'and a rear surface 1032 which is coupled (i.e., the surface 1032 ') with the bottom surface 1028 of the assembly 1001. Copper wire conductors 120 and 122 engage with the intermediary 1030 and 1032, as explained below.

Spring contacts 1034 and 1036 are each held by Mylar retainers 1038 and 1040, respectively. Mylar retainers 1038 and 1040 may be made of any suitable material which includes heat shrinkable plastic. The spring contacts 1034 and 1036 are strategically located and extend within the switching cable housing 1030 and 1032 and the switching slides 1042 and 1044 respectively. The front surface 1030 'of the intermediary 1030 is mounted to the front surface 1026 by either press-fit molding tape, ultrasonic welding or epoxy. A couple of opposites

525 544 • · · ·· ····· «« ·· · · · · ··· · · · · · ···· · · · ··· · · β · ft ····· · ··· · · · · · · · ·· ··· ······································· On 100 tabs 1009 and 1009 ′ extend from surface 1026 and guide segments 1002 and 1004 respectively into recess holes which (not shown) extend inwards from the surface 1030 '. The pins 1009 and 1009 'keep the intermediary 1030 in line with the cable housings 1006-1014. Pins (not shown) extend from the surface 1026 of the control segments 1002 and 1004 to keep the intermediary 1032 in line with the cable housings 1006-1014. Spring contacts 1034 and 1036 include ground contact spring contacts and signal switching spring contacts, which is explained below. A pair of control pins 1046 and 1048 are provided on the rear panel for mounting the electrical connector 1000. Control pins 1046 and 1048 extend through holes 1050 and 1035 and 1048 and 1033, respectively, and are coupled with the connection mechanism.

As shown in Fig. 10, a cylindrical guide base 1003 extends from the guide segment 1002 for receiving the guide pin 1048. The guide segment 1004 has a similar guide base body (not shown) for receiving the guide pin 1046. The guide segments 1002 and 1004 are each individually threaded 29 , which are located at a right angle from the control base body 1003, and are aligned with corresponding holes 1061 and 1063 in intermediary 1030 and holes 1080 and 1082 in intermediary slide 1042. Threaded fasteners extend from the daughter board for attaching the electrical connector 1000 by threading in the threaded inserts 1027 and 1029.

Reference is now made to Fig. 11 where it is more clearly seen that Mylar plate 1038 comprises a plurality of punched holes. The punched holes exhibit a specific pattern for retaining and positioning the spring contacts in the holes of intermediaries 1030 and 1032 and of intermediary slides 1042 and 1044. The holes used to hold the signal switching spring contacts must have a high tolerance to keep the spring contacts secured, but still not so hard as to compress the spring contacts too much and significantly change their outer diameter.

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The punched holes 10 * 70, 1072, 1074 and 1076 are in a vertical line for receiving retaining pins 1090, 1092, 1094 and 1096 in the intermediary 1030.

Holes 1404 and 1406 and retaining pins 1090-1096 maintain the intermediate slide 1042 in line with the intermediary 1030. The retention pins 1090-1096 are of sufficient length to allow the intermediate slide 1042 to bias to the extended position of springs 1091 and 1093, which are 1095 and 1093 1097 in the surface 1030 '' of the intermediary 1030. The retention pins 1090-1096 are in height with or below the surface 1092 in the retracted position. The spring contacts 1034 maintain the line setting of the Mylar plate 1038 relative to the intermediary 1030 and the intermediary slide 1042. The intermediary 1030 includes an upper set of holes 1110 for receiving the leads of the conductor 1020, intermediate holes 1112 for receiving the central leads of the conductor 1022, and a downward the leads of the conductor 1024. Each intermediary has multiple ground holes, for example four ground holes, in which the spring contacts are placed to contact the outer conductive layer 128 of each of the conductors 1020, 1022 and 1024. For example, with reference to the conductor 1020 shown in Fig. 11, the intermediary 1030 has holes 1120, 1122, 1124 and 1126. The grinder plate has corresponding holes 1130, 1132, 1134 and 1136. Each intermediary 1030 and 1032 comprises a plurality of recesses formed to fit the exterior of each conductor 1020, 1022 and 1024. As shown in Figs. 11 and 12, the electrical conductors have a straight center section and rounded outer sections. The spring contacts located in holes 1130, 1132,

1134 and 1136 will be in contact with the outer cable jacket 128 of the conductor and will provide a grounding and electrical shielding between adjacent two-axis cables. The depression 1150 extends inwardly from the front surface 1032 'of the intermediary 1032. For example, the depression 1150 may comprise opposing curved walls.

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A · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a · a ·

1160 and 1162 which are interconnected by straight sections 1170 and 1172. The straight sections 1170 and 1172 are shown as extending horizontally. The recess 1150 is formed to receive the outer cable jacket 128 of the twinax cable.

Reference is now made to Fig. 12, where the mediator 1032 is shown in magnification. It should be appreciated that the intermediaries 1030 and 1032 are identical except for the opposing holes used for the control pins 1046 and 1048, each extending through the intermediary 1032 into the control segments 1002 and 1004. The holes 1048 and 1050 are offset relative to a longitudinal center line of the the intermediate slide 1044, which is also holes 1033 and 1035, which are aligned therewith. In contrast, the holes 1066 and 1068 are in the mediator 1030 on the center line, just like the holes in the mediator slide 1048.

Each central conductor 120 and 122 has associated multiple spring contacts. For example, as shown in Fig. 12, there are two holes 1260 and 1262 which are in line with the central conductors 120 and 122. There are also two central spring contacts (not shown) which have contact with the central conductors 120 and 122 and which have a end of holes 1260 and 1262. The front surface of insulator 124 can reach the bottom of recess 1150. Referring to the recess 1150, there are four spring contacts 1250, 1252, 1254 and 1256 installed in holes 1280-1284. The holes 1280-1284 are offset holes and intersect the periphery of the depression 1150. An earth contact, preferably a spring contact (not shown), is installed in each of the holes 1250-1256 and these spring contacts are used as ground contact with the electrically conductive outer cable jacket 128 of the central leader. Four earth contacts provide excellent shielding. Additional holes or spring contacts can be added to improve the curtailment reduction.

It should be noted that holes 1250 are placed centrally between the signal switching spring contacts 1260 and 1262.

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The hole 1254 is displaced closer to the hole 1260 relative to the center of the depression 1150, while the hole 1270 is displaced in the opposite direction in the adjacent depression 1152. It should be noted that excellent electrical shielding is provided without the need for 360 ° coverage for each of the twinax cables. . Thus, adjacent, vertically aligned recesses have offset holes for spring contacts. As the holes are displaced, a larger part of the circumference is shielded.

Reference is now made to Figures 13A, B and C as well as to the switching slide 1042, whereby it should be noted that there are four holes 1370, 1372, 1374 and 1376 that are vertically aligned with each other for receiving pins 1090, 1092, 1094 and 1096 respectively. Preferably, the intermediary is spring loaded in a direction away from the intermediary 1030. This protects the spring contacts from being damaged or disrupted during transport and assembly.

It should be understood that the explanation is provided only for the sets of holes at the far left and the hole pattern repeats. The top conductor 1020 has a set of corresponding holes in the intermediary 1042.

Hole 1330, for receiving an earth spring contact, is in line with holes 1130 in the Mylar plate and with holes 1120 in the intermediary 1030. Hole 1332 is in line with holes 1132 in

Mylar plate and with holes 1122 in the intermediary. Hole 1334 is in line with holes 1134 in Mylar plate and with holes 1124 in intermediary 1030. Hole 1336 is in line with holes 1136 in Mylar plate and with holes 1126 in intermediary 1030. Similarly, holes 1380 are aligned with holes 1080 in

Mylar plate 1038 and with holes 1110 in intermediary 1030.

In Fig. 13A, the intermediary 1032 is shown in an extended position, in which the spring contacts are below the surface 1042 '' or as a maximum of 0.020 above the surface 1042 '' and are thereby protected during transport of the electrical conductor 1000. As shown in Fig. 13A, there is a gap. between the surface 1032 '' of the mediator 1032 and the surface 1042 of the mediator slide.

The spring contacts held between the intermediary 1030 and

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<img file="SE525544C2_D0009.tif" />

The intermediary slide 1048 is in contact with the daughter card 20. However, the intermediary 1032 is and the switching slide 1044 in contact with the back panel 22.

The back panel circuit board with control has a plurality of conductive contact plates 1390. The contact plates have two signal conveying conductors 1392 and 1394 which are to be brought into contact with the signal conveying spring contacts and with an outer ground section 1396 (see Fig. 14). The contact plates 1390 preferably do not have to be through plated holes. The contact plates 1390 may be surface mounted or may have offset through holes. By avoiding pierced holes, the capacitive effects associated with the holes are reduced and the speed can be increased.

It is important to provide shielding for the length of the exposed central conductor and for the length of the signal transmitting spring contacts to prevent overhearing between adjacent twinax cables. The aforementioned connector preferably achieves this shielding by using four spring contacts connected to ground. These spring contacts provide less than 360® shielding, but testing has revealed that the shielding level is sufficient to provide data rates up to 10 Gb / s or higher.

Furthermore, Mylar plate 1038 retains the signal transmitting spring contacts by compressing the spring contact around the circumference without significantly reducing the outer diameter. Thus, the diameter of the spring contact does not change significantly when pushed into the circuit board. Preferably, the force exerted on the spring contacts in a direction away from the PC board is relatively small and thus allows the use of a simple connection mechanism. By changing the shape, number and stability of the conductive elements, the contact resistance, contact force and compressibility can be selected over a wide range to meet the needs of the specific application. The total combined contact force of the spring contacts 1039 and 1036 against the contact 5425 544 surfaces 1390 is low due to the resilient construction and compressibility of the springs.

While the interconnection system in the parent application described above has a number of advantages over known interconnection systems, many disadvantages have been discovered in the practical uses of such interconnection systems. Namely, a significant number of precision components were needed for the production of such interconnection systems, which increased production costs and decreased production gains. In addition, it was found that mounting such interconnection systems with unprotected spring contacts was extremely difficult given the fragility of the spring contacts, which also increased production costs and decreased production gains.

In view of the above, a detailed study of the interconnection systems described above was made to determine how their disadvantages could be eliminated. The applicant determined that by using high hats in conjunction with spring contacts, the resulting improved interconnection system could be substantially simplified and the number of components needed significantly reduced compared to the interconnection systems described above, which reduced production costs and production gains. In addition, the mounting of such improved interconnection systems was simplified by mounting such enhanced interconnection systems by using high-end hats in collaboration with the spring contacts, which reduced production costs and increased production gains.

A high cap is a solid metal cylinder that creates contact with the spring contacts and contact surfaces of the PCB. One end of the barrel has a shoulder that extends in a plane substantially perpendicular to an axis of the barrel. Such hats are manufactured in sizes that allow the insertion of spring contacts. For example, high hats are manufactured by Technical Wire Products, Inc. i

Piscataway, New Jersey for use with

:.4-/

525 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Fuzz Buttons ™. The closed end of the high-cap cylinder may be flat, hemispherical, tapered, or include saw teeth or points which facilitate obtaining good electrical contact with its coupling contact.

The following is a description of an example of an embodiment according to the present invention. It should be noted that the embodiment described below is for illustrative purposes only and it should be noted that the present invention is not limited to the embodiment shown.

Fig. 14 is an exploded view of an exemplary embodiment of an electrical connector according to the principles of the present invention. When comparing the connector 2000 in Figure 14 with the connector 1000 in Figure 10, it is immediately noticed that there are significantly fewer elements at the connector 2000 in Figure 14. This reduction of elements reduces manufacturing costs while simplifying the assembly of the connector.

In Fig. 14, now referred to, the elements 2001 substantially correspond to the elements 1001 in Fig. 10, but with one exception. Namely, the two-axis cable sections 2020, 2022 and 2024 have their central conductors on the same plane as their respective external conductors. It has been noted that it is unnecessary for the central leaders to be stretched beyond the plan of their respective external leaders. This simplifies the manufacture of the twine shaft sections 2020, 2022 and 2024 and reduces its costs, while making them stronger by the exposed central conductors of the twine shaft sections 1020, 1022 and 1024 in Fig. 10 being vulnerable to bending or damage.

In Fig. 14, now referred back to, the elements 2036 and 2034 are not only the spring contacts 1036 and 1034 of Fig. 10, but include spring contacts and their corresponding high caps, the details of which will be discussed below. Intermediaries 2042 and 2044 comprise control ports 2048, 2050, 2080 and 2082 used for placement of their respective intermediaries, using control 544 control pins 2048 and 2046 in the case of intermediary 2044. The control pins for intermediary 2042 are not shown. Elements 2036 and 2034 may also include semi-rigid spring contacts in one piece, which will be discussed later.

Fig. 15 is a view of a partially mounted connector. The end portions 2100 are located at the ends of the spacer 2110. In the connector shown in Fig. 15, the spacers 2110 comprise a greater number of twine shaft sections than those in Fig. 14. As the spacers 2110 are identical, this allows a manufacture of connectors of varying sizes using the same components.

It also reduces manufacturing and production costs while simplifying the assembly of connectors of varying sizes. However, although a particular number of two-axis cable sections is shown for each spacer, the present invention is not limited thereto. Connectors of varying sizes can be easily manufactured using a small number of different identical elements. A plurality of guide pin openings 2150 are shown for each end portion 2100. Only two of the three openings 2150 are used in the manufacture of the connector, which will be discussed below.

Fig. 16 is another view of the spacers 2110 and their relationship to the corresponding two-axis cable sections. Although not clearly shown in this drawing, spacers 2110 may include small pins and connector openings to allow spacers to be aligned and clamped together. Other alignment and attachment techniques can also be used.

After the elements shown in Figs. 15 and 16 are mounted, as shown in Fig. 17, they can be permanently connected by superstructure or encapsulation to create a uniform subassembly capable of withstanding both mechanical and thermal impacts which are substantially impervious to moisture. .

:.:in

525 544 ·« ·*· * · ·· · ·· · ·« ···· · ·· · ·· ·· ···· ····· ···· · ·· · · · · · · ···· · · · ···· · ·

Figure 18 is a view of a portion of a switch 2300 of the connector of Figure 14. The switch 2300 includes a pair of openings 2305 which are connected to the corresponding conductor 2210 shown in Figure 17. The switch 2300 comprises four openings positioned in such a way that they correspond to the openings 2220 of the connector shown in Fig. 17. This allows one of the intermediary pairs 2300 to be fixed to the connector shown in Figure 17 using, for example, screws or pins, which are inserted through the openings of the intermediary 2300 into the openings 2220 of the connector shown in Figure 17.

The model for the openings 2310, 2320, 2330 and 2340 for each two-axis cable section is shown in Fig. 18. the openings 2320 and 2340 will each include high caps which will include spring contacts therein which will be connected to the central conductor of a respective two-axis cable section, while the openings 2310 and 2330 will each include high caps which will include spring contacts therein; which will be connected to the shielding conductor of a respective two-axis cable section. The number of high caps which will include spring contacts therein, which will be connected to the shielding conductor of a respective two-axis cable section, is not limited to two as in this exemplary embodiment.

Referring to Fig. 19, four high hats 2410, 2420, 2430 and 2440, three of which are shown, have been inserted into respective apertures 2310, 2320, 2330 and 2340 in the intermediary 2300. Similarly, high hats will be inserted into the remaining respective apertures. in the mediator 2300. The openings are made large enough to allow vertical movement relative to the mediator 2300, which will be discussed below.

As shown in Fig. 20, each of spring contacts 2510, 2520, 2530 and 2540 is inserted against respective high caps 2410, 2420, 2430 and 2440. These spring contacts are sufficiently resilient to be retained

525 544 of the hats, but can still move in relation to the hats. Since a substantial portion of the spring contacts 2510, 2520, 2530 and 2540 are disposed within their respective cores in the intermediary 2300, they are less likely to be damaged in relation to the exposed spring contacts 1034 and 1036 of the connector of Figure 10.

Fig. 21 shows a simple twine shaft section 2600 provided by its corresponding high caps 2410, 2420, 2430 and 2440 and spring contacts 2510, 2520, 2530 and 2540. As can be seen, spring contacts 2520 and 2540 connect to the inner conductor of the single twine shaft section 2600 while spring contacts 25 and 2510 connects to the simple two-axis cable section 2600 outer shielding conductor.

Fig. 21 is a partial close-up view showing the relationship between the simple twine shaft section 2600 and its respective spring contacts 2520, 2530 and 2540 and its respective high caps 2420, 2430 and 2440. Note that in Fig. 21A, the high caps 2420, 2430 and 2440 are shown as having ends. As noted above, it has been discovered that semicircular or tapered ends can provide sufficient electrical contact for the high caps, thereby reducing their manufacturing cost.

Fig. 22 shows an intermediary 2300 with all its respective two-axis cable sections and spring contacts and high caps in place, which intermediary is arranged side of a circuit board 2600. Fig. 23 shows the device of Fig. 22 with a superstructure or enclosure shown but no intermediary, while Fig. 24 shows the device. in Fig. 23 with the switches 2300 in place and with the connector fixed to a circuit board 2600.

Below is a description of the assembly of a connector in accordance with an exemplary embodiment of the present invention, which description refers to Figures 14-24.

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Initially, spacers, such as spacers 2110 in Fig. 15, and twine shaft sections, such as sections 2020, 2022, and 2024 in Fig. 14, are clamped together until a connector size of appropriate size has been fitted.

Since the spacers 2110 are identical, it is only necessary, if they are designed to accept twine shaft sections of, for example, seven different sizes, to manufacture seven different sizes of twine shaft sections that can be used for mounting a connector of any suitable size, which allows economical size production by minimizing the number of different components needed for mounting connectors of different sizes.

As shown in Figure 15, the end portions 2100 are fixed to each end of the spacer assembly and the resulting assembly is interconnected, usually by superstructure or encapsulation, using appropriate encapsulation. Other means such as screws, pins, rivets or adhesives may also be used to connect the end pieces and the spacer assembly. After mounting, the resulting structure becomes the one shown in Figure 17.

The next mounting step is to take two mediators, such as the mediator 2300 shown in Fig. 18, and insert high-fitting hats of suitable size into each suitable opening in the two mediators, such as top hats 2410, 2420, 2430 and 2440 and the mediator 2300 shown in Figs. 19. Then, as shown in Fig. 20, the spring contacts are placed in each high cap of each intermediary. Since the high caps have shoulders larger than the openings in the intermediaries and because the suspension of the spring contacts prevents them from being pulled out of the high caps, the resulting structure shown in Figure 20 is relatively stable and can be moved without the risk of losing components, especially if the intermediary is held horizontal. . The spring contacts can be inserted into their respective hats before the hats are inserted into their respective openings.

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A resulting intermediary structure, as shown in FIG. 20, is then coupled to each end of the structure, as shown in FIG. 17, by using control means 2210 and corresponding openings 2305 for alignment purposes. The suspension of the spring contacts facilitates their creation of good electrical contact with the inner conductors and the outer shielding of each of the two-axis cable sections. Furthermore, the spring contacts of the spring contacts facilitate the extension of the hats beyond the openings of their respective intermediaries, to enable them to establish good electrical contact with the circuit boards to which they are to be connected.

The intermediaries are then fixed to the structure, as shown in Fig. 24, using suitable fixing means, such as screws, rivets, studs or binders. The resulting structure is then fixed to its switching circuit boards, as shown in Fig. 24, by using control pins and openings 2150 for alignment purposes. The control pins themselves can be used for locking purposes or other suitable connector locking means can be used to fix the connector to its connector circuit board. As noted above, the suspension of the spring contacts serves to drive their respective high caps to the connector contacts on the circuit board, to facilitate good electrical connection therebetween.

Furthermore, as previously noted, the complete clutch assembly is relatively robust and can withstand handling without damage, since the complete clutch assembly has no exposed spring contacts but instead exposed only small portions of the high caps.

While these interconnecting systems have been described as advantageous for use in backplane systems, these interconnecting systems can also find utility in many other applications, where circuit boards must have tightly packed electrical interconnections between them.

Although the spring contacts have been shown in the illustrative example placed inside top hats, it is

525 544 contemplates that the present invention may use semi-rigid spring contacts in one piece instead of the spring contact / high-hat arrangement, such as that shown in the parallel running U.S. patent application with Serial No. xxxxxxxx, entitled One Piece Semi-Rigid Electrical Contact, filed herewith and with the same applicant.

It will be apparent to those skilled in the art that the present invention fulfills all the above objects. Having read the foregoing description, those skilled in the art will be capable of making various changes, equivalent exchanges, and various other aspects of the invention, which are broadly described herein. It is intended, therefore, that the protection granted for this purpose should be limited only to the definition in the appended claims and its equivalents.

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