HIGH SPEED PLUG CONNECTOR

Abstract

A connector for use with high speed signals. The connector has a housing, which includes a base portion extending in a longitudinal direction and a tongue portion extending from the base portion in a mating direction perpendicular to the longitudinal direction. The housing has slots extending through the base portion to surfaces of the tongue portion and configured to hold terminals. The housing has a lossy material sized and shaped to couple with at least the portions of ground terminals held in the base portion along their lengths. The lossy material may protrude towards spaces between the portions of signal terminals held in the base portion along their lengths. The tail portions of the terminals may jog toward a plane that the lossy material extends. Such a connector may be used to meet signal integrity requirements in connectors designed for 64 Gbps and beyond.

Claims

1. An electrical connector comprising: a housing comprising a base portion extending in a longitudinal direction, a tongue portion extending from the base portion in a mating direction perpendicular to the longitudinal direction, and a plurality of slots extending through the base portion to surfaces of the tongue portion; a plurality of conductive elements each held by one slot of the plurality of slots of the housing, the plurality of conductive elements comprising signal conductors and ground conductors; and a lossy material disposed in the housing at a joint between the based portion and the tongue portion such that the housing is reinforced.

2. The electrical connector of claim 1, wherein the lossy material is molded to the housing to span the joint between the base portion and the tongue portion.

3. The connector of claim 1, wherein: the plurality of conductive elements each comprises a first portion extending in the mating direction and disposed on the surfaces of the tongue portion, a second portion opposite the first portion and extending out of the base portion, and a third portion extending between the first portion and the second portion, and the lossy material is coupled to at least part of the first portions of the ground conductors.

4. The connector of claim 1, wherein: the plurality of conductive elements each comprises a contact portion extending in the mating direction and held by the tongue portion, a tail portion opposite the contact portion and extending out of the base portion, and an intermediate portion extending between the contact portion and the tail portion, for each conductive element, the intermediate portion comprises a first section held in the base portion and a second section held by the tongue portion, and the lossy material is coupled to both the first sections and second sections of the ground conductors.

5. The connector of claim 1, wherein: the lossy material is coupled to the ground conductors along the entire length of the base portion in the mating direction.

6. The connector of claim 1, wherein: the plurality of slots of the housing comprise a first row of slots disposed along a first surface of the tongue portion and a second row of slots disposed along a second surface of the tongue portion, the second surface opposite the first surface, the housing comprises a chamber disposed between the first row of slots and the second row of slots, and the lossy material is disposed in the chamber.

7. The connector of claim 1, wherein: the tongue portion of the housing comprises a platform comprising a raised surface, and the lossy material comprises a corresponding platform such that the lossy material is brought closer to the conductive elements held in the slots extending on the raised surface of the platform of the tongue portion of the housing than without the corresponding platform of the lossy material.

8. The connector of claim 1, wherein: the signal conductors are disposed in pairs separated by the ground conductors, and the lossy material comprises portions protruding towards spaces between the signal conductors of the pairs.

9. An electrical connector comprising: a housing comprising a base portion extending in a longitudinal direction, a tongue portion extending from the base portion in a mating direction perpendicular to the longitudinal direction, and a plurality of slots extending through the base portion to surfaces of the tongue portion; a plurality of conductive elements each held by one slot of the plurality of slots of the housing, the plurality of conductive elements comprising a plurality of pairs of signal conductors separated by ground conductors; and a lossy material disposed in the housing, wherein, for each pair of signal conductors, the lossy material comprises a portion protruding towards a space between the signal conductors of the pair.

10. The connector of claim 9, wherein: the lossy material spans a joint between the base portion and the tongue portion.

11. The connector of claim 9, wherein: the lossy material is molded to the housing in the joint between the base portion and the tongue portion.

12. The connector of claim 9, wherein: for each pair of signal conductors, the portion of the lossy material protruding towards the space between the signal conductors of the pair extends along the entire length of the base portion in the mating direction.

13. The connector of claim 9, wherein: for each pair of signal conductors, the portion of the lossy material protruding towards the space between the signal conductors of the pair has a dovetail-shaped cross-section.

14. The connector of claim 9, wherein: the lossy material comprises protrusions elongating in the mating direction and coupled to the ground conductors.

15. The connector of claim 14, wherein: the portions of the lossy material protruding towards the spaces between the signal conductors of the pairs are disposed between the protrusions coupled to the ground conductors.

16. The connector of claim 15, wherein: the portions of the lossy material protruding towards the spaces between the signal conductors of the pairs are shorter than the protrusions coupled to the ground conductors in the mating direction.

17. An electrical connector comprising: a housing comprising a base portion extending in a longitudinal direction, a tongue portion extending from the base portion in a mating direction perpendicular to the longitudinal direction; and a plurality of conductive elements each comprising a contact portion extending in the mating direction and a tail portion opposite the contact portion and extending out of the base portion, the plurality of conductive elements comprising a first plurality of conductive elements and a second plurality of conductive elements, wherein: the tail portions of the first plurality of conductive elements jog towards the second plurality of conductive elements, and the tail portions of the second plurality of conductive elements jog towards the first plurality of conductive elements.

18. The connector of claim 17, wherein: the tail portions of the plurality of conductive elements comprise mounting surfaces aligned on a same plane.

19. The connector of claim 18, wherein: the plurality of conductive elements each comprises an intermediate portion extending between the contact portion and the tail portion, and for each of the plurality of conductive elements, the tail portion comprises a straight section extending from the intermediate portion, an end section comprising the mounting surface, and a transition section extending between the straight section and the end section.

20. The connector of claim 19, wherein: the transition sections of the plurality of conductive elements are of a same length.

21. The connector of claim 17, wherein: the housing comprises a first row of slots extending through the base portion to a first surface of the tongue portion, and a second row of slots extending through the base portion to a second surface of the tongue portion, and the first plurality of conductive elements each is disposed in one slot of the first row of slots and the second plurality of conductive elements each is disposed in one slot of the second row of slots.

22. The connector of claim 17, comprising: a lossy material disposed in the housing and elongating in the longitudinal direction between the first plurality of conductive elements and the second plurality of conductive elements.

23. The connector of claim 17, wherein: the tongue portion of the housing comprises a platform comprising a raised surface, and the contact portions of selected ones of the first plurality of conductive elements are disposed on the raised surface.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0078] The above and other aspects of the present application will be more thoroughly understood and appreciated below when read in conjunction with the appended drawings. It should be noted that the appended drawings are only schematic and are not drawn to scale. In the appended drawings:

[0079] FIG. 1 is a perspective view of a plug connector viewed from the front upper direction according to some embodiments;

[0080] FIG. 2 is another perspective view of the plug connector of FIG. 1 viewed from the rear upper direction;

[0081] FIG. 3 is yet another perspective view of the plug connector of FIG. 1 viewed from the left below direction;

[0082] FIG. 4 is an exploded view of the plug connector of FIG. 1;

[0083] FIG. 5 is a top view of the plug connector of FIG. 1;

[0084] FIG. 6 is a front view of the plug connector of FIG. 1;

[0085] FIG. 7 is a bottom view of the plug connector of FIG. 1;

[0086] FIG. 8 is a rear view of the plug connector of FIG. 1;

[0087] FIG. 9 is an enlarged view of the area circled by dashed lines in FIG. 5;

[0088] FIG. 10 is a sectional perspective view of the plug connector of FIG. 1 taken along the line A-A in FIG. 5;

[0089] FIG. 11 is a sectional perspective view of the plug connector of FIG. 1 taken along the line A-A in FIG. 5, with the conductive terminals and the lossy material of the plug connector hidden to show the chamber in the insulative housing;

[0090] FIG. 12 is a cross-sectional view of the plug connector in FIG. 1 taken along line A-A in FIG. 5;

[0091] FIG. 13A is a front view similar to that of FIG. 6, except that the insulative housing of the plug connector is removed to show the conductive terminals and the lossy material in the plug connector;

[0092] FIG. 13B is an enlarged view of the area circled by dashed lines in FIG. 13A;

[0093] FIG. 14A is a perspective view of a portion of the conductive terminals of the plug connector of FIG. 1;

[0094] FIG. 14B is a plan view of the portion of the conductive elements of FIG. 14A;

[0095] FIG. 15 is a left side view of the plug connector of FIG. 1, with the insulative housing of the plug connector hidden to show the conductive terminals and the lossy material in the plug connector; and

[0096] FIG. 16 is a flow chart, illustrating the steps for manufacturing the plug connector of FIG. 1, according to some embodiments.

LIST OF REFERENCE NUMERALS

[0097] 1 plug connector [0098] 100 insulative housing [0099] 101 base portion [0100] 103 longitudinal direction [0101] 105 tongue portion [0102] 105a first outer surface [0103] 105b second outer surface [0104] 107 mating direction [0105] 109 chamber [0106] 111 terminal slot [0107] 111a protruding portion [0108] 113 first platform [0109] 113a first platform surface [0110] 115 mounting platform [0111] 115a mounting surface [0112] 117 mount receiving portion [0113] 200 terminal [0114] 200a ground terminal [0115] 200b signal terminal [0116] 201 contact portion [0117] 203 tail portion [0118] 203a end section [0119] 203b straight section [0120] 203c transitional section [0121] 205 intermediate portion [0122] 205a first section [0123] 205b second section [0124] 207 first set of conductive terminals [0125] 207a first subset of conductive terminals [0126] 207b second subset of conductive terminals [0127] 209 second set of conductive terminals [0128] 211 reduced head [0129] 211a step [0130] 300 lossy material [0131] 301a first protrusion [0132] 301b second protrusion [0133] 301c third protrusion [0134] 301d fourth protrusion [0135] 302 platform [0136] 400 mount [0137] X1 first central axis [0138] X2 second central axis [0139] X3 third central axis [0140] X4 fourth central axis.

DETAILED DESCRIPTION

[0141] The inventors have recognized and appreciated connector design techniques that satisfy electrical and mechanical requirements to support greater bandwidth through high frequency operation. Some of these techniques may synergistically support both higher frequency connector operation and miniaturization. These techniques may be used in any suitable combination to meet signal integrity requirements in connectors designed for 64 Gbps and beyond.

[0142] An electrical connector may include a housing, which may include a base portion extending in a longitudinal direction and a tongue portion extending from the base portion in a mating direction perpendicular to the longitudinal direction. The tongue portion may be thinner than the base portion and configured to be inserted into a complementary electrical component, such as an opening of a receptacle connector. The housing may include slots extending through the base portion to surfaces of the tongue portion. The connector may include conductive elements each held in one slot. The conductive elements each may include a contact portion adjacent the surfaces of the tongue portion and configured to make contact with a complementary contact portion of the complementary electrical component. Each conductive element may include a tail portion extending out of the base portion and configured to mount to another electrical component such as a printed circuit board.

[0143] The inventors have recognized and appreciated that integrally disposing a lossy material in the base portion of the housing can improve the performance of the connector, while improving the strength of the connector, compared with the conventional approach of assembling inserts into the housing that may make the tongue portion prone to crack. In some embodiments, the housing may be formed with a chamber sized and shaped into which the lossy material is molded, such as in a dual injection molding process. The lossy material may be coupled to at least the portions of ground terminals held in the base portion along their lengths. The lossy material may include portions protruding towards spaces between the portions of signal terminals held in the base portion along their lengths.

[0144] In some embodiments, the tongue portion of the housing may include a platform having terminals held thereon. The lossy material may include a corresponding platform such that the lossy material is brought closer to the terminals held on the platform of the tongue portion of the housing. In some embodiments, the tail portions of the terminals may jog toward a plane in which the lossy material extends. Such a configuration may be used in a connector with at least two rows of conductive elements held within the housing such that contact portions of conductive elements in two different rows are exposed on opposing sides of the tongue portion. The tails of the conductive elements in the two rows may jog towards each other such that the tails may be mounted to a surface of a substrate (such as a PCB) that is aligned with a central portion of the connector. Such a configuration may shorten the longest transition sections of the tail portions relative to a connector configured to be mounted to a PCB below the tails of both rows. Such a configuration may enable the conductive elements to have transition sections of a same length and may improve performance of the connector and also enable more compact design with lower profile.

[0145] FIGS. 1 to 15 illustrate a plug connector 1 according to a preferred embodiment of the present application. The plug connector 1 may be combined with a mated receptacle connector to constitute an electrical connector assembly. Such electrical connector assembly are capable of providing an industry standard interface such as SFF-8639 to establish an electrical connection between a storage drive (such as a hard disk drive (HDD), a solid state drive (SSD), an optical disk drive (ODD)) and a circuit board (such as a backplane, a midplane, a drive carrier board). The plug connector 1 is configured for mounting to the circuit board and the receptacle connector is configured for connecting the storage drive to the plug connector 1, whereby the plug connector 1 may establish an electrical connection between the circuit board and the receptacle connector, and the receptacle connector may establish an electrical connection between the storage drive and the plug connector 1. In this way, the electrical connection assembly composed of the plug connector 1 and the receptacle connector may establish an electrical connection between the storage drive and the circuit board so as to enable signal and/or power transfer. Such electrical connector assembly may be referred to as “storage drive connector”.

[0146] As shown in FIGS. 1 to 8, the plug connector 1 includes an insulative housing 100. The insulative housing 100 includes a base portion 101 extending along a longitudinal direction 103, a tongue portion 105 extending from the base portion 101 along a mating direction 107 perpendicular to the longitudinal direction 103 and configured to be plugged into a receptacle connector (not shown) mated with the plug connector 1. The base portion 101 and the tongue portion 105 are integral. The insulative housing 100 may be formed by any suitable manufacturing process in the art such as injection molding. The insulative housing 100 may be partially or entirely formed of an insulative material. Examples of insulative materials that are suitable for forming the insulative housing 100 include, but are not limited to, plastic, nylon, liquid crystal polymer (LCP), polyphenyline sulfide (PPS), high temperature nylon or polyphenylenoxide (PPO) or polypropylene (PP).

[0147] With continuing reference to FIGS. 1 to 8, the plug connector 1 further includes a plurality of conductive terminals 200. Each of the plurality of terminals 200 may be formed from a conductive material. The conductive material suitable for forming the terminals 200 may be a metal or metal alloy, such as a copper or copper alloy.

[0148] With further reference to FIGS. 14A and 14B, FIGS. 14A and 14B schematically illustrate a portion of the plurality of conductive terminals 200. Each conductive terminal 200 may include a contact portion 201, a tail portion 203, and an intermediate portion 205 extending between the contact portion 201 and the tail portion 203. The contact portion 201 is configured for establishing an electrical connection with a corresponding conductive terminal of the receptacle connector terminal (not shown), and the tail portion 203 is configured for mounting to a circuit board, and specifically attached to a conductive trace or other conductive structure on the circuit board, by utilizing any suitable technique such as surface mount technology (SMT) and pin immersion solder paste method (PiP). As shown in FIGS. 14A and 14B, the plurality of conductive terminals 200 may include ground terminals (“G”) 200a and a plurality of pairs of signal terminals (“S”) 200b. Each pair of signal terminals 200b constitutes a differential signal pair for transmitting differential signals. For example, a first signal terminal in each pair of signal terminals 200b may be energized by a first voltage, and a second signal terminal may be energized by a second voltage. The voltage difference between the first and second signal terminals represents a signal. The ground terminals 200a may be arranged adjacent to each pair of signal terminals 200b to separate the plurality of pairs of signal terminals 200b from each other to reduce crosstalk between signals, thereby improving signal integrity. These terminals are aligned in a “G-S-S-G-S-S . . . G-S-S-G” pattern, with each pair of signal terminals 200b sharing a ground terminal 200a. It should be appreciated that FIGS. 14A and 14B illustrate only a portion of the plurality of conductive terminals 200 and that the plurality of conductive terminals 200 may also include other conductive terminals. These other conductive terminals may be the same as or similar to (e.g., having different dimensions from those of) the ground terminal 200a and the signal terminal 200b, and/or may include power terminals for transmitting power. It is noted that although the ground terminals are identified as 200a and the signal terminals are identified as 200b among the accompanying drawings, this does not mean that the terminals are limited to having identical dimensions.

[0149] Turning back to FIGS. 1 to 8, each of the plurality of conductive terminals 200 is held in the insulative housing 100 with the contact portion 201 extending in the mating direction 107 and being exposed through the outer surface of the tongue portion 105 for establishing an electrical connection with a corresponding conductive terminal of the receptacle connector, and with the tail portion 203 extending out of a side of the base portion 101 opposite to the tongue portion 105 for mounting to the circuit board. The base portion 101 of the insulative housing 100 may be formed with terminal channels or slots to allow a plurality of conductive terminals 200 to be inserted therethrough.

[0150] The plug connector 1 further includes a lossy material arranged in the insulative housing 100. As is known in the art, “lossy materials” generally refers to herein materials that are conductive but with some loss, or materials which absorb an electromagnetic energy by another physical mechanism over the frequency range of interest. Lossy materials can be formed from lossy dielectric and/or poorly conductive and/or lossy magnetic materials. Magnetically lossy material can be formed, for example, from materials traditionally regarded as ferromagnetic materials, such as those that have a magnetic loss angle tangent value of being greater than approximately 0.05 in the frequency range of interest. The “magnetic loss angle tangent value” is the ratio of an imaginary part to a real part of the complex electrical permeability of the material. Practical lossy magnetic materials or mixtures containing lossy magnetic materials may also exhibit useful amounts of dielectric loss or conductive loss effects over portions of the frequency range of interest. Lossy material can be formed from material traditionally regarded as non-dielectric materials, such as those that have an electric loss angle tangent value of greater than approximately 0.05 in the frequency range of interest. The “electric loss angle tangent value” is the ratio of the imaginary part to the real part of the complex electrical permittivity of the material. Lossy materials can also be formed from materials that are generally thought of as conductors, but are either relatively poor conductors over the frequency range of interest, contain conductive particles or regions that are not sufficiently dispersed such that they do not provide high conductivity or otherwise are prepared with properties that lead to a relatively weak bulk conductivity compared to a good conductor, such as copper, over the frequency range of interest. Lossy materials typically have a bulk conductivity of about 1 Siemen/meter to about 10,000 Siemens/meter and preferably about 1 Siemen/meter to about 5,000 Siemens/meter. In some embodiments, a material with a bulk conductivity of between about 10 Siemens/meter and about 200 Siemens/meter may be used. As a specific example, a material with a conductivity of about 50 Siemens/meter may be used. However, it should be appreciated that the conductivity of the material may be selected empirically or through an electrical simulation using known simulation tools to determine a suitable conductivity that provides a suitably low crosstalk with a suitably low signal path attenuation or insertion loss. Lossy materials may be partially conductive materials, such as those that have a surface resistivity of between 1 Ω/square and 100,000 Ω/square. In some examples, the electrically lossy material has a surface resistivity of between 10 Ω/square and 1000 Ω/square. As a specific example, the material may have a surface resistivity of between about 20 Ω/square and 80 Ω/square.

[0151] The lossy material 300 extends at least in the base portion 101 and is electrically coupled to at least some of the ground terminals 200a of the plurality of conductive terminals 200. This configuration eliminates the need to form a recess at the tongue portion 105 as compared to the prior art. This enables to improve the integrity of the plug connector 1 and reduce the likelihood of breakage of the tongue portion 105 from the base portion 101 during plugging and unplugging, thereby improving the reliability and service life of the plug connector 1. In addition, the lossy material can be placed closer to the intermediate portions of the ground terminals 200a retained in the base portion 101 as compared to the prior art, thereby improving signal integrity. The insulative housing of the plug connector 1 further includes a chamber 109 formed in the insulative housing 100. In some embodiments, the lossy material may be prefabricated as an insert to be inserted into the chamber 109 and be electrically coupled to at least some of the ground terminals 200a of the plurality of conductive terminals 200. In some other embodiments, as shown in FIGS. 10 to 13B, the lossy material 300 may be injection-molded into the chamber 109 and be electrically coupled to at least some of the ground terminals 200a of the plurality of conductive terminals 200. That is, the lossy material 300 is a lossy material piece that is injection-molded into the chamber 109 of the insulative housing 100. Many benefits of injection molding the lossy material 300 into the chamber 109 to form the lossy material piece will be described in detail below in connection with FIGS. 10 to 13B. However, it should be appreciated that the present application is not limited thereto, and that the lossy material 300 may also be arranged in the insulative housing 100 through other suitable techniques to provide the benefits described above.

[0152] The lossy material 300 may be such a lossy material that can flow into the chamber 109 by the injection molding process and subsequently cure into a desired shape at a desired position in the chamber 109. This lossy material 300 may be a member with a fixed shape, and thus it may also be referred to as “lossy material piece”. In some examples, the lossy material may be formed by adding to a binder a filler that contains conductive particles. Conductive particles that may be used as a filler to form a lossy material include, but are not limited to, carbon or graphite formed as fibers, flakes, nanoparticles, or other types of particles. Metal in the form of powder, flakes, fibers or other particles may also be used to provide suitable electrically lossy properties. The binder may be a thermoplastic material including but not limited to liquid crystal polymer (LCP) and nylon. Further, many alternative forms of binder materials may be used. Curable materials, such as epoxies, may serve as a binder. In addition, materials, such as thermosetting resins or adhesives, may be used. In some examples, the melting temperature of the lossy material 300 is lower than that of the material used to form the insulative housing 100 to prevent the insulative housing 100 from melting and deforming during injection molding of the lossy material 300 into the chamber 109.

[0153] Electrically coupling the lossy material 300 to at least some of the ground terminals 200a of the plurality of conductive terminals 200 allows to reduce the effect of electrical resonance, thereby improving signal integrity. In particular, when the electrical resonance occurs at a frequency within the operating frequency range of the plug connector 1, the integrity of the high-speed signal passing through the plug connector 1 deteriorates. The deterioration in the integrity of the signal passing through the plug connector 1 is partially caused by the loss of signal energy coupled into the resonant signal, which means that less signal energy passes through the plug connector 1. The deterioration in the integrity of the signal passing through the plug connector 1 is also partially caused by the coupling of the resonant signal from the ground terminals 200a to the signal terminals 200b. The resonant signal accumulates and possesses a high amplitude, so that when the resonant signal is coupled from the ground terminals 200a to the signal terminals 200b, it will generate a large amount of noise that interferes with the signal. Sometimes, the resonant signal coupled to the signal terminals 200b is also referred to as crosstalk. As is known in the art, the frequency at which electrical resonance occurs is related to the length of the ground terminals supporting the electrical resonance, the reason is that the wavelength of the resonant signal is related to the length of the ground terminals supporting the resonance, and the frequency is inversely related to the wavelength. Electrically coupling the lossy material 300 to the ground terminals 200a may enable energy coupled into the ground terminals 200a and accumulated into a resonant signal to be dissipated in the lossy material 300, which makes the occurrence of electrical resonance less likely, thereby increasing signal integrity and improving the operating frequency range of the plug connector 1.

[0154] In addition, as compared to the prior art, injection molding the lossy material 300 into the chamber 109 eliminates the need to form a recess at the tongue portion 105, and the lossy material 300 can completely fill or substantially completely fill the chamber 109. That is, after injection molding the lossy material 300 into the chamber 109, the chamber 109 is completely or substantially completely occupied by the lossy material 300. This allows the integrity of the plug connector 1 to be improved and the likelihood of breakage of the tongue portion 105 from the base portion 101 during plugging and unplugging to be reduced, thereby increasing the reliability and service life of the plug connector 1.

[0155] As shown in FIGS. 1 to 10, a plurality of conductive terminals 200 are arranged to be a first set of conductive terminals 207 and a second set of conductive terminals 209 spaced apart from each other in the plug connector 1. The lossy material 300 is disposed between the first set of conductive terminals 207 and the second set of conductive terminals 209 and extends therebetween. Each set of the first set of conductive terminals 207 and the second set of conductive terminals 209 includes ground terminals 200a and a plurality of pairs of signal terminals 200b. Each pair of the plurality of pairs of signal terminals 200b constitutes a differential signal pair, and the ground terminals 200a separates the plurality of pairs of signal terminals 200b from each other. The outer surface of the tongue portion 105 of the insulative housing 100 includes a first outer surface 105a and a second outer surface 105b opposite to the first outer surface 105a. Each of the first outer surface 105a and the second outer surface 105b is parallel to the longitudinal direction 103 and the mating direction 107. The contact portion 201 of each conductive terminal in the first set of conductive terminals 207 is exposed through the first outer surface 105a, and the contact portion 201 of each conductive terminal in the second set of conductive terminals 209 is exposed through the second outer surface 105b. The intermediate portion 205 of each conductive terminal in the first set of conductive terminals 207 and the second set of conductive terminals 209 is retained at least partially in the base portion 101 of the insulative housing 100. In some examples, as shown in FIG. 10, a first section 205a of the intermediate portion 205 of the ground terminal 200a is retained in the base portion 101 and a second section 205b extends out from the base portion 101 to the tongue portion 105. However, it should be appreciated that in some examples, the intermediate portion 205 of each conductive terminal in the first set of conductive terminals 207 and the second set of conductive terminals 209 may be retained in the base portion 101 of the insulative housing 100 in its entirety. It should also be appreciated that the first section 205a of the intermediate portion 205 may include barb features to help resist plugging and unplugging forces, thereby retaining the conductive terminals firmly in the base portion 101. It should also be appreciated that the plug connector 1 may include only one set of the first set of conductive terminals 207 and the second set of conductive terminals 209.

[0156] As shown in FIG. 11, the tongue portion 105 includes a plurality of terminal slots 111 recessed from the outer surfaces (i.e., the first outer surface 105a and the second outer surface 105b). At least the contact portion 201 of each of the plurality of conductive terminals 200 is received in a corresponding one of the plurality of terminal slots 111. In some examples, as shown in FIG. 10, the contact portion 201 and the second section 205b of the intermediate portion 205 of each of the plurality of conductive terminals 200 are received in a corresponding one of the plurality of terminal slots 111.

[0157] In order to electrically couple the lossy material 300 to at least some of the plurality of conductive terminals 200, the lossy material 300 includes a plurality of protrusions extending towards these ground terminals 200a. The lossy material 300 is electrically coupled to a corresponding one of these ground terminals 200a through each of these protrusions. In some examples, each of the plurality of protrusions is electrically coupled to the intermediate portion 205 of a corresponding one of these ground terminals 200a. The position where the ground terminals 200a are coupled together defines an end of the structure that supports electrical resonance. For example, if the protrusion of the lossy material 300 is electrically coupled to the ground terminal 200a in the middle of the ground terminal 200a, the ground terminal 200a is not one long structure supporting electrical resonance, but two structures supporting electrical resonance, each of the two structures has a length which is half the length of the ground terminal 200a. The wavelength of the electric resonance also becomes half, but the frequency of the electric resonance will be doubled. In other words, with the lossy material 300, the electrical resonance that interferes with the operation of the plug connector 1 occurs at twice the frequency, i.e., the plug connector 1 is able to operate in twice the frequency range, compared to the case without the lossy material 300. It should be appreciated that, as an alternative, the lossy material 300 may include a plurality of protrusions extending towards all the ground terminals 200a of the plurality of conductive terminals 200.

[0158] In some embodiments, each of the plurality of protrusions is in direct contact with the intermediate portion 205 of a corresponding one of these ground terminals 200a to enable electrical coupling. In particular, as shown in FIG. 10 and as described above, a first section 205a of the intermediate portion 205 of the ground terminal 200a is retained in the base portion 101 and a second section 205b extends out from the base portion 101 to the tongue portion 105. The first section 205a is retained in the base portion 101 and is exposed in the chamber 109. A corresponding protrusion (marked with 301a in FIG. 10) is in direct contact with at least the exposed first section 205a of the intermediate portion 205 to enable electrical coupling. The second section 205b and the contact portion 201 are received in the terminal slot 111. The chamber 109 extends from the base portion 101 to the tongue portion 105 such that the lossy material 300 extends from the base portion 101 into the tongue portion 105, and a portion of the corresponding protrusion is exposed at the bottom of the terminal slot 111 and is in direct contact with the second section 205b.

[0159] In some other embodiments, each of the plurality of protrusions is disposed sufficiently close to the intermediate portion 205 of a corresponding one of these ground terminals 200a to capacitively couple with the intermediate portion 205. In this example, there is a gap between the protrusion and the corresponding intermediate portion 205. In an alternative example, the gap may be filled by the insulative housing 100 such that the protrusion and the corresponding intermediate portion 205 are spaced apart by the insulative housing 100. In an alternative example, the chamber 109 extends from the base portion 101 to the tongue portion 105 such that the lossy material 300 can be injection-molded into the tongue portion 105.

[0160] In some embodiments, as shown in FIGS. 12 and 15, the lossy material 300 extends to a first side of the base portion 101 from which the tail portion 203 of the conductive terminal 200 protrudes. As compared to the prior art, this allows the tail portion 203 of the conductive terminal 200 to be arranged closer to the lossy material 300, thereby improving signal integrity.

[0161] In some embodiments, the lossy material 300 includes multiple pieces of lossy material, and each of the multiple pieces of lossy material couples a corresponding portion of the ground terminals 200a of the plurality of conductive terminals 200 together. As shown in FIGS. 4, 10, 12, 13A and 13B, the lossy material 300 includes two pieces of lossy material, and each of the two pieces of lossy material couples a corresponding portion of the ground terminals 200a in the first set of conductive terminals 207 and the second set of conductive terminals 209 together. In some examples, the lossy material 300 electrically couples at least some of the ground terminals 200a in the first set of conductive terminals 207 with at least some of the ground terminals 200a in the second set of conductive terminals 209. In some examples, as shown in FIGS. 13A and 13B, the lossy material 300 includes a plurality of first protrusions 301a extending towards the ground terminal 200a in the first set of conductive terminals 207 and a plurality of second protrusions 301b extending towards the ground terminal 200a in the second set of conductive terminals 209. Each of the plurality of first protrusions 301a is electrically coupled to the intermediate portion 205 of a corresponding one of the ground terminals 200a in the first set of conductive terminals 207, and each of the plurality of second protrusions 301b is electrically coupled to the intermediate portion 205 of a corresponding one of the ground terminals 200a in the second set of conductive terminals 209. As noted above, such electrical coupling may be direct contact or capacitive coupling. In some examples, as shown in FIGS. 13A and 13B, the plurality of first protrusions 301a may be offset from the plurality of second protrusions 301b in the longitudinal direction 103. In other words, the plurality of first protrusions 301a are not aligned with the plurality of second protrusions 301b in the longitudinal direction 103. Through providing that the plurality of first protrusions 301a are offset from the plurality of second protrusions 301b in the longitudinal direction 103, it is possible to allow for an offset between the conductive terminals 200 in the first set of conductive terminals 207 and the second set of conductive terminals 209, so as to further reduce interference between the conductive terminals 200, thereby further improving signal integrity. It should be appreciated that in some other examples, the lossy material 300 is a single piece of lossy material and couples all the ground terminals 200a of the plurality of conductive terminals 200 together.

[0162] In some embodiments, as shown in FIGS. 4, 13A, and 13B, the lossy material 300 further includes a plurality of third protrusions 301c and a plurality of fourth protrusions 301d. Each of the plurality of third protrusions 301c extends towards a space between the intermediate portions 205 of each pair of the plurality of pairs of signal terminals 200b in the first set of conductive terminals 207. Each of the plurality of fourth protrusions 301d extends towards a space between the intermediate portions 205 of each pair of the plurality of pairs of signal terminals 200b in the second set of conductive terminals 209. Each of the plurality of third protrusions 301c does not extend to a position between the intermediate portions 205 of each pair of the plurality of pairs of signal terminals 200b in the first set of conductive terminals 207, and each of the plurality of fourth protrusions 301d does not extend to a position between the intermediate portions 205 of each pair of the plurality of pairs of signal terminals 200b in the second set of conductive terminals 209. Each of the plurality of third protrusions 301c and the plurality of fourth protrusions 301d forms an interlocking mechanism with the insulative housing 100. In this way, the binding force between the lossy material 300 and the insulative housing 100 can be increased to prevent them from cracking and separating during the injection molding process and subsequent use. In some examples, as shown in FIGS. 13A and 13B, each of the plurality of third protrusions 301c and the plurality of fourth protrusions 301d is elongated along the mating direction 107 and has a dovetail-shaped cross-section. It should be appreciated that in some other examples, the plurality of third protrusions 301c and the plurality of fourth protrusions 301d may also be in any other suitable forms so as to form an interlocking mechanism with the insulative housing 100.

[0163] In some embodiments, as shown in FIGS. 1 to 6, 10 and 11, the tongue portion 105 further includes a first platform 113 protruding from a first outer surface 105a of the tongue portion 105. The first platform 113 defines a first platform surface 113a parallel to the first outer surface 105a. It should be appreciated that the first platform surface 113a may also be considered as part of the first outer surface 105a. The first set of conductive terminals 207 includes a first subset of conductive terminals 207a and a second subset of conductive terminals 207b. The contact portion 201 of each conductive terminal 200 in the first subset of conductive terminals 207a of the first set of conductive terminals 207 is exposed through the first platform surface 113a. The conductive terminals 200 in the first subset of conductive terminals 207a and the conductive terminals 200 in the second subset of conductive terminals 207b are aligned along the longitudinal direction 103, respectively. Each of the conductive terminals 200 in the second set of conductive terminals 209 are aligned along the longitudinal direction 103. The first platform 113 may provide a dummy-proof design to prevent the plug connector 1 from being intentionally or unintentionally inserted into the receptacle connector in a wrong orientation. In some embodiments, the lossy material 300 may include a corresponding platform 302, which may bring the lossy material closer to the conductive terminal 207a held on the platform 113. In some examples, as shown in FIG. 13A, the lossy material 300 is only electrically coupled to the ground terminal 200a in the second subset of conductive terminals 207b. For example, the second subset of conductive terminals 207b may be divided into at least two parts by the first platform. The lossy material 300 includes multiple pieces of lossy material (two pieces in FIG. 13A), and each piece of the multiple pieces of lossy material 300 is electrically coupled to the ground terminals 200a in a corresponding one of the at least two parts.

[0164] In some embodiments, as shown in FIGS. 9, 14A, and 14B, each of the plurality of conductive terminals 200 further includes a reduced head 211 extending from the contact portion 201 opposite to the intermediate portion 205 along the mating direction 107. The reduced head 211 is received in the terminal slot 111. The reduced head 211 is provided with steps 211a on both sides along the mating direction 107, and both side walls of each of the plurality of terminal slots 111 are provided with protrusions 111a configured to abut against the steps 211a of the reduced head 211 of a corresponding conductive terminal 200 to prevent the corresponding conductive terminal from buckling.

[0165] In some embodiments, as shown in FIGS. 1 to 3, 5 and 7, the contact portions 201 of the ground terminals 200a of the plurality of conductive terminals 200 have a longer length than those of the signal terminals 200b so that when the plug connector 1 is mated with the receptacle connector, the ground terminals 200a will contact with the conductive terminals of the receptacle connector prior to the signal terminal 200b.

[0166] In some embodiments, as shown in FIGS. 12 and 15, the tail portion 203 of each conductive terminal 200 in the first set of conductive terminals 207 and the tail portion 203 of each conductive terminal 200 in the second set of conductive terminals 209 are configured to deflect towards a plane (not shown) between the first set of conductive terminals 207 and the second set of conductive terminals 209, respectively, such that end sections 203a of the tail portion 203 of each conductive terminal 200 in the first set of conductive terminals 207 and the tail portion 203 of each conductive terminal 200 in the second set of conductive terminals 209 are configured for mounting to the circuit board are in the same plane (as indicated by the dashed lines in FIGS. 12 and 15). In this way, it is possible to reduce a mounting profile (height) of the plug connector 1 on the circuit board. When the plug electrical connector 1 is mounted in the electronic system (not shown), the plug electrical connector 1 takes up less space so that the space in the electronic system can be better utilized, thus enabling the entire assembly including the plug connector 1 and the electronic system to be more miniaturized. It should be appreciated that the plane towards which the tail portion 203 of each conductive terminal 200 in the first set of conductive terminals 207 and the tail portion 203 of each conductive terminal 200 in the second set of conductive terminals 209 deflect is not necessarily a middle plane between the first set of conductive terminals 207 and the second set of conductive terminals 209.

[0167] As shown in FIGS. 12 and 15, the end sections 203a of the tail portions 203 of the second set of conductive terminals 209 are closer to the lossy material 300 than the end sections 203a of the tail portions 203 of the first set of conductive terminals 207. However, it should be appreciated that the present application is not limited thereto, and it can be contemplated that the end sections 203a of the tail portions 203 of the first set of conductive terminals 207 are closer to the lossy material 300 than the end sections 203 of the tail portions 203 of the second set of conductive terminals 209.

[0168] As shown in FIGS. 12, 14A, 14B and 15, the tail section 203 of each of the plurality of conductive terminals 200 further includes a straight section 203b extending parallelly from the intermediate portion 205, and a transition section 203c transitioning from the straight section 203b to the end section 203a. The end section 203a is parallel to the straight section 203b and offset from the straight section 203b. As shown in FIGS. 12 and 15, the straight section 203b and the end section 203a of the tail section 203 of each conductive terminal 200 in the first set of conductive terminals 207 define a first central axis X1 and a second central axis X2, respectively. The straight section 203b and the end section 203a of the tail section 203 of each conductive terminal 200 in the second set of conductive terminals 209 define a third central axis X3 and a fourth central axis X4, respectively. The second central axis X2 and the fourth central axis X4 are coplanar in a plane parallel to the longitudinal direction 103 and the mating direction 107. A central separation between the first central axis X1 and the third central axis X3 is greater than a distance between the first central axis X1 and the second central axis X2 and greater than a distance between the third central axis X3 and the fourth central axis X4. As used herein, the central separation between the two central axes refers to the distance between projections of the two central axes in a plane perpendicular to the longitudinal direction 103. Further, as used herein, the distance between one central axis line and the other central axis line refers to the distance between them in a plumb line. In some examples, for example in the case without the first platform 113 described above, the central separation between the first central axis X1 and the third central axis X3 may be equal to the distance between the first central axis X1 and the second central axis X2 plus the distance between the third central axis X3 and the fourth central axis X4.

[0169] In some embodiments, as shown in FIGS. 1, 2, 3, 5, 7 and 8, the insulative housing 100 further includes at least one mounting platform 115 (two in the figures) extending from the base portion 101 opposite to the tongue portion 105 in the mating direction 107. Each of the at least one mounting platform 115 has a mounting surface 115a configured for mounting to a circuit board (not shown), and is co-planar with surfaces of the end section 203a of the tail portion 203 of each conductive terminal 200 in the first set of conductive terminals 207 and the end portion 203a of the tail portion 203 of each conductive terminal 200 in the second set of conductive terminals 209 facing a mounting direction (not shown), wherein the mounting direction is perpendicular to the mating direction 107 and the longitudinal direction 103 as mentioned above. In some examples, the mounting platform 115 may also include a structure for guiding and positioning the plug connector 1 when the plug connector 1 is mounted to the circuit board.

[0170] In some embodiments, as shown in FIGS. 1 to 9, the insulative housing 100 also includes mount receiving portions 117 at both ends of the base portion 101 along the longitudinal direction 103 for receiving the mounts 400. The mounts 400 may be used to retain the plug connector 1 securely on the circuit board. The mounts 400 are illustrated in the figures to be in the form of a tab, however, it should be appreciated that the present application is not limited thereto.

[0171] A method for manufacturing the aforementioned plug connector 1 is described below in connection with FIG. 16.

[0172] As shown in FIG. 16, at step S101, the insulative housing 100 of the plug connector 1 is formed, wherein the insulative housing 100 comprises the base portion 101 extending along the longitudinal direction 103, the tongue portion 105 extending from the base portion 101 in the mating direction 107 perpendicular to the longitudinal direction 103 and configured to be plugged into the receptacle connector, and the chamber 109 formed in the insulative housing 100. As described above, the insulative housing 100 may be formed by any suitable manufacturing process in the art, such as an injection molding.

[0173] Next, at step S102, the lossy material 300 is injection-molded into the chamber 109. This step may also be referred to as a secondary injection molding.

[0174] Finally, at step S103, the plurality of conductive terminals 200 are inserted into and retained in the insulative housing 100, with the contact portion 201 of each of the plurality of conductive terminals 200 extending along the mating direction 107 and being exposed through the outer surface of the tongue portion 105 for establishing an electrical connection with a corresponding conductive terminal of the receptacle connector, and with the tail portion 203 extending out of the base portion 101 from a side of the base portion 101 opposite to the tongue portion 105 for mounting to the circuit board. The step of inserting and retaining the plurality of conductive terminals 200 in the insulative housing 100 includes electrically coupling at least some of the ground terminals 200a of the plurality of conductive terminals 200 with the lossy material 300. This allows to reduce the effects of electrical resonance, thereby improving signal integrity. In addition, as compared to the prior art, injection molding the lossy material 300 into the chamber 109 eliminates the need to form a recess at the tongue portion 105, and the lossy material 300 is able to completely fill or substantially completely fill the chamber 109. This allows for improved integrity of the plug connector 1 and reduces the likelihood of breakage of the tongue portion 105 from the base portion 101 during plugging and unplugging, thereby improving the reliability and service life of the plug connector 1.

[0175] It should be appreciated that each of the steps shown in FIG. 16 may further include providing the features or combination of features described above in connection with FIGS. 1 to 15, i.e., providing each of the features of the plug connector 1 described above in connection with FIGS. 1 to 15.

[0176] Although details of specific configurations of conductive elements and housings are described above, it should be appreciated that such details are provided solely for purposes of illustration, as the concepts disclosed herein are capable of other manners of implementation. In that respect, various connector designs described herein may be used in any suitable combination, as aspects of the present disclosure are not limited to the particular combinations shown in the drawings.

[0177] Having thus described several embodiments, it is to be appreciated various alterations, modifications, and improvements may readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.

[0178] Furthermore, although many inventive aspects are shown and described with reference to a plug connector having a right angle configuration, it should be appreciated that aspects of the present disclosure is not limited in this regard, as any of the inventive concepts, whether alone or in combination with one or more other inventive concepts, may be used in other types of electrical connectors, such as receptacle connectors, card edge connectors, backplane connectors, stacking connectors, mezzanine connectors, I/O connectors, chip sockets, etc.

[0179] In some embodiments, mounting ends were illustrated as surface mount elements that are designed to fit within pads of printed circuit boards. However, other configurations may also be used, such as press fit “eye of the needle” compliant sections, spring contacts, solderable pins, etc.

[0180] All definitions, as defined and used, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0181] Numerical values and ranges may be described in the specification and claims as approximate or exact values or ranges. For example, in some cases the terms “about,” “approximately,” and “substantially” may be used in reference to a value. Such references are intended to encompass the referenced value as well as plus and minus reasonable variations of the value.

[0182] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

[0183] The claims should not be read as limited to the described order or elements unless stated to that effect. It should be understood that various changes in form and detail may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the following claims and equivalents thereto are claimed.