U.S. patent application number 14/959293 was filed with the patent office on 2017-06-08 for pluggable connector and unitary housing shell configured to transfer thermal energy of the pluggable connector.
The applicant listed for this patent is TYCO ELECTRONICS CORPORATION. Invention is credited to Alan Weir Bucher.
Application Number | 20170164511 14/959293 |
Document ID | / |
Family ID | 58798723 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170164511 |
Kind Code |
A1 |
Bucher; Alan Weir |
June 8, 2017 |
PLUGGABLE CONNECTOR AND UNITARY HOUSING SHELL CONFIGURED TO
TRANSFER THERMAL ENERGY OF THE PLUGGABLE CONNECTOR
Abstract
Pluggable connector includes a connector housing having a
unitary housing shell that includes a top wall, a bottom wall that
is spaced apart from the top wall, and a side wall that extends
between and joins the top and bottom walls. The pluggable connector
also includes a communication assembly positioned within an
interior cavity of the pluggable connector. The communication
assembly includes internal electronics that generate thermal energy
during operation. The top wall has an exterior surface that forms
an output area configured to dissipate the thermal energy
therefrom. The bottom wall has an interior surface that is coupled
to the internal electronics such that the thermal energy is
conveyed from the internal electronics into the bottom wall. The
unitary housing shell forms a seamless thermal-transfer path that
extends from the bottom wall, through the side wall, and to the
output area.
Inventors: |
Bucher; Alan Weir; (Manheim,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TYCO ELECTRONICS CORPORATION |
Berwyn |
PA |
US |
|
|
Family ID: |
58798723 |
Appl. No.: |
14/959293 |
Filed: |
December 4, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 13/665 20130101;
G02B 6/4272 20130101; G02B 6/4284 20130101 |
International
Class: |
H05K 7/20 20060101
H05K007/20; H01R 13/66 20060101 H01R013/66 |
Claims
1. A pluggable connector comprising: a connector housing having a
unitary housing shell that includes a top wall, a bottom wall that
is spaced apart from the top wall, and a side wall that extends
between and joins the top and bottom walls, the connector housing
having an interior cavity that is partially defined by the top
wall, the bottom wall, and the side wall; and a communication
assembly positioned within the interior cavity, the communication
assembly including internal electronics that generate thermal
energy during operation of the pluggable connector; wherein the top
wall has an exterior surface that forms an output area configured
to dissipate the thermal energy therefrom, the bottom wall having
an interior surface that is coupled to the internal electronics
such that the thermal energy is conveyed from the internal
electronics into the bottom wall, wherein the unitary housing shell
forms a seamless thermal-transfer path that extends from the bottom
wall, through the side wall, and to the output area.
2. The pluggable connector of claim 1, wherein the unitary housing
shell forms a back side opening that is opposite the bottom wall,
the back side opening being adjacent to the top wall and positioned
between the top wall and a trailing end of the pluggable
connector.
3. The pluggable connector of claim 2, wherein the communication
assembly includes a circuit board that is coupled to the internal
electronics, the circuit board including a plurality of mating
terminals that are positioned along a leading edge of the circuit
board, wherein the back side opening is sized and shaped to permit
the leading edge of the circuit board to be inserted through the
back side opening and positioned adjacent to a leading end of the
pluggable connector.
4. The pluggable connector of claim 3, wherein the trailing end is
opposite the leading end and has a cable opening, the pluggable
connector further comprising a communication cable that is received
through the cable opening at the trailing end.
5. The pluggable connector of claim 3, further comprising a back
cover that is coupled to the unitary housing shell and covers the
back side opening, the back cover opposing the bottom wall with a
portion of the interior cavity therebetween.
6. The pluggable connector of claim 1, wherein the pluggable
connector has a leading end that includes a cavity opening, wherein
the unitary housing shell forms a front side opening that is
positioned between the cavity opening and the bottom wall.
7. The pluggable connector of claim 6, further comprising a front
cover that is coupled to the unitary housing shell and covers the
front side opening, the front cover opposing the top wall with a
portion of the interior cavity therebetween.
8. The pluggable connector of claim 1, wherein the side wall is a
first side wall and the thermal-transfer path is a first
thermal-transfer path, the unitary housing shell including a second
side wall that opposes the first side wall with at least a portion
of the interior cavity therebetween, the top and bottom walls
extending between and joining the first and second side walls,
wherein the unitary housing shell forms a second seamless
thermal-transfer path that extends from the bottom wall, through
the second side wall, and to the output area.
9. The pluggable connector of claim 1, wherein the top wall has an
inner wall edge and the bottom wall has an inner wall edge, the
inner wall edges of the top and bottom walls having different axial
locations relative to a longitudinal axis that extends between
leading and trailing ends of the pluggable connector, wherein the
exterior surface is an exterior surface of the connector housing,
the bottom wall including a portion of the exterior surface.
10. The pluggable connector of claim 1, wherein the unitary housing
shell has a leading shell section that includes the top wall and a
trailing shell section that includes the bottom wall, the leading
shell section defining a front side opening that is opposite the
top wall, the trailing shell section defining a back side opening
that is opposite the bottom wall, the connector housing further
comprising a front cover and a back cover that cover the front and
back side openings, respectively.
11. The pluggable connector of claim 1, wherein the unitary housing
shell includes a majority of an exterior of the connector
housing.
12. The pluggable connector of claim 1, wherein the internal
electronics include an electro-optical engine.
13. A connector housing for a pluggable connector, the connector
housing comprising: a top wall having an exterior surface that
includes an output area; a bottom wall having an interior surface
that is configured to couple to internal electronics of the
pluggable connector and absorb thermal energy therefrom; and a pair
of opposing side walls that are each coupled to the top and bottom
walls, the top and bottom walls extending between and joining the
opposing side walls, wherein the top and bottom walls are
configured to form at least portions of top and bottom sides,
respectively, of the pluggable connector; wherein the top wall, the
bottom wall, and the opposing side walls form a unitary housing
shell, the unitary housing shell having first and second seamless
thermal-transfer paths that extend from the bottom wall to the
output area of the top wall, each of the first and second
thermal-transfer paths extending from the bottom wall, through a
respective side wall of the pair of opposing side walls, and the
top wall.
14. The connector housing of claim 13, wherein the unitary housing
shell forms a back side opening that is opposite the bottom wall,
the back side opening being adjacent to the top wall and positioned
between the top wall and a trailing end of the connector
housing.
15. The connector housing of claim 14, wherein the back side
opening is sized and shaped to permit a leading edge of a circuit
board to be inserted through the back side opening.
16. The connector housing of claim 14, further comprising a back
cover that is coupled to the unitary housing shell and covers the
back side opening, the back cover opposing the bottom wall with a
portion of the interior cavity therebetween.
17. The connector housing of claim 13, wherein the first and second
thermal-transfer paths are symmetrical paths that surround the
interior cavity.
18. The connector housing of claim 13, wherein the top wall has an
inner wall edge and the bottom wall has an inner wall edge, the
inner wall edges of the top and bottom walls having different axial
locations relative to a longitudinal axis that extends between
leading and trailing ends of the pluggable connector, wherein the
exterior surface is an exterior surface of the connector housing,
the bottom wall including a portion of the exterior surface.
19. The connector housing of claim 13, wherein the unitary housing
shell has a leading shell section that includes the top wall and a
trailing shell section that includes the bottom wall, the leading
shell section defining a front side opening that is opposite the
top wall, the trailing shell section defining a back side opening
that is opposite the bottom wall, the connector housing further
comprising a front cover and a back cover that cover the front and
back side openings, respectively.
20. The connector housing of claim 13, wherein a longitudinal axis
extends between leading and trailing ends of the pluggable
connector when constructed, each of the first and second
thermal-transfer paths including a longitudinal component that
extends parallel to the longitudinal axis.
Description
BACKGROUND
[0001] The subject matter herein relates generally to a pluggable
connector that is configured to transfer thermal energy (or heat)
generated within the pluggable connector to an exterior of the
pluggable connector for dissipation into the surrounding
environment.
[0002] Pluggable connectors may be used to transmit data and/or
electrical power to and from different systems or devices. For
example, a cable assembly (or plug assembly) typically includes two
or more pluggable connectors that are interconnected through one or
more communication cables. Data signals may be transmitted through
the communication cable(s) in the form of optical signals and/or
electrical signals. Electrical power may also be transmitted
through the communication cable(s). Each pluggable connector
includes a connector housing having a leading end that is mated
with a receptacle assembly and a back end that is coupled to the
corresponding communication cable. For some types of pluggable
connectors, the pluggable connector includes a circuit board within
the connector housing. The circuit board has contact pads that are
exposed at the leading end of the connector housing. During a
mating operation, the leading end is inserted into a cavity of the
receptacle assembly and advanced in a mating direction until the
contact pads of the circuit board engage corresponding contacts of
a mating connector of the receptacle assembly.
[0003] A common challenge that developers of pluggable connectors
often confront is heat management. Heat generated by internal
electronics within the pluggable connector can degrade performance
or even damage the pluggable connector. For example, pluggable
connectors may include an electro-optical (E/O) engine that is
coupled to an interior circuit board of the pluggable connector.
The E/O engine transforms data signals from an electrical form to
an optical form or vice versa. This transformation process can
generate a substantial amount of heat within the pluggable
connector.
[0004] To dissipate the heat, the pluggable connector engages a
heat sink when the pluggable connector is mated to the receptacle
assembly. The heat sink is typically positioned along a top surface
of the pluggable connector and is pressed against the top surface
to maintain an intimate engagement throughout operation. Heat
generated within the pluggable connector is absorbed by the
connector housing and transferred along a thermal path to the top
surface. Although the thermal path in known pluggable connectors
allows heat to transfer to the top surface, it is desirable to
improve the efficiency of this transfer so that developers may
create other connector configurations and/or increase the
throughput of the pluggable connectors.
[0005] Accordingly, there is a need for a pluggable connector that
provides improved heat transfer while minimizing a likelihood of
damage to internal electronics.
BRIEF DESCRIPTION
[0006] In an embodiment, a pluggable connector is provided that
includes a connector housing having a unitary housing shell that
includes a top wall, a bottom wall that is spaced apart from the
top wall, and a side wall that extends between and joins the top
and bottom walls. The connector housing has an interior cavity that
is partially defined by the top wall, the bottom wall, and the side
wall. The pluggable connector also includes a communication
assembly positioned within the interior cavity. The communication
assembly includes internal electronics that generate thermal energy
during operation of the pluggable connector. The top wall has an
exterior surface that forms an output area configured to dissipate
the thermal energy therefrom. The bottom wall has an interior
surface that is coupled to the internal electronics such that the
thermal energy is conveyed from the internal electronics into the
bottom wall. The unitary housing shell forms a seamless
thermal-transfer path that extends from the bottom wall, through
the side wall, and to the output area.
[0007] In some embodiments, the unitary housing shell forms a back
side opening that is opposite the bottom wall. Optionally, the
communication assembly includes a circuit board that is coupled to
the internal electronics. The circuit board may include a plurality
of mating terminals that are positioned along a leading edge of the
circuit board. The back side opening may be sized and shaped to
permit the leading edge of the circuit board to be inserted through
the back side opening and positioned adjacent to a leading end of
the pluggable connector.
[0008] In an embodiment, a connector housing for a pluggable
connector is provided that includes a top wall having an exterior
surface that includes an output area. The connector housing also
includes a bottom wall having an interior surface that is
configured to couple to internal electronics of the pluggable
connector and absorb thermal energy therefrom. The connector
housing also includes a pair of opposing side walls that are each
coupled to the top and bottom walls. The top and bottom walls
extend between and join the opposing side walls. The top and bottom
walls are configured to form at least portions of top and bottom
sides, respectively, of the pluggable connector. The top wall, the
bottom wall, and the opposing side walls form a unitary housing
shell. The unitary housing shell has first and second seamless
thermal-transfer paths that extend from the bottom wall to the
output area of the top wall. Each of the first and second
thermal-transfer paths extends from the bottom wall, through a
respective side wall of the pair of opposing side walls, and the
top wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a plug and receptacle
assembly formed in accordance with an embodiment.
[0010] FIG. 2 is an exploded view of a connector housing that may
be used in assembling a pluggable connector in accordance with an
embodiment.
[0011] FIG. 3 is an isolated top perspective view of a unitary
housing shell in accordance with an embodiment that is a part of
the connector housing of FIG. 2.
[0012] FIG. 4 is an isolated bottom perspective view of the unitary
housing shell.
[0013] FIG. 5 illustrates a side cross-section of the unitary
housing shell during an assembly process.
[0014] FIG. 6 illustrates a side cross-section of a fully assembled
pluggable connector in accordance with an embodiment that includes
the connector housing of FIG. 2.
DETAILED DESCRIPTION
[0015] Embodiments set forth herein include plug and receptacle
assemblies, plug assemblies, pluggable connectors, connector
housings, and unitary housing shells that provide at least one
seamless thermal-transfer path. For example, the thermal-transfer
path may extend from a first wall where thermal energy is absorbed
to an opposite second wall where the thermal energy is dissipated.
Because the thermal-transfer path (or paths) are seamless, the
thermal energy may be conveyed more quickly and/or more efficiently
from the source of the thermal energy.
[0016] FIG. 1 is a perspective view of a plug and receptacle
assembly 100 formed in accordance with an embodiment that includes
a plug assembly 102 and a receptacle assembly 104. The plug and
receptacle assembly 100 may also be referred to as a communication
system, and the plug assembly 102 may also be referred to as a
cable assembly. The receptacle assembly 104 is mounted to a circuit
board 106. The circuit board 106 may be, for example, a daughter
card or a mother board. The plug assembly 102 includes a pluggable
connector 108 that is an input/output (I/O) module capable of
repeatedly mating with the receptacle assembly 104. In FIG. 1, the
plug and receptacle assembly 100 is oriented with respect to
mutually perpendicular axes, including a mating axis 191, a lateral
axis 192, and an elevation axis 193.
[0017] The plug assembly 102 includes a communication cable 110
that is coupled to a trailing end 114 of the pluggable connector
108. The communication cable 110 may be affixed to the trailing end
114 such that the communication cable 110 may not be separated from
the pluggable connector 108 without damaging the pluggable
connector 108 or the communication cable 110. Alternatively, the
communication cable 110 may be readily separable from the trailing
end 114. Although not shown, the plug assembly 102 may include
another pluggable connector 108 that is attached to an opposite end
of the communication cable 110. The pluggable connector 108 has a
leading end 112 that is opposite the trailing end 114. A
longitudinal axis 194 of the pluggable connector 108 extends
between the leading end 112 and the trailing end 114 and is
parallel to the mating axis 191.
[0018] The receptacle assembly 104 has a receptacle housing 116. In
some embodiments, the receptacle housing 116 may be stamped and
formed from sheet metal to form a receptacle cage. In other
embodiments, the receptacle housing 116 may be formed from other
manufacturing methods. The receptacle housing 116 defines a
communication port 118 that provides access to a receiving cavity
120 within the receptacle housing 116. The communication port 118
and the receiving cavity 120 are configured to receive a portion of
the pluggable connector 108. For example, the leading end 112 of
the pluggable connector 108 is configured to be inserted through
the communication port 118 and into the receiving cavity 120.
[0019] To insert the leading end 112 into the receiving cavity 120,
the pluggable connector 108 is aligned with respect to the
communication port 118 and the receiving cavity 120 and advanced
through the communication port 118 in a mating direction M.sub.1.
The mating direction M.sub.1 is parallel to the mating axis 191.
The leading end 112 is advanced toward a mating connector 122 that
is disposed within the receiving cavity 120. The pluggable
connector 108 and the mating connector 122 form a pluggable
engagement.
[0020] Optionally, the receptacle assembly 104 includes a
thermal-transfer module (not shown), such as a heat sink, that is
configured to engage the pluggable connector 108 when the pluggable
connector 108 is mated with the receptacle assembly 104 and
disposed within the receiving cavity 120. For instance, the
receptacle housing 116 has a top side 124 that includes an opening
126 therethrough. In some embodiments, the thermal-transfer module
may be mounted to the top side 124 and extend along the opening
126. The thermal-transfer module may have a surface (not shown)
that intimately engages the pluggable connector 108 when the
pluggable connector 108 is positioned within the receiving cavity
120. As such, the thermal-transfer module may absorb thermal energy
generated by the pluggable connector 108. In alternative
embodiments, the pluggable connector 108 may be cooled by directing
forced air (not shown) across the opening 126.
[0021] The communication cable 110 is configured to transmit data
signals and, optionally, electrical power. In alternative
embodiments, the communication cable 110 may only transmit
electrical power. In an exemplary embodiment, the communication
cable 110 includes optical fibers that are configured to transmit
data signals in the form of optical signals. The optical fibers may
be communicatively coupled to internal electronics 320 (shown in
FIG. 5) of the pluggable connector 108, such as an electro-optical
(E/O) engine, integrated circuits, processing units, or other
circuitry. In other embodiments, the communication cable 110
includes insulated wires having jackets that surround wire
conductors. The wire conductors may be configured to transmit
electrical signals and/or electrical power.
[0022] In particular embodiments, the plug and receptacle assembly
100 is a high speed pluggable input/output (I/O) interconnect
assembly. The plug and receptacle assembly 100, the plug assembly
102, and/or the pluggable connector 108 may be configured for
various applications. Non-limiting examples of such applications
include storage networking, cluster computing, high performance
computing, and telecommunications. The plug and receptacle assembly
100, the plug assembly 102, and/or the pluggable connector 108 may
be used with switches, hubs, storage systems, storage devices,
adapters, controllers, network interface cards (NICs), servers,
switches, host bus adapters (HBAs), and routers. By way of one
example, the pluggable connector 108 and/or the receptacle assembly
104 may be part of a quad small form-factor pluggable (QSFP)
interconnect system, such as the QSFP+ system available from TE
Connectivity. As another example, the pluggable connector 108
and/or the receptacle assembly 104 may be part of a CDFP
interconnect system, which is a standard developed through a
multi-source agreement. The plug and receptacle assembly 100 may be
capable of achieving high data rates, such as data rates that
exceed 20 gigabits per second (Gbps), 50 Gbps, 100 Gbps, or more.
The plug and receptacle assembly 100 may also be configured to
satisfy various industry standards, such as Ethernet, Fibre
Channel, and InfiniBand. In other embodiments, the plug and
receptacle assembly 100 may transmit data at slower speeds.
[0023] The pluggable connector 108 has a connector housing 130 that
includes the leading end 112 and the trailing end 114. When the
connector housing 130 is fully assembled (as shown in FIG. 1 or
FIG. 6), the connector housing 130 encloses an interior cavity 304
(shown in FIG. 5) where the internal electronics 320 (FIG. 5) are
located. The interior cavity 304 extends between the leading end
112 and the trailing end 114 and may open to the leading end 112.
The connector housing 130 has a plug section or portion 134 that is
sized and shaped to be inserted through the communication port 118
and into the receiving cavity 120 of the receptacle assembly 104.
The connector housing 130 also includes a body section or portion
136 that is not inserted into the receiving cavity 120. The plug
section 134 includes the leading end 112. The body section 136
includes the trailing end 114 and may be configured to be gripped
by an individual.
[0024] In an exemplary embodiment, the body section 136 includes at
least a portion of the internal electronics 320. Alternatively or
in addition to the internal electronics 320 being within the body
section 136, the plug section 134 may include at least a portion of
the internal electronics 320. The connector housing 130 has an
exterior surface 156 that includes a designated area 157, which is
hereinafter referred to as an output area or engagement area. The
output area 157 is configured to align with the opening 126 and,
optionally, engage the thermal-transfer module. As described
herein, the connector housing 130 forms a seamless thermal-transfer
path that conveys thermal energy generated through the connector
housing 130 to the output area 157.
[0025] The pluggable connector 108 includes a pair of circuit
boards 140, 141 that each have a leading edge 142 with mating
terminals 144. The circuit boards 140, 141 may coincide with
respective planes that extend parallel to the mating and lateral
axes 191, 192. In alternative embodiments, the pluggable connector
108 may have only one circuit board or may not include a circuit
board. In an exemplary embodiment, the mating terminals 144 are
electrical contacts or, more specifically, contact pads. The
circuit boards 140, 141 are disposed within the interior cavity 304
(FIG. 5) and exposed at the leading end 112. The mating terminals
144 are configured to engage corresponding terminals (not shown) of
the mating connector 122 in the receptacle assembly 104. The mating
terminals 144 may be other types of electrical contacts, such as
contact beams, in other embodiments.
[0026] The plug section 134 of the connector housing 130 includes
plug sides 151, 152, 153, 154 that extend parallel to the
longitudinal axis 194 (or the mating axis 191) and between the
leading end 112 and the body section 136. The plug sides 151, 153
face in opposite directions along the lateral axis 192 and extend
lengthwise along the longitudinal axis 194 (or the mating axis 191)
between the body section 136 and the leading end 112. The plug
sides 152, 154 face in opposite directions along the elevation axis
193 and extend lengthwise along the longitudinal axis 194 (or the
mating axis 191) between the body section 136 and the leading end
112. The plug sides 152, 154 extend laterally between the plug
sides 151, 153. When the pluggable connector 108 is mated with the
receptacle assembly 104, the thermal-transfer module (not shown) of
the receptacle assembly 104 may engage the output area 157 of the
exterior surface 156 along the plug side 152.
[0027] The body section 136 of the connector housing 130 includes
body sides 161, 162, 163, 164 that extend parallel to the
longitudinal axis 194 (or the mating axis 191) and between the
trailing end 114 and the plug section 134. The body sides 161, 163
face in opposite directions along the lateral axis 192 and extend
lengthwise along the longitudinal axis 194 (or the mating axis 191)
between the trailing end 114 and the plug section 134. The body
sides 162, 164 face in opposite directions along the elevation axis
193 and extend lengthwise along the longitudinal axis 194 (or the
mating axis 191) between the trailing end 114 and the plug section
134. The body sides 162, 164 extend laterally between the body
sides 161, 163.
[0028] Although the elevation axis 193 appears to extend parallel
to the force of gravity in FIG. 1 with gravity pulling the
receptacle assembly 104 toward the circuit board 106, it should be
understood that the plug and receptacle assembly 100 and its
components may have other spatial orientations. For example, the
lateral axis 192 may extend parallel to the force of gravity.
Although spatially relative terms, such as "top" "bottom," "front,"
and "back" may be used in the description and claims for describing
a spatial relationship between two elements or features, it should
be understood that such terms do not require a particular
orientation for the pluggable connector 108 or the assembly 100.
For example, a top wall may be located below a bottom wall, with
respect to gravity, depending on the orientation of the
component.
[0029] As used herein, the terms "front," "forward," "forwardly,"
and derivatives thereof refer to a direction defined by a vector
extending from the trailing end 114 toward the leading end 112.
Conversely, the terms "back," "rearward," "rearwardly," and
derivatives thereof refer to a direction that is opposite the
forward direction. The rearward direction is defined by a vector
that extends away from the leading end 112 toward the trailing end
114. The terms "lateral," "laterally," and derivatives thereof
refer to a direction that is generally parallel with the plane
defined by the circuit board 106 or a plane that is parallel to the
mating and lateral axes 191, 192.
[0030] FIG. 2 is an exploded view of the connector housing 130. In
the illustrated embodiment, the connector housing 130 includes a
unitary housing shell 202, a front or first cover 204, and a back
or second cover 206. In other embodiments, the connector housing
130 may include a unitary housing shell and only one of the front
or back covers 204, 206 or a different cover. Yet in other
embodiments, the connector housing 130 only includes a unitary
housing shell 202. The unitary housing shell 202 is now hereinafter
referred to simply as the "housing shell."
[0031] The housing shell 202 includes a leading shell section 210
and a trailing shell section 212 that are coupled to each other.
The leading shell section 210 includes a front side opening 214,
and the trailing shell section 212 includes a back side opening
216. The front cover 204 is configured to be coupled to the housing
shell 202 and cover the front side opening 214. The back cover 206
is configured to be coupled to the housing shell 202 and cover the
back side opening 216.
[0032] The front and back covers 204, 206 may be secured to the
housing shell 202 in fixed positions. For example, an adhesive may
be positioned along an interface or seam that is defined between
the housing shell 202 and the respective cover. The front and back
covers 204, 206 may also form an interference fit (e.g., snap fit)
with the housing shell 202. When the connector housing 130 is fully
assembled (as shown in FIG. 1 and FIG. 6), the connector housing
130 encloses the interior cavity 304 (FIG. 5), except for a cavity
opening 236 (shown in FIG. 5) where the mating terminals 144 are
disposed.
[0033] The housing shell 202 is a unitary structure that provides a
seamless thermal-transfer path as described herein. The unitary
structure constitutes a single element or part of the pluggable
connector 108 (FIG. 1). The unitary structure does not include
multiple discrete parts that are affixed to each other and form
joints or seams therebetween. More specifically, it is not
necessary for the seamless thermal-transfer path to cross an
interface between discrete structures of the same or different
material. By way of example, the housing shell 202 may be molded,
die-cast, machined, or stamped-and-formed from a thermally
conductive material (e.g., metal material). The thermally
conductive material may include, for example, zinc, aluminum, and
copper. The front and back covers 204, 206 are discrete components
and may be formed from the same material or from a different
material.
[0034] In the illustrated embodiment, the housing shell 202
constitutes a majority of the connector housing 130 and includes a
majority of an exterior of the connector housing 130. When the
connector housing 130 is formed, the exterior of the front and back
covers 204, 206 form respective portions of the exterior surface
156 of the connector housing 130. In other embodiments, however,
the housing shell 202 may not form a majority of the connector
housing and/or may not include a majority of the exterior surface
156.
[0035] Also shown in FIG. 2, the back cover 206 includes a recess
218 that opens to the exterior of the connector housing 130. The
recess 218 is sized and shaped to receive a tether or pull tab 228
(shown in FIG. 1). Although not shown, the tether 228 may be
operably coupled to a release mechanism for disconnecting the
pluggable connector 108 (FIG. 1) and the receptacle assembly 104
(FIG. 1).
[0036] FIGS. 3 and 4 illustrate top and bottom isolated perspective
views of the housing shell 202. The housing shell 202 includes a
top wall 220, a bottom wall 222, and a pair of opposing side walls
224, 226, which may also be referred to as first and second side
walls 224, 226. In some embodiments, the housing shell 202 includes
only one of the side walls 224, 226.
[0037] In the illustrated embodiment, the top wall 220 forms the
plug side 152 (FIG. 1) of the plug section 134 (FIG. 1) and
includes the output area 157 of the exterior surface 156. In FIGS.
3 and 4, the exterior surface 156 is shown along the housing shell
202. It should be understood that the exterior surface 156 may
include portions of the front and back covers 204, 206 (FIG. 2).
The bottom wall 222 forms the body side 164 (FIG. 1) of the body
section 136 (FIG. 1). The housing shell 202 includes an interior
surface 230. Similar to the exterior surface 156, the interior
surface 230 may be formed by the housing shell 202 and surfaces of
the front and back covers 204, 206.
[0038] As shown in FIG. 3, the bottom wall 222 includes one or more
input areas 232 of the interior surface 230. Each of the input
areas 232 represents a portion of the interior surface 230 that
couples to internal electronics 320 as described below. In addition
to the input area 232, the interior surface 230 along the top wall
220 may include one or more input areas 234 (FIG. 4) that are
configured to couple to internal electronics 320.
[0039] The leading shell section 210 is formed by the top wall 220
and forward portions of the side walls 224, 226. The trailing shell
section 212 is formed by the bottom wall 222 and rearward portions
of the side walls 224, 226. Each of the side walls 224, 226 extends
between and joins the top and bottom walls 220, 222. As such, each
of the leading shell section 210 and the trailing shell section 212
are defined by portions of the side walls 224, 226. The leading and
trailing shell sections 210, 212 are coupled to each other at joint
regions 244 and 246. The side wall 224 includes the joint region
244, and the side wall 226 includes the joint region 246. The back
side opening 216 is adjacent to the top wall 220 and opposite the
input area(s) 232 such that the input area(s) 232 face the back
side opening 216. The front side opening 214 is adjacent to the
bottom wall 222 and opposite the input area(s) 234 such that the
input area(s) 234 face the front side opening 214.
[0040] Optionally, the trailing shell section 212 may include a
trailing or rearward wall 248. The trailing wall 248 may include or
define the trailing end 114 (FIG. 1) of the pluggable connector 108
(FIG. 1). The trailing wall 248 forms a portion of the housing
shell 202. In other embodiments, however, the trailing wall 248 may
be a separable wall or a cover that is coupled to the housing shell
202. In other embodiments, the trailing wall 248 may form a portion
of the back cover 206 (FIG. 2). As shown, the trailing wall 248 may
include a cable opening (e.g., slot) 250 that is sized and shape to
receive the communication cable 110. Yet in other embodiments, the
trailing wall is not used and the communication cable 110 (FIG. 1)
includes a boot that encloses the interior cavity.
[0041] With respect to FIG. 3, embodiments may form first and
second seamless thermal-transfer paths 240, 242 (indicated by
dashed lines) that extend from one or more of the input areas 232
of the bottom wall 222 to the output area 157 of the top wall 220.
The thermal energy may be absorbed from the internal electronics
320 (FIG. 5) and transferred through the housing shell 202 to the
output area 157. More specifically, the first seamless
thermal-transfer path 240 extends through the bottom wall 222, the
side wall 224, and the top wall 220. The second seamless
thermal-transfer path 242 extends through the bottom wall 222, the
side wall 226, and the top wall 220. The output area 157 represents
the portion of the exterior surface 156 that aligns with the
opening 126 (FIG. 1) of the receptacle assembly 104 (FIG. 1). In
FIG. 3, the output area 157 appears as only one surface area. In
other embodiments, however, the output area 157 may include
separate surface areas.
[0042] The first and second thermal-transfer paths 240, 242 through
the housing shell 202 are devoid of material discontinuities in
which the thermal energy must cross or traverse a seam between
discrete components. A seam may include, for example, an interface
between two discrete components that abut each other or an
interface between two discrete components that are joined through
an adhesive or other intervening material (e.g., foam).
[0043] As indicated by the dashed lines in FIG. 3, each of the
thermal-transfer paths 240, 242 may include a first lateral
component 251, a first vertical component 252, a longitudinal
component 253, a second vertical component 254, and a second
lateral component 255. It should be understood that the transfer of
heat from the input area(s) 232 to the output area 157 is not a
single narrow path but a general conduction or conveyance of the
thermal energy that is directed through the material of the housing
shell 202 from the input area(s) 232 to the output area 157. The
direction of the conduction is determined by, at least in part, the
location and size of the input area(s) 232, the location and size
of the output area 157, and the shape of the housing shell 202.
Nonetheless, the general conduction includes the directional
components 251-255. The longitudinal components 253 are forward
components that extend along the side walls 224, 226 and, in
particular, through the joint regions 244, 246, respectively, that
join the leading shell section 210 and the trailing shell section
212.
[0044] It is noted that the thermal-transfer paths 240, 242 do not
exclude the possibility of some thermal energy being transferred
across seams or interfaces. For example, thermal energy may
traverse a seam 330 (shown in FIG. 6) between the front cover 204
(FIG. 2) and the housing shell 202 and/or a seam 332 (shown in FIG.
6) between the back cover 206 (FIG. 2) and the housing shell 202.
Nonetheless, a substantial amount of the thermal energy that is
dissipated through the output area 157 may be transferred through
one or more of the thermal-transfer paths 240, 242. In some
embodiments, at least 30% of the thermal energy that is dissipated
through the output area 157 may be transferred through the
thermal-transfer paths 240, 242. In particular embodiments, a
majority of the thermal energy (e.g., at least 50%) that is
dissipated through the output area 157 may be transferred through
the thermal-transfer paths 240, 242. In more particular
embodiments, at least 75% of the thermal energy that is dissipated
through the output area 157 may be transferred through the
thermal-transfer paths 240, 242. However, unless recited otherwise,
embodiments set forth herein and in the claims are not limited to
particular percentage. In some embodiments, a nominal or
insubstantial amount of the thermal energy that is dissipated
through the output area 157 is transferred through the seams 330,
332. Determination of the path(s) taken by thermal energy that is
dissipated through the output area 157 may be made through
simulation or direct testing (e.g., thermal imaging).
[0045] FIG. 5 illustrates a side cross-section of the housing shell
202 during an assembly process in which the communication assembly
302 is inserted into the interior cavity 304. As shown, the
communication assembly 302 includes the circuit board 141 and the
internal electronics 320. Although not shown, the internal
electronics 320 may be communicatively coupled to optical fibers
and/or electrical conductors of the communication cable 110 (FIG.
1). The internal electronics 320 are, in turn, communicatively
coupled to the mating terminals 144. The internal electronics 320
may include electrical and/or optical circuits through which
current or light propagates. The internal electronics 320 may
generate a substantial amount of heat during operation of the
pluggable connector 108.
[0046] In some embodiments, the front and back side openings 214,
216 are sized and shaped relative to each other to permit the
insertion of the communication assembly 302 (and the communication
assembly 301 shown in FIG. 6) into the interior cavity 304. For
example, the communication assembly 302 may be inserted through the
back side opening 216 into the interior cavity 304 and toward the
cavity opening 236. Accordingly, the communication assembly 302 may
be inserted in a generally forward direction. In other embodiments,
one or more of the communication assemblies 301, 302 may be led
through the front side opening 214. In such embodiments, the
communication assemblies 301, 302 may be inserted in a generally
rearward direction.
[0047] With respect to the illustrated embodiment, the leading edge
142 of the circuit board 141 is advanced through the back side
opening 216 and generally toward the leading end 112 at a
non-orthogonal angle 334. As shown, the top wall 220 has an inner
wall edge 306 that defines a portion of the back side opening 216,
and the bottom wall 222 has an inner wall edge 308 that defines a
portion of the front side opening 214. The inner wall edges 306,
308 are separated by a working gap 310 that includes a vertical
component 312 and a longitudinal component 314. The vertical and
longitudinal components 312, 314 may be measured along the
elevation axis 193 and the longitudinal axis 194, respectively. As
such, the inner wall edges 306, 308 have different axial locations
relative to the mating axis 191 (or the longitudinal axis 194 (FIG.
1)). In some embodiments, the axial locations are spaced apart such
that the top and bottom walls 220, 222 do not overlap each other.
In other embodiments, however, the top and bottom walls 220, 222
may at least partially overlap each other or the inner wall edges
306, 308 may align with each other.
[0048] The working gap 310 or, more specifically, the vertical and
longitudinal components 312, 314 are configured to permit the
communication assembly 302 to be inserted through the working gap
310 such that the circuit board 141 has a non-orthogonal
orientation with respect to the elevation axis 193 and the
longitudinal axis 194. The front side opening 214 is configured to
permit a portion of the circuit board 141 to extend therethrough.
The working gap 310 is also configured to permit the circuit board
141 to be rotated within the interior cavity 304 so that the
internal electronics 320 may couple to the input area 232. More
specifically, the circuit board 141 may be rotated about an axis of
rotation that extends parallel to the lateral axis 192. The circuit
board 141 may be rotated toward the input area 232 of the bottom
wall 222.
[0049] In particular embodiments, the internal electronics 320 may
engage a thermally-conductive substance 326 that secures the
internal electronics 320 to the input area 232. The
thermally-conductive substance 326 may be, for example, an
adhesive, a putty, an underfill, and/or an encapsulant. It is noted
that these terms (i.e., adhesive, putty, underfill, encapsulant)
are not necessarily mutually exclusive. The thermally-conductive
substance 326 may include, for example, thermally-conductive
particles (e.g., metal particles) that are dispersed within a
compliant material (e.g., silicone) that permits the
thermally-conductive substance 326 to be molded or pressed into a
desired shape. By permitting the circuit board 141 to be positioned
within the interior cavity 304 and rotated toward the input area
232, the internal electronics 320 may be pressed into the
thermally-conductive substance 326. In some embodiments, the
thermally-conductive substance 326 may be actively cured or allowed
to passively cure.
[0050] FIG. 6 illustrates a side cross-section of the pluggable
connector 108. As shown, the communication assemblies 301, 302 have
been operably positioned within the interior cavity 304. The
interior cavity 304 is define by the interior surface 230, which
includes surfaces of the housing shell 202, the front cover 204,
and the back cover 206. As shown, the front cover 204 has been
coupled to the housing shell 202 such that the front cover 204
covers the front side opening 214. The front cover 204 opposes the
top wall 220 with the interior cavity 304 therebetween. The back
cover 206 has been coupled to the housing shell 202 such that the
back cover 206 covers the back side opening 216. The back cover 206
opposes the bottom wall 222 with the interior cavity 304
therebetween.
[0051] The cavity opening 236 is defined by a front edge 340 of the
housing shell 202 and a front edge 342 of the front cover 204. The
front edge 340 may be substantially three-sided and the front edge
342 may close the three sides. The mating terminals 144 are
positioned proximate to the lead end 112. For example, the mating
terminals 144 may be located at the cavity opening 236, positioned
a nominal depth within the interior cavity 304, or clear the front
edge 340 such that the mating terminals 144 are positioned a
nominal distance away from the cavity opening 236.
[0052] The internal electronics 320 of the communication assembly
301 and the internal electronics 320 of the communication assembly
302 have been secured to the respective input areas 234, 232. In
the illustrated embodiment, the internal electronics 320 are
thermally coupled to the respective wall through a thermal bridge
364 and the thermally-conductive substance 326. For example, the
thermal bridge 364 may comprise a substantially single material
that efficiently transfers heat. Accordingly, the top and bottom
walls 220, 222 may not directly engage the internal electronics
320. Nonetheless, thermal energy generated may be conveyed from the
internal electronics 320 to the respective wall and, more
specifically, at the respective input area.
[0053] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the various embodiments without departing from its scope.
Dimensions, types of materials, orientations of the various
components, and the number and positions of the various components
described herein are intended to define parameters of certain
embodiments, and are by no means limiting and are merely exemplary
embodiments. Many other embodiments and modifications within the
spirit and scope of the claims will be apparent to those of skill
in the art upon reviewing the above description. The patentable
scope should, therefore, be determined with reference to the
appended claims, along with the full scope of equivalents to which
such claims are entitled.
[0054] As used in the description, the phrase "in an exemplary
embodiment" and the like means that the described embodiment is
just one example. The phrase is not intended to limit the inventive
subject matter to that embodiment. Other embodiments of the
inventive subject matter may not include the recited feature or
structure. In the appended claims, the terms "including" and "in
which" are used as the plain-English equivalents of the respective
terms "comprising" and "wherein." Moreover, in the following
claims, the terms "first," "second," and "third," etc. are used
merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means--plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.112(f),
unless and until such claim limitations expressly use the phrase
"means for" followed by a statement of function void of further
structure.
* * * * *