QSFP-DD backshell

1. A backshell of a Quad Small Form-factor Pluggable Double Density (QSFP-DD) plug configured to be connected to the end of a QSFP-DD copper cable, having external dimensions and shape which are compliant with the industry standards for a QSFP backshell, the backshell comprising:

a) a locking latch comprising a top side and a side part;

b) a pull tab comprising two sections that are located on opposite sides of the top side of the locking latch;

c) a circular cable inlet located through an end wall of the backshell; and

d) a circular groove located in the cable inlet;

wherein:

i) the edge of the top side of the locking latch ends at a location spaced away from the end wall of the backshell and the two sections of the pull-tab are connected by two strips of connecting piece that passes under the top side of the locking latch leaving a portion of the end wall of the backshell between them the two strips;

ii) a part of the portion of end wall is cleared away to enlarge the diameter of the cable inlet to the backend of the connector; and

iii) the circular groove located in the cable inlet and end wall of the backshell are configured to allow a flange on an over-molded strain relief to fit into the groove and to allow the end wall of the backshell to fit into a circumferential groove on the over-molded strain relief, thereby preventing separation of the QSFP-DD copper cable from the QSFP-DD connector.

2. The backshell of claim 1 configured to connect to a QSFP-DD copper cable, wherein the QSFP-DD copper cable is a bundled cable formed by bundling at least two bulk cables that together comprise 16 twisted pairs of copper conductors.

3. The backshell of claim 2 , wherein the diameter of the copper conductors is 26 American Wire Gauge (AWG).

4. A backshell and cable assembly comprising a backshell as claimed in claim 1 and a QSFP-DD copper cable, which is a bundled cable formed by bundling at least two bulk cables that together comprise 16 twisted pairs of copper conductors.

5. The assembly of claim 4 , wherein the diameter of the copper conductors is 26 American Wire Gauge (AWG).

6. The assembly of claim 4 , wherein the bundled cable is formed from one of:

a) two bulk cables each containing eight twisted pairs of copper conductors;

b) four bulk cables each containing four twisted pairs of copper conductors;

c) eight bulk cables each containing two twisted pairs of copper conductors; and

d) sixteen bulk cables each containing two twisted pairs of copper conductors.

7. The assembly of claim 4 , wherein the bulk cables are bundled together to form a bundled cable according to the following steps:

a) a length of the outer jacket of each bulk cable is removed to expose the twisted pairs of conductors and the braiding of each bulk cable is pulled back and untangled;

b) the exposed lengths of the pairs of conductors from all bulk cables are bundled together by wrapping a thermally and electrically insulating film around them;

c) the cable shielding braid is arranged to minimize the thickness of the bundle;

d) the combined pairs are wrapped with glue covered cloth to simulate a single 16 pair bulk cable;

e) a section of the pairs from which the outer jacket was removed in the first step and part of the unremoved jacket on the bulk cables is covered with a heatshrink;

f) a strain relief is over-molded onto the bundled pairs and partially covering the heatshrink; and

g) copper foil tape is wrapped around the shielding braid of the bundle of pairs of conductors after the over-molded strain relief.

8. The assembly of claim 7 , wherein the thermally and electrically insulating film in the bundled cable is Kapton® manufactured by DuPont or the like.

9. The assembly of claim 7 , wherein the glue covered cloth in the bundled cable is Acetate Cloth Electrical Tape manufactured by 3M™ or the like.

10. The assembly of claim 7 , wherein spacers are added under the cloth to maintain the shape of the bundle.

11. The assembly of claim 7 , wherein the heatshrink material in the bundled cable is Heat Shrink Thin-Wall Tubing manufactured by 3M™.

12. A method for manufacturing a backshell and cable assembly comprising a backshell as claimed in claim 1 , and a QSFP-DD copper cable, which is a bundled cable formed by bundling at least two bulk cables that together comprise 16 twisted pairs of copper conductors, comprising the steps of:

a) removing a length of the outer jacket of each bulk cable to expose the twisted pairs of conductors and the braiding of each bulk cable is pulled back and untangled;

b) bundling the exposed lengths of the pairs of conductors from all bulk cables together by wrapping a thermally and electrically insulating film around them;

c) arranging the cable shielding braid to minimize the thickness of the bundle;

d) wrapping the combined pairs with glue covered cloth to simulate a single 16 pair bulk cable;

e) covering a section of the pairs from which the outer jacket was removed in the first step and part of the unremoved jacket on the bulk cables with a heatshrink;

f) over-molding a strain relief onto the bundled pairs and partially covering the heatshrink; and

g) wrapping copper foil tape around the shielding braid of the bundle of pairs of conductors after the over-molded strain relief.

13. The method of claim 12 , wherein the thermally and electrically insulating film in the bundled cable is Kapton® manufactured by DuPont or the like film.

14. The method of claim 12 , wherein the glue covered cloth in the bundled cable is Acetate Cloth Electrical Tape manufactured by 3M™ or the like.

15. The method of claim 12 , wherein spacers are added under the cloth to maintain the shape of the bundle.

16. The method of claim 12 , wherein the heatshrink material in the bundled cable is Heat Shrink Thin-Wall Tubing manufactured by 3M™ or the like.