U.S. patent application number 11/359934 was filed with the patent office on 2006-06-29 for interconnection device and system.
Invention is credited to Che-Yu Li.
Application Number | 20060141815 11/359934 |
Document ID | / |
Family ID | 32996388 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060141815 |
Kind Code |
A1 |
Li; Che-Yu |
June 29, 2006 |
Interconnection device and system
Abstract
A connector system including first housing having a first
header, the first header including one or more conductive pads that
are in electrical communication with a conductor. A second housing
that is mateable with the first housing and includes a second
header positioned on a mating face. The second header includes one
or more conductive pad that are electrically engaged with a
conductor and positioned in confronting relation with the one or
more conductive pads of the first header. An interposer located
between the first header and the second header, with a woven
contact that extends continuously through the interposer toward
conductive pads on the first and second headers. The interposer is
movable between a first position where the woven contact is spaced
away from the at least one of the conductive pads, and a second
position where woven contact electrically engages one of the
conductive pads.
Inventors: |
Li; Che-Yu; (Roslyn,
NY) |
Correspondence
Address: |
DUANE MORRIS LLP;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Family ID: |
32996388 |
Appl. No.: |
11/359934 |
Filed: |
February 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11082364 |
Mar 17, 2005 |
7029289 |
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11359934 |
Feb 21, 2006 |
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10736280 |
Dec 15, 2003 |
7040902 |
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11082364 |
Mar 17, 2005 |
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60457076 |
Mar 24, 2003 |
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60457258 |
Mar 25, 2003 |
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60462143 |
Apr 8, 2003 |
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Current U.S.
Class: |
439/66 |
Current CPC
Class: |
H01L 2224/451 20130101;
H01L 2924/01019 20130101; H01L 2924/00014 20130101; H01L 2924/14
20130101; H01L 2924/01029 20130101; H01L 2924/01078 20130101; H01L
2924/01005 20130101; H01R 12/714 20130101; H01R 13/2464 20130101;
H01L 24/45 20130101; H01L 2924/01046 20130101; H01R 13/33 20130101;
H01L 2224/49111 20130101; H01L 2224/451 20130101; H01L 2924/01045
20130101; H01L 2924/01047 20130101; H01L 2924/01082 20130101; H01R
13/2407 20130101; H01L 2924/30107 20130101; H01R 13/24 20130101;
H01L 2224/451 20130101; H01L 23/49827 20130101; H01L 24/72
20130101; H01L 2924/01027 20130101; H01L 2924/00014 20130101; H01L
24/49 20130101; H01L 2224/45147 20130101; H01L 2924/01074 20130101;
H01L 2924/01075 20130101; H01L 2924/3011 20130101; H01L 2924/00014
20130101; H01L 2924/00 20130101; H01L 2224/05599 20130101; H01L
23/49811 20130101; H01L 2924/00014 20130101; H01R 12/716 20130101;
H01L 2224/45147 20130101; H01L 2924/01006 20130101; H01L 2924/01033
20130101; H01L 2924/01079 20130101; H01R 12/52 20130101; H01L
2924/3025 20130101; H05K 3/325 20130101; H01R 4/58 20130101 |
Class at
Publication: |
439/066 |
International
Class: |
H01R 12/00 20060101
H01R012/00 |
Claims
1.-24. (canceled)
25. A connector system comprising: a first housing having a first
header positioned on a mating face, said first header including at
least one conductive pad that is in electrical communication with a
conductor; a second housing that is mateable with said first
housing and including a second header positioned on a mating face,
said second header including at least one conductive pad that is
electrically engaged with a conductor and is positioned in
confronting relation with said at least one conductive pad of said
first header; and an interposer located between said first header
and said second header, with at least one woven contact comprising
an open-ended substantially cylindrical spring comprising a
plurality of conductors having a longitudinal axis, wherein said
conductors comprise an absence of either elastic or plastic
deformations such that longitudinal deflection of said spring
results in substantially only elastic deformation of said plurality
of conductors that extends continuously through said interposer so
as to have a first portion projecting outwardly toward said at
least one conductive pad of said first header and a second portion
projecting outwardly toward said at least one conductive pad of
said second header, wherein said interposer is movable between (i)
a first position wherein said first and second portions of said at
least one woven contact are spaced away from said at least one
conductive pad, and (ii) a second position wherein said first and
second portions of said at least one woven contact electrically
engage said at least one conductive pad.
26. A connector system according to claim 25 wherein said first and
second housings include a conductor receiving passageway extending
through a base wall and surrounded by an annular wall that together
define an interior recess into which wire-receiving passageway
opens.
27. A connector system according to claim 25 wherein each of said
first and second headers includes a first face comprising at least
one opening leading into at least one blind hole and a second face
on which is located said at least one conductive pad.
28. A connector system according to claim 27 wherein said at least
one blind hole is defined by a surface within said header including
a layer of conductive metal and said at least one conductive pad is
in electrical communication with said layer of conductive
metal.
29. A connector system according to claim 25 wherein each of said
first and second headers includes a first face comprising a
plurality of openings each leading into a blind hole and a second
face on which is located a plurality of conductive pads.
30. A connector system according to claim 29 wherein each of said
plurality of blind holes is defined by a surface within said header
including a layer of conductive metal, and further wherein one of
each of said plurality of conductive pads is in electrical
communication with said layer of conductive metal in one of said
plurality of blind holes.
31. A connector system according to claim 30 wherein each of said
plurality of conductive pads hermetically seals said blind bore
from the ambient environment, and provides an electrically
conductive pathway.
32. A connector system according to claim 25 comprising an o-ring
fixedly positioned on a face of one of said first and second
headers so as to be in surrounding relation to said at least one
conductive pad.
33. A connector system according to claim 29 comprising an o-ring
fixedly positioned on a face of one of said first and second
headers so as to be in surrounding relation to said plurality of
conductive pads.
34. A connector system according to claim 25 wherein said
interposer includes at least one through-bore in which said woven
contact is positioned so as to be located between said at least one
conductive pad located on said first and said at least one
conductive pad located on second headers.
35. A connector system according to claim 25 comprising at least
one pilot pin projecting outwardly from at least one of said first
and second headers.
36. A connector system according to claim 35 wherein said
interposer includes at least one pilot hole positioned so that each
slidingly receives and guides one of said at least one pilot
pin.
37. A connector system according to claim 25 comprising three pilot
pins projecting outwardly from at least one of said first and
second headers.
38. A connector system according to claim 37 wherein said
interposer includes three pilot holes positioned so that each
slidingly receives and guides one of said three pilot pins.
39. A connector system according to claim 25 wherein said
interposer includes woven contacts that are lodged within
through-bores and fixed in place such that a first engagement
portion of each of said woven contacts projects outwardly from a
first side surface of said interposer and a second engagement
portion of each of said woven contacts projects outwardly from a
second side surface of said interposer.
40. A connector system according to claim 25 further comprising a
guide-cradle is located on an interior surface of at least one of
said first and second housings, said guide-cradle defining a
wire-receiving passageway extending through a mating face that is
surrounded by an annular wall which together define an interior
recess into which said wire-receiving passageway opens.
41. A connector system according to claim 40 wherein said
guide-cradle provides support and organization for conductors
entering said first and second housing.
42. A connector system according to claim 40 wherein at least one
of said first header and said second header is positioned within
said interior recess of said at least one guide-cradle, wherein
each of said first and second headers includes a first face
comprising a plurality of openings each (i) leading into a blind
hole and, (ii) confronting said wire-receiving passageway, and a
second face on which is located a plurality of conductive pads.
43. A connector system according to claim 42 wherein each of said
plurality of blind holes is defined by a surface within said header
including a layer of conductive metal, and further wherein one of
each of said plurality of conductive pads is in electrical
communication with said layer of conductive metal in one of said
plurality of blind holes.
44. A connector system comprising: a first housing having a first
header positioned on a mating face, said first header including at
least one conductive pad that is in electrical communication with a
conductor; a second housing that is mateable with said first
housing and including a second header positioned on a mating face,
said second header including at least one conductive pad that is
electrically engaged with a conductor and is positioned in
confronting relation with said at least one conductive pad of said
first header; and an interposer located between said first header
and said second header, with at least one woven contact formed by a
process comprising (i) interlacing a plurality of conductors so as
to form a continuous cylinder wherein said interlaced conductors
elastically engage one another so as to be substantially only
elastically deformed, (ii) annealing said continuous cylinder so as
to substantially eliminate said elastic engagement of said
conductors; and (iii) cutting said continuous cylinder so as to
form at least one open-ended cylindrical woven contact extending
continuously through said interposer so as to have a first portion
projecting outwardly toward said at least one conductive pad of
said first header and a second portion projecting outwardly toward
said at least one conductive pad of said second header, wherein
said interposer is movable between (i) a first position wherein
said first and second portions of said at least one woven contact
are spaced away from said at least one conductive pad, and (ii) a
second position wherein said first and second portions of said at
least one woven contact electrically engage said at least one
conductive pad.
45. A connector system according to claim 44 wherein said first and
second housings include a conductor receiving passageway extending
through a base wall and surrounded by an annular wall that together
define an interior recess into which wire-receiving passageway
opens.
46. A connector system according to claim 44 wherein each of said
first and second headers includes a first face comprising at least
one opening leading into at least one blind hole and a second face
on which is located said at least one conductive pad.
47. A connector system according to claim 46 wherein said at least
one blind hole is defined by a surface within said header including
a layer of conductive metal and said at least one conductive pad is
in electrical communication with said layer of conductive
metal.
48. A connector system according to claim 44 wherein each of said
first and second headers includes a first face comprising a
plurality of openings each leading into a blind hole and a second
face on which is located a plurality of conductive pads.
49. A connector system according to claim 48 wherein each of said
plurality of blind holes is defined by a surface within said header
including a layer of conductive metal, and further wherein one of
each of said plurality of conductive pads is in electrical
communication with said layer of conductive metal in one of said
plurality of blind holes.
50. A connector system according to claim 49 wherein each of said
plurality of conductive pads hermetically seals said blind bore
from the ambient environment, and provides an electrically
conductive pathway.
51. A connector system according to claim 44 comprising an o-ring
fixedly positioned on a face of one of said first and second
headers so as to be in surrounding relation to said at least one
conductive pad.
52. A connector system according to claim 48 comprising an o-ring
fixedly positioned on a face of one of said first and second
headers so as to be in surrounding relation to said plurality of
conductive pads.
53. A connector system according to claim 44 wherein said
interposer includes at least one through-bore in which said woven
contact is positioned so as to be located between said at least one
conductive pad located on said first and said at least one
conductive pad located on second headers.
54. A connector system according to claim 44 comprising at least
one pilot pin projecting outwardly from at least one of said first
and second headers.
55. A connector system according to claim 54 wherein said
interposer includes at least one pilot hole positioned so that each
slidingly receives and guides one of said at least one pilot
pin.
56. A connector system according to claim 44 comprising three pilot
pins projecting outwardly from at least one of said first and
second headers.
57. A connector system according to claim 56 wherein said
interposer includes three pilot holes positioned so that each
slidingly receives and guides one of said three pilot pins.
58. A connector system according to claim 44 wherein said
interposer includes woven contacts that are lodged within
through-bores and fixed in place such that a first engagement
portion of each of said woven contacts projects outwardly from a
first side surface of said interposer and a second engagement
portion of each of said woven contacts projects outwardly from a
second side surface of said interposer.
59. A connector system according to claim 44 further comprising a
guide-cradle is located on an interior surface of at least one of
said first and second housings, said guide-cradle defining a
wire-receiving passageway extending through a mating face that is
surrounded by an annular wall which together define an interior
recess into which said wire-receiving passageway opens.
60. A connector system according to claim 59 wherein said
guide-cradle provides support and organization for conductors
entering said first and second housing.
61. A connector system according to claim 59 wherein at least one
of said first header and said second header is positioned within
said interior recess of said at least one guide-cradle, wherein
each of said first and second headers includes a first face
comprising a plurality of openings each (i) leading into a blind
hole and, (ii) confronting said wire-receiving passageway, and a
second face on which is located a plurality of conductive pads.
62. A connector system according to claim 61 wherein each of said
plurality of blind holes is defined by a surface within said header
including a layer of conductive metal, and further wherein one of
each of said plurality of conductive pads is in electrical
communication with said layer of conductive metal in one of said
plurality of blind holes.
Description
[0001] This application is a continuation-in-part of copending
patent application Ser. No. 10/736,280, filed Dec. 15, 2003, and
entitled Electrical Contact, which application claims the benefit
of U.S. Provisional Patent Application No. 60/457,076, filed Mar.
24, 2003, U.S. Provisional Patent Application No. 60/457,258, filed
Mar. 25, 2003, and U.S. Provisional Patent Application No.
60/462,143, filed Apr. 8, 2003, and is also related to U.S.
Provisional Patent Application No. 60/586,777, filed on Jul. 9,
2004.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the electrical
interconnection devices, and more particularly to electrical
connectors that are at the interface between a first electronic
device and a substrate, mating electrical connector, or a circuit
board within an electronic system.
BACKGROUND OF THE INVENTION
[0003] Electrical connectors are used in many electronic systems.
As miniaturization of the electronic systems becomes more
prevalent, the dimensions of the connector itself decrease but the
number of signal circuits routed through the connector increases.
This results in an increasing number of signals in the limited
space of the connector. As the signal circuits are spaced closer
and the transmission speed of the signals increases,
electromagnetic interference (EMI) and crosstalk become a serious
problem. It is desirable that the components of an interconnection
path be optimized for signal transmission characteristics;
otherwise, the integrity of the system will be impaired or
degraded. Such characteristics include low inductance, increased
current carrying capacity, suitable roll-off, and reduced ground
bounce. Continuous efforts have been made to develop electrical
connectors that have as little effect as possible on electronic
system performance and integrity.
[0004] Inductance is one concern in designing a connector,
particularly when that connector is to be used in a signal
transmission portion of a high speed electronic system. An example
of one such connector is a so called "board-to-board" connector. A
board-to-board connector provides the electrical, and often
mechanical interface between printed circuit boards (PCB's) in an
electronic system. Such connectors often have an elongated housing
defining an elongated array of receptacles or slots for receiving a
mating edge of the printed circuit board, or a field of pins
projecting from the surface of the PCB that are mated to a
corresponding field of contact receptacles. In many applications,
such connectors are mounted on two or more PCB's commonly referred
to as "daughter boards", which are mounted to a "mother board."
[0005] An inductive effect results from the interconnection of the
PCB's which acts to change the characteristic impedance of the
circuit and thereby negatively affect the signal transmission
capacity of the system. Accordingly, it is desirable to reduce the
inductive effects due to the interconnection of the PCB's, and
thereby fulfill a need for an interconnection system that reduces
inductive effects between the boards being connected. It would also
be desirable to increase the current carrying capacity between the
PCB's. Examples of such prior art board-to-board connectors may be
found in U.S. Pat. Nos. 6,790,048; 6,776,668; 6,733,305; 6,729,890;
6,609,914; 6,599,138; 6,464,515; 6,338,630; 6,312,263; 6,183,315;
6,089,883; 6,220,903; 6,059,610; 6,036,504; 5,921,787; 5,876,219;
and 5,873,742, which patents are hereby incorporated herein by
reference.
[0006] Electrical connectors are often used in environments where
they are exposed to dust and dirt, and may even be used in
environments where they are subject to splash or immersion in
water. It is desirable to seal the connector assembly to protect
the terminals from exposure to the external environment. Very often
the connector bodies are each formed with a plurality of passages
that extend into the connector bodies from a cable end, and into
which the cables and their terminals are received. In a sealed
connector application, a seal is provided about the cable such
that, when installed in the corresponding passage, it serves to
seal the passage from the outside environment. The connectors are
also sometimes filled with a potting material which will cover the
rear entry of the electrical connector so as to protect it from the
ingress of contaminants. It is necessary to prevent the entry of
contaminants into the interior of the electrical connector, since
these contaminants corrode the electrical contact surfaces which
often leads to intermittent or unreliable electrical connections.
Many types of seals and sealed connector systems are known for
keeping contaminants from entering an electrical connector housing.
Examples of such prior art sealed connector systems may be found in
U.S. Pat. Nos. 6,821,145; 6,767,250; 6,547,584; 6,383,003;
6,132,251; 6,109,945; 6,050,839; 5,823,824; 5,785,544; 5,775,944;
5,595,504; 5,356,304; 4,983,344; 4,961,713; 4,944,688; 4,934,959;
4,895,529; 4,832,615; 4,776,813; 4,772,231; 4,085,993; 4,150,866;
and 4,639,061, which patents are hereby incorporated herein by
reference.
[0007] All of the foregoing connector systems rely upon one or more
resilient conductive contacts having a variety of shapes, sizes,
and spring characteristics. A commonly used form of resilient
conductive contact includes an interconnection end for matting with
a corresponding end of a mating contact or PCB, and a termination
end for terminating a circuit trace or wire. These ends are often
connected by a resilient portion of the contact which provides for
the storage of elastic energy. Prior art resilient conductive
contacts may be a single metal structure in the form of a spring to
provide the required elastic response during service while also
serving as a conductive element for electrical connection.
Typically, a combination of barrier metal and noble metal platings
are applied to the surface of the spring for corrosion prevention
and for electrical contact enhancement. It is often the case that
these platings are not of sufficient thickness for electrical
conduction along only the surface of the spring. Examples of such
prior art resilient conductive contacts may be found in U.S. Pat.
Nos. 5,653,598; 5,173,055; 5,059,143; 4,906,194; 4,927,369;
4,699,593; and 4,354,729, which patents are hereby incorporated
herein by reference.
[0008] One problem in the art exists in that a good material for
the construction of a spring, such as a high strength steel, is not
a very good electrical conductor. On the other hand, a good
electrical conductor, such as a copper alloy or precious metal,
often does not provide adequate spring properties. There has been a
need in the connector arts for a more resilient conductive contact
which incorporates the seemingly opposing requirements of good
spring properties, temperature resistance, and high conductivity.
Therefore, an improved electrical contact for use in an electrical
connector is needed which can overcome the drawbacks of
conventional electrical contacts. It is desirable that a good
electrical contact element possess the following attributes: (a)
usable in a wide variety of inter-connection structures; (b) a
large elastic compliance range and low contact forces; (c) capable
of transmitting high frequency signals and high currents; (d)
capable of withstanding high operating temperatures; and (e)
exhibiting high durability, i.e. >500 K repeated
deflections.
[0009] The prior art has been devoid of at least one of the
foregoing attributes necessary for a universally applicable
electrical connector.
SUMMARY OF THE INVENTION
[0010] The present invention provides a connector system including
a first housing having a first header positioned on a mating face.
The first header includes at least one conductive pad that is
electrically engaged with a conductor such as a wire. A second
housing is provided that is mateable with the first housing, and
includes a second header positioned on a mating face. The second
header includes at least one conductive pad that is electrically
engaged with a conductor, such as a wire, and is positioned in
confronting relation with the at least one conductive pad of the
first header. A contact interposer is located between the first
header and the second header. The contact interposer includes at
least one contact that extends continuously through the contact
interposer so as to have a portion projecting outwardly toward the
at least one conductive pad of the first header and another portion
projecting outwardly toward the at least one conductive pad of the
second header. The contact interposer is movable between (i) a
first position in which the portions of the at least one contact
are spaced away from the conductive pads, and (ii) a second
position in which the portions of the at least one contact
electrically engage both of the conductive pads.
[0011] The at least one contact is often formed from a precursor
material, such as an etched or stamped metal sheet, or a plurality
of interlaced metal wires. The precursor materials may be formed
into a tube or other appropriate shape, and annealed to set their
structural form. The annealed structure may then be cut into short
segments to form a plurality of individual electrical contacts. The
precursor materials are often formed by photo-etching a sheet of
conductive material into a mesh with openings of predetermined size
and shape. The mesh may also be made by stamping with a
conventional metal working die. Alternatively, the precursor
material may be made by manipulating a plurality of wires so as to
interlace the wires into a unitary structure in the form of a mesh.
This embodiment of electrical contact is often formed by weaving or
braiding a plurality of wires together to form a mesh, annealing
the mesh, and cutting the annealed mesh so as to form a plurality
of individual electrical contacts that each have an extended
elastic range as a result of the annealing process. The preferred
structural forms include woven and folded structures of one or more
pleats formed from the precursor material. Such a folded structure
can be made by pressing a unitary mesh structure in a die adapted
to form pleated or folded structure in the mesh, followed by
annealing the pleated or folded mesh while resident in the die to
set permanently the structural form. It is then cut to form
individual electrical contacts. The desired form of the electrical
contact can be made by first rolling a portion of the precursor
material in to a tube and followed by annealing under a constraint
to set the form factor permanently. The tubular structure is then
cut into short segments to form individual electrical contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other features and advantages of the present
invention will be more fully disclosed in, or rendered obvious by,
the following detailed description of the preferred embodiments of
the invention, which are to be considered together with the
accompanying drawings wherein like numbers refer to like parts and
further wherein:
[0013] FIG. 1 is a perspective view of a wire-to-wire connector
assembly formed in accordance with the present invention;
[0014] FIG. 2 is a perspective view of a woven electrical contact
of a type used in connection with one embodiment of the present
invention;
[0015] FIG. 3 is a perspective view, partially in phantom,
illustrating the winding of individual wires about a central core
during the manufacture of the electrical contact shown in FIG.
2;
[0016] FIG. 4 is a cross-sectional view of a wire of the type used
in forming the electrical contact shown in FIGS. 2 and 3;
[0017] FIG. 5 is a cross-sectional view, similar to FIG. 4, but
showing an insulating layer placed on the outer surface of
wire;
[0018] FIG. 6 is a top elevational view of an embodiment of wire
mesh used to form an alternative electrical contact that may be
used with the present invention;
[0019] FIG. 7 is a magnified view of the mesh shown in FIG. 6;
[0020] FIG. 8 is a top view of the mesh shown in FIG. 7,
illustrating the process of being rolled into a tubular
contact;
[0021] FIG. 9 is a perspective view of the tubular contact shown in
FIG. 8;
[0022] FIG. 10 is a top end view of a portion of the mesh shown in
FIG. 7, after pleating so as to form yet another embodiment of
electrical contact;
[0023] FIG. 11 is a cross-sectional perspective and exploded view
of a wire-to-wire connector formed in accordance with the present
invention;
[0024] FIG. 12 is a partially cross-sectional view of a contact
interposer and electrical contacts arranged in accordance with the
present invention;
[0025] FIG. 13 is a perspective, partially exploded view of an
alternative contact interposer accepting pleaded electrical
contacts formed in accordance with the present invention;
[0026] FIG. 14 is a cross-sectional view of the wire-to-wire
connector shown in FIG. 11;
[0027] FIG. 15 is a cross-sectional view of a fully mated
wire-to-wire connector shown in FIGS. 11 and 14;
[0028] FIG. 16 is a perspective view of an alternative embodiment
of the present invention arranged in a board-to-board connector
system;
[0029] FIG. 17 is a cross-sectional view of the board-to-board
connector system shown in FIG. 16;
[0030] FIG. 18 is a cross-sectional view similar to that shown in
FIG. 17, but illustrating a fully mated position;
[0031] FIG. 19 is a perspective exploded view of a board-to-board
connector system similar to that shown in FIG. 16, but without
housings;
[0032] FIG. 20 is a cross-sectional view of a board-to-board
connector system shown in FIG. 19;
[0033] FIG. 21 is a cross-sectional view similar to that shown in
FIG. 20, but illustrating a fully mated position;
[0034] FIG. 22 is an exploded perspective view of a wire-to-ribbon
cable connector system formed in accordance with the present
invention;
[0035] FIG. 23 is a cross-sectional exploded view of the
wire-to-ribbon cable connector system shown in FIG. 19; and
[0036] FIG. 24 is a cross-sectional view similar to that shown in
FIG. 23, but illustrating a fully mated position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] This description of preferred embodiments is intended to be
read in connection with the accompanying drawings, which are to be
considered part of the entire written description of this
invention. The drawing figures are not necessarily to scale and
certain features of the invention may be shown exaggerated in scale
or in somewhat schematic form in the interest of clarity and
conciseness. In the description, relative terms such as
"horizontal," "vertical," "up," "down," "top" and "bottom" as well
as derivatives thereof (e.g., "horizontally," "downwardly,"
"upwardly," etc.) should be construed to refer to the orientation
as then described or as shown in the drawing figure under
discussion. These relative terms are for convenience of description
and normally are not intended to require a particular orientation.
Terms including "inwardly" versus "outwardly," "longitudinal"
versus "lateral" and the like are to be interpreted relative to one
another or relative to an axis of elongation, or an axis or center
of rotation, as appropriate. Terms concerning attachments, coupling
and the like, such as "connected" and "interconnected," refer to a
relationship wherein structures are secured or attached to one
another either directly or indirectly through intervening
structures, as well as both movable or rigid attachments or
relationships, unless expressly described otherwise. The term
"operatively connected" is such an attachment, coupling or
connection that allows the pertinent structures to operate as
intended by virtue of that relationship. In the claims,
means-plus-function clauses, if used, are intended to cover the
structures described, suggested, or rendered obvious by the written
description or drawings for performing the recited function,
including not only structural equivalents but also equivalent
structures.
[0038] Referring to FIGS. 1, 16, and 22, a wide variety of
electrical interconnection systems and connectors may be formed in
accordance with the present invention, such as a wire-to-wire
connector system 100, a board-to-board connector system 200, or a
wire-to-ribbon connector system 300. In these and other connector
systems one or more electrical contacts 2 are arranged in an
interposer assembly 3 including a contact interposer 5, one or more
terminal headers 7, and one or more pilots 9 (FIGS. 1-2 and 11-14).
Interposer assembly 3 provides for proper alignment and orientation
of electrical contacts 2 within the particular connector system
where, owing to the resilient structure of electrical contact 2
which has a significantly increased elastic range and high speed
signal transmission characteristics, the connector system provides
enhanced operating characteristics as compared to prior art
electrical interconnection systems.
[0039] More particularly, electrical contacts 2 each comprise a
large elastic range as a result of being formed so as to comprise
an interlaced or woven, annealed metal structure that provides a
plurality of individual beam-sections 6 (FIG. 2). Electrical
contact 2 may be formed by weaving at least three or four discrete
wires 8 together, i.e., manipulating the wires together so as to
interlace them to form a unitary structure, to thereby form an
electrical contact precursor mesh 12 in either a tubular
configuration (FIGS. 2-3) or a sheet (FIGS. 6-8).
[0040] Advantageously, the tubular embodiments of the present
invention are free standing, requiring no central or longitudinal
interiorly located support structure around which the wires are
wound or, an outer or inner support structure within which the
wires reside in a formed electrical contact configuration, since
the combination of interlacing and annealing wires 8 removes the
need for any additional integral or over-layed, co-extruded, or
over-molded structural support. In other words, electrical contacts
2 can be operated for their intended purpose while simply
comprising a mesh that has been manipulated to take a shape
suitable for interconnecting two or more adjacent structures. It is
in this sense then that electrical contacts 2 of the present
invention are said to comprise an unsupported structure.
[0041] In one woven embodiment, three to eight stainless steel
wires 8 are woven together to form a tubular electrical contact 2.
In this arrangement, each wire 8 takes a helical path so as to be
interlaced with each adjacent wire 8, while at the same time, each
wire 8 only undergoes a substantially elastic deformation, i.e.,
each wire 8 would exhibit bending properties wholly consistent with
the elastic limit portion of its underlying material's
characteristic "stress-strain" or "force-deflection" curve.
Substantially no plastic deformation is caused to occur in wires 8
during this manufacturing step. Also, it should be understood that
at the points of intersection/overlap 9 of wires 8 in mesh 12, no
bonding or other mechanical interconnection exists between the
adjacent portions of wires 8. As a result of this structural
arrangement, the adjacent portions of each wire 8 that define each
of the intersection/overlap points 9 are movable relative to one
another. It has been found, in braided or interlaced structures,
that mechanical stability may be achieved when the ratio of the
diameter of the contact and the lay length is smaller than about
two-thirds, when cut into short segments even after annealing,
where the lay length is the length per wire turn. Thus electrical
contacts 2 having a diameter less than about five mils may be
manufactured with adequate results.
[0042] Significantly, once woven tubular electrical contact 2 is
annealed so as to stress relieve wires 8, particularly at the
plurality of intersection/overlap points 9. Metals, such as
stainless steel and copper, comprise a generally cubic crystal
structure. It is the particular variation of this crystalline
structure (face-centered-cubic) that gives these metals their
ductility allowing for elastic bending of wires 8 into curved
shapes, e.g., by winding or braiding about a removable mandrel 20
(FIG. 3) However in the present invention, wires 8 suffer no such
defect dislocation or plastic deformation during weaving. Instead,
annealing elastically deformed wires 8 in mesh 12 substantially
eliminates the elastic strain stored within the wires so that
slippage of the metal crystals occurs in a controlled manner. In
this way, the metal is composed of regular crystals that have taken
a set in their woven configuration by relieving the elastic strain
induced in each wire by the interlacing or weaving process. Thus,
instead of wires 8 springing apart when cut into individual
electrical contacts 2, they tend to maintain their combined
structural integrity, and remain woven together.
[0043] In the present invention, the forming of electrical contacts
2 involves only essentially elastic deformation in rolling,
braiding, and other processes. Under elastic deformation the formed
structure cannot be maintained without a supporting constraint.
Otherwise the structure will fall apart as a result of elastic
rebound. Advantageously, electrical contacts 2 may be formed by
constraining them in a precursor form, then annealing them at a
sufficiently high temperature which together with the stored
elastic stress, allows dislocations to be generated and moved so as
to permanently set the shape of the electrical contact thus
relaxing the stored elastic strain. The extent of deformation in
the elastic range is limited so that the shape of the wire
cross-section, for example, will not be altered and it will be
easier to design the die or other means of constraint.
[0044] Referring to FIGS. 6, 7, and 10, a folded or pleated
structure may be formed by annealing the structure while still
elastically deformed in a properly designed die or other fixture
which serves as the constraint. For a rolled electrical contact
structure, a properly designed constraint to maintain the tubular
form is necessary during annealing (FIGS. 8 and 9). In one
embodiment, mesh 12 is wrapped upon itself so as to form a
plurality of overlapping layers providing a substantially helical
structure to the tube. In the case of a braided tubular structure,
before cutting, the structure itself acts as a constraint during
annealing.
[0045] The annealing of mesh 12 relieves the elastic strain that is
inherent in wires 8 as a result of the weaving process,
particularly at intersection/overlap points 9 where wires 8 are
elastically deformed so as to bend or curve. Absent this annealing
step and structure, wires 8 and mesh 12 would simply spring apart
in the absence of any additional internal or external support
structure affixed to mesh 12, e.g., a polymeric or elastomeric
support core or shell. The combination of weaving individual wires
8 into a structure having inherent macro-elastic properties, with
an annealing step to set the individual wires 8 in their woven
structural arrangement, provides for significantly enlarged force
deflection properties. Thus when woven into mesh 12 according to
the invention, and then annealed, plurality of wires 8 provide a
resilient electrical contact structure having a significantly
increased elastic range. To maintain a good surface condition heat
treatment should be carried out in a controlled atmosphere furnace
at the appropriate temperature for the particular grade of
stainless steel or, in a less preferred embodiment, alloy of copper
which may also be oil quenched to achieve maximum hardness.
[0046] According to the present invention, electrical contact 2 may
be fabricated from three, four, or more loosely woven or braided
conductive fibers or wires using, e.g., a conventional wire
braiding machine (not shown). For example, wire braiding machines
have long been used in industry to braid metallic or composite wire
into electrical or electronic cable as an electromagnetic shield,
or into hydraulic hose and cordage as a load bearing structure. One
such braiding machine that is suitable for forming electrical
contact 2 is a maypole type machine wherein carriers for bobbins
carrying the individual wires 8 to be woven, are moved by horn
gears or notched rotors on a deck with all of the carriers
following alternating circular or arcuate paths around a braiding
point. In the present invention, the braiding point may be disposed
along a removable cylindrical mandrel 20, or some other removable
center support (FIG. 3). Half the bobbin carriers travel in one
direction around the braiding point (located along removable
cylindrical mandrel 20) following one alternating path, while the
other half of the carriers travel in the opposite direction around
the braiding point following another alternating path which crosses
the first path at each alternating direction. As the two sets of
carriers travel in opposite directions around the braiding point,
each crossing the path of the other, the wires leaving the bobbins
are interwoven as they converge to the braiding point. A continuous
tube of electrical contact precursor material is drawn from the
conventional wire braiding machine. The electrical contact
precursor is then annealed followed by processing through a cutting
station where it is cut transversely into individual electrical
contacts 2. Such machines are well known in the art, e.g., as
disclosed in U.S. Pat. Nos. 3,783,736; 5,085,211; 5,257,571; and
5,931,077, which are all incorporated herein by reference.
[0047] Another type of braiding machine useful for forming
electrical contact 2 is known as a rotary braiding machine (not
shown). In these machines, there is a set of inner carriers, a set
of outer carriers and a set of strand deflectors located between
the inner and outer carriers. The inner and outer carriers are
rotated so as to follow a circular path about the braiding point in
opposite directions. The deflectors stand in the pathway of the
strands from the outside carriers. These deflectors cause the wires
from the outer carrier to cross the path of the inner carrier thus
interweaving the wires. The interwoven wires then converge to the
braiding point to form the woven electrical contact 2. Here again,
a continuous tube of electrical contact precursor material is drawn
from the rotary braiding machine, annealed, and then processed
through a cutting station where it is cut transversely into
individual electrical contacts 2. Such machines are also well known
in the art, e.g., as disclosed in U.S. Pat. No. 4,275,638, which
patent is incorporated herein by reference.
[0048] Suitable electrically-conductive fibers or wires include
virtually any fiber material having a bulk resistivity below about
100 .mu..OMEGA.-cm, and preferably about 2 to 5 .mu..OMEGA.-cm.
Typically, the electrically-conductive fibers will be conductive
metal wires, such as, tungsten and its alloys, stainless steel, or
alloys of copper, that may have portions coated with highly
conductive metals (identified by reference numeral 25 in FIG. 2),
such as, silver, palladium, rhodium, gold, and the various alloys
thereof. These highly conductive metals may extend along a first
interconnect portion 31 or a second interconnect portion 33 of each
electrical contact 2 (FIG. 12). Alternatively, suitable
electrically conductive fibers can be prepared by modifying
electrically insulating fibers, such as by introducing a
conductivity-imparting agent, e.g., metal particles, to a natural
or synthetic polymer or other material, such as carbon. While
polymer composites may not be able to withstand typical annealing
temperature, a ceramic/metal composite may be used with good
effect.
[0049] Typically, electrically-conductive wires suitable for use in
the present invention will have a diameter in the range from about
0.025 to 0.1 millimeters. The spacing between adjacent conductors
(identified by reference numeral 26 in FIG. 2) are typically in the
range from about 0.1 to 0.5 millimeters as measured between
opposing wire intersection points 9. Referring to FIGS. 4 and 5,
wires 8 may either be bare or have an insulation coating 27 applied
to their outer surface. In all cases, the weave should be
sufficiently loose, with gaps or interstices remaining between
adjacent wires 8 so that during longitudinally applied compression,
wires 8 form a plurality of elastically deformable beam-sections 6
so as to provide a required spring force. Advantageously,
electrical contact 2 is subjected to an annealing process so as to
substantially set each individual wire 8 in its bent or curved
shape and as a structural element or constituent of woven mesh 12.
Annealing for a stainless steel wire is conducted at temperatures
ranging from about 500.degree. C. to about 600.degree. C., with
about 550.degree. C. being preferred for most applications.
[0050] In one alternative embodiment of the invention, wires 8 may
be woven into an initially flat mesh 40 (comprising warp and weft
wires) which then may be formed so as to create a variety of
contact structures (FIGS. 6 and 7). For example, mesh 40 may be
rolled upon itself so as to form a rolled contact 42 (FIGS. 8 and
9). Mesh 40 may be wrapped upon itself so as to form a plurality of
overlapping layers providing a substantially helical structure to
rolled contact 42. Each rolled contact 42 may then be cut from mesh
40 and assembled within a connector system, as will hereinafter be
disclosed in further detail. Alternatively, mesh 40 may be folded
so as to create a plurality of pleats 45 defined by a plurality of
troughs 47 and ridges 49 (FIG. 10). A contact edge 50 is defined
along the perimeter of pleats 45. Pleated electrical contacts 45
may then be cut from mesh 40. In this way, pleats 45 act to support
the contact within openings 35 (FIG. 13). Engaging contact edge 50
of pleated electrical contact 45 deforms pleated electrical contact
45 to produce a resultant contact force. Here again, annealing
pleated contact 45 or rolled contact 42 under a constraint allows
for a set to be created in wires 8. In the case of pleated
electrical contacts 45, a suitable forming tool, having a pleated
punch and die set, may be closed on mesh 40 during the annealing
process in order to maintain the structural arrangement in
elastically formed wires 8.
[0051] Referring to FIGS. 1-2, and 11-20, electrical contacts 2 may
be associated with a wide variety of electrical interconnection
systems with good effect. For example, electrical contacts 2 may be
positioned and supported within a wire-to-wire interconnection
device 100. A typical wire-to-wire interconnection device 100 that
is suitable for use with electrical contacts 2 includes a pair of
substantially circular mateable dielectric housings 60 and 61 that
are each molded from a suitable polymer material. Polymeric
materials useful in this invention include any material useful in
the electronics industry, including, without limitation,
thermoplastics (crystalline or non-crystalline, cross-linked or
non-cross-linked), thermosetting resins or blends or composites
thereof. Illustrative examples of useful thermoplastic polymers
include, without limitation, polyolefins, such as polyethylene or
polypropylene, copolymers (including terpolymers, etc.) of olefins
such as ethylene and propylene, with each other and with other
monomers such as vinyl esters, acids or esters of unsaturated
organic acids or mixtures thereof, halogenated vinyl or vinylidene
polymers such as polyvinyl chloride, polyvinylidene chloride,
polyvinyl fluoride, polyvinylidene fluoride and copolymers of these
monomers with each other or with other unsaturated monomers,
polyesters, such as poly(hexamethylene adipate or sebacate),
poly(ethylene terephthalate) and poly(tetramethylene
terephthalate), polyamides such as Nylon-6, Nylon-6,6, Nylon-6,10,
Versamids, polystyrene, polyacrylonitrile, thermoplastic silicone
resins, thermoplastic polyethers, thermoplastic modified cellulose,
polysulphones and the like. Examples of some thermosetting resins
useful herein include, without limitation, epoxy resins, such as
resins made from epichlorohydrin and bisphenol A or epichlorohydrin
and aliphatic polyols, such as glycerol, and which can be
conventionally cured using amine or amide curing agents. Other
examples include phenolic resins obtained by condensing a phenol
with an aldehyde, e.g., phenol-formaldehyde resin.
[0052] Housing 60 often includes a conductor or wire-receiving
passageway 64 extending through a base wall 66 and surrounded by an
annular wall 67 that together define an interior recess 69 into
which wire-receiving passageway 64 opens (FIG. 11). Housing 61
often includes a wire-receiving passageway 70 extending through a
base wall 72 and surrounded by an annular wall 74 that together
define an interior recess 77 into which wire-receiving passageway
70 opens. In the illustrated embodiment, annular wall 67 has an
outer diameter that is slightly smaller than the inner diameter of
annular wall 74, and includes threads 76 along a portion of its
length so that housing 60 may be received in corresponding threads
78 on an inner surface of annular wall 74 of housing 61 (FIGS. 1
and 11-15). Thus when housing 60 is mated with housing 61 and
rotated, the pair of housings 60,61 move toward one another so as
to close the distance between the confronting inner surfaces of
base walls 66 and 72 (FIG. 15). It will be understood that such
wire-to-wire connector systems may include a wide variety of
alternative structures for securely inserting housing 60 into
housing 61, e.g., latches, bayonet mounts, interference fits,
etc.
[0053] A pair of guide-cradles 80,81 are often located within
housings 60,61 on the interior surface of base walls 66,72,
respectively. Guide-cradle 80 often includes a wire-receiving
passageway 84 extending through a mating face and surrounded by an
annular wall that together define an interior recess into which
wire-receiving passageway 84 opens. Guide-cradle 81 includes a
wire-receiving passageway 91 extending through a mating face and
surrounded by an annular wall that together define an interior
recess into which wire-receiving passageway 91 opens. Guide-cradles
80, 81 provide support and organization for wires 99 entering
housings 60,61. It will be understood that a wire-crimp contact
terminal 101 may also be received within passageways 84,91 so as to
form an electrical or signal transmission pathway.
[0054] Interposer assembly 3 includes a contact interposer 5, a
pair of termination headers 7, and one or more pilot pins 9.
Interposer assembly 3 is positioned between housings 60,61 with
some portions located within housing 60 and other portions located
on housing 61 (FIGS. 11 and 14). Contact interposer 5 is often
formed from a standard epoxy and fiber glass printed wiring board
(PCB) 102 having a plurality of through-bores 104 defined through
its thickness and arranged in a regular pattern or array of
predetermined shape and center-line spacing (FIG. 12). Of course,
contact interposer 5 may comprise other materials, e.g., ceramics,
polymers, and/or composite materials. One or more pilot holes 106
are defined through contact interposer 5. Electrical contacts 2 are
lodged within through-bores 104 and fixed in place via a force fit,
an adhesive material, or solder located within each through-bore
104 such that a first engagement portion 31 projects outwardly from
a first side surface of contact interposer 5 and a second
engagement portion 33 projects outwardly from a second side surface
of contact interposer 5.
[0055] Termination header 7 may be formed from a standard epoxy and
fiber glass printed wiring board (PCB) material having a plurality
of through-bores 112 defined through its thickness and arranged in
a regular pattern or array that is complementary to the pattern of
through-bores 104 in contact interposer 5 (FIGS. 11, 14, and 15).
One or more pilot holes 114 are also defined through portions of
termination header 7 in locations that will allow for coaxial
alignment with pilot holes 106 of contact interposer 5 when
interposer assembly 3 is positioned within housings 60 and 61. Of
course, termination headers 7 may comprise other materials, e.g.,
ceramics, polymers, and/or composite materials. Advantageously,
through-bores 112 are plated throughout their internal length with
a conductive metal, e.g., tin, gold, or the like, and closed off at
an interior end. In this way, a terminal pad 118 is formed on face
117 of each terminal header 7 (FIG. 14) so as to hermetically seal
through-bores 112 from the ambient environment, but provide an
electrically conductive pathway to wires 99 or wire-crimp terminal
contact 101. Terminal pads 118 are arranged on face 117 of each
terminal header 7 in a regular pattern or array that is
complementary to the pattern of through-bores 104 in contact
interposer 5. An o-ring 119 or equivalent may be fixedly positioned
on face 117 of one of terminal headers 7 so as to be in surrounding
relation to the array of terminal pads 118.
[0056] Interposer assembly 3 is mounted within a wire-to-wire
connector 100 in the following manner. Guide-cradles 80, 81 are
first positioned within housing 60, 61, respectively, such that
wire-receiving passageways 84 of guide-cradle 80 are arranged in
coaxially aligned relation with wire-receiving passageway 64 of
housing 60, and wire-receiving passageways 91 of guide-cradle 81
are arranged in coaxially aligned relation with wire-receiving
passageway 70 of housing 61. Once in this position, a termination
header 7 is positioned on each mating face of each guide-cradle 80,
81. In this position, terminal pads 118 face outwardly. Pilot pins
9 are then fixedly positioned within pilot holes 114 of at least
one of termination headers 7 (shown within housing 61 in FIGS. 11,
14, and 15). It will be understood that guide-cradles 80,81 are
mounted within housings 60,61 such that at least one of housings
60,61 may rotate freely about its respective guide-cradle. In this
way, the positional and electrical correspondence between terminal
pads 118 on each terminal header 7 will be maintained during mating
of housing 60 to housing 61. With pilot pins 9 located in pilot
holes 114, a contact interposer 5 may be positioned within the
wire-to-wire connector system 100. More particularly, a contact
interposer 5 having a plurality of electrical contacts 2 positioned
within through-bores 104 is arranged in confronting coaxial
relation with termination header 7 which has pilot pins 9
positioned within pilot holes 114. Once in this position, contact
interposer 5 is moved toward termination header 7 so that pilot
pins 9 are received within pilot holes 106. The tips of pilot pins
9 may then be swaged or otherwise capped so as to prevent contact
interposer 5 from easily sliding off pilot pins 9.
[0057] Wire conductors 99 or wire-crimp terminal contact 101 are
then inserted through wire-receiving passageways 64, 70, 84, and
91, respectively, so that a conductive end portion of each is
positioned within a plated-through-hole 112 of each termination
header 7 (FIG. 14). In this position, each wire 99 or wire-crimp
terminal contact 101 is then soldered in place so as to create an
electrical engagement and signal transmission pathway with the
underside of a conductive pad 118 on each termination header 7.
[0058] With wires 99 or wire-crimp terminal contact 101
electrically engaged with termination headers 7, within housings
60, 61, housing 60 may be mated to housing 61 so as to complete
wire-to-wire connector 100. Referring to the exemplary sequence
illustrated in FIGS. 14 and 15, housing 60 is oriented so as to be
in confronting coaxial relation with housing 61 such that threads
76 on the lower outer surface of annular wall 67 engage
corresponding threads 78 of annular wall 74 of housing 61. Once in
this position, one of housings 60, 61 is rotated relative to the
other so as to cause threads 76, 78 to engage one another and
thereby pull housings 60, 61 toward one another. As this occurs,
conductive pads 118 on termination header 7 of housing 60 move
toward engagement portions 31 of each electrical contact 2 that is
positioned in contact interposer 5. Conductive pads 118 engage
electrical contacts 2 and thereby cause contact interposer 5 to
slide toward housing 61 upon, and guided by pilot pins 9 so as to
move engagement portions 33 of each electrical contact 2 towards
conductive pads 118 of termination header 7 positioned within
housing 61. Engagement portions 33 of each electrical contact 2
thus engage conductive pads 118 of termination header 7 in housing
61 so as to complete each electrical circuit.
[0059] Of course a wide variety of connector systems may employ
interposer assembly 3 so as to operate in accordance with the
present invention. For example, a board-to-board connector system
200 may be formed having a interposer assembly 3 as follows.
Referring to FIGS. 16-18, in simplified form a board-to-board
connector system 200 may include a pair of mateable housings
202,203 in which interposer assembly 3 may be positioned. Of
course, interposer assembly 3 may be employed for board-to-board
applications without the use of housings 202,203 with adequate
results (e.g., board-to-board connector system 201 shown in FIGS.
19-21). In an embodiment that includes housings, each will often
include an annular side wall 206,207 that surrounds a centrally
disposed opening 209,210, with an annular ledge 212,214 that is
arranged to project into the opening from the bottom of annular
side wall 206,207 (FIG. 17). In the illustrated embodiment, annular
wall 206 is slightly smaller than annular wall 207 so that housing
202 may be received within a portion of housing 203. Thus when
housing 202 is mated with housing 203, the pair of housings move
toward one another so as to close the distance between the
confronting inner surfaces of annular ledge 212,214 (FIG. 18). It
will be understood that such board-to-board connector systems may
include a wide variety of alternative structures for securely
inserting and holding housing 202 in engagement with housing 203,
e.g., latches, an interference fit, a threaded rod, nut and spring
mounting system 216, etc.
[0060] Interposer assembly 3 includes a contact interposer 5, a
pair of termination headers 217, and one or more pilot pins 9, and
is positioned between housings 202,203 with some portions located
on housing 202 and other portions located on housing 203 (FIGS. 17
and 18). Contact interposer 5 is again formed from a standard epoxy
and fiber glass printed wiring board (PCB) 102 having a plurality
of through-bores 104 defined through its thickness and arranged in
a regular pattern or array of predetermined shape and center-line
spacing (FIGS. 12 and 17). One or more pilot holes 106 are defined
through contact interposer 5. Electrical contacts 2 are lodged
within through-bores 104 and fixed in place within each
through-bore 104 as previously described, such that a first
engagement portion 31 projects outwardly from a first side surface
of contact interposer 5 and second engagement portion 33 projects
outwardly from a second side surface of contact interposer 5 (FIG.
12).
[0061] Termination headers 217 are also formed from a standard
epoxy and fiber glass printed wiring board (PCB) material having a
plurality of conductive vias 220 defined through their thicknesses
and arranged in a regular pattern or array that is complementary to
the pattern of through-bores 104 in contact interposer 5. One or
more pilot holes 114 are again defined through portions of each
termination header 217 in locations that will allow for coaxial
alignment with pilot holes 106 when interposer assembly 3 is
positioned on housings 202 and 203. Vias 220 may comprise
plated-through holes that extend through the thickness of each
termination header 217, and that are plated along their internal
length with a conductive metal, e.g., tin, gold, or the like, and
closed off at both ends. Alternatively, vias 220 may be solid or
semi-solid, electrically conductive structures, e.g., slugs or
posts of copper, carbon, or other electrically conductive
materials. In this way, a pair of terminal pads 218,219 are formed
on both outer faces 222, 223 of each terminal header 217 so as to
provide an electrically conductive pathway to corresponding
terminal pads 225 located on printed wiring board 228 (FIG. 17). An
o-ring 119 or equivalent may be fixedly positioned on outer face
223 of one of terminal headers 217 so as to be in surrounding
relation to the array of terminal pads 218, if sealing is required
for a particular application.
[0062] Interposer assembly 3 is mounted within a board-to-board
connector system 200 in much the same manner as with wire-to-wire
connector system 100. More particularly, termination headers 217
are positioned such that a peripheral edge surface of each outer
face 223 engages a respective annular ledge 212,214 of housings
202,203. In this position, terminal pads 218 face outwardly toward
the corresponding pads 225 on printed wiring board 228. Pilot pins
9 are then fixedly positioned within pilot holes 114 of at least
one of termination headers 217 (shown within housing 203 in FIGS.
16,17, and 18). With pilot pins 9 located in pilot holes 114, a
contact interposer 5 may be positioned within the connector system
200. More particularly, a contact interposer 5 having a plurality
of electrical contacts 2 positioned within through-bores 104 is
arranged in confronting coaxial relation with termination header
217 which has pilot pins 9 positioned within pilot holes 114. Once
in this position, contact interposer 5 is moved toward termination
header 217 so that pilot pins 9 are received within pilot holes
106. The tips of pilot pins 9 may then be swaged or otherwise
capped so as to prevent contact interposer 5 from sliding off pilot
pins 9. In another embodiment, housing 202, 203 may be discarded
with adequate results (FIGS. 19-21).
[0063] Housing 202 may be mated to housing 203 so as to complete
board-to-board connector system 200 in the following manner.
Referring to the exemplary sequence illustrated in FIGS. 17 and 18,
housing 202 is oriented so as to be in confronting coaxial relation
with housing 203 such that termination headers 217 are facing one
another with contact interposer 5 positioned between them. Once in
this position, housings 202, 203 are moved toward one another,
e.g., by actuation of nut and spring mounting system 216. As this
occurs, conductive pads 218 on termination header 217 of housing
202 move toward engagement portions 31 of each electrical contact 2
that is positioned in contact interposer 5. Conductive pads 218
engage electrical contacts 2 and thereby cause contact interposer 5
to slide toward housing 203 upon, and guided by pilot pins 9 so as
to move engagement portions 33 of each electrical contact 2 towards
conductive pads 218 of termination header 217 positioned within
housing 203. Engagement portions 33 of each electrical contact 2
thus engage conductive pads 218 of termination header 7 in housing
203 so as to complete each electrical circuit.
[0064] In another example, a wire-to-ribbon cable connector system
300 may be formed having a interposer assembly 3 as follows.
Referring to FIGS. 22-24, in simplified form a wire-to-ribbon
connector system 300 includes a pair of mateable housings 302,303
in which interposer assembly 3 may be positioned upon guide-cradles
80, 81 as previously discussed hereinabove. In this embodiment,
each housing 302,303 includes a base wall 306,307 that is
surrounded by an annular wall 309,310. Base wall 310 defines an
interior recess 314 within housing 303. In the illustrated
embodiment, annular wall 309 is slightly smaller in diameter than
annular wall 310 so that housing 302 may be received within a
portion of housing 303. Thus when housing 302 is mated with housing
303, the pair of housings move toward one another so as to close
the distance between the confronting inner surfaces of base walls
306,307 (FIG. 22-24). It will be understood that wire-to-ribbon
connector system 300 may include a wide variety of alternative
structures for securely inserting and holding housing 302 in
engagement with housing 303, e.g., latches, an interference fit, a
threaded rod, bayonet mount, etc.
[0065] Interposer assembly 3 includes a contact interposer 315, a
termination header 317, one or more pilot pins 9, and is positioned
between housings 302,303 with some portions located on housing 302
and other portions located on housing 303. A pair of guide-cradles
80,81 are often located within housings 302,303 on the interior
surface of base walls 306,307, respectively, and as previously
described hereinabove. Contact interposer 315 is formed from a
standard epoxy and fiber glass printed wiring board (PCB) 102
having a plurality of through-bores 104 defined through its
thickness and arranged in a regular pattern or array of
predetermined shape and center-line spacing (see, FIG. 12) however
in a wire-to-ribbon embodiment of the invention electrical contacts
2 are often arranged in a circular pattern. It should be noted that
contact interposer 315 may have a wide variety of physical shapes,
as dictated by a particular connector structure. One or more pilot
holes 106 are defined through contact interposer 315. Electrical
contacts 2 are lodged within through-bores 104 and fixed in place
within each through-bore 104 as previously described, such that a
first engagement portion 31 projects outwardly from a first side
surface of contact interposer 5 and second engagement portion 33
projects outwardly from a second side surface of contact interposer
5.
[0066] Termination headers 317 may be formed from a standard epoxy
and fiber glass printed wiring board material having a plurality of
interconnect 322 arranged through their thicknesses. One or more
pilot holes 324 are defined through portions of termination header
317 in locations that will allow for coaxial alignment with pilot
holes 106 when interposer assembly 3 is positioned on housings 302
and 303. In this embodiment, interconnect 322 may be
plated-through-holes or solid conductive structures or combination
of both, e.g., tin, gold, or the like, and closed off at both ends.
In this way, a pair of terminal pads 318, 319 are formed on outer
faces 326, 327 of terminal header 317 so as to provide an
electrically conductive pathway to corresponding wires 99 and
ribbon cable 333 (e.g., via solder) within base walls 306,307,
respectively (FIG. 22-24). Terminal pads 318 are arranged on outer
face 326 of terminal header 317 in a regular pattern or array that
is complementary to the pattern of through-bores 104 in contact
interposer 315. An o-ring 119 or equivalent may be fixedly
positioned adjacent to outer face 326 of terminal headers 317 so as
to be in surrounding relation to the array of terminal pads
318.
[0067] Interposer assembly 3 is mounted within a wire-to-ribbon
connector system 300 in much the same manner as with wire-to-wire
connector system 100 and board-to-board connector system 200. More
particularly, termination header 317 is positioned on base wall 306
of housing 302. Pilot pins 9 are then fixedly positioned within
pilot holes 324 of termination header 317 (shown within housing 302
in FIG. 20). With pilot pins 9 located in pilot holes 324, a
contact interposer 315 may be positioned within the connector
system. More particularly, a contact interposer 315 having a
plurality of electrical contacts 2 positioned within through-bores
104 is arranged in confronting coaxial relation with housing 303
which has pilot pins 9 positioned within pilot holes 324. Once in
this position, contact interposer 315 is moved toward housing 303
so that pilot pins 9 are received within pilot holes 106. The tips
of pilot pins 9 may then be swaged or otherwise capped so as to
prevent contact interposer 315 from sliding off pilot pins 9.
[0068] Housing 302 may be mated to housing 303 so as to complete
wire-to-ribbon connector system 300. Referring to the exemplary
sequence illustrated in FIGS. 23 and 24, housing 302 is oriented so
as to be in confronting coaxial relation with housing 303 such that
base walls 306,307 are facing one another with contact interposer 5
positioned between them. Once in this position, housings 302, 303
are moved toward one another so that housing 302 engages housing
302. As this occurs, conductive pads 318 on termination header 317
of housing 302 move toward engagement portions 31 of each
electrical contact 2 that is positioned in contact interposer 315.
Conductive pads 318 engage electrical contacts 2 and thereby cause
contact interposer 315 to slide toward housing 303 upon, and guided
by pilot pins 9 so as to move engagement portions 33 of each
electrical contact 2 towards conductive pads 318 positioned within
housing 303. Engagement portions 33 of each electrical contact 2
thus engage conductive pads 323 in housing 303 so as to complete
each electrical circuit.
[0069] It is to be understood that the present invention is by no
means limited only to the particular constructions herein disclosed
and shown in the drawings, but also comprises any modifications or
equivalents within the scope of the claims.
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