US20060141815A1 - Interconnection device and system - Google Patents
Interconnection device and system Download PDFInfo
- Publication number
- US20060141815A1 US20060141815A1 US11/359,934 US35993406A US2006141815A1 US 20060141815 A1 US20060141815 A1 US 20060141815A1 US 35993406 A US35993406 A US 35993406A US 2006141815 A1 US2006141815 A1 US 2006141815A1
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- Prior art keywords
- connector system
- header
- conductive
- interposer
- face
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- H01R13/24—Contacts for co-operating by abutting resilient; resiliently-mounted
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- H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
- H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
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- Engineering & Computer Science (AREA)
- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- General Physics & Mathematics (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Measuring Leads Or Probes (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
- Details Of Connecting Devices For Male And Female Coupling (AREA)
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.
Description
- 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.
- 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.
- 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.
- 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.”
- 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.
- 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.
- 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.
- 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.
- The prior art has been devoid of at least one of the foregoing attributes necessary for a universally applicable electrical connector.
- 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.
- 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.
- 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:
-
FIG. 1 is a perspective view of a wire-to-wire connector assembly formed in accordance with the present invention; -
FIG. 2 is a perspective view of a woven electrical contact of a type used in connection with one embodiment of the present invention; -
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 inFIG. 2 ; -
FIG. 4 is a cross-sectional view of a wire of the type used in forming the electrical contact shown inFIGS. 2 and 3 ; -
FIG. 5 is a cross-sectional view, similar toFIG. 4 , but showing an insulating layer placed on the outer surface of wire; -
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; -
FIG. 7 is a magnified view of the mesh shown inFIG. 6 ; -
FIG. 8 is a top view of the mesh shown inFIG. 7 , illustrating the process of being rolled into a tubular contact; -
FIG. 9 is a perspective view of the tubular contact shown inFIG. 8 ; -
FIG. 10 is a top end view of a portion of the mesh shown inFIG. 7 , after pleating so as to form yet another embodiment of electrical contact; -
FIG. 11 is a cross-sectional perspective and exploded view of a wire-to-wire connector formed in accordance with the present invention; -
FIG. 12 is a partially cross-sectional view of a contact interposer and electrical contacts arranged in accordance with the present invention; -
FIG. 13 is a perspective, partially exploded view of an alternative contact interposer accepting pleaded electrical contacts formed in accordance with the present invention; -
FIG. 14 is a cross-sectional view of the wire-to-wire connector shown inFIG. 11 ; -
FIG. 15 is a cross-sectional view of a fully mated wire-to-wire connector shown inFIGS. 11 and 14 ; -
FIG. 16 is a perspective view of an alternative embodiment of the present invention arranged in a board-to-board connector system; -
FIG. 17 is a cross-sectional view of the board-to-board connector system shown inFIG. 16 ; -
FIG. 18 is a cross-sectional view similar to that shown inFIG. 17 , but illustrating a fully mated position; -
FIG. 19 is a perspective exploded view of a board-to-board connector system similar to that shown inFIG. 16 , but without housings; -
FIG. 20 is a cross-sectional view of a board-to-board connector system shown inFIG. 19 ; -
FIG. 21 is a cross-sectional view similar to that shown inFIG. 20 , but illustrating a fully mated position; -
FIG. 22 is an exploded perspective view of a wire-to-ribbon cable connector system formed in accordance with the present invention; -
FIG. 23 is a cross-sectional exploded view of the wire-to-ribbon cable connector system shown inFIG. 19 ; and -
FIG. 24 is a cross-sectional view similar to that shown inFIG. 23 , but illustrating a fully mated position. - 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.
- 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 moreelectrical contacts 2 are arranged in aninterposer assembly 3 including acontact interposer 5, one or moreterminal headers 7, and one or more pilots 9 (FIGS. 1-2 and 11-14).Interposer assembly 3 provides for proper alignment and orientation ofelectrical contacts 2 within the particular connector system where, owing to the resilient structure ofelectrical 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. - 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 fourdiscrete wires 8 together, i.e., manipulating the wires together so as to interlace them to form a unitary structure, to thereby form an electricalcontact precursor mesh 12 in either a tubular configuration (FIGS. 2-3 ) or a sheet (FIGS. 6-8 ). - 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 thatelectrical contacts 2 of the present invention are said to comprise an unsupported structure. - In one woven embodiment, three to eight
stainless steel wires 8 are woven together to form a tubularelectrical contact 2. In this arrangement, eachwire 8 takes a helical path so as to be interlaced with eachadjacent wire 8, while at the same time, eachwire 8 only undergoes a substantially elastic deformation, i.e., eachwire 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 inwires 8 during this manufacturing step. Also, it should be understood that at the points of intersection/overlap 9 ofwires 8 inmesh 12, no bonding or other mechanical interconnection exists between the adjacent portions ofwires 8. As a result of this structural arrangement, the adjacent portions of eachwire 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. Thuselectrical contacts 2 having a diameter less than about five mils may be manufactured with adequate results. - Significantly, once woven tubular
electrical contact 2 is annealed so as to stress relievewires 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 ofwires 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 elasticallydeformed wires 8 inmesh 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 ofwires 8 springing apart when cut into individualelectrical contacts 2, they tend to maintain their combined structural integrity, and remain woven together. - 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. - 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. - The annealing of
mesh 12 relieves the elastic strain that is inherent inwires 8 as a result of the weaving process, particularly at intersection/overlap points 9 wherewires 8 are elastically deformed so as to bend or curve. Absent this annealing step and structure,wires 8 andmesh 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 weavingindividual wires 8 into a structure having inherent macro-elastic properties, with an annealing step to set theindividual wires 8 in their woven structural arrangement, provides for significantly enlarged force deflection properties. Thus when woven intomesh 12 according to the invention, and then annealed, plurality ofwires 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. - 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 formingelectrical contact 2 is a maypole type machine wherein carriers for bobbins carrying theindividual 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 removablecylindrical 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 individualelectrical 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. - 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 wovenelectrical 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 individualelectrical 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. - Suitable electrically-conductive fibers or wires include virtually any fiber material having a bulk resistivity below about 100 μΩ-cm, and preferably about 2 to 5 μΩ-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 inFIG. 2 ), such as, silver, palladium, rhodium, gold, and the various alloys thereof. These highly conductive metals may extend along afirst interconnect portion 31 or asecond 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. - 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 inFIG. 2 ) are typically in the range from about 0.1 to 0.5 millimeters as measured between opposing wire intersection points 9. Referring toFIGS. 4 and 5 ,wires 8 may either be bare or have aninsulation coating 27 applied to their outer surface. In all cases, the weave should be sufficiently loose, with gaps or interstices remaining betweenadjacent 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 eachindividual wire 8 in its bent or curved shape and as a structural element or constituent of wovenmesh 12. Annealing for a stainless steel wire is conducted at temperatures ranging from about 500° C. to about 600° C., with about 550° C. being preferred for most applications. - 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 rolledcontact 42. Each rolledcontact 42 may then be cut frommesh 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 ofpleats 45 defined by a plurality oftroughs 47 and ridges 49 (FIG. 10 ). Acontact edge 50 is defined along the perimeter ofpleats 45. Pleatedelectrical contacts 45 may then be cut frommesh 40. In this way, pleats 45 act to support the contact within openings 35 (FIG. 13 ). Engagingcontact edge 50 of pleatedelectrical contact 45 deforms pleatedelectrical contact 45 to produce a resultant contact force. Here again, annealingpleated contact 45 or rolledcontact 42 under a constraint allows for a set to be created inwires 8. In the case of pleatedelectrical contacts 45, a suitable forming tool, having a pleated punch and die set, may be closed onmesh 40 during the annealing process in order to maintain the structural arrangement in elastically formedwires 8. - 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 withelectrical contacts 2 includes a pair of substantially circular mateabledielectric housings -
Housing 60 often includes a conductor or wire-receivingpassageway 64 extending through abase wall 66 and surrounded by anannular wall 67 that together define aninterior recess 69 into which wire-receivingpassageway 64 opens (FIG. 11 ).Housing 61 often includes a wire-receivingpassageway 70 extending through abase wall 72 and surrounded by anannular wall 74 that together define aninterior recess 77 into which wire-receivingpassageway 70 opens. In the illustrated embodiment,annular wall 67 has an outer diameter that is slightly smaller than the inner diameter ofannular wall 74, and includesthreads 76 along a portion of its length so thathousing 60 may be received in correspondingthreads 78 on an inner surface ofannular wall 74 of housing 61 (FIGS. 1 and 11 -15). Thus whenhousing 60 is mated withhousing 61 and rotated, the pair ofhousings 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 insertinghousing 60 intohousing 61, e.g., latches, bayonet mounts, interference fits, etc. - A pair of guide-
cradles housings base walls cradle 80 often includes a wire-receivingpassageway 84 extending through a mating face and surrounded by an annular wall that together define an interior recess into which wire-receivingpassageway 84 opens. Guide-cradle 81 includes a wire-receivingpassageway 91 extending through a mating face and surrounded by an annular wall that together define an interior recess into which wire-receivingpassageway 91 opens. Guide-cradles wires 99 enteringhousings crimp contact terminal 101 may also be received withinpassageways -
Interposer assembly 3 includes acontact interposer 5, a pair oftermination headers 7, and one or more pilot pins 9.Interposer assembly 3 is positioned betweenhousings 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 ormore pilot holes 106 are defined throughcontact 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 afirst engagement portion 31 projects outwardly from a first side surface ofcontact interposer 5 and asecond engagement portion 33 projects outwardly from a second side surface ofcontact interposer 5. -
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 ormore pilot holes 114 are also defined through portions oftermination header 7 in locations that will allow for coaxial alignment withpilot holes 106 ofcontact interposer 5 wheninterposer assembly 3 is positioned withinhousings 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, aterminal pad 118 is formed onface 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 towires 99 or wire-crimp terminal contact 101.Terminal pads 118 are arranged onface 117 of eachterminal header 7 in a regular pattern or array that is complementary to the pattern of through-bores 104 incontact interposer 5. An o-ring 119 or equivalent may be fixedly positioned onface 117 of one ofterminal headers 7 so as to be in surrounding relation to the array ofterminal pads 118. -
Interposer assembly 3 is mounted within a wire-to-wire connector 100 in the following manner. Guide-cradles housing passageways 84 of guide-cradle 80 are arranged in coaxially aligned relation with wire-receivingpassageway 64 ofhousing 60, and wire-receivingpassageways 91 of guide-cradle 81 are arranged in coaxially aligned relation with wire-receivingpassageway 70 ofhousing 61. Once in this position, atermination header 7 is positioned on each mating face of each guide-cradle terminal pads 118 face outwardly. Pilot pins 9 are then fixedly positioned withinpilot holes 114 of at least one of termination headers 7 (shown withinhousing 61 inFIGS. 11, 14 , and 15). It will be understood that guide-cradles housings housings terminal pads 118 on eachterminal header 7 will be maintained during mating ofhousing 60 tohousing 61. Withpilot pins 9 located inpilot holes 114, acontact interposer 5 may be positioned within the wire-to-wire connector system 100. More particularly, acontact interposer 5 having a plurality ofelectrical contacts 2 positioned within through-bores 104 is arranged in confronting coaxial relation withtermination header 7 which haspilot pins 9 positioned within pilot holes 114. Once in this position,contact interposer 5 is moved towardtermination header 7 so that pilot pins 9 are received within pilot holes 106. The tips ofpilot pins 9 may then be swaged or otherwise capped so as to preventcontact interposer 5 from easily sliding off pilot pins 9. -
Wire conductors 99 or wire-crimp terminal contact 101 are then inserted through wire-receivingpassageways hole 112 of each termination header 7 (FIG. 14 ). In this position, eachwire 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 aconductive pad 118 on eachtermination header 7. - With
wires 99 or wire-crimp terminal contact 101 electrically engaged withtermination headers 7, withinhousings housing 60 may be mated tohousing 61 so as to complete wire-to-wire connector 100. Referring to the exemplary sequence illustrated inFIGS. 14 and 15 ,housing 60 is oriented so as to be in confronting coaxial relation withhousing 61 such thatthreads 76 on the lower outer surface ofannular wall 67 engage correspondingthreads 78 ofannular wall 74 ofhousing 61. Once in this position, one ofhousings threads housings conductive pads 118 ontermination header 7 ofhousing 60 move towardengagement portions 31 of eachelectrical contact 2 that is positioned incontact interposer 5.Conductive pads 118 engageelectrical contacts 2 and thereby causecontact interposer 5 to slide towardhousing 61 upon, and guided bypilot pins 9 so as to moveengagement portions 33 of eachelectrical contact 2 towardsconductive pads 118 oftermination header 7 positioned withinhousing 61.Engagement portions 33 of eachelectrical contact 2 thus engageconductive pads 118 oftermination header 7 inhousing 61 so as to complete each electrical circuit. - 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 ainterposer assembly 3 as follows. Referring toFIGS. 16-18 , in simplified form a board-to-board connector system 200 may include a pair ofmateable housings interposer assembly 3 may be positioned. Of course,interposer assembly 3 may be employed for board-to-board applications without the use ofhousings board connector system 201 shown inFIGS. 19-21 ). In an embodiment that includes housings, each will often include anannular side wall opening annular ledge annular side wall 206,207 (FIG. 17 ). In the illustrated embodiment,annular wall 206 is slightly smaller thanannular wall 207 so thathousing 202 may be received within a portion ofhousing 203. Thus whenhousing 202 is mated withhousing 203, the pair of housings move toward one another so as to close the distance between the confronting inner surfaces ofannular 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 holdinghousing 202 in engagement withhousing 203, e.g., latches, an interference fit, a threaded rod, nut andspring mounting system 216, etc. -
Interposer assembly 3 includes acontact interposer 5, a pair oftermination headers 217, and one ormore pilot pins 9, and is positioned betweenhousings 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 ormore pilot holes 106 are defined throughcontact 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 afirst engagement portion 31 projects outwardly from a first side surface ofcontact interposer 5 andsecond engagement portion 33 projects outwardly from a second side surface of contact interposer 5 (FIG. 12 ). -
Termination headers 217 are also formed from a standard epoxy and fiber glass printed wiring board (PCB) material having a plurality ofconductive vias 220 defined through their thicknesses and arranged in a regular pattern or array that is complementary to the pattern of through-bores 104 incontact interposer 5. One ormore pilot holes 114 are again defined through portions of eachtermination header 217 in locations that will allow for coaxial alignment withpilot holes 106 wheninterposer assembly 3 is positioned onhousings Vias 220 may comprise plated-through holes that extend through the thickness of eachtermination 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 ofterminal pads outer faces terminal header 217 so as to provide an electrically conductive pathway to correspondingterminal pads 225 located on printed wiring board 228 (FIG. 17 ). An o-ring 119 or equivalent may be fixedly positioned onouter face 223 of one ofterminal headers 217 so as to be in surrounding relation to the array ofterminal pads 218, if sealing is required for a particular application. -
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 eachouter face 223 engages a respectiveannular ledge housings terminal pads 218 face outwardly toward thecorresponding pads 225 on printedwiring board 228. Pilot pins 9 are then fixedly positioned withinpilot holes 114 of at least one of termination headers 217 (shown withinhousing 203 inFIGS. 16,17 , and 18). Withpilot pins 9 located inpilot holes 114, acontact interposer 5 may be positioned within theconnector system 200. More particularly, acontact interposer 5 having a plurality ofelectrical contacts 2 positioned within through-bores 104 is arranged in confronting coaxial relation withtermination header 217 which haspilot pins 9 positioned within pilot holes 114. Once in this position,contact interposer 5 is moved towardtermination header 217 so that pilot pins 9 are received within pilot holes 106. The tips ofpilot pins 9 may then be swaged or otherwise capped so as to preventcontact interposer 5 from sliding off pilot pins 9. In another embodiment,housing FIGS. 19-21 ). -
Housing 202 may be mated tohousing 203 so as to complete board-to-board connector system 200 in the following manner. Referring to the exemplary sequence illustrated inFIGS. 17 and 18 ,housing 202 is oriented so as to be in confronting coaxial relation withhousing 203 such thattermination headers 217 are facing one another withcontact interposer 5 positioned between them. Once in this position,housings spring mounting system 216. As this occurs,conductive pads 218 ontermination header 217 ofhousing 202 move towardengagement portions 31 of eachelectrical contact 2 that is positioned incontact interposer 5.Conductive pads 218 engageelectrical contacts 2 and thereby causecontact interposer 5 to slide towardhousing 203 upon, and guided bypilot pins 9 so as to moveengagement portions 33 of eachelectrical contact 2 towardsconductive pads 218 oftermination header 217 positioned withinhousing 203.Engagement portions 33 of eachelectrical contact 2 thus engageconductive pads 218 oftermination header 7 inhousing 203 so as to complete each electrical circuit. - In another example, a wire-to-ribbon
cable connector system 300 may be formed having ainterposer assembly 3 as follows. Referring toFIGS. 22-24 , in simplified form a wire-to-ribbon connector system 300 includes a pair ofmateable housings interposer assembly 3 may be positioned upon guide-cradles housing base wall annular wall Base wall 310 defines aninterior recess 314 withinhousing 303. In the illustrated embodiment,annular wall 309 is slightly smaller in diameter thanannular wall 310 so thathousing 302 may be received within a portion ofhousing 303. Thus whenhousing 302 is mated withhousing 303, the pair of housings move toward one another so as to close the distance between the confronting inner surfaces ofbase 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 holdinghousing 302 in engagement withhousing 303, e.g., latches, an interference fit, a threaded rod, bayonet mount, etc. -
Interposer assembly 3 includes acontact interposer 315, atermination header 317, one ormore pilot pins 9, and is positioned betweenhousings housing 302 and other portions located onhousing 303. A pair of guide-cradles housings base walls 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 inventionelectrical contacts 2 are often arranged in a circular pattern. It should be noted thatcontact interposer 315 may have a wide variety of physical shapes, as dictated by a particular connector structure. One ormore pilot holes 106 are defined throughcontact 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 afirst engagement portion 31 projects outwardly from a first side surface ofcontact interposer 5 andsecond engagement portion 33 projects outwardly from a second side surface ofcontact interposer 5. -
Termination headers 317 may be formed from a standard epoxy and fiber glass printed wiring board material having a plurality ofinterconnect 322 arranged through their thicknesses. One ormore pilot holes 324 are defined through portions oftermination header 317 in locations that will allow for coaxial alignment withpilot holes 106 wheninterposer assembly 3 is positioned onhousings 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 ofterminal pads outer faces terminal header 317 so as to provide an electrically conductive pathway to correspondingwires 99 and ribbon cable 333 (e.g., via solder) withinbase walls FIG. 22-24 ).Terminal pads 318 are arranged onouter face 326 ofterminal header 317 in a regular pattern or array that is complementary to the pattern of through-bores 104 incontact interposer 315. An o-ring 119 or equivalent may be fixedly positioned adjacent toouter face 326 ofterminal headers 317 so as to be in surrounding relation to the array ofterminal pads 318. -
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 onbase wall 306 ofhousing 302. Pilot pins 9 are then fixedly positioned withinpilot holes 324 of termination header 317 (shown withinhousing 302 inFIG. 20 ). Withpilot pins 9 located inpilot holes 324, acontact interposer 315 may be positioned within the connector system. More particularly, acontact interposer 315 having a plurality ofelectrical contacts 2 positioned within through-bores 104 is arranged in confronting coaxial relation withhousing 303 which haspilot pins 9 positioned within pilot holes 324. Once in this position,contact interposer 315 is moved towardhousing 303 so that pilot pins 9 are received within pilot holes 106. The tips ofpilot pins 9 may then be swaged or otherwise capped so as to preventcontact interposer 315 from sliding off pilot pins 9. -
Housing 302 may be mated tohousing 303 so as to complete wire-to-ribbon connector system 300. Referring to the exemplary sequence illustrated inFIGS. 23 and 24 ,housing 302 is oriented so as to be in confronting coaxial relation withhousing 303 such thatbase walls contact interposer 5 positioned between them. Once in this position,housings housing 302 engageshousing 302. As this occurs,conductive pads 318 ontermination header 317 ofhousing 302 move towardengagement portions 31 of eachelectrical contact 2 that is positioned incontact interposer 315.Conductive pads 318 engageelectrical contacts 2 and thereby causecontact interposer 315 to slide towardhousing 303 upon, and guided bypilot pins 9 so as to moveengagement portions 33 of eachelectrical contact 2 towardsconductive pads 318 positioned withinhousing 303.Engagement portions 33 of eachelectrical contact 2 thus engage conductive pads 323 inhousing 303 so as to complete each electrical circuit. - 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.
Claims (39)
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.
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Also Published As
Publication number | Publication date |
---|---|
US20050191906A1 (en) | 2005-09-01 |
WO2004095897A3 (en) | 2005-08-11 |
US20060189176A1 (en) | 2006-08-24 |
US7040902B2 (en) | 2006-05-09 |
US20060141832A1 (en) | 2006-06-29 |
US20040192080A1 (en) | 2004-09-30 |
US20050164534A1 (en) | 2005-07-28 |
US20060211276A1 (en) | 2006-09-21 |
WO2004095897A2 (en) | 2004-11-04 |
US7029289B2 (en) | 2006-04-18 |
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