The Whitaker Corporation

Precision Interconnect, Inc.

David F Miller

Scott S Corbett, Iii

Jerry Martyniuk

Daniel DeLessert

Larry L Davis

Michael L Demeter

James Francis McIntire

Iosif Korsunsky

Richard C Schroepfer

Alexander William Hasircoglu

Roy W Fox, Jr

Laurence A Daane

An electrical connector 2, suitable for use as a plug for a Universal Serial Bus cable assembly, includes a plurality of terminals 4 that are partially insert molded in a nonconductive housing 36. A distal end 6 of each terminal 4 is recessed from the front end 38 of the housing 36. The terminals 4 are insert molded while still on a carrier and a weakened section 14 is formed at the distal end 6. After the housing 36 is molded, a tensile force is applied to fracture each terminal 4 at the weakened section 14 so that the distal end 6 of each terminal is recessed where it cannot inadvertently contact shields 54, 64 on the plug 2 or a mating receptacle 62. The rear of the housing is overmolded, and the insert molded housing 36 includes sections completely surrounding the terminals 4 so that the overmolded material cannot flow onto a housing mating surface 42 or onto a terminal mating section 10.

Electrical connector with insert molded housing

Connectors for attachment to cables including a large number of very small flexible conductors (26) or coaxial conductor pairs (74). In a first embodiment very small contacts (36) are arrayed on a flat mating surface (28) of the connector body (22). Contacts (36) are raised slightly above the mating surface by plating conductive metal to form raised bumps (42) on one of a pair of connectors (14, 16). Insulated individual conductors (26) are placed through apertures (48) defined in a substrate acting as a template, and are fastened in place by potting material (50) before shaping the mating surface (28) of the connector body (22) or (24) is shaped. Pin and socket combinations (30, 32) are used to align mating connectors with each other. In other connectors (176, 178) contact bases (198, 200) to be plated may be defined precisely by photoresist lithography on a cover layer (192) attached to the template substrate (180, 182), and an elastomeric layer (190 ) may be provided between the cover layer and the template substrate. In other connectors (90, 146, 240, 460) shields of coaxial conductor pairs and shields of flex circuits are connected electrically to conductive common layers (98, 154, 246, 474) on the rear side of the substrate. In one connector (370) flex circuit conductor traces are exposed on a mating face (394) as contacts (396, 398).

Connector with monolithic multi-contact array

Connectors for attachment to cables including a large number of very small flexible conductors or conductor pairs, in which very small contacts are provided as an array exposed on a flat mating surface. Contacts may be raised slightly above the flat surface by plating conductive metal to form raised bumps on one of a pair of connectors. Individual conductors are placed through apertures defined in a substrate acting as a template, and are potted in place before shaping the mating surface of the connector. Contact bases to be plated may be defined precisely by photoresist lithography on a cover layer attached to the template substrate, and an elastomeric layer may be provided between the cover layer and the template substrate. Pin and socket combinations are used to align mating connectors with each other.

Method of making connector with monolithic multi-contact array

A connector system for interconnecting single or multiple pairs of flex circuits. A single pair of clamping bodies interconnects the respective ones of multiple pairs of electrical conductors in the form of conductor traces carried on respective pairs of flexible substrates, by pressing the flex circuits together between slender fluid-filled flexible bladders held in channels defined in the confronting sides of the clamping bodies. Alignment pins keep the flex circuits and clamping bodies aligned properly with each other, and alignment portions of the flex circuits correspond in thickness to that of the electrically interconnecting portions, to keep the flex circuits and clamping bodies parallel with each other. The clamping bodies are urged toward one another by clamping screws.

Hydrostatic connector for flex circuits

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Aloha, OR, United States of America

David F Miller