Amp LLC

The Whitaker Corporation

Paul D Zakary

Albert N Schultz, Jr

Donald G Stillie

Homer E Henschen

This invention is directed to an electrical interconnection system composed of a plurality of interconnected circuit panel subassemblies, where each subassembly is preferably formed by a reaction injection molding (RIM) process. Each subassembly includes a plurality of spaced apart sites for establishing electrical contact to an electrical component, and an encapsulated conductive grid network joining certain of the respective spaced apart sites. A feature of this invention is that the conductive grid network includes flexible, insulative conductors which are unencapsulated and extend between adjacent pairs of subassemblies. By this arrangement, it is possible to fabricate and terminate the subassemblies, planarly arranged, by robotics, whereupon the subassemblies may then be moved relative to each other to form a nonplanar or three-dimensional assembly, such as an electromechanical structure to which further electrical components may be secured.

Electrical interconnection system

A circuit panel subassembly suitable for use in an eletromechanical apparatus includes a plurality of wires formed within an electrically conductive grid imbedded within a reaction injection molded panel which forms a part of the housing of the electromechanical apparatus. Wires are deployed in a pattern by using a wire organizing frame and the electrically conductive grid and the frame are subsequently imbedded in a reaction injection molded panel. Terminals attached to the ends of the wires remain exposed at spaced apart locations where components are to be mounted. Separate connector housings can be attached to the panel over the exposed terminals and other components or matable connectors can be attached thereto. The entire apparatus can be constructed robotically.

Method of making molded electrical interconnection system

A circuit panel subassembly suitable for use in an electromechanical apparatus includes a plurality of wires formed within an electrically conductive grid imbedded within a reaction injection molded panel which forms a part of the housing of the electromechanical apparatus. Wires are deployed in a pattern by using a wire organizing frame and the electrically conductive grid and the frame are subsequently imbedded in a reaction injection molded panel. Terminals attached to the ends of the wires remain exposed at spaced apart locations where components are to be mounted. Separate connector housings can be attached to the panel over the exposed terminals and other components or matable connectors can be attached thereto. The entire apparatus can be constructed robotically.

Molded electrical interconnection system

An electrical connector has two mounting base portions with a cylindrical portion extending therebetween. The cylindrical portion is wrapped with a film having a plurality of conductive signal traces disposed on the outer surface thereof for interconnecting corresponding circuitry on two substrates. The inner surface of the film includes a screen printed ground plane thereon for partially shielding the signal traces, thereby preventing crosstalk between lines on the printed circuit boards. The first end of the film is attached to the body and the film is wrapped around the body until the second end overlaps the first end, which commons the ground traces disposed on the outer surface of the film to the ground plane disposed on the inner surface of the film.

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Winston-Salem, NC, United States of America

Paul D Zakary