Contactor with multiple redundant connecting paths

Abstract

A contact array includes: (1) a plurality of uniform columns each for providing electrical continuity between things respectively in contact with opposite ends of the columns, each column means having a memory urging it to be straight, and (2) an elastomeric carrier, reinforced with a polymer, to which all the columns are affixed, for holding them parallel to each other, spaced apart, aligned along an axis normal to them, and preferably symmetrical with respect to the axis. The carrier also forces the columns to be uniformly arcuate along the axis. The opposite ends of the columns define respective opposite contact margins of the array. A housing defines a chamber for containing the array. Two opposite walls of the chamber define respective openings through which the contact margins protrude for accepting compressive contact forces that are applied during operation. The chamber further includes space to allow further, unobstructed, resilient arcuation of all the columns whenever the contact force is applied to the margins. Each column can include a plurality of bundled, elongated leaves of conductive material, each leaf having a memory urging it to be straight. The array can be moveable back and forth, over a range, in the directions that the forces are applied to the contact margins to equalize the forces. Several novel methods for manufacturing the contactors are also described.