Round connector with spring helix

Apparatuses and methods of manufacturing woven electrical connectors is disclosed. In one embodiment, the connector is formed with a continuous wire having adjacent sections with passageways formed from the wire through which loading elements may be inserted. In some embodiments, the loading elements include spring band clips and/or helical spring coils.

BACKGROUND

The present invention is directed to electrical connectors and in particular to woven electrical connectors and methods used to manufacture them.

2. Discussion of Related Art

Components of electrical systems sometimes need to be interconnected using electrical connectors to provide an overall, functioning system. These components may vary in size and complexity, depending on the type of system and many require connections to power sources. Examples of such power connectors are shown in U.S. Patent Application Publication No. 2004/0214454, presently assigned to the assignee of this presentation and hereby incorporated by reference in its entirety.

SUMMARY

In one aspect, the invention relates to a multi-contact electrical connector. The multi-contact electrical connector includes a conductive wire defining a plurality of adjacent sections including a first section and an adjacent second section, the first section having a first portion of the first section comprising a plurality of peaks and valleys and a second portion of the first section continuous with the first portion of the first section comprising a plurality of valleys and peaks, the second portion of the first section is looped back adjacent the first portion of the first section whereby the plurality of peaks and valleys of the first portion of the first section align with the plurality of valleys and peaks, respectively, of the second portion of the first section to define a plurality of passageways in the first section of a plurality of sections, wherein the second portion of the first section is continuous with a first portion of the adjacent second section, the first portion of the second section comprising a plurality of peaks and valleys and a second portion of the second section continuous with the first portion of the second section comprising a plurality of valleys and peaks, the second portion of the second section is looped back adjacent the first portion of the second section whereby the plurality of peaks and valleys of the first portion of the second section align with the plurality of valleys and peaks, respectively, of the second portion of the second section to define a plurality of passageways in the second section of the plurality of sections; and a loading element disposed within the plurality of passageways to bias a plurality of peaks into contact with a mating connector when connected thereto.

In another aspect, the invention relates to an electrical connector. The electrical connector includes a conductive wire defining a plurality of adjacent sections including a first section and an adjacent second section, the first section having a first portion of the first section comprising a plurality of peaks and valleys and a second portion of the first section continuous with the first portion of the first section comprising a plurality of valleys and peaks, the second portion of the first section is looped back adjacent the first portion of the first section whereby the plurality of peaks and valleys of the first portion of the first section align with the plurality of valleys and peaks, respectively, of the second portion of the first section to define a plurality of passageways in the first section of a plurality of sections, wherein the plurality of sections are disposed about a circumference to form a substantially cylindrical shape and wherein adjacent sections are longitudinally offset from one another is such that each of the passageways of one section are offset from each of the passageways of an adjacent section; and a helically shaped biasing element disposed within the plurality of passageways to bias a plurality of peaks into contact with a mating connector when connected thereto.

In a different aspect, the invention relates to an electrical connector. The electrical connector includes a conductive wire defining a plurality of adjacent sections including a first section and an adjacent second section, the first section having a first portion of the first section comprising a plurality of peaks and valleys and a second portion of the first section continuous with the first portion of the first section comprising a plurality of valleys and peaks, the second portion of the first section is looped back adjacent the first portion of the first section whereby the plurality of peaks and valleys of the first portion of the first section align with the plurality of valleys and peaks, respectively, of the second portion of the first section to define a plurality of passageways in the first section of a plurality of sections, wherein the plurality of sections are disposed about an arc circumference to form a substantially arcuate shape having the plurality of passageways disposed about an arc; and an arcuate shaped biasing element disposed within adjacent passageways to bias a plurality of peaks into contact with a mating connector when connected thereto.

In a further aspect, the invention relates to a method of forming an electrical connector. The method includes providing a conductive wire, the wire having a first section and a second section; plastically deforming the first section of the wire with a forming tool to define at least one first section passageway; with the same wire, plastically deforming the second section of the wire with the forming tool to define at least one second section passageway; arranging the first and second sections to be laterally adjacent one other such that the at least one first section passageway generally aligns with the at least one second section passageway; inserting a loading element through the passageways of adjacent sections.

Various embodiments of the present invention provide certain advantages. Not all embodiments of the invention share the same advantages and those that do may not share them under all circumstances.

Further features and advantages of the present invention, as well as the structure of various embodiments of the present invention are described in detail below with reference to the accompanying drawings.

DETAILED DESCRIPTION

Aspects of the invention provide an electrical connector that may overcome the disadvantages of prior art connectors. The present invention is also directed to methods of manufacturing connectors. As discussed in the above-referenced U.S. Patent Application Publication No. 2004/0214454, connectors for providing power to an electrical component include a set of conductive wires formed with peaks and valleys resulting in passageways through which a loading fiber is disposed. The loading fiber can be tensioned using any suitable tensioning arrangement so that the conductive wires can be biased into engagement with a connector. As shown in schematically inFIGS. 1A and 1B, elastic non-conductive elements88may be tensioned in the direction of arrows93A and93B, to provide a predetermined tension in a non-conductive element, which in turn may provide a predetermined contact force between the conductors90and the mating contact96.

In the example illustrated inFIG. 1a, the non-conductive element88may be tensioned such that the non-conductive element88makes an angle95with respect to a plane99of the mating conductor96, so as to press the conductors90against the mating contact96. In this embodiment, more than one conductor90may be making contact with the mating conductor96. Alternatively, as illustrated inFIG. 1b, a single conductor90may be in contact with any single mating conductor96, providing the electrical contact as discussed above. Similar to the previous example, the non-conductive element88is tensioned in the directions of the arrows93aand93b, and makes an angle97with respect to the plane of the mating contact96, on either side of the conductor90.

It is to be appreciated that the conductors and non-conductive and insulating fibers making up a weave may be extremely thin, for example having diameters in a range of approximately 0.0001 inches to approximately 0.020 inches, and thus a very high density connector may be possible using the woven structure. Because the woven conductors are locally compliant, as discussed above, little energy may be expended in overcoming friction, and thus the connector may require only a relatively low normal force to engage a connector with a mating connector element. This may also increase the useful life of the connector as there is a lower possibility of breakage or bending of the conductors occurring when the connector element is engaged with the mating connector element.

As discussed herein, the utilization of conductors being woven or intertwined with loading elements can provide particular advantages for electrical connector systems. Designers are constantly struggling to develop (1) smaller electrical connectors and (2) electrical connectors which have minimal electrical resistance. The woven connectors described herein can provide advantages in both of these areas. The total electrical resistance of an assembled electrical connector is generally a function of the electrical resistance properties of the male-side of the connector, the electrical resistance properties of the female-side of the connector, and the electrical resistance of the interface that lies between these two sides of the connector. The electrical resistance properties of both the male and female-sides of the electrical connector are generally dependent upon the physical geometries and material properties of their respective electrical conductors. The electrical resistance of a male-side connector, for example, is typically a function of its conductor's (or conductors') cross-sectional area, length and material properties. The physical geometries and material selections of these conductors are often dictated by the load capabilities of the electrical connector, size constraints, structural and environmental considerations, and manufacturing capabilities.

Another critical parameter of an electrical connector is to achieve a low and stable separable electrical resistance interface, i.e., electrical contact resistance. The electrical contact resistance between a conductor and a mating conductor in certain loading regions can be a function of the normal contact force that is being exerted between the two conductive surfaces. As can be seen inFIG. 1b, the normal contact force F of a woven connector is a function of the tension T exerted by the loading element88, the angle97that is formed between the loading element88and the contact mating surface of the mating conductor96, and the number of conductors90of which the tension T is acting upon. As the tension T and/or angle97increase, the normal contact force F also increases. Moreover, for a desired normal contact force F there may be a wide variety of tension T/angle97combinations that can produce the desired normal contact force. Although the mating surface96is shown as generally flat, the surface can be any suitable shape, such as a curve for example, where the mating connector is formed as a plug having a round cross-section.

FIGS. 2a-cillustrate some exemplary embodiments of how conductor(s)302can be woven onto loading elements304. The conductor302ofFIGS. 2a-cis self-terminating and, while only one conductor302is shown, persons skilled in the art will readily appreciate that additional conductors302will usually be present within the depicted embodiments.FIG. 2aillustrates a conductor302that is arranged as a straight weave. The conductor302forms a first set of peaks364and valleys366, wraps back upon itself (i.e., is self-terminated) and then forms a second set of peaks364and valleys366that lie adjacent to and are offset from the first set of peaks364and valleys366. A peak364from the first set and a valley366from the second set (or, alternatively, a valley366from the first set and a peak364from the second set) together can form a loop362. Loading elements304can be located within (i.e., be engaged with) the loops362.FIG. 2billustrates a conductor302that is arranged as a crossed weave. The conductor302ofFIG. 2bforms a first set of peaks364and valleys366, wraps back upon itself and then forms a second set of peaks364and valleys366which are interwoven with, and are offset from, the first set of peaks364and valleys366. Similarly, peaks364from the first set and valleys366from the second set (or, alternatively, valleys366from the first set and peaks364from the second set) together can form loops362, which may be occupied by loading elements304. As shown, the cross-weave alternates at every peak and valley. However, the present invention is not limited in this respect as the cross-weave may occur at every other (or some other suitable multiple) peak and valley.

FIG. 2cdepicts a self-terminating conductor302that is cross woven onto four loading elements304. The conductor302ofFIG. 2cforms five loops362a-e. In certain exemplary embodiments, a loading element(s)304is located within each of the loops362that are formed by the conductors302. However, not all loops362need to be occupied by a loading element304.FIG. 2c, for example, illustrates an exemplary embodiment where loop362cdoes not contain a loading element304. It may be desirable to include unoccupied loops362within certain conductor302—loading element304weave embodiments so as to achieve a desired overall weave stiffness (and flexibility). Having unoccupied loops362within the weave may also provide improved operations and manufacturing benefits. When the weave structure is mounted to a base, for example, there may be a slight misalignment of the weave relative to the mating conductor. This misalignment may be compensated for due to the presence of the unoccupied loop362. Thus, by utilizing loops that are unoccupied, compliance of the weave structure to ensure better conductor/mating conductor conductivity while keeping the weave tension to a minimum may be achieved. Utilizing unoccupied loops362may also permit greater tolerance allowances during the assembly process.

Tests of a wide variety of conductor302—loading element304weave geometries can be performed to determine the relationship between normal contact force310and electrical contact resistance. Referring toFIG. 3, the total electrical resistance of various woven connector embodiments, as represented on y-axis314, can be determined over a range of normal contact forces, as represented on x-axis316. As represented inFIG. 3, the general trend318indicates that as the normal contact force (in Newtons (N)) increases, the contact resistance component of the total electrical resistance (in milli-ohms (mOhms)) generally decreases. Persons skilled in the art will readily recognize, however, that the decrease in contact resistance only extends over a certain range of normal contact forces; any further increases over a threshold normal contact force will produce no further reduction in electrical contact resistance. In other words, trend318tends to flatten out as one moves further and further along the x-axis316.

From the data ofFIG. 3, for example, one can then determine a normal contact force (or range thereof) that is sufficient for minimizing a woven connector's electrical contact resistance. As persons skilled in the art will readily appreciate, the vast majority of the conventional electrical connectors that are available today operate with normal contact forces ranging from about 0.35 to 0.5 N or higher. As is evident by the data represented inFIG. 3, by generating multiple contact points on conductors302of a woven connector system, very light loading levels (i.e., normal contact forces) can be used to produce very low and repeatable electrical contact resistances. The data ofFIG. 3, for example, can demonstrate that for many of the woven connector embodiments, normal contact forces of between approximately 0.020 and 0.045 N may be sufficient for minimizing electrical contact resistance. Such normal contact forces thus represent an order of magnitude reduction in the normal contact forces of conventional electrical connectors.

Additionally, in some power connector embodiments, each conductor302of a connector is in electrical contact with the adjacent conductor(s)302. Providing multiple contact points along each conductor302and establishing electrical contact between adjacent conductors302further ensures that the multi-contact woven power connector embodiments are sufficiently load balanced. Moreover, the geometry and design of the woven connector prohibit a single point interface failure. If the conductors302located adjacent to a first conductor302are in electrical contact with mating conductors306, then the first conductor302will not cause a failure (despite the fact that the contact points of the first conductor302may not be in contact with a mating conductor306) since the load in the first conductor302can be delivered to a mating conductor306via the adjacent conductors302.

In certain exemplary embodiments, the conductors302can include copper or copper alloy (e.g., C110 copper, C172 Beryllium Copper alloy) wires having diameters between 0.0002 and 0.010 inches or more. Alternatively, the conductors may be flat ribbon wires having comparable rectangular cross-section dimensions. The conductors302may also be plated to prevent or minimize oxidation, e.g., nickel plated or gold plated. Acceptable conductors302for a given woven connector embodiment should be identified based upon the desired load capabilities of the intended connector, the mechanical strength of the candidate conductor302, the manufacturing issues that might arise if the candidate conductor302is used and other system requirements, e.g., the desired tension T. The conductors302of the power circuit512exit a back portion of the housing530and may be coupled to a termination contact or other conductor element through which power can be delivered to the power connector500. As is discussed in more detail below, the loading elements304of the power circuit512are capable of carrying or providing a tension T that ultimately translates into a contact normal force being asserted at the contact points of the conductors302. In exemplary embodiments, the loading elements304may include or be formed of nylon, fluorocarbon, polyaramids and paraaramids (e.g., Kevlar®, Spectra®, Vectran®), polyamids, conductive metals and natural fibers, such as cotton, for example, coupled to a biasing element. In most exemplary embodiments, the loading elements304have diameters (or widths) of about 0.010 to 0.002 inches. However, in certain embodiments, the diameter/widths of the loading elements304may be as low as 18 microns when high performance engineered fibers (e.g., Kevlar) are used. In one embodiment, the loading elements304are formed of a non-conducting material.

FIGS. 3-5depict an exemplary embodiment of a multi-contact woven power connector. Referring toFIG. 3, power connector800includes a woven connector element810and a mating connector element830. The woven connector element810comprises a housing812, a faceplate814, a power circuit827, a return circuit829and termination contacts822a,822b. The power circuit827and return circuit829terminate at termination contacts822a,822b, respectively, which are located on the backside of the woven connector element810. Alignment holes816facilitate the mating of the mating connector element830to the woven connector element810and are disposed within the faceplate814and the housing812. Mating connector element830comprises a housing832, alignment pins834, mating conductors838a,838b(as shown inFIG. 5) and termination contacts836a,836b. Mating conductors838a,838bterminate at termination contacts836a,836b, respectively, which are located on the backside of the mating connector element830.

The woven connector element810of the power connector800is shown in greater detail inFIGS. 4a-4b.FIG. 4ashows the woven connector element810with the faceplate814removed, whileFIG. 4bshows the woven connector element810with the faceplate814installed. As seen inFIG. 4a, in addition to the alignment holes816, woven connector element810also includes holes818which can facilitate the installation of the faceplate814onto the housing812. The woven connector element810further includes several loading elements304and several tensioning springs824. In exemplary power connector800, different sets of loading elements304and tensioning springs824are utilized on the power circuit827and return circuit829sides of the woven connector element810. The power circuit827comprises several conductors302which are woven onto several loading elements304in accordance with the teachings of the present disclosure. The return circuit829similarly comprises several conductors302. The conductors302of the return circuit829are woven onto several loading elements304. In one embodiment, the conductors302of the power circuit827and the return circuit829are self-terminating. In the depicted exemplary power circuit827, the conductors302of the power circuit827are each woven onto four loading elements304while the conductors302of the return circuit829are each woven onto four different loading elements304. The ends of the loading elements304of the power circuit827side of the woven connector element810are coupled, i.e., attached, to tensioning springs824. In certain exemplary embodiments, the tensioning springs824of the woven connector element810surround the outside of the weaves that are made from conductor302and loading element304. In other embodiments, however, the tension springs824need not surround the weaves. In a preferred embodiment, each loading element304is coupled to a separate independent tension spring824, e.g., a first loading element304is coupled to a first tensioning spring824, a second loading element304is coupled to a second tensioning spring824, etc. The ends of the loading elements304of the return circuit829side of the woven connector element810are similarly coupled to independent tensioning springs824. By independently coupling the loading elements304to separate tensioning springs824, the power connector800's electrical connection capabilities become more redundant and resistant to failure.

As depicted in the exemplary embodiment ofFIGS. 4a-b, the conductors302of the power circuit827, when woven onto the corresponding loading elements304, form a woven tube having a space826adisposed therein. When woven onto the corresponding loading elements304, the conductors302of the return circuit829form a woven tube having a space826bdisposed therein. In most exemplary embodiments, the cross-sections of the woven tubes are symmetrical. In certain exemplary embodiments, such as woven connector element810, for example, the cross-sections of the woven tubes are circular.

FIG. 5shows the mating connector element830ofFIG. 3from an opposite view. Referring toFIG. 5, the mating connector element830includes mating conductors838a,838b. Mating conductors838a,838bterminate at termination contacts836a,836b, respectively, which are located on the backside of the mating connector element830. In certain exemplary embodiments, the mating conductors838a,838bare rod-shaped (e.g., pin-shaped) and have contact mating surfaces that are circumferentially disposed along the mating conductors838a,838b. The mating conductors838a,838bare appropriately sized (e.g., length, width, diameter, etc.) so that, upon engaging the mating conductor element830to the woven connector element810(or vice versa), electrical connections between the conductors302of the power circuit827and the return circuit829and the contact mating surfaces of the mating conductors838a,838b, respectively, can be established. In certain exemplary embodiments, the diameters of the mating conductors838range from approximately 0.01 inches to approximately 0.4 inches.

As has been discussed herein, contact between the conductors302and the contact mating surfaces of the mating conductors838can be established and maintained by the loading elements304. For example, when mating conductor838aof the mating conductor element830is inserted into the space826aof the power circuit827(of the woven connector element810), the mating conductor838acauses the weave of the conductors302and loading elements304of the power circuit827to expand in a radial direction. In doing so, the weave expands to a sufficient degree that the ends of the loading elements304which, in this example, are attached to the tensioning springs824are pulled closer together. This forces the tensioning springs824to deform elastically and tension is produced in the loading elements304which thus results in the desired normal contact forces being exerted at the contact points of the conductors302. Similarly, when mating conductor838bof the mating conductor element830is inserted into the space826bof the return circuit829, the mating conductor838bcauses the conductor302/loading element304weave of the return circuit829to expand in a radial direction. In the power connector800embodiment, the tensile loads within the loading elements304are generated and maintained by the elastic deformation of the tensioning springs824; when the weave expands, the loading elements304are pulled by the tensioning springs824, and thus are placed in tension. However, as will become apparent below, in certain embodiments, the connector systems do not need to utilize tensioning springs, spring mounts, spring arms, etc. to generate and maintain the tensile loads within the loading elements, as the loading elements (which may be referred to as biasing elements) themselves can provide the requisite force.

When the mating connector element830is being engaged with the woven connector element810, the faceplate814of the woven connector element810may assist in properly aligning the mating conductors838a,838bwith the spaces826a,826b, respectively, of the woven connector element810. The faceplate814also serves to protect the weaves of the woven connector element810. To further facilitate the insertion of the mating conductors838a,838binto spaces826a,826b, the ends of the mating conductors838a,838bmay be chamfered.

The use of rod-shaped mating conductors838with corresponding tube-shaped weaves allows the power connector800to become more space efficient, in terms of number of electrical contact points per unit volume, for example, than is generally possible with other types of multi-contact woven power connectors. The utilization of this arrangement, moreover, allows for the compact incorporation of tensioning springs that surround the weaves, which provides the longest length spring with the largest deflection under load for such a small package area. Furthermore, since the radius of the rod-shaped mating conductors838a,838bcan be made quite small, as compared to the woven power connector systems having other shapes, the tension needed within loading elements304to generate the desired normal contact force at the contact points can thus be lowered. For these reasons, power connector800, for example, can achieve a power density that is about twice that of the power connectors500,600while maintaining the same low insertion force and number of multiple redundant contacts.

Power connector800includes a power circuit827and a return circuit829. In accordance with the teachings of the present disclosure, however, in other embodiments the woven connector element may only comprise power circuits. Thus, in some embodiments, the return circuit829of woven connector element810, for example, is replaced with a power circuit827. In yet other embodiments, the woven connector element may include three or more power circuits. Such embodiments may also further include one or more return circuits. By having more than one power circuit being located within the woven connector element, power can be transferred across the power connector in a distributed fashion. By using a multiple-power circuit connector, the individual loads being transferred across each power circuit of the connector can be lowered (as compared to a single power circuit embodiment) while maintaining the same total power load capabilities across the connector.

FIG. 6depicts a further exemplary embodiment of a multi-contact woven power connector in accordance with the teachings of the present disclosure. The power connector900ofFIG. 6includes a woven connector element910and a mating connector element930. The woven connector element910comprises a housing912, an optional faceplate (not shown), several conductors302, loading elements304and tensioning springs924, and a termination contact922. The conductors302form a power circuit827that terminates at the termination contact922that is located on the backside of the woven connector element910. The ends of the loading elements304are attached to the tensioning springs924. In a preferred embodiment, each loading element304is attached to a separate independent tension spring924. Conductors302are woven onto the loading elements304to form a woven tube having a space disposed therein. However, unlike the woven connector element810of connector800, woven connector element910only includes a single weave, e.g., woven tube. Thus, the woven connector element910only has a single power circuit927; woven connector element910does not include a return circuit.

Mating connector element930includes a housing932, a mating conductor938and a termination contact936. Mating conductor938terminates at termination contact936, which is located on the backside of the mating connector element930. The mating conductor938is rod-shaped and has a contact mating surface circumferentially disposed along its length. The mating conductor938is appropriately sized so that when the mating conductor element930is coupled to the woven connector element910, electrical connections between the conductors302of the power circuit927and the contact mating surfaces of the mating conductors938can be established. Specifically, when mating conductor938of the mating conductor element930is inserted into the center space of the woven tube of the woven connector element910, the mating conductor938causes the weave of the conductors302and loading elements304to expand in a radial direction. In doing so, the weave expands to a sufficient degree that the ends of the loading elements304which are attached to the tensioning springs924are pulled closer together. This forces the tensioning springs924to deform elastically and tension is produced in the loading elements304. With the appropriate amount of tension being present within the loading elements304, the desired normal contact forces are exerted at the contact points of the conductors302that make up the power circuit927.

In certain embodiments, power connector900having a single power circuit927without a return circuit, could be used as a “power cable” to “bus bar” connector. Persons of ordinary skill in the art, however, will readily recognize that power connector900may be used for a wide variety of other connector applications.

The woven electrical connectors can be manufactured through a process including the acts of 1) forming the first set of strands so as to produce passageways and 2) inserting loading elements into the passageways. The formed strands may be terminated to a conductor, and the ends of the loading elements may be terminated. Although in the exemplary process the steps are performed in this order, they may be performed in different orders, as the invention is not limited in this respect. In some embodiments, additional processing may also be performed. For instance, some embodiments include the additional acts of loading the connector into a housing, and quality testing the construction of the connector. In other embodiments some of these acts may be eliminated altogether.

One exemplary embodiment of forming the strands to produce a power connector is disclosed in the above referenced U.S. Patent Application Publication No. 2004/0214454. Briefly, the strands are formed as individual elements in various forming fixtures. The individual formed strands or segments, as shown inFIGS. 2a-2cmay then be woven with a loading element to form a power connector. However, as will be explained below, the strands or segments may be formed from a continuous wire where the segments are thus joined together in a continuous fashion. Thus, in one embodiment, individual strands302(seeFIGS. 2a-2c) are not required to be formed and trimmed, as woven electrical connectors may be made up of a single relatively long wire that incorporates adjacent segments together as one continuous piece. In this respect, it may be advantageous to form a woven electrical connector out of a continuous wire for added reliability in processing, as manufacturing challenges may arise when forming and orienting individual strands302separately in a suitable way. In addition, a common step of forming woven electrical connectors includes coating the wire with gold and/or any other suitable conductive material. In this respect, individually positioning separate strands302for plating may be a cumbersome task. As a result, with a woven electrical connector formed from a continuous wire, the conductive wireform comes “pre-assembled” as the adjacent segments are already connected to one another. A single plating step may be performed subsequently after the wire is appropriately formed, allowing for a relatively uniform coat thickness for all of the adjacent segments. Regarding forming the continuous wire in a suitable configuration of adjacent segments, several embodiments concerning the process of forming will be presented below.

FIGS. 7aand7bshow illustrative embodiments of the connector incorporating various loading elements. The continuous wire1100may have curved regions1104that are configured as passageways to house an appropriate loading element. Furthermore, the continuous wire may have elongated regions1102that may serve to interact with the connection ferrule1302. In this regard, elongated regions1102may have a mating surface for a connection as well as a firm mechanical attachment to be made.

In different embodiments, the shape of the continuous wire1100, as inserted into the ferrule, may vary. In some embodiments, the formed connector may take on a cylindrical shape, as shown inFIG. 8a. In other embodiments as depicted inFIG. 8b, the entrance to the connector that is further away from the ferrule1302may have a larger diameter than at a location closer towards the ferrule1302. In further embodiments, the formed connector may take on an hour glass shape, as shown inFIG. 8c.

FIGS. 9aand9bshow one illustrative embodiment of a continuous wire1100prior to engagement with a biasing element or ferrule. The continuous wire1100is made up of adjacent sections11081,11082, . . . ,1108Nthat together are formed from a single conductive wire with each segment including two portions1109and1110that are positioned directly adjacent to one another and aligned such that a passageway may be formed through the curved regions1104of each portion.

FIG. 9adepicts a perspective view of a continuous wire1100that shows several sections11081,11082, . . . ,1108Nthat are also directly adjacent to one another. In this regard, the passageways formed by the curved regions1104of each portion are made longer with every section that is placed directly adjacent to another section. Beginning end1101of section11081of continuous wire1100is also depicted inFIG. 9a.

FIG. 9bshows a side plan view of continuous wire1100with only one section11081, made up of two portions1109and1110, being visible along with beginning end1101. In various embodiments, each portion1109and1110of each section1108of the continuous wire1100may have an elongated region1102and a curved region1104. In further embodiments, the curved region1104may form a number of peaks and valleys and the elongated region1102may be substantially straight. As shown inFIG. 9b, section11081is made up of portion1109and portion1110. Portion1109includes curved region110411and elongated region110211. Portion1110also includes curved region110412and elongated region110212. Curved region110411of portion1109may have a number of peaks and valleys that extend into a relatively straight elongated region110211which provides a mating surface for ferrule1302. The continuous wire1100then bends around to form portion1110adjacent to portion1109. Portion1110may include elongated region110212which provides a mating surface for ferrule1302, extending into curved region110412, which also has a number of valleys and peaks.

As depicted inFIG. 9b, the elongated region110212of section1110may be spaced a distance S from elongated region110211of portion1109. In addition, valleys and peaks of curved region110412of portion1110may align with the peaks and valleys of curved region110411of portion1109, respectively, to form any suitable number of passageways1106through the continuous connector1100. In the embodiment shown inFIGS. 9aand9b, four passageways1106extend straight through the connector1100in a direction substantially perpendicular to the formed wire. It should be understood that any suitable number of passageways1106may be formed with curved regions1104of continuous wire1100. In this regard, continuous wire1100may be formed into a substantially cylindrical shape such that sections11081and1108Nmay be positioned in close proximity to one another. As a result, passageways1106may be connected to one another to form a circular path. As previously described, it may be possible to insert a biasing element into each of the passageways as desired.

In another aspect of the present invention, peaks and valleys may be shaped with any suitable degree of curve. In some embodiments, peaks and valleys may be curved in an undulating fashion as in a sinusoidal shape as revealed byFIG. 9bfor curved regions110411and110412. In other embodiments, peaks and valleys may be formed with right angles in a step shape type fashion, or may include sharp transitions in the form of a “V” and/or a “A”.

In various embodiments, continuous wire1100may be left flat with sections adjacent to one another, as shown inFIG. 9a. In further embodiments, continuous wire1100may be rolled into a substantially cylindrical shape, as depicted inFIGS. 7aand7b, with sections also adjacent to one another.

In more illustrative embodiments, as shown inFIG. 9c, passageways1107may not extend in a direction substantially perpendicular to the formed wire, as adjacent sections11081, . . . ,1108Nmay be offset relative to one another so that passageways1107may extend in a direction that makes an appropriate angle with the formed wire. InFIG. 9c, perpendicular to the formed wire is defined according to the direction parallel to the thin dotted lines provided. In this regard, when continuous wire1100is in a planar shape, a passageway1107may been seen as making a non-perpendicular angle with the formed wire.

Alternatively, when rolled into a substantially cylindrical shape with sections11081and1108Npositioned in close proximity adjacent to one another, a passageway1107may be seen as a spiral shape. InFIG. 9c, when in a planar configuration, passageways1107run along thick dashed lines with double arrows. As a result, it may be possible to insert a biasing element shaped as a helical coil through the passageways1107. In various non-limiting embodiments, any number of passageways1107may be present in continuous wire1100. Indeed, it is possible for only one passageway to be present in continuous wire1100.

In forming the continuous wire1100as shown inFIGS. 9aand9b, various embodiments will now be described herein for how to manipulate a long conductive wire into a suitable shape with appropriately formed sections with passageways running through as described previously. In many cases, shapes may be formed and the wire may be wrapped in a suitable manner and sequence. In some embodiments, shapes are formed and the wire is wrapped simultaneously. In other embodiments, shapes are formed first and the wire is subsequently wrapped. In further embodiments, the wire is wrapped and shapes are subsequently formed.

In one illustrative embodiment of a process where there continuous wire1100may be formed, shapes may be formed in conjunction with the wire being wrapped. In this regard, a spring or wire forming machine may be used with a servomechanism for multi-axial control. Typical wire forming machines incorporate a rotor for winding the wire as desired along with using machine operated arms that contain die components that are customized for cutting, shaping, and forming wires with high precision. One example of an appropriate spring forming machine for forming continuous wire1100includes the Simco CNC-620 machine. As a wire controllably slides out of a feed tube, the machine may perform a variety of discrete bending operations that allow for a well-defined continuous wire1100form to be produced.

FIGS. 10aand10bdepict another illustrative embodiment of a process where the continuous wire1100may be formed out of a single conductive wire. In this regard, shapes are formed first and the wire is subsequently wrapped.

FIG. 10ashows a plan view of curved regions1104of the wire along with elongated regions1102where the curved regions1104are formed by any suitable technique. In some embodiments, a curved regions1104may be formed through rolling around a mandrel or a number of mandrels. In other embodiments, a curved region1104may be formed through use of an appropriate bending tool, machine, or combination thereof. In this aspect,FIG. 10ashows one portion1109of a section.

FIG. 10bdepicts a plan view of portion1109aligned with portion1110to form a segment with passageways1106that run through curved regions1104of the portions. In this aspect, portion1110may be curved around to substantially align with portion1109as desired in any suitable manner. In various embodiments, one portion may be curved around to align with another portion through rolling around a mandrel. In other embodiments, one portion may be curved around to align with another portion through use of an appropriate bending tool, machine, or combination thereof.

FIG. 10cdepicts a perspective view of a third portion1111aligned with portions1109and1110to further lengthen passageways1106that run through curved regions1104of the portions. Similar to that described above, portion1111may be curved around to substantially align with portions1109and1110as appropriately desired. In this regard, it can be seen that other portions of continuous wire1100may be curved in such as fashion to align portions suitably adjacent to one another. In various embodiments, the process of bending continuous wire1100using suitable techniques may be repeated as desired to form a continuous wire1100that is planar as shown inFIG. 9a. A longitudinal offset may also be provided as desired according to that shown inFIG. 9c.

In yet another illustrative embodiment for forming a continuous wire1100out of a single conductive wire, the wire may be wrapped first and then shapes can be formed in any suitable fashion. In this respect, a long wire may be wound according to the length desired for each of the sections. Once the wire is bent such that portions are appropriately positioned adjacent to one another, curved regions are suitably formed such that passageways may be formed accordingly. In various embodiments, any appropriate tool, machine, or combination thereof may be used to form the curved regions within the portions of wire.

In different aspects, continuous wire1100may be made out of any suitable conductive material. In some embodiments, continuous wire1100may be formed out of soft copper, beryllium copper alloy, or any other appropriate form of copper. In other embodiments, continuous wire1100may be formed out of any other material with suitable ductility and conductivity properties such as, but not limited to, platinum, lead, tin, aluminum, silver, carbon, gold, or any combination or alloy thereof, and the like.

In other aspects of the present invention, the continuous wire1100may be rolled into a substantially cylindrical shape for insertion into a ferrule1302. In some embodiments, continuous wire1100may be wrapped around a mandrel so as to be shaped in a suitably cylindrical fashion. In other embodiments, continuous wire1100may be placed within a tube so as to be shaped in a suitably cylindrical manner. In further embodiments, as a biasing element may be positioned within passageways in the continuous wire so as to provide enhanced contact between the connector wire and the ferrule, the biasing element may also contribute to formation of the continuous wire1100into a shape having a substantially cylindrical profile.

It should be appreciated that the wire forming techniques employed to manufacture the continuous wireform shown and described herein may not necessarily produce a flat wireform as shown inFIG. 9a. Instead, the various manufacturing processes chosen may impart an arc or curl on the wireform. Subsequent processing of the wireform can either flatten the wireform to resemble that shown inFIG. 9aor further curve it into a round connector. Thus, this further processing may minimize the impact of such a manufacturing issue.

As discussed above and as discussed in the above referenced U.S. Patent Application Publication No. 2004/0214454, the conductive wires may be woven with a non-conductive loading fiber that is subsequently tensioned to create a contact force on the wire segments. However, the present invention is not limited in this regard as other suitable arrangements for biasing the wire segments into contact with the mating surface may be employed. Thus, in further aspects, one or more biasing elements may be placed within passageways formed from the conductive wire in order to allow for enhanced connective properties. Biasing elements may provide a normal contact force on the conductive wire once it is mated to another connection element, thus, as will be explained below, the biasing element can be a self-contained loading element wherein the biasing element itself provides a spring force on the conductive wire providing the appropriate mating contact force on the mating connector. Thus, as used herein, a “loading element” refers broadly to any element that alone or in combination with other elements can bias the conductive wire, whereas a “biasing element” refers to an element that itself can impart a bias on the conductive wire. In this sense, then, a loading element may include a biasing element.

In different embodiments, the biasing element may be made from any suitable material, such as, but not limited to any combination of steel, stainless steel, beryllium copper, phosphor bronze, nitinol, plastic, and/or any other appropriate material. In other embodiments, a biasing element may be made as a spring that, once deformed, returns elastically back to its original shape. The biasing element may be positioned in one or more passageways of the continuous wire1100such that a bias force may facilitate outer areas of the wire to come into suitable contact with a mating surface of a connector when a connection is made.

In further embodiments, a biasing element that is made as a spring may incorporate varying spring constant rates that directly affect the degree of elasticity for the spring. In this regard, it may be desirable for spring constant rates to vary along each passageway1106of the continuous wire1100. As a non-limiting example, it may be desirable for the tension of the most exterior passageway1106of the continuous wire1100furthest from the ferrule1302to have less tension than the passageway1106of the continuous wire1100closest to the ferrule1302. In this regard, with varying degrees of spring constant rates, which may lead to varying degrees of tension in passageways1106of the continuous wire1100, connections may be more easily facilitated. Yet as connections are made easier, the quality of connection, mechanically and/or electrically, does not have to be sacrificed.

As described above, the shape of the continuous wire1100, for example the diameter of passageways, may vary at different regions. In this respect, although not necessarily so, tension provided by a spring biasing element may be varied such that shapes of passageways may be affected as desired.

In one illustrative embodiment of the present invention, one or more clips may be used as a biasing element in the electrical connector, providing for improved connection contacts to be made. In this respect, clips may have a substantially arcuate shape so as to complement the cylindrical aspect of the continuous wire1100. In another aspect, ends of the clips may be turned back so that the clips are sufficiently held in place once inserted within passageways of the continuous wire1100. In yet a different aspect, any desired number of clips may be inserted through passageways of the continuous wire1100. In a non-limiting example, a clip may be inserted into each passageway of the continuous wire1100.

FIGS. 11aand11bdepict a clip1200shown in perspective and plan views. In the embodiment shown, clip1200has an arcuate portion1202that includes two separate ends1204aand1204b. In some embodiments, separate ends1204aand1204bmay be bent back in a hook-like fashion, as depicted inFIGS. 11aand11b, allowing for the clip1200to remain secure within a passageway1106of the continuous wire1100. In other embodiments, separate ends1204aand1204bmay be blocked off so that the clip1200remains secure within a passageway1106. In this regard, separate ends1204aand1204bmay take on the form of a cap in the shape of a pin head, a ball, or any other suitable form. In one example, once it is desired for separate ends1204aand1204bto be capped, it may be possible for a cap to be physically attached to the ends in an appropriate manner. In another example, it may be possible for heat and/or other suitable radiation to be used in forming an aggregate from separate ends1204aand1204b. In this regard, heat may cause one of the ends to become molten and ball up, acting as a suitable capping element. It may also be possible for separate ends1204aand1204bto be bent back and capped in combination.

In other embodiments of a clip1200, separate ends1204aand1204bare not bent back or capped at all, but remain separate. In even more embodiments, once a clip1200is inserted into the continuous wire1100it may be possible to fuse the separate ends together into a continuous band.

In illustrative embodiments of the present invention, clips1200may be placed within passageways1106of the continuous wire1100and the clip-wire assembly may be appropriately inserted into a connection ferrule. Alternatively, the continuous wire1100may be inserted into the connection ferrule, and the clips1200may subsequently be inserted through the passageways1106. It should also be understood that any desired number of clips may be used with the continuous wire1100and in any suitable combination. In an exemplary embodiment, shown inFIG. 7a, each passageway of the continuous wire1100may have a single clip inserted throughout. In other examples, multiple clips may be inserted into a single passageway, or passageways may be left unfilled without a clip.

In other aspects of the present invention, clips1200may be a part of the process for the continuous wire1100to be formed into a substantially cylindrical shape. In some embodiments, substantially arcuate clips1200may be fed into passageways1106of the continuous wire1100. In this regard, insertion ends of the clips may be bent back after the clips are suitably situated within passageways of continuous wire1100. In other embodiments, clips may begin relatively straight in shape and inserted into passageways of continuous wire1100. In this regard, insertion ends of the clips are bent back only after proper positioning into passageways is performed. Once the clips are fully inserted into the passageways, the clips may then be formed into a substantially arcuate shape along with the continuous wire1100. It should be understood that any desired number of clips may be inserted into passageways of the continuous wire1100, simultaneously and/or subsequently, as desired. Once the assembly of clips and continuous wire1100are suitably formed, then the insertion ends of the clips may be bent back or shaped accordingly.

FIG. 12depicts one illustrative embodiment of a clip1200that may be inserted into passageways1106of the continuous wire1100. In this regard, clip1200includes a separate end1204athat contains a bent back hook and an arcuate region1202much like that depicted inFIGS. 11aand11b. For insertion into passageways1106of continuous wire1100, a straight region1203and an insertion end1208are provided. For assembly, as the insertion end1208is positioned through any suitable passageway1106of continuous wire1100, clip1200may slide through the passageway1106with the shape of continuous wire1100conforming to the arcuate profile of region1202. In the embodiment shown, once the insertion end1208is fully through and the passageway is suitably positioned along the arcuate region1202, straight region1203may be trimmed off such that another separate end similar to that of end1204amay arise. As a result, the new end may be bent accordingly or could be subject to an appropriate capping treatment as described previously. In various embodiments, multiple clips1200may be inserted into passageways of continuous wire1100simultaneously.

FIG. 13shows a further illustrative embodiment of a biasing element formed as a dual clip1210, where two clips are effectively connected together. As depicted, the dual clip1210has separate ends that are bent back similarly as clip1200, but a connection is made between two clips at a connection region1216. It should be understood that the dual clip1210is not limited to that shown inFIG. 13, as the ends of the clips may be capped, may be fused together, do not have to be bent back, or any combination thereof, similarly to that of clip1200.

Similar to that of clip1200,FIG. 14shows that dual clip1210may also be inserted into passageways1106of continuous wire1100. In this regard, dual clip1210would typically be inserted into two passageways1106simultaneously for each dual clip1210. Herein, connection region1216joins two arcuate regions1212together, extending into straight regions1213aand1213b, and eventually giving rise to insertion ends1218aand1218b. To assemble, insertion ends1218aand1218bare positioned through respective passageways1106of continuous wire1100and may be slid through such that the shape of continuous wire1100conforms to the arcuate profile of region1212. Once the passageways are appropriately positioned along arcuate region1212, straight regions1213aand1213bmay be trimmed off to a suitable length complementing connection region1216. The new end may then be bent accordingly or could be subject to an appropriate capping treatment as described previously. In some embodiments, multiple dual clips1210may be inserted into passageways of continuous wire1100simultaneously.

In another illustrative embodiment of the present invention, a helical coil1250may be used as a biasing element in the electrical connector. In this respect, the coil1250may have a substantially arcuate shape similar to that of clips1200and1210described above so as to complement the cylindrical aspect of the continuous wire1100. Indeed, for some embodiments, a longer clip may be used and formed into helical coil1250such that a longitudinal offset exists upon a 360 degree rotation of the coil. In the same regard, ends of a coil may be turned back so that the coil may be sufficiently held in place once inserted within passageways of the continuous wire1100. In yet a different aspect, any desired number of coils may be inserted through passageways of the continuous wire1100, typically one after another.

FIG. 15shows a helical coil1250according to one embodiment of the present invention. As shown, a pitch exists in the arcuate region1252that offsets the coil any appropriate longitudinal distance P. In other aspects, separate ends1254aand1254bare provided, either of which may be inserted through passageways of the continuous wire1100. Although not shown inFIG. 15, it is possible for either or both of the separate ends1254aand/or1254bto be bent back or capped, as described above for embodiments that includes clips.

In various illustrative embodiments of the present invention, coils1250may be placed through passageways1106in the continuous wire1100and the coil-wire assembly may be appropriately inserted into a connection ferrule1302. In this regard, as the helical coil1250is inserted into passageways of the continuous wire1100, the continuous wire1100would conform to the pitch of the helical coil1250, having a longitudinal offset distance P. It should be understood that any desired number of coils1250may be used with the continuous wire1100in any suitable combination. In some embodiments, one passageway of the continuous wire1100may have a single coil inserted throughout as desired. In other embodiments, multiple passageways of continuous wire1100may have multiple coils inserted throughout as desired.

In further aspects, a helical coil1250may contribute to the process of forming the continuous wire1100into a substantially cylindrical shape. In some embodiments, the continuous wire1100starts out in a substantially planar configuration and an insertion end of the helical coil1250enters a passageway1106of the continuous wire1100. In this regard, the helical coil1250may then be twisted on to the continuous wire1100in a screw fashion such that the wire winds around according to the pitch of helical coil1250. In other embodiments, an insertion end of the helical coil may enter the entrance of a passageway in the continuous wire1100and the continuous wire1100may be pushed on to the helical coil1250such that the wire winds around according to the pitch of the helical coil1250. Indeed, a combination of twisting the helical coil1250and pushing the continuous wire1100on to the helical coil1250may be implemented together. Once the helical coil1250is fully inserted into the continuous wire1100, the insertion end of the coil may be bent back and/or capped as desired, similarly to that described above for the clips.

In more aspects of the present invention, a ferrule1302may be provided for a more secure connection to be made. In this regard, the conductive wire1100may have a mating region that comes into contact with a ferrule1302in a manner that provides a strong mechanical and electrical connection. The elongated region1102of the continuous wire1100may be connected to a ferrule1302, as shown inFIGS. 7aand7b, in any suitable manner. In this regard, the elongated portion1102may be firmly attached to the ferrule1302so as to form a secure mechanical attachment along with having a well suited electrical connection. In some embodiments, solder paste may also be used as added material in providing for an enhanced connection. In other embodiments, a crimping mechanism may be utilized in order to minimize extraneous movement of any parts once the connection is made. In further embodiments, a clamp may be used from an outside tool in order to make the connection more firm.

FIG. 16shows an illustrative embodiment of a ferrule1302that includes an inner ferrule1310and an outer ferrule1320. In between the inner ferrule1310and the outer ferrule1320is located a ferrule passage1330through which an elongated region1102of continuous wire1100may enter to create a connection. In the embodiment depicted inFIG. 16, inner ferrule1310and outer ferrule1320are slanted to form an angle upon entrance of the wire1100into the ferrule passage1330. In this respect, the mating surface of the elongated region1102may slide through the passage1330defined by the inner ferrule1310and the outer ferrule1320at the angle such that the diameter of the elongated region1102may increase. At the end of the passage1330, the outer ferrule1320extends out further than the inner ferrule1310. Once the elongated region1102reaches over the end of the inner ferrule1310but not further than the extension of the outer ferrule1320, the back end1340of the outer ferrule1320may be bent over toward the inner ferrule1310in a manner such that the elongated region1102of the wire may be firmly connected in a crimped attachment as the wire1100may be caught by the connection between the outer ferrule1320curving over the inner ferrule1310. In some embodiments, pressure is applied to the back end of outer ferrule1320and the elongated region1102of the wire1100for a crimping mechanism to occur. It should be understood that it is not requirement of the present invention for the inner ferrule1310to form an angled passage1330with outer ferrule1320.

In another embodiment, solder may be used to aid the mechanical and electrical attachment of elongated region1102of a cylindrical continuous wire1100that may be inserted into a ferrule1302. In this regard, the wire1100may be inserted through a passage1330formed by an inner ferrule1310and an outer ferrule1320through which the elongated region1102of the wire1100may slide and molten solder may be spread throughout the passage1330. In some embodiments, once the elongated region1102slides straight through the passage by an appropriate insertion distance, molten solder may be applied evenly to the passage to allow the elongated region1102to be electrically connected and mechanically attached to the ferrule passage1330. As the solder is then allowed to cool, the connection may result in a strong mechanical and electrical attachment.

In other embodiments, a crimping mechanism, in the form of press tool application or other suitable method, may be applied on the outer ferrule on any appropriate side in bringing together the wire-ferrule assembly so as to make the connection between the elongated region1102and the ferrule1302more secure. In some embodiments, pressure from an outside tool may be applied from the back end of the outer ferrule1320. In other embodiments, pressure from an outside tool may be applied from the outer edges of the outer ferrule1320.

It should be understood that there several ways in which the elongated region1102of the continuous wire1100may mate suitably well with the ferrule1302. Indeed, a combination of the techniques described could be used. As a non-limiting example, a passage1330made by inner ferrule1310and outer ferrule1320may be formed at an angle and molten solder may be added in addition to crimping by any appropriate pressure applying mechanism. Indeed, it is also not a necessary requirement for any of the techniques described to be used for the elongated region1102of the continuous wire1100to be connected to the ferrule in a suitable manner.

It should be appreciated that although the above-illustrative embodiments include combinations of the various described features, the present invention is not limited in this regard as any feature(s) described herein may be employed in any suitable combination. Thus, for example, the connector formed with a continuous wire may be employed with either spring elements or a non-conductive loading band that are subsequently tensioned with a tensioning element, as the present invention is not limited in this regard.

It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. Other embodiments and manners of carrying out the invention are possible. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. In addition, it is to be appreciated that the term “connector” as used herein refers to each of a plug and jack connector element and to a combination of a plug and jack connector element, as well as respective mating connector elements of any type of connector and the combination thereof. It is also to be appreciated that the term “conductor” refers to any electrically conducting element, such as, but not limited to, wires, conductive fibers, metal strips, metal or other conducting cores, etc.

Having thus described various illustrative embodiments and aspects thereof, modifications and alterations may be apparent to those of skill in the art. Such modifications and alterations are intended to be included in this disclosure, which is for the purpose of illustration only, and is not intended to be limiting. The scope of the invention should be determined from proper construction of the appended claims, and their equivalents.