Elastomeric connector having a plurality of fine pitched contacts, a method for connecting components using the same and a method for manufacturing such a connector

An elastomeric connector having fine pitched contacts is provided in addition to a method for connecting components using such a connector and a method of manufacturing the same. The connector includes a body formed from an elastomeric material with contacts arranged to extend through the body and exposed at each side of the body. The contacts are bent to form a contact surface that is oriented at an angle with respect to the sides of the body. The contacts may include a radiused section that is formed in the elastomeric material. Grooves may be formed in the body of the connector separating adjacent contacts and providing additional flexibility of the connector.

BACKGROUND OF THE INVENTION 
The present invention generally relates to a connector, particularly a high 
density connector. More specifically, the present invention relates to an 
elastomeric connector particularly suitable for interconnection between a 
device and a printed circuit board or between two or more printed circuit 
boards requiring fine pitch interconnection. The present invention further 
relates to a method for connecting two components and a method for 
manufacturing such a connector. 
It is, of course, generally known to provide connectors for providing 
interconnection between components, such as printed circuit boards and 
other devices that require the interconnection under conditions of high 
density, fine pitch, as well as requiring high performance. 
An important consideration in the manufacture and design of elastomeric 
connectors is the contact force applied to the connectors which affects 
the performance and reliability of the same. This is particularly relevant 
for connectors that are repeatedly mated and unmated with the devices or 
printed circuit boards in which they are associated. In addition, taking 
this factor into consideration, current elastomeric connectors are costly 
to manufacture and nonetheless often encounter problems such as permanent 
deformation of the contact or contacts of the connector due to the large 
contact forces required when using the same. 
In addition, most known elastomeric connectors do not provide "wiping 
action" to break down oxidation layers produced through use of the 
connector. Without the wiping action, oxidation layers or buildup is often 
formed on the contact causing the connector to become unreliable in its 
performance. Wiping action serves to clean the metallic contacts during 
insertion and assists in maintaining clean surfaces at the interface 
during operation of the device in which the connector is implemented. 
Wiping action is particularly important for separable connectors that 
require repetitive mating and unmating and also in environments where dust 
can be a factor. 
A need, therefore, exists for an improved elastomeric connector that 
overcomes the deficiencies of known elastomeric connectors and improves 
the reliability and performance of the contact even through repeated usage 
of the same. In addition, a method for connecting components using such a 
connection as well as a method for manufacturing such a connector are also 
needed. 
SUMMARY OF THE INVENTION 
The present invention relates to a high density elastomeric connector with 
contacts that absorb the force applied to the connector. In addition, the 
present invention provides an elastomeric connector with electrical 
contacts molded into an elastomer that provide wiping action. A method for 
connecting components and a method for manufacturing such a connector are 
also provided. 
In an embodiment of the present invention, a connector is provided. The 
connector has a body formed from an elastomeric material having a first 
side and a second side. A plurality of contacts is arranged uniformly in 
the body such that each contact integrally extends from the first side to 
the second side of the body wherein ends of each of the plurality of 
contacts are exposed at each of the first side and the second side. 
In an embodiment, the contacts are bent at a point near each of the ends to 
form a contact surface such that the contact surfaces are oriented at an 
angle with respect to the sides of the body. 
In an embodiment, each of the plurality of contacts is substantially 
parallel to one another. 
In an embodiment, a portion of each of the contacts in the elastomeric 
material of the body includes a radiused section. The radiused section is 
substantially at a point halfway between the first side and the second 
side. 
In an embodiment, the angle between the contact surfaces and the sides of 
the body is acute. 
In an embodiment, the contact surfaces include a particle formed thereon. 
The particle is made from diamonds. 
In an embodiment, a lip is integrally formed with each of the contact 
surfaces and each is formed at an angle with respect to the contact 
surface. 
In an embodiment, third and fourth sides are perpendicular to the first and 
second sides of the body wherein the first, second, third and fourth sides 
define the body. Grooves may be formed in the third and fourth sides of 
the body wherein the grooves separate adjacent contacts extending through 
the body. 
In an embodiment, the elastomeric material is silicone. 
In another embodiment of the present invention, a method is provided for 
connecting two components. The method comprises the steps of: providing a 
connector wherein the connector has a body formed from an elastomeric 
material, the body having a first side and a second side; providing a 
plurality of contacts arranged uniformly and extending between the first 
side and the second side of the body of the connector wherein each of the 
plurality of contacts has a contact surface that is exposed at the first 
side and the second side of the body; and connecting components to the 
connector thereby providing an electrical connection between the 
components via the connector. 
In an embodiment, particles are provided on the contact surfaces of the 
contacts. 
In an embodiment, grooves are formed in the body of the connector. 
In an embodiment, the contact surfaces are compressed during connection of 
the components. 
In an embodiment, each of the, plurality of contacts includes a non-linear 
section formed in the body of the connector. 
In another embodiment of the present invention, a method for manufacturing 
a connector is provided. The method comprises the steps of: providing a 
plurality of contacts in chain form or with carriers; molding elastomeric 
material forming a body around a portion of the contacts wherein the 
contacts are substantially spaced and parallel to one another; and 
removing a carrier member at ends of each of the plurality of contacts 
such that only a finite portion forming a contact surface is exposed 
adjacent the body. 
In an embodiment, a radiused section is provided in each of the plurality 
of contacts before molding such that the radiused section is within the 
body after molding. 
In an embodiment, particles are provided on the contact surfaces. 
In an embodiment, grooves are formed in exterior walls of the body. 
It is, therefore, an advantage of the present invention to provide an 
elastomeric connector, a method of manufacturing such a connector, as well 
as a method of connecting components having a contact or a plurality of 
contacts that absorbs the majority of the force applied to the connector. 
Another advantage of the present invention is to provide an elastomeric 
connector, a method of manufacturing such a connector, as well as a method 
of connecting components that implements electrical contacts molded into 
an elastomer. 
Yet another advantage of the present invention is to provide an elastomeric 
connector, a method of manufacturing such a connector, as well as a method 
of connecting components with contacts that provide a wiping action 
particularly suitable for removing buildup on the contact from oxidation. 
And, another advantage of the present invention is to provide an 
elastomeric connector, a method of manufacturing such a connector, as well 
as a method of connecting components that implements contacts that are 
resilient and do not permanently deform. 
Moreover, an advantage of the present invention is to provide an 
elastomeric connector, a method of manufacturing such a connector, as well 
as a method of connecting components wherein the connector is manufactured 
via injection molding and/or progressive stamping. 
A still further advantage of the present invention is to provide an 
elastomeric connector, a method of manufacturing such a connector, as well 
as a method of connecting components that is inexpensive. 
Yet another advantage of the present invention is to provide an elastomeric 
connector, a method of manufacturing such a connector, as well as a method 
of connecting components wherein the connector can be manufactured in 
various shapes to meet specific requirements. 
And, another advantage of the present invention is to provide an 
elastomeric connector, a method of manufacturing such a connector, as well 
as a method of connecting components that has contacts with high density 
and a fine pitch that also operates in a reliable manner and with high 
electrical and mechanical performance. 
Additional features and advantages of the present invention are described 
in, and will be apparent from, the detailed description of the presently 
preferred embodiments and from the drawings.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS 
The present invention generally relates to an elastomeric connector having 
contacts that are preferably insert molded into an elastomeric material, 
such as silicone. The elastomeric connector allows interconnection 
between, for example, a device and a printed circuit board or between two 
printed circuit boards requiring high density and fine pitch 
interconnection. The present invention further provides a method of 
connecting components using an elastomeric connector as well as a method 
of manufacturing such a connector. 
Referring now to the drawings wherein like numerals refer to like parts, 
FIG. 1 illustrates an embodiment of a connector 1 of the present 
invention. The connector 1 is formed from a body 10 and a plurality of 
contacts 12 extending from an exterior side 14 at one end of the body 10 
through a width of the body 10 to an opposite exterior side 16 of the body 
10. Preferably, the body 10 is constructed from an elastomeric material, 
such as silicone. As a result, the body 10 is flexible and capable of 
manipulation into various shapes and positions and provides a resiliency 
in order to help provide a spring force. 
The contacts 12 of the present invention are preferably constructed from 
beryllium copper and have a thickness of approximately 0.003 inches. The 
contact may be plated with gold or plated with gold and nickel. Spacing 
between adjacent ones of the contacts 12 generally designated at X in FIG. 
4 is approximately 0.019 inches or half millimeter or greater. To 
manufacture the connector 1, the contacts 12 may be provided on a carrier 
(not shown) that connects adjacent contacts. Preferably, the carrier 
uniformly connects the contacts integrally with the carrier. 
As illustrated in FIG. 1, the portion of the contact 12 within the body 10 
of the connector 1 is substantially linear between the exterior sides 
14,16 except for a radiused section 18 formed substantially at a midpoint 
between the exterior sides 14, 16 of the body 10. 
As further illustrated in FIG. 1, the contact 12 is exposed at the exterior 
sides 14,16 exterior to the body 10 of the connector 1. In an embodiment, 
exterior to the body 10, the contact 12 is bent at an edge 20 forming a 
contact surface 22 which, in turn, preferably forms an acute angle between 
the contact surface 22 and the exterior sides 14,16 of the body 10. At an 
edge 24 of the contact 12, a lip 26 is formed by bending the contact 12 as 
illustrated. The lip 26 helps to provide a defined point of electrical 
contact apart from the rough edge where the contact was sheared and 
separated from the carrier. As a result, symmetrical contact surfaces 22 
are formed on each of the exterior sides 16,18 of the body 10 of the 
connector 1. The contact surfaces 22 provide connections between, for 
example, two printed circuit boards located on each side of the connector 
1 or a printed circuit board and another device, as another example. 
Referring now to FIG. 2, a cross-sectional view of another embodiment of a 
connector 1' of the present invention is illustrated. The connector 1' 
includes a body 10 and a plurality of contacts 12'. Formed on the 
plurality of contacts 12' are particles 28, such as diamond particles 
plated on a contact surface 22' of the contact 12'. Although illustrated 
on only one side of the body 10 of the connector 1', the particles 28 may 
also be plated to the contact surfaces 22' on the opposite side of the 
body 10. The particles 28 assist in breaking down oxidation layers formed 
through oxidation on the contact surfaces 22'. 
FIG. 3 illustrates a cross-sectional view of the connector 1 in a position 
between, for example, two printed circuit boards (not shown) or a device 
and a printed circuit board, for example, i.e. during use of the connector 
1. As shown, the contact surfaces 22 of the connector 1 are compressed 
such that the lip 26 of the contact 12 engages or otherwise contacts the 
exterior sides 14,16 of the body 10 of the connector 1. In turn, the 
contact 12 may also flex internally within the body 10 of the connector 1 
as illustrated. That is, the elastomeric material of the body 10 allows 
for the flexure of the contact 12 within the interior of the body 10 due 
to the compression of the contact surfaces 22 of the contacts 12. Although 
the contact surfaces 22 are shown engaged or contacting the body 10, it 
should be understood that any degree of compression of the contact surface 
22 of the contact 12 may result from implementation of the connector 1 in 
a system requiring a connection. In a preferred embodiment, once the 
contact surface 33 abuts against the exterior sides 14,16 of the elastomer 
body 10, the two members, e.g. the contact surface 22 and the elastomer 
body 10, compress simultaneously to provide the desired contact force. The 
contacts 12 and elastomeric body 10 combine to provide a predetermined 
spring force or compression distance dependent on the thickness and volume 
and composition of the elastomeric body 10 and the shape, weight and 
composition of the contacts 12. In a preferred embodiment, the connector 
has a working range of compression of between 0.005 inches to 0.025 
inches. 
Referring again to FIG. 1 and as more clearly shown in FIG. 5, grooves 30 
are provided on an exterior surface of the body 10 of the connector 1. The 
grooves 30 in the body 10 may be used for alignment and location of the 
connector 1 during use. The grooves 30 are formed during the injection 
molding process of the elastomeric material onto the contacts 12. The 
shape or depth or geometric features of the grooves 30 may be designed to 
control the overall resiliency of the body. However, different shapes may 
be formed during the molding process to meet different requirements as 
required. Further, the positioning of the elastomer body within a 
receptacle or frame may be specifically designated in order to control the 
resiliency of the elastomer body. 
It should be understood that various changes and modifications to the 
presently preferred embodiments described herein will be apparent to those 
skilled in the art. Such changes and modifications may be made without 
departing from the spirit and scope of the present invention and without 
diminishing its attendant advantages. It is, therefore, intended that such 
changes and modifications be covered by the appended claims.