Electrical connector having compliant contacts and a circuit board assembly including the same

Electrical connector having a plurality of compliant contacts coupled to a connector body. Each of the compliant contacts includes a base portion and first and second legs extending from the base portion to respective distal ends in a mounting direction. Each of the first and second legs includes an inner edge and an outer edge. Each of the inner edges extends from the base portion to a corresponding inflection area. A gap between the first and second legs decreases as the inner edges approach the corresponding inflection areas in the mounting direction. The inflection areas of the inner edges directly interface with each other at a contact zone.

BACKGROUND

The subject matter herein relates generally to compliant contacts and an electrical connector including the same that are configured to engage an electrical component, such as a circuit board.

Electrical connectors may be interconnected to circuit boards using compliant or press-fit contacts that form a mechanical and electrical coupling with the circuit board. For this purpose, the circuit boards include a plurality of thru-holes extending through a thickness of the circuit board. The thru-holes are typically “plated” to form plated thru-holes (PTHs) by covering inner surfaces that define the thru-holes with a conductive material, such as copper. Traces or other conductive elements that are connected to the conductive material of the PTHs form electrical pathways from the corresponding PTH to another portion of the circuit board.

To interconnect the circuit board and the electrical connector, the compliant contacts from the electrical connector are inserted into corresponding PTHs. Each compliant contact frictionally engages the conductive material within the PTH. For example, eye-of-needle (EON) contacts include a narrow beam of sheet metal that has a hole stamped therethrough. Outer edges of the EON contact have convex profiles proximate to the hole such that the outer edges arch or bow outwardly. A maximum diameter between the outer edges is slightly larger than a diameter of the PTH. When the EON contact is inserted into the PTH, the outer edges proximate to the hole engage the conductive material of the PTH.

However, conventional compliant contacts typically have a length that is more than sufficient for contacting an interior surface of the PTH. For example, manufacturers often desire for the compliant contacts to engage the PTH at a depth that is proximate to a first signal layer in the circuit board. After engaging the PTH at a first depth, the conventional compliant contacts generally continue to extend to a second depth. This additional length between the first and second depths (hereinafter referred to as a stub portion of the compliant contact) may cause unwanted noise with the surrounding PTH. To reduce the noise, the PTHs may be backdrilled to remove at least some of the plated conductive material that extends beyond the first depth. Backdrilling, however, can increase the cost of the circuit board.

In addition to the above, conventional compliant contacts are typically manufactured in a manner that is consistent with certain standards. For example, it is difficult to manufacture EON contacts in which the hole of the EON contact has a width that is less than a thickness of the stock material that forms the EON contact. As such, the ratio between the hole width and the stock thickness is typically 1.0 to 1.0. For certain configurations of a compliant contact, the ratio may be, at the very least, 0.85 to 1.0. Ratios less than this are typically not commercially reasonable, because the stock material is difficult to shape during manufacturing.

Accordingly, there is a need for a compliant contact that is capable of mechanically and electrically coupling to PTHs while having smaller dimensions than conventional compliant contacts.

BRIEF DESCRIPTION

In an embodiment, an electrical connector for being mounted to a circuit board having plated thru-holes (PTHs) is provided. The electrical connector includes a connector body having a mounting side that is configured to be mounted to the circuit board and a plurality of compliant contacts coupled to the mounting side and configured to be inserted into corresponding PTHs of the circuit board. Each of the compliant contacts includes a base portion coupled to the mounting side of the electrical connector and first and second legs extending in a mounting direction from the base portion to respective distal ends. The distal ends are physically discrete. Each of the first and second legs includes an inner edge and an outer edge. The outer edges are configured to engage the corresponding PTH. Each of the inner edges extends from the base portion to a corresponding inflection area. A gap between the first and second legs decreases as the inner edges approach the corresponding inflection areas in the mounting direction. The inflection areas of the inner edges directly interface with each other at a contact zone.

In an embodiment, a circuit board assembly is provided that includes a circuit board having plated thru-holes (PTHs) that extend therethrough. The PTHs are defined by respective interior surfaces of the circuit board. The circuit board assembly also includes an electrical connector having a mounting side that is coupled to the circuit board and a plurality of compliant contacts that project form the mounting side. Each of the compliant contacts of the plurality is inserted into one of the PTHs. Each of the compliant contacts includes a base portion coupled to the mounting side of the electrical connector and first and second legs that extend from the base portion to respective distal ends. The distal ends are physically discrete. Each of the first and second legs includes an inner edge and an outer edge. The outer edges of the first and second legs are engaged to the interior surface of the corresponding PTH, and the inner edges of the first and second legs engage each other at a contact zone. A gap exists between the inner edges of the first and second legs and between the base portion and the contact zone.

In an embodiment, a method of manufacturing compliant contacts is provided. The method includes providing a sheet of conductive material and stamping a plurality of contact bodies from the sheet of the conductive material. Each of the contact bodies includes a base portion and first and second legs extending from the base portion to respective distal ends. The first and second legs have corresponding inner edges that face each other and are spaced apart. The method also includes permanently deforming the first and second legs such that the corresponding inner edges engage each other at a contact zone, wherein a gap that is defined between the inner edges exists between the base portion and the contact zone.

DETAILED DESCRIPTION

FIG. 1illustrates an exploded perspective view of a communication system100that includes a first circuit board assembly102and a second circuit board assembly104. For reference, the circuit board assemblies102,104are arranged with respect to mutually perpendicular axes191,192,193, including a central mating axis191, a mounting axis192, and a lateral axis193. During a mating operation, the circuit board assembly102is advanced along the mating axis191toward the circuit board assembly104. In the illustrated embodiment, the circuit board assembly104is a backplane assembly, and the circuit board assembly102is a daughter card assembly configured to directly engage the backplane assembly. Embodiments set forth herein, however, are not limited to backplane (or midplane) applications.

The circuit board assembly104includes a circuit board108and an electrical connector110mounted to the circuit board108. The circuit board108may be, for example, a mother board. The electrical connector110may be referred to as a mating connector or header connector. The electrical connector110has a contact array (or header array)112of electrical contacts that include signal contacts114and ground contacts116. InFIG. 1, the signal contacts114are arranged in pairs in which each signal pair is partially surrounded by a respective ground contact116. The signal contacts114are configured to transmit data signals, such as differential signals, and the ground contacts116are configured to electrically shield the signal contacts114. For example, each of the ground contacts116may be C-shaped or L-shaped and partially surround a single pair of the signal contacts114. In the illustrated embodiment, the contact array112also includes ground shields or walls118. The ground shields118are arranged along an outer column of the contact array112and may also be configured to electrically shield corresponding signal contacts114.

The electrical connector110also includes a connector housing120. As shown, the connector housing120includes a pair of sidewalls122,124that define a connector-receiving space126therebetween. The sidewalls122,124oppose each other and are spaced apart from each other along the mounting axis192. The contact array112is located within the connector-receiving space126. The connector housing120may have other configurations in alternative embodiments. For example, in one alternative embodiment, the connector housing120may include another pair of sidewalls that are spaced apart from each other along the lateral axis193.

The circuit board assembly102includes an electrical connector130, which may also be referred to as a receptacle connector. In some embodiments, the electrical connector130includes a module assembly132and a connector shroud or housing134that is coupled to the module assembly132. For example, the module assembly132includes a series of discrete or distinct contact modules135that are stacked side-by-side when the module assembly132is assembled. The contact modules135may be coupled to one another directly or indirectly. For example, the contact modules135may be coupled to the connector shroud134such that the contact modules135are indirectly coupled to one another by the connector shroud134. In other embodiments, the contact modules135may directly engage each other to hold the contact modules135side-by-side.

In some embodiments, the module assembly132and the connector shroud134may be referred to collectively as a connector body131of the electrical connector130. As shown, the connector body131includes separable components, such as the connector shroud134and the module assembly132. However, in other embodiments, one or more components may be combined. For instance, the module assembly132may include features that are similar to the features of the connector shroud134as described herein. In such embodiments, a separate connector shroud may not be required. As another example, in the illustrated embodiment, the module assembly132includes discrete contact modules135. In other embodiments, however, the module assembly may be a single structure that includes similar features as the multiple contact modules described herein.

The connector shroud134is configured to be inserted into the connector-receiving space126and mate with the connector housing120. The electrical connector130includes a mating side136and a mounting side140. The mating side136may include a portion of the connector shroud134that faces the electrical connector110along the mating axis191. In alternative embodiments that do not utilize a connector shroud, the module assembly132may include the mating side136. The mounting side140faces in a mounting direction along the mounting axis192.

Each of the mating side136and the mounting side140has a corresponding contact array that includes signal contacts and ground contacts disposed along the corresponding side of the connector body131. For example, the mating side136includes a communication array (not shown) of signal and ground contacts that engage the contact array112. The mounting side140includes a mounting array144, which may have respective signal contacts and ground contacts, which are generally referred to hereafter as compliant contacts200.

The circuit board assembly102also includes a circuit board or daughter card148. The circuit board148is configured to interface with the mounting side140. More specifically, the circuit board148includes a board array150of plated thru-holes (PTHs)152. The PTHs152are arranged to receive respective compliant contacts200of the mounting array144. As used herein, a “plated thru hole” (or PTH) is not required to extend entirely through the circuit board148or be manufactured in a particular manner.

FIG. 2is a plan view of the compliant contact200coupled to the mounting side140of the connector body131. As described in greater detail below, the compliant contact200may be stamped and formed from a sheet of conductive material, such as sheet metal, to include the features described herein. However, the compliant contact200is not required to be manufactured using a particular process or processes. The compliant contact200as shown inFIG. 2represents the compliant contact200in an operative condition in which the compliant contact200is ready for insertion into one of the corresponding PTHs152(FIG. 1).

In some embodiments, the compliant contact200is configured to operate as a signal contact or as a ground contact for the electrical connector130(FIG. 1). It is understood, however, that the compliant contact200is not limited to backplane applications and may be used to engage a PTH or a PTH-like interface of other electrical components. In other embodiments, the compliant contact200may operate as a power contact for transmitting electrical power.

In the illustrated embodiment, the compliant contact200includes a base portion202and first and second legs220,230that are coupled to the base portion202and extend in a mounting direction M1from the base portion202to respective distal ends208,210. The mounting direction M1is away from the mounting side140. The compliant contact200is oriented with respect to a longitudinal axis212that extends from a center of the base portion202and generally parallel to and between the first and second legs220,230. At different points along the longitudinal axis212, the longitudinal axis212may be equi-spaced between the first and second legs220,230. For example, with respect toFIG. 2, the first and second legs220,230may be symmetrical relative to a plane that extends through the longitudinal axis212and bisects the compliant contact200. Also shown, the first and second legs220,230extend a common depth DY1that is measured from the base portion202to the distal ends208,210or along the longitudinal axis212. In other embodiments, the first and second legs220,230do not extend the same depth DY1. In certain embodiments, the depth DY1is at most 1.50 mm or, more specifically, at most 1.20 mm. In more particular embodiments, the depth DY1may be less than 1.00 mm.

The first and second legs220,230may directly interface with each other at a first contact zone214and a second contact zone216. When used to describe the relationship between two elements, the term “directly interface” includes the two elements directly engaging each other, having a nominal gap therebetween, or being positioned to directly face each other with a small distance therebetween. For example, small spaces may exist between the first and second legs220,230at the contact zones214,216when the first and second legs220,230directly interface each other. A “contact zone,” as used herein, represents a region where the first and second legs220,230are configured to engage each other when the compliant contact200is within the PTH152.

The first and second legs220,230are physically discrete elements that are only coupled to each other through the base portion202. Unlike an eye-of-needle (EON) contact, which includes separate beam portions that are joined to each other at each end, the first and second legs220,230are distinct elements. More specifically, the first and second legs220,230are distinct elements from the base portion202to the respective distal ends208,210and including the distal ends208,210. Unlike the EON contacts, the first and second legs220,230from the base portion202to the respective distal ends208,210are not joined by being part of a continuous piece of material of the compliant contact200. For instance, even if the distal ends208,210physically engage each other, the distal ends208,210may be readily separable when not located within the PTH152. Thus, the distal ends208,210may be characterized as being physically discrete even if the distal ends208,210engage each other.

The first leg220has an inner edge222and an outer edge224that face in generally opposite directions. It is understood that the inner and outer edges222,224may be part of a single continuous edge that extends from the base portion202to the distal end208along the inner edge222and then back to the base portion202along the outer edge224. The outer edge224represents a portion of the continuous edge that generally faces or directly engages an interior surface262(shown inFIG. 5) of the PTH152. Each of the inner and outer edges222,224extends from the base portion202to the distal end208. More specifically, the inner edge222extends from a bridge edge291that joins the first and second legs220,230to the distal end208. The outer edge224extends from an outer base edge292to the distal end208. The inner edge222represents a portion of the continuous edge that generally faces or engages the other second leg230. The inner and outer edges222,224define a width W1of the first leg220. As shown, the width W1of the first leg220may be substantially uniform for almost an entire length of the first leg220. In other embodiments, such as those shown inFIGS. 9-11, the width W1of the compliant contact200may not be uniform.

Similarly, the second leg230has an inner edge232and an outer edge234that face in generally opposite directions. Again, it is understood that the inner and outer edges232,234may be part of a single continuous edge. Each of the inner and outer edges232,234extends from the base portion202to the distal end210. More specifically, the inner edge232extends from a bridge edge291to the distal end210, and the outer edge234extends from an outer base edge293to the distal end210. The outer edge234is configured to engage the interior surface262(FIG. 5). The inner and outer edges232,234define a width W2of the second leg230. As shown, the width W2of the second leg230may be substantially uniform for almost an entire length of the second leg230and may be substantially equal to the width W1.

The first and second legs220,230and/or the inner edges222,232have non-linear profiles that form first and second gaps240,242. The non-linear profiles may be wave-like or serpentine. In other embodiments, however, the first and second legs220,230and/or the inner edges222,232may be substantially linear. The inner edges222,232face each other and have a separation distance SD therebetween. The separation distance SD may be zero at the contact zones214,216.

In the illustrated embodiment, as the inner edges222,232extend away from the mounting side140, the inner edges222,232extend from the base portion202to respective inflection areas226,236and then to respective inflection areas228,238. As used herein, an “inflection area” of a leg represents a localized area of an inner edge that is closer to the longitudinal axis than other areas of the inner edge that immediately precede or, in some cases, immediately follow the inflection area. The inflection area may be similar to a point of inflection on a graph. For example, as the inner edges222,232approach the inflection area226,236, respectively, each of the inner edges222,232extends toward and becomes closer to the longitudinal axis212. The first gap240is defined longitudinally between the base portion202and the first contact zone214and laterally between the inner edges222,232. The first gap240decreases as the inner edges222,232approach the inflection areas226,236, respectively.

As another example, the inner edges222,232extend away from the longitudinal axis212as the inner edges222,232extend from the inflection areas226,236, respectively, in the mounting direction M1. As the inner edges222,232approach the inflection area228,238, respectively, each of the inner edges222,232extends toward and becomes closer to the longitudinal axis212. The inner edges222,232directly interface with each other at the second contact zone216. The second gap242is defined longitudinally between the first contact zone214and the second contact zone216and laterally between the inner edges222,232. Thus, the inner edges222,232may initially extend away from each other and away from the longitudinal axis212when the inner edges222,232extend from the contact zone214in the mounting direction M1and then curve to extend toward each other and toward the longitudinal axis212as the inner edges222,232approach the second contact zone216.

As shown inFIG. 2, each of the first and second gaps240,242has a respective length LG1, LG2that is measured along the longitudinal axis212. More specifically, the length LG1of the first gap240is measured between the base portion202to the contact zone214. The length LG2of the second gap242is measured between the first and second contact zones214,216. In the illustrated embodiment, the length LG1is shorter than the length LG2. Also shown inFIG. 2, the gap242may have an elongated diamond shape.

In the illustrated embodiment, the first and second gaps240,242are separated from each other by the contact zone214when the first and second legs220,230directly engage each other at the contact zone214. It is understood, however, that the first and second legs220,230may not directly engage each other at the contact zone214or at the contact zone216. Accordingly, the first and second gaps240,242may be considered part of a larger gap if the first and second legs220,230do not engage each other.

In the illustrated embodiment, the inner edges222,232directly interface with each other from respective contact points229,239at the contact zone216to the respective distal ends208,210. Thus, the inflection area228is defined between the contact point229and the distal end208, and the inflection area239is defined between the contact point239and the distal end210. The distal ends208,210form a portion of the corresponding inflection areas228,238. In other embodiments, the distal ends208,210may be separated from each other and from the longitudinal axis212as the inner edges222,232extend from the second contact zone216toward the distal ends208,210. For instance, due to manufacturing tolerances, the distal ends208,210may not directly interface with each and a nominal gap may exist between the inner edges222,232from the distal ends208,210to the contact zone216.

FIGS. 3 and 4are cross-sections of the first and second legs220,230taken along lines3-3and4-4, respectively, inFIG. 2.FIG. 3extends through the first and second legs220,230at the inflection areas226,236, andFIG. 4extends through the first and second legs220,230where a maximum separation distance, referenced as SDM, exists between the inner edges222,232within the second gap242. In some embodiments, the inner edges222,232(FIG. 4) between the base portion202(FIG. 2) and the respective inflection areas226,236(shown inFIG. 3) coincide with a contact plane P1that includes the longitudinal axis212. Likewise, in some embodiments, the inner edges222,232between the inflection areas226,236and the distal ends208,210(FIG. 2) coincide with the contact plane P1. In more particular embodiments, the entire first and second legs220,230coincide with the contact plane P1.

With respect toFIG. 4, the compliant contact200has a maximum width WMthat is measured between the outer edges224,234along the contact plane P1. In an exemplary embodiment, the first and second legs220,230have substantially uniform cross-sectional dimensions such that the maximum width WMand the maximum separation distance SDMoccur at the cross-section of the compliant contact200. However, in alternative embodiments, the maximum width WMmay occur at a different cross-section. When the first and second legs are inserted into the corresponding PTH152(FIG. 1), the maximum separation distance SDMwill become smaller than the distance shown inFIG. 4.

The first and second legs220,230also have a stock thickness TS, which may be equal to the thickness, in some embodiments, of the sheet material from which the compliant contact200(FIG. 1) was stamped. The compliant contacts200may have a size ratio between the corresponding maximum separation SDMand the corresponding stock thickness TS. In some cases, embodiments set forth herein may achieve a size ratio that conventional compliant contacts are not able to achieve. For example, prior to being inserted into the PTH152, the size ratio (SDM:TS) may be at most 1.00. In certain embodiments, the size ratio may be at most 0.85 and, in particular embodiments, the size ratio is at most 0.75 prior to being inserted into the PTH152. More specifically, the size ratio is at most 0.67 prior to being inserted into the PTH152. After being inserted into the PTH152, the size ratio may be reduced. For example, the size ratio may be at most 0.65 and, in more particular embodiments, the size ratio may be at most 0.50 when within the PTH152. In other embodiments, the size ratio after being inserted into the PTH152may be at most 1.00, at most 0.85, or at most 0.75. In other embodiments, the compliant contacts200have a size ratio that is greater than 1.00.

FIG. 5is a cross-section of the circuit board148illustrating the compliant contact200inserted into the PTH152. The circuit board148has a board surface250that interfaces with the mounting side140(FIG. 1) of the connector body131(FIG. 1). The circuit board148includes a substrate252having a plurality of stacked dielectric, ground, and signal layers (not shown) and a thru-hole254extending into the substrate252from an opening256that is defined along the board surface250. The thru-hole254has an inner surface258that is plated with a conductive material260thereby forming the PTH152.

The PTH152has an interior surface262that defines an interior diameter DHof the PTH152. The interior diameter DHis less than the maximum width WM(FIG. 4) of the compliant contact200. When the compliant contact200is advanced in the mounting direction M1into the PTH, the distal ends208,210are initially inserted through the opening256of the PTH152. As the compliant contact200continues to advance, the outer edges224,234engage the interior surface262of the conductive material260such that the first and second legs220,230are deflected radially inward. The inner edges222,232engage or, if already engaged, press against each other at the first and second contact zones214,216. The first and second legs220,230may be permanently deformed such that the first and second legs220,230are capable of being inserted into the PTH152. When the compliant contact200is inserted into the PTH152, the outer edges224,234exert a radially outward force against the interior surface262due to radially-inward deflection of the first and second legs220,230. As such, the compliant contact200may be mechanically and electrically coupled to the PTH152.

Embodiments set forth herein include compliant contacts that are capable of being inserted into PTHs having different diameters and engaging the interior surfaces of the PTHs such that the compliant contact and the PTH are mechanically and electrically coupled. The different diameters may be intentionally designed or as a result of manufacturing tolerances. The first and second gaps240,242enable the compliant contact200to be inserted into PTHs152having different diameters. By way of example, the diameter DHmay range between about 0.25 mm to about 0.65 mm. When the diameter DHis smaller than shown inFIG. 5, the first and second gaps240,242permit the first and second legs220,230to be deflected inwardly.

Depending on the size of the diameter DHand the dimensions of the compliant contact200, the outer edges224,234engage the interior surface262of the PTH152at contact areas266,268. The contact areas266,268begin at a depth DY2, which is measured from the opening256of the PTH152. In some embodiments, the depth DY2of the contact areas266,268may range from about 0.20 mm to about 0.85 mm from the board surface250. In more particular embodiments, the depth DY2of the contact areas266,268may range from about 0.20 mm to about 0.60 mm from the board surface250. Moreover, the compliant contact200has a maximum depth DY3within the PTH152measured from the board surface250to the distal ends208,210. In some embodiments, the maximum depth DY3may be at most 1.00 mm. In more particular embodiments, the maximum depth DY3may be at most 0.85 mm.

A stub portion270of the compliant contact200may correspond to a portion of the compliant contact200that does not directly contact the PTH152along the outer edges224,234. In the illustrated embodiment, the stub portion270corresponds to the segments of the first and second legs220,230immediately after the contact areas266,268. More specifically, the stub portion270includes the segment of the first leg220that extends between the contact area266and the distal end208and the segment of the second leg230that extends between the contact area268and the distal end210. A length LSof the stub portion270may be measured as the difference between the maximum depth DY3and the depth DY2of the contact areas266,268. In some embodiments, the length LSmay be at most 0.90 mm or, more specifically, at most 0.70 mm. In more particular embodiments, the length LSmay be at most 0.65 mm or, even more particularly, at most 0.50 mm.

FIG. 6is a flowchart illustrating a method300of manufacturing the compliant contact200(shown inFIGS. 8 and 9). The method300is described with respect toFIGS. 7-9and may be used to form the compliant contact200and the various features or modifications described herein. In various embodiments, certain steps of the method300may be omitted or added, certain steps may be combined, certain steps may be performed simultaneously, certain steps may be performed concurrently, certain steps may be split into multiple sub-steps, certain steps may be performed in a different order, or certain steps or series of steps may be re-performed in an iterative fashion.

With respect toFIGS. 6 and 7, the method300includes providing (at302) a sheet312of conductive material. The sheet312of the conductive material may be sheet metal. In particular embodiments, the conductive material is capable of transmitting electrical current at a desired electrical performance that is consistent with the electrical performance of high-speed electrical connectors. For example, the sheet metal may include copper, copper alloy, or another metal that is capable of transmitting electrical current.

At304, the sheet312of the conductive material is stamped to provide a plurality of contact bodies318. For example, the stamping (at304) may include stamping a leadframe314from the sheet312. As shown, the leadframe314has a plurality of signal conductors316that include the contact bodies318. More specifically, each of the signal conductors316extends from a corresponding mating end320, through a conductor segment322, and to one of the contact bodies318. InFIG. 7, the leadframe314includes six (6) signal conductors316that have different lengths.

When the electrical connector130(FIG. 1) is fully constructed, the signal conductors316may be overmolded to form the contact modules135(FIG. 1). In alternative embodiments, the contact bodies318are not part of a larger leadframe. Instead, the sheet312may be stamped to only form the contact bodies318without mating ends or conductor segments. Alternatively or in addition to the stamping at304, the sheet312and the contact bodies318may be processed by other means, such as etching and/or coating.

FIG. 7also shows an enlarged view of one of the contact bodies318. The contact body318has many of the same features of the compliant contact200(FIG. 1). For example, the contact body318includes the base portion202and first and second legs220,230that extend from the base portion202to the respective distal ends208,210. As shown, the inner edges222,232face each other and are spaced apart by the separation distance SD. The inner edges222,232have non-linear profiles that are caused by the stamping (at304).

As described above, the sheet312and the contact bodies318have the stock thickness TS(FIG. 4) In some embodiments, the dimensions of the contact bodies318may be configured to satisfy certain manufacturing standards. The contact body318has a size ratio (SDM:TS) in which the maximum separation distance SDM(FIG. 4) represents a maximum value of the separation distance SD between the inner edges222,232. In some embodiments, the size ratio is at least 0.75 or, more specifically, at least 0.85 after the contact bodies318are stamped but prior to the inner edges222,232being moved toward each other. In some embodiments, the size ratio is at least 1.00 after the contact bodies318are stamped but prior to the inner edges222,232being moved toward each other. More specifically, the separation distance SD in some embodiments may be equal to or greater than the stock thickness TS.

The method300also includes permanently deforming (at306) the first and second legs220,230such that the inner edges222,232move toward each other.FIG. 8illustrates one such method in which the permanently deforming (at306) may include deflecting (at308) the first and second legs220,230toward each other. For example, a die324may have a cavity326defined by an interior wall328. The interior wall328may have a predetermined shaped in order to deform the contact body318into a designated configuration. More specifically, the interior wall328may be configured to engage the outer edges224,234so that the first and second legs220,230, respectively, are deflected toward each other. The contact body318includes joints330,332that join the first and second legs220,230to the base portion202. When the outer edges224,234are engaged by the die324, the first and second legs220,230may bend about the joints330,332, respectively, such that the first and second legs220,230are permanently deformed and move toward each other. More specifically, the die324deflects the first and second legs220,230until the respective inflection areas226,236directly interface with each other at the contact zone214thereby forming the first gap240and the respective inflection areas228,238directly interface each other at the contact zone216thereby forming the second gap242. The interior wall328may also deform the distal ends208,210into a designated shape such that the distal ends208,210directly interface with each other.

The method300also includes pressing (at310) into the stock thickness TS(FIG. 4) of the contact body318such that the first and second legs220,230are permanently deformed and move toward each other. The pressing (at310) may also be referred to as swaging the contact body318. With respect toFIG. 9, swaging posts (not shown) may directly engage a side surface336of the contact body318and press into the side surface336to displace the conductive material of the contact body318thereby moving the first and second legs220,230. In some embodiments, the swaging posts may engage localized regions338,340(indicated by dashed lines) proximate to or at the joints330,332, respectively. In some embodiments, the localized regions338,340may include the outer edges224,234, respectively. When the swaging posts are punched into the stock thickness TSalong the side surface336, the conductive material may be displaced thereby forcing the first and second legs220,230toward each other until the inflection areas226,236directly interface each other at the contact zone214and the inflection areas228,238directly interface each other at the contact zone216. The compliant contact200may have swage marks342,344caused by the pressing (at310). The compliant contact200may have a reduced thickness at the swage marks that is less than the stock thickness TS. When the inner edges222,232directly interface each other to form the first and second contact zones214,216, the first and second gaps240,242are also formed.

FIGS. 10-12are plan views of compliant contacts400,430, and460, respectively, which may be formed using the method300(FIG. 6) or other processes and may have similar features as the compliant contact200(FIG. 1). The compliant contacts400,430, and460are ready for insertion into corresponding PTHs (not shown). With respect toFIG. 10, the compliant contact400includes a base portion402and first and second legs404,406that are coupled to the base portion402and extend from the base portion402to respective distal ends408,410. The first and second legs404,406are physically discrete elements that are only coupled to each other through the base portion402. The compliant contact400is oriented with respect to a longitudinal axis412that extends through a center of the base portion402and generally parallel to and between the first and second legs404,406. As shown in the plan view ofFIG. 10, the first and second legs404,406may be symmetrical with respect to the longitudinal axis412.

The first leg404has an inner edge414and an outer edge416that face in generally opposite directions. Similarly, the second leg406has an inner edge418and an outer edge420that face in generally opposite directions. As the inner edges414,418extend away from the base portion402toward the distal ends408,410, respectively, the inner edges414,418extend to respective inflection areas422,424. As the inner edges414,418approach the inflection area422,424, respectively, the inner edges414,418extend toward each other. The first and second legs404,406directly interface with each other at a contact zone415. A gap426is defined longitudinally between the base portion402and the contact zone415and laterally between the inner edges414,418. The gap426decreases as the inner edges414,418approach the inflection areas422,424, respectively, or the contact zone415.

Unlike the compliant contact200, each of the first and second legs404,406includes only one inflection area such that the compliant contact400has only one contact zone. Nonetheless, in some embodiments, the outer edges416,420may exert a suitable force for mechanically and electrically coupling the compliant contact400and the PTH (not shown).

With respect toFIG. 11, the compliant contact430may have a similar shape as the compliant contact400(FIG. 10). The compliant contact430has first and second legs432,434. The first leg430has inner and outer edges433,443, and the second leg434has inner and outer edges435,445. The first leg432has a width W3measured between the inner and outer edges433,443, and the second leg434has a width W4measured between the inner and outer edges435,445.

Unlike the compliant contact400, the compliant contact430has edge projections436,438along the inner edges433,435, respectively. The edge projections436,438project toward the opposing leg. The edge projection436defines an inflection area440of the inner edge433, and the edge projection438defines an inflection area442of the inner edge435. In the illustrated embodiment, the edge projections436,438are formed by increasing the widths W3, W4, respectively. In particular embodiments, the inflection areas440,442represent where the first and second legs432,434, respectively, have maximum values of the corresponding widths W3, W4. When the compliant contact430is inserted into a PTH (not shown), the edge projections436,438may engage each other at a contact zone444. The inner edges433,435may also engage each other at a contact zone446.

With respect toFIG. 12, the compliant contact460may have a similar shape as the compliant contact400(FIG. 10) or the compliant contact430(FIG. 11). However, as shown, the compliant contact460has multiple edge projections462,464along an inner edge466and multiple edge projections472,474along an inner edge476. When the compliant contact460is inserted into a PTH (not shown), the edge projections462,472engage each other at a contact zone480and the edge projections464,474engage each other at a contact zone482. The inner edges466and476may also engage each other at a contact zone488. Accordingly, the inner edges466,476may engage each other at three separate contact zones.

Also shown inFIG. 12, the compliant contact400has outer edges484,486. Edge portions485,487of the outer edges484,486extend parallel to each other such that the outer edges484,486along the edge portions485,487have a uniform width W5. The width W5may be slightly larger than a diameter of the PTH (not shown) that receives the compliant contact400.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

As used in the description, the phrase “in an exemplary embodiment” and the like means that the described embodiment is just one example. The phrase is not intended to limit the inventive subject matter to that embodiment. Other embodiments of the inventive subject matter may not include the recited feature or structure. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.