Abstract:
The invention is an electrical connector that provides a connection system that releasably connects the circuit paths of a flexible conductive circuit to a printed circuit board having a corresponding row of contacts, without the need for soldering, crimping or welding operations, or extensive preparation of the flexible circuit before connection. One embodiment has at least one spring contact formed in a cover; at least one rotatable cam; and a base with a circuit alignment window for initial alignment of a flexible conductive circuit introduced into the connector. The cover and base snap together to house the rotatable cam(s). The connection, when using at least one cam, is made by feeding the circuit into a slot in the cam, then rotating the cam to bring the circuit into contact with the spring contact which has a tapered insulation plane that pierces and peels back the dielectric covering of the conductive circuit to make a direct metal to metal, gas tight contact between the deflectable contact and the conductors of the conductive circuit. Wrapping the circuit around the cam during the connection process provides stability to the connection and takes strain off of the connection site, thereby providing a more stable and reliable connection. In the alternative, a connection module with an activation portion and a contact support portion may be used to house the deflectable spring contact. A deflection ridge is formed in the activation portion. The deflection ridge presses the circuit into the tapered insulation plane of the deflectable contact which is formed in the contact support portion, thereby allowing the tapered insulation plane to pierce the dielectric of the flexible circuit. In all embodiments, the displaced dielectric may be reused, by being heated until it reflows, to add stability to the newly formed connection.

Description:
FIELD OF THE INVENTION 
     The invention relates generally to multi-terminal or multi-contact electrical connectors to connect electrical contacts of various shapes. The invention relates more specifically to electrical connectors of the insulation piercing, gas tight electrical connection type to quickly and inexpensively interconnect a wide variety of contacts to conventional flexible circuit, tape cable or encapsulated round wire harness. Most specifically the invention relates to an electrical connector that terminates more than twice the number of contacts per inch than a conventional insulation displacing connector and eliminates the expense of soldering, crimping or welding usually associated with the attachment of a connector contact to an interconnect circuit. 
     BACKGROUND OF THE INVENTION 
     Conventional electrical connectors are designed to connect the circuit paths of a flexible circuit to a spring contact system. Usually the surface of the flexible circuit needs to be prepared before connection. Preparation of a flexible circuit usually includes labor intensive activities such as stripping off the dielectric, cleaning the exposed conductor or wire and then soldering each individual conductor of the spring contact system to each conductor or wire of the flexible circuit. As part of the reason many connectors require intensive preparation of the flexible circuit, many conventional connectors do not provide a wiping action to clean the conductors of the flexible circuit. Some connectors also do not provide a gas tight seal when the electrical connection is made, allowing air to contact the conductors causing oxidation, and consequent degradation in the quality of the connection due to the oxidation on the conductors. 
     Many conventional multi-terminal connectors comprise male and female housings that fasten together to secure coupling of terminals mounted within the housings. Many connectors require a fair amount of force to completely engage the many terminals being connected. Zero insertion force type connectors aim at reducing or eliminating the force typically needed to make the connection. In reducing the force, some connector systems use camming devices or cam lock features. Cam lock features typically include one or more cam surfaces on an operator handle or lever that is mounted to the housing of one of the connector halves to be mated. The other connector housing has one or more protruding cam followers to engage the cam surface(s) so that as the lever or handle is moved in the desired direction, the cam surface(s) act on the cam follower(s), drawing the connector halves together and forcing secure engagement of the contacts. 
     Other zero insertion force type connectors conventionally have a housing mounting a plurality of terminals in a generally parallel array. An actuator, such as a pressure member, is used to press the flexible flat cable, flexible printed circuit board or the like against contact portions of the terminals. In order to keep the size of the connectors relatively small, and the insertion force required to connect the terminals to a minimum, some connectors have been designed with actuators or pressure members which are rotatably or pivotally mounted on the housing for movement between first, open positions allowing free insertion of the cables into the connector housings, and second, closed positions for clamping the flat cables against the contact portions of the terminals. 
     One of the problems with connectors having rotatable actuators, cams or pressure members is the tendency of moving the pressure member back toward its open position when undesired external forces are applied to the flexible flat cable. The flexible flat cable tends to raise and rotate the pressure member, thereby releasing the flexible flat cable from the connector, and possibly damaging the terminals in the process of the flexible flat cable being pulled out of or disconnected from the connector. 
     Thus there is a need for an inexpensive, easily assembled connector that eliminates the expensive, time consuming preparation steps common to use of most connectors, and that eliminates strain on the electrical connection or inadvertent disconnection, by securely locking the flexible flat cable, flexible printed circuit board, round wire interconnect or the like in place within the connect, while producing a gas tight seal. 
     SUMMARY 
     The basic embodiment of the invention is a connector that accurately aligns each contact to its assigned conductor. Individual contacts of at least one contact or at least one compound dynamic contact gradually engage the conductive circuit (flat flexible cable, flexible printed circuit board, round wire interconnect) and apply sufficient force to pierce, via a tapered insulation plane on each contact, through the circuit&#39;s dielectric but not its individual conductors. The contact(s) are deflected, in a first deflection range, by the circuit&#39;s conductor in such a way as to skive off (remove, peel off) all the insulating dielectric and a majority of the adhesive on one side of the conductive circuit without totally piercing the conductor. 
     In one embodiment, may be a rotatable cam or cylinder into which the circuit passes. A portion of the circuit is retained in the cam. The circuit may enter partially or pass all the way through the cam. As the cam or cylinder rotates through its rotation cycle, the conductive circuit is wrapped around it, and the cam or cylinder includes raised features designed to lift at least one conductor of a flexible circuit into an electrical connection with a deflectable contact and to then lift the deflectable contact into a second deflection range. The contact(s), as it is deflected into the second deflection range, moves the contact&#39;s insulation plane into a neutral (non-cutting) position and significantly increases the contact force on the circuit&#39;s conductor. 
     This sequence of mechanical events brings the optional force concentrators on the contact(s) into a high pressure connection with the conductive circuit&#39;s conductors. The contact is designed to apply sufficient pressure between each contact and its mating conductor to pierce through any remaining adhesive and make a metal to metal, or surface finish to surface finish gas-tight electrical connection. In another embodiment, there may be a contact module containing at least one compound dynamic contact, but with a contact activation portion instead of a cam. In either embodiment, a simple contact having an insulation plane pierces and peels back the top layer of dielectric from a flexible conductive circuit such that a partial seal is formed between each contact and the individual conductors of the flexible conductive circuit. 
     Therefore an aspect of invention is to provide an interconnect system to quickly and inexpensively interconnect a wide variety of shapes of contacts to conventional conductive circuits such as flexible circuit, tape cable, or encapsulated round wire harness. 
     Another aspect of the invention is to provide an interface within the connector&#39;s body wherein the connector is adaptable to an application specific contact shape exiting the connector body. Exiting contacts may be designed as a simple pin for insertion into a printed circuit board or a complex spring designed to mate with other connectors. 
     A further aspect of the invention is to provide a connector that eliminates the expense of removing the insulation and cleaning the conductors of the flexible circuit and soldering, crimping or welding that is usually associated with the attachment of a connector contact to an interconnect circuit. 
     Yet another aspect is to provide a sealing mechanism wherein the displaced dielectric and adhesive of the conductive circuit are compressed against the side walls of the connector housing providing a partial contact to conductor seal. The seal can be easily made permanent by heating each circuit conductor to a temperature that causes the dielectric to flow and thereby seal the contact to conductor interface. 
     A still further aspect is to provide a connector that only pierces through the upper layer of a conductive circuit&#39;s dielectric, leaving the base laminate layer intact. By eliminating the need to remove or penetrate the base layer of dielectric, the conductive circuit&#39;s dimensional stability is maintained and tearing or damaging the conductive circuit is avoided. Also any risk of changing the conductive circuit&#39;s electrical or dielectric parameters is avoided. 
     A further aspect of the invention is to provide a connector that can be mounted to the end of a flexible conductive circuit without first removing the dielectric from the terminating area, that can be mounted without the use of tooling, and that can be easily coupled to a mating connector with minimal hand movements and without having to observe the connection site. 
     Still another aspect is to provide a connector that is relatively easy and inexpensive to make in quantity. 
     Still another aspect is to provide a connector that configures the flexible circuit in a manner that strain relieves the circuit and in so doing protects the contact to conductor electrical interface. 
     Still another aspect is to provide a low pressure contact system that may be used in those applications requiring a gold to gold interface or a ZIF (zero insertion force) style connector. In this type of application the flexible circuits insulating overlay must be first removed from the circuit before it is inserted into the connector. 
     Other aspects of the invention will be exemplified by the following drawing figures, detailed description of the preferred embodiments of the invention, and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a  is an exploded cross sectional end view of the connector embodiment using a cam. 
     FIG. 1 b  is an exploded front view of the connector of FIG. 1 a.    
     FIG. 2 a  is a top view of a compound dynamic contact, showing, in this example, two individual contacts, spaced apart by dielectric, and laminated together. 
     FIG. 2 b  is a side plan view of a contact with compression notches and force concentrators showing the first deflection range. 
     FIG. 2 c  is a side plan view of a contact with compression notches and force concentrators, showing the second deflection range as the compression notches collapse. 
     FIG. 3 a  is a cross sectional view of the activation cam, and at least one contact, with a circuit inserted. 
     FIG. 3 b  is a front view of the activation cam showing the various circuit alignment systems used. 
     FIG. 3 c  is a back view of an activation cam, where a flexible circuit would exit the cam if the circuit were to pass through the cam. 
     FIG. 3 d  is an end view of an activation cam. 
     FIG. 3 e  is a sectional view taken along Line “A—A” of FIG. 3 d  without a flexible circuit installed. 
     FIG. 3 f  is a sectional view taken along line “A—A” of FIG. 3 d  with a flexible circuit installed. 
     FIG. 3 g  is a top view of a flexible circuit usable with the invention, and having precisely located holes placed through the dielectric separating the individual circuit conductors, to guide the circuit into the connector. 
     FIG. 4 is a cross sectional view of the activation cam after it has been rotated, showing how the contact(s) pierces and peels back the dielectric insulation from the conductive flexible circuit to make a direct contact between the contact(s) and the conductors of the conductive flexible circuit. This figure also shows an optional second contact. 
     FIG. 5 a  is a cut away side view of the activation module embodiment of the invention, with a flexible circuit contact inserted. 
     FIG. 5 b  is an end view of the activation portion of the embodiment that does not use a cam. 
     FIG. 5 c  is a side view of the activation portion of the embodiment that does not use a cam. 
     FIG. 5 d  is an end view of the contact support portion of the embodiment that does not use a cam. 
     FIG. 5 e  is a side view of the contact support portion of the embodiment that does not use a cam. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, like reference numerals refer to like elements throughout. Most basically the invention comprises a spring contact which may have a tapered insulation plane that can pierce and peel back the top layer of dielectric of a flexible circuit and form a gas-tight, surface finish to surface finish seal. 
     One embodiment of the invention is connector  10  which has three basic parts, as shown in FIG. 1 a , a molded cover  12  which may have at least one molded-in, press fit, heat swaged, or otherwise attached deflectable spring contact  14  which may be a single contact or a compound dynamic contact, at least one free-floating, activation cam  16  rotatably disposed within the molded cover  12 , and a molded base  18 . The molded cover  12  and base  18  form a housing in which activation cam  16  is rotatably mounted, and the at least one deflectable spring contact  14  is connectable to at least one conductive circuit  20  such as a flexible printed circuit board, flat flexible cable or round wire interconnect. 
     A key to the invention is the deflectable contact  14 . Contact  14  is geometrically shaped and mechanically designed and positioned in relationship to a flexible conductive circuit  20  to, when force is applied, be stiff enough to press into contact with exposed conductors of the at least one conductive circuit. If a tapered insulation plane  22  is used, contact  14  should be stiff enough to pierce through the top layer of an insulating dielectric  20   a , but compliant enough to be deflected along the conductive layer in such a manner as to cause contact  14  to travel over the surface of the conductive circuit and scrape off the top layer of insulating dielectric  20   a  and 0.0001″ to 0.001″ of the conductive layer&#39;s surface to make a reliable electric connection that is at least partially sealed. The piercing and scraping process sufficiently deflects spring contact  14  to generate the control force necessary to make and maintain a reliable electrical interconnection between contact  14  and the conductive material of conductive circuit  20 . As shown in FIG. 1 b , base  18  also may include a circuit alignment window  30  to provide rough initial alignment of conductive circuit  20  with cam  16  when circuit  20  enters connector  10 . 
     The connector is designed for ease of assembly. It can be snapped together, for example using snap mechanisms  44  as shown in FIG. 1 a , and therefore eliminates expensive, time consuming ultrasonic or heat fusing assembly equipment typically needed to form conventional electrical connectors. In addition the connector  10  can therefore be easily disassembled and repaired or parts replaced as necessary. Connector  10  may contain one, or two or more, single or compound dynamic contacts  14  and activation cams  16  as required to terminate two or more conductive circuits  20 . Cam(s)  16  may be formed in varying round and oval shapes in order to accommodate conductive circuits of different thicknesses, yet all varieties of cam  16  fit in one size cover  12  and base  18 . For example, cam  16  may be oval, or may be round, or cylindrical, with raised features to lift at least one conductor of a flexible, conductive circuit into electrical connection with a deflectable contact, and as the cam continues to rotate, lift the contact from a first to a second deflection range. 
     As shown, for example, in FIGS. 1 a ,  1   b , and  2   a , molded cover  12  contains at least one spring contact  14 . As shown in FIG. 2 a , spring contact  14  may be multiple individual contacts laminated together to form a compound contact. A compound contact  14  may also be formed of layers of contacts that may be stacked vertically or horizontally and shaped to accommodate contact deflection and applied pressure requirements of any particular chosen application. Cover  12  adds structural support to the connector  10  and maintains orientation of the spring contact(s)  14  being connected during the assembly process. Contact pitch, alignment, configuration and stored energy (contact mass and deflection range) are design dependent features and may be easily adjusted to accommodate special requirements. Special requirements may include, but are not limited to, modifying contact pitch center or power requirements within a particular connector, or accommodating special dielectric requirements such as thicker or thinner dielectrics. The configuration of contact(s)  14 , including the length, thickness, and structural make up, in combination with the mechanical advantages of the connector  10 , and cam  16 , allow connector  10  to be easily adaptable for use with various conductive circuits  20 . 
     Whether single or compound, contact  14  is a flat design that allows it to reliably connect to closely packed conductors. To maintain the desired stored energy in contact  14 , a compound contact is formed from a composite laminated contact design, as shown in FIG. 2 a . Compound dynamic contact  14  is two or more individual contacts that are laminated together to create a mechanically sound contact structure. For example, 0.005″ thick contacts are separated by a thin film dielectric, about 0.001″ thick, placing the contacts on 0.006″ pitch centers. By laminating two or more individual contacts together with a structurally enhanced dielectric that has, for example, been created with its molecular, granular or fiber particles oriented to accommodate movement in one direction over another, contact mass and deflection range, and electrical characteristics can be significantly improved while using contacts that are 50% or more thinner than those required to achieve the same results using individual contacts. Components layers of a compound contact may be stacked either vertically or horizontally to accommodate the dynamics and pressure requirements of a particular application. The invention thus can terminate to tightly packed conductors. The use of a structurally enhanced dielectric increases a compound contact&#39;s strength through the laminating process. FIG. 2 a  illustrates a compound dynamic contact  14  capable of terminating to conductors on 0.006 inch pitch centers. 
     The material, thickness and width of contact(s)  14  is selected based on the particular application&#39;s required contact deflection range and interconnect force. Contact(s)  14  may be formed from a spring wire or may be etched or stamped from a spring material. Contact  14 , formed in the manner of the invention, stores and applies the necessary contact pressure on demand. Contact  14  provides a wiping contact, as it is connected to a conductor. The deflection capability of contact  14  compensates for variations in the thickness of conductive circuits  20  being connected with connector  10 . In composite contact  14 , the dielectric laminating the individual contacts together provides required insulating material and stabilizes individual contacts, thus insuring that the individual contacts maintain their spaced relationship, and any mechanical requirements. 
     The single or compound deflectable contact  14  may have, at the end that connects to an electrically conductive circuit  20 , a tapered, pointed insulation plane  22 , as shown in FIG. 1 a ,  2   b ,  2   c ,  3   a , and  4 . During connection, the rotating cam  16  lifts the circuit  20  forcing it to engage the pointed insulation plane  22  which then pierces and peels off the top dielectric and adhesive from the conductive circuit  20 , thereby exposing the circuit&#39;s conductor, while leaving the base or bottom layer of dielectric intact. Thus, unlike conventional insulation-displacing connectors and contacts which penetrate and weaken the circuit&#39;s base dielectric, the invention provides a contact and process that maintains the structural integrity of a circuit&#39;s base dielectric laminate by electrically terminating to the surface of each conductor. 
     Also, optionally, at the connection end of contact  14  may be a plurality of force concentrators  24  that accentuate pressure at the interface between spring contact  14  and circuit conductor  20  as required to penetrate any remaining adhesive not peeled back by insulation plane  22  and also to scrape off about 0.0001″ to 0.001″ of the conductive material of conductor  20  to clean off any metal oxides, such as tin or copper oxide, that may have formed on the conductive material, to create a metal to metal, gas tight electrical connection between spring contact  14  and conductive circuit  20 . 
     Compared to conventional high density contacts and connectors, compound dynamic contacts  14  have two or more deflection ranges A and B through which they flex during connection, as best shown in FIGS. 2 b  and  2   c . The force each contact  14  applies as it passes through the deflection ranges may be controlled by optional contact compression notches  26 , also shown in FIGS. 2 b  and  2   c . FIG. 1 a  shows a contact  14  with no force concentrators or compression notches. The first deflection range A provides force strong enough to pierce and peel off the dielectric of conductive circuit  20 , but not to pierce the metal (for example, copper) conductors. The force supplied in the first deflection range A is determined by the minimum thickness of the contact, as shown in FIG. 2 b . If compression notches  26  are used, as the compression notches close, they activate the stored energy of the entire contact  14 . By way of general example, if the contact&#39;s body is twice as thick as the thinnest portion of the compression notch, then closing the notch will approximately double the contact&#39;s applied force. The typical force required to pierce and peel the dielectric off its conductor may be as little as 75 grams while Applicant&#39;s invention can generate and maintain approximately  150  grams of contact force to achieve a gas tight connection. At least a partially sealed contact  14  to conductor  20  interface occurs as the peeled off, displaced dielectric of conductive circuit  20  compresses around the mating conductors. The partial seal is formed of adhesive and dielectric (for example, polyester). The seal is caused in part by the compliant nature of the dielectric and adhesive of conductive circuit  20 , in part by the memory induced into the dielectric of flexible circuit  20  during the laminating process, and in part by the ‘desire’ of the dielectric and adhesive of conductive circuit  20  to reoccupy the space from where it was peeled, where contact  14  is now present. The seal can easily be made permanent by heating each individual contact of contact(s)  14  to a temperature that causes the dielectric to re-flow (melt) and thereby seal the contact to circuit interface. Thus, the dielectric, instead of being scraped off and discarded, can essentially be reused in situ to reform around the newly made electrical connection. 
     As described above maybe at least one compound dynamic contact  14  molded into cover  12 . However a second compound dynamic contact  42  may be molded in to base  18  such that a compound dynamic contact is positioned on either side of cam  16 , about 180 degrees apart, as shown in FIG. 4, to increase the density of contacts that may be connected within connector  10 . Shown in FIG. 4 is an optional force concentration extender  40  which may be molded into contact  14  and/or  42 , or cover  12  or base  18  to provide additional compression force to aid contact  14  in piercing and peeling the dielectric of circuit  20 . 
     As shown in FIG. 1 a , activation cam  16  is housed within molded cover  12  and base  18 . When disposed in cover  12  and base  18 , cam  16  accurately aligns with compound dynamic contact  14  and, during connection, aligns the individual conductors of conductive circuit  20  to the individual contacts of contact(s)  14 . Cam  16  is rotated to make the electrical connection. Cam  16  is rotatable by inserting an activation tool (not shown) into cam activation socket  32 , shown in FIGS. 1 a  and  3   d . As a security feature, cam activation socket may have a customized shape, requiring a customized tool for operation such that only a user with the appropriately shaped tool could activate the cam. 
     In one embodiment of the invention, to form the electrical connection, conductive circuit  20  is inserted into connector  10  and roughly aligned by circuit alignment window  30  in base  18 . Circuit  20  then passes into cam  16  via circuit receptacle slot or notch  38  as shown in FIGS. 1 a  and  3   d . In this particular illustration, notch  38  extends through cam  16 . However, notch  38  need only be able to capture and hold circuit  20  inside cam  16 . Thus, depending on the application, it is not necessary that a slot extend all the way through cam  16 . There may be simply a slot or notch formed partially through cam  16 , into which circuit  20  is inserted, wherein circuit  20  is not able to pass completely through cam  16  but rather is retained in the notch or slot. Circuit  20  is fed into cam  16 . Cam  16  is then rotated, which wraps circuit  20  around cam  16  and forces spring contact  14  to contact exposed conductors of circuit  20 , or if using a contact  14  with tapered insulation plane  22 , to pierce the dielectric  20   a  of circuit  20  and skive off both the dielectric and adhesive  20   a  of circuit  20  sufficient to expose the conductor, for example copper, contained therein. The force exerted by contact  14  is strong enough to peel off the top layer of dielectric and adhesive  20   a , but does not pierce the conductor. It merely shaves the surface of the conductor. Because of the oval or raised shape of cam  16 , contact  14  and circuit  20  are compressed into a gas tight connection. The insertion of circuit  20  into cam  16 , the wrapping action of cam  16  on circuit  20  and the peeling of the dielectric  20   a  and adhesive of circuit  20  by spring contact  14  is shown in FIGS. 3 a  and  4 . As noted contact  14  may or may not have the tapered, piercing insulation plane  22 . An instance where insulation plane  22  would not be used would be if the connection to be made were a gold/gold connection. In such a connection one would not want to pierce and possibly damage the soft gold, and would use a blunt ended low pressure, or zero-insertion force contact. In this type of application the flexible circuit&#39;s insulating overlay must be removed from the circuit before it is inserted into the connector. 
     In addition, base  18  aids in providing structural support, component orientation, and initial alignment of circuit  20 . Base  18  orients all components, cam  16  and cover  12  into their proper location, and easily snaps to cover  12 , requiring no tools or special skills. As shown in FIG. 1 a , base  18  also includes a cam orientation indicator or on-off lock  28  that locks cam  16  open (rotatable) or closed (non-rotatable) as required. As discussed above, circuit alignment window  30  of base  18 , shown in FIG. 1 b , provides initial alignment of circuit  20  to circuit receptacle notch  38  of cam  16 . Base  18  is relatively easy to manufacture in quantity and its exterior configuration can be easily modified to mate with other commercially available connectors, or designed to interlock with other connectors  10  of the invention to form a modular connector block (not shown). Thus connector blocks having two or more rows of external pins are possible. 
     In addition connector  10  may have other features which enhance alignment and connection. Alignment ribs  34  disposed on cam  16  aid in aligning the free floating cam  16  to spring contact  14 , and also function to straighten, separate and align individual contact pins of contact  14  in the event they may have become bent or out of alignment or proper spacing. The space between alignment ribs  34  precisely matches the thickness of the contact(s)  14  thus removing any alignment tolerance and making fine line attachment possible. Molded-in, tapered registration or alignment pins or posts  36  on cam  16  work in combination with the rotating, locking motion of cam  16  to grab circuit  20 , through accurately installed alignment holes  48 , shown in FIG. 3 g , designed to receive the alignment pins  36 , and in so doing, accurately align the conductors of circuit  20  to the molded-in deflectable contact  14  as cam  16  is rotated. Alignment holes  48  would need to be created in circuit  20  by a user or manufacturer. 
     Also included on cam  16  may be conductor alignment grooves, notches or troughs  46  which start approximately 0.050″ inside the circuit receptacle notch  38  and taper from the surface to a depth equal to or greater than the laminating trough found between each conductor of a flexible circuit  20 . The alignment grooves/notches  46  reach their maximum depth at the point the circuit  20  exits cam  16  in an embodiment in which circuit  20  passes through cam  16 . The alignment notches  46  continue around the outer surface of the cam  16  for a distance not greater than ⅛ of the cam&#39;s overall circumference. The depth of the alignment notches  46  decreases from the circuit exit point until it blends with the cam&#39;s outer surface. The side walls of each alignment notch  46  are angled in such a manner as to center each conductor  20 . The alignment notches  46  are built into activation cam  16 , as shown in FIGS. 3 b ,  3   c  and  3   e . The alignment notches  46  are designed to take advantage of the laminating troughs between each conductor of circuit  20 . The laminating troughs are created during the laminating process that forms circuit  20  as the dielectric is compressed around each conductor. The troughs in the dielectric of circuit  20  work in conjunction with cam  16 &#39;s molded-in registration pins  36 , and alignment holes  48  of circuit  20 , to guide the conductors into proper alignment. The alignment system of the invention is a redundant system to ensure proper alignment of conductors of circuit  20  and contacts  14 . In addition to providing an additional alignment feature, alignment notches  46  also prevent circuit discontinuity, damage or disengagement under vibration. Thus, use of activation cam(s)  16  and deflectable contact(s)  14  can accurately align conductors of a fine line (conductors on 0.006 inch pitch centers) flexible circuit to their assigned contacts. Use of cam(s)  16  and its alignment ribs  34 , registration pins  36 , and alignment grooves/notches  46  significantly reduces the stack up (or compounding) of assembly tolerances. 
     During connection, as shown in FIG. 4, progressive circuit insertion may be attained by angling the apex of cam  16  in a manner that allows an individual contact of compound dynamic contact  14  to mate with an individual conductor of circuit  20 , one contact at a time. This technique significantly reduces circuit insertion force, because one conductor at a time is mated, as opposed to mating  40  or more at a time, even though  40  or more conductors may be mated using connector  10 . Additionally, as mentioned above, strain is eliminated on the individual contacts and conductors by wrapping circuit  20  around cam  16  during the connection sequence. Wrapping circuit  20  around cam  16  creates a friction/compression lock on circuit  20  which equalizes stress across the whole circuit  20 , thereby protecting circuit  20  from stress and strain within connector  10 . Thus, rotating cam  16  structurally supports circuit  20  and forces each contact  14 , whether single or compound, to pierce the dielectric of circuit  20  (if applicable and not forming a gold to gold connection) and make contact with each conductor of circuit  20 . In addition the shape of cam  16  may be varied to accommodate circuits  20  of various thickness, yet will still fit in a cover  12  and base  18  of one, uniform size. In summary, cam(s)  16  can accurately align itself to a row of deflectable contacts and, once aligned, orient individual conductors of a flexible conductive circuit to mate with their assigned contacts. Rotating the cam(s) forces the flexible circuit to engage the deflectable contact(s) and complete the electrical inter-connection. 
     Most conductive circuits  20  are formed with a bottom or base layer of dielectric with adhesive to attach the dielectric to the conductor, the conductor, and then a top layer of adhesive and a top layer of dielectric. A great deal of force is not required to be provided by connector  10  and contacts  14  because only one (the top) layer of dielectric is pierced and peeled by the invention. 
     To activate and attach the spring contact(s), in one embodiment as described above, a rotating cam  16  may be used, however, in another embodiment, the connector containing the spring contact(s) may be a contact module  100 , as shown in FIGS. 5 a - 5   e , instead of a cam with a cover and base. Contact activation module  100  aligns spring contact  102  with a circuit  104  using built-in contact deflection activation ridge  106  (similar in function to alignment ribs  34  on cam  16 ), a circuit alignment notch  108 , and tapered alignment pins  110  to properly align circuit  104 . A spring contact  102  is shown with a tapered insulation plane  102   a . Spring contact  102  is deflected as circuit  104  passes over activation ridge  106 , and then pierces and peels back the top layer of dielectric  104   a  and adhesive of circuit  104 , as circuit  104  passes through contact module  100 . 
     Contact(s)  102 , as with contact  14 , may be a single or compound spring contact with a tapered insulation plane  102   a . Contact(s)  14  and  102  are the elements that actually form the connection—whether by piercing and peeling back the flexible circuit&#39;s dielectric or simply making contact with the conductors of the flexible circuit. Contact(s)  102  may also have at least one optional force concentrator  112  that interacts with deflection ridge  106  to ensure good contact between contact(s)  102  and the conductors of circuit  104 . 
     Contact module  100  is comprised in part of a contact support portion  114  which houses contact(s)  102 , optional for fine alignment of circuit  104 , tapered alignment pins  110 , at least one module alignment slot  124 , and at least one locking hole  122 . There is also a contact activation portion  116  which comprises registration pins  118 , which roughly align circuit  104 , activation deflection ridge  106 , at least one circuit alignment notch  108 , and flexible locking arms  120 . Arms  120  snap into the at least one latching hole  122  in contact support portion  114  to secure contact support portion  114  and contact activation portion  116  together to form contact module  100 . 
     The assembly sequence for contact module  100  is as follows. Flexible circuit  104  is roughly aligned to registration pins  118  of activation portion  116  and aligned in circuit alignment notch(es)  108 . Activation portion  116  is then aligned and inserted into contact support portion  114  using alignment module slot(s)  124 . Tapered registration pins  110  of support portion  114  further align circuit  104  as activation portion  116  is inserted into support portion  114 . The insertion of activation portion  116  forces, in this particular example, the insulation plane  102   a  of contact(s)  102  to pierce the dielectric of circuit  104  and peel off the dielectric  104   a , thereby exposing the conductor. Contact(s)  102  is then forced into compression as deflection ridge  106  aligns to force concentrators  112  which forces contact(s)  102  to compress against the exposed conductors of circuit  104 , creating a gas-tight, surface finish to surface finish connection. Activation portion  116  and contact support portion  114  are secured together using arms  120  of activation module  116  and latching holes  122  of support portion  114 . 
     In all embodiments, strain is reduced because the force required in the present invention is required only to pierce one layer of the dielectric and peel it back, not to pierce the conductor itself, nor peel off all of the dielectric. 
     The multi-task connection function performed in essentially one fluid step has many technical (as discussed above) and cost advantages. Conventional ‘high density’ (contacts on pitch centers less than 0.040 inches) connectors require the removal of the covering dielectric and a soldering or welding operation to attach the connector contacts to the circuit&#39;s conductor(s). The attachment process becomes more difficult as the circuit&#39;s density (number of conductors per circuit) increases. Typical problems increasing the cost of high density connector attachment include; solder bridging, contact misregistration (alignment), conductor delamination and cold solder joints. The invention eliminates all of the previously mentioned problems by, in one process, piercing through the dielectric of the flexible circuit and making a surface finish to surface finish or metal to metal, gas tight connection using the tapered insulation plane and optional force concentrators of the contact(s)  14  or  102 . However, the same spring connection mechanism may be used with a blunt ended contact  14  or  102 , to form delicate, for example gold to gold, connections. 
     The invention coordinates the alignment of a high density, fine line, flexible circuit to a mating compound dynamic contact. Thus the connector provides an essentially fluid process for terminating a conductive circuit, and can terminate up to 80 lines per inch. The process is essentially a two step process, when using an embodiment with a cam. First, free floating activation cam  16  is precisely located to spring contact(s)  14  in the housing comprising cover  12  and base  18 , using tapered alignment ribs  34  on cam  16 . Next, tapered registration pins  36  of cam  16  work in combination with tapered conductor alignment notches  46  built into cam  16  and with the rotation of cam  16  to grab circuit  20  and accurately align the conductors of circuit  20  to the spring contact  14  of cover  12 . Tapered alignment notches  46  of cam  16  also lock circuit  20  in place to provide stability to circuit  20  and the connection being made. 
     In the alternative, the connection sequence for the embodiment using an contact module with activation and support portions was discussed above, and it can be seen that, with either embodiment, the compliant, flexible, deflectable spring contact(s) compensate for variations in the thickness of the flexible circuit and provide a predictable and reliable contact force. The simple, mechanical components of the invention insure long term reliability. Each spring contact may be positioned to penetrate more than one insulating layer, in order to electronically mate with a flexible circuit having two or more conductive layers. When using a cam, the apex of the cam, and the alignment ribs, may be angled in a manner that allows a single contact of the spring contact to mate with a single circuit conductor of the flexible circuit, one connection at a time. This one by one connection significantly reduces contact insertion force required. Similarly the deflection ridge of the activation portion of the contact module may be angled to provide one by one connection. 
     The contact(s) and cam(s) may be individually sized to accommodate specific electrical needs, and the connector may be formed to accommodate more than one spring contact and more than one cam. The connector housing the spring contact(s) may be made connectable to form blocks of connectors, depending on the desired task or application. Such possible applications include; the use of a PTH (plated through hole) flexible circuit to change signal direction within the connector or build in test points, active and passive components may be attached to the circuit, or the flexible circuit may be built with an integral network of fuses designed to protect the modules it joins. 
     In all embodiments, the invention provides a housing for optional tapered or blunt spring contacts, and deflects the spring contact(s), if tapered, to activate its stored energy to pierce and peel back the dielectric of a flexible circuit to make and maintain a reliable electrical interconnection between the spring contact and the conductors of the flexible circuit. The invention provides one fluid process with no scraping or other preparation of the flexible circuit required before introduction of the flexible circuit to the spring contact(s). 
     The foregoing provides non-limiting description of the invention, for purposes of illustration, and it is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is defined by the appended claims and their equivalents.