Abstract:
An electrical connector assembly comprising a housing having an interior chamber defining at least one lead frame plane, and identical sets of non-identical lead frame elements. The lead frame plane has a reference point. The lead frame elements are mounted in the interior chamber and aligned within at least one lead frame plane. The lead frame elements are adjustable along the lead frame plane between multiple levels with respect to the reference point. The multiple mating levels of the lead frame elements are created from only one lead frame. The mating levels are selected by the individual lead frame elements being positioned with respect to the reference point. The electrical connector also comprises N lead frame elements, each of which is adjustable between M mating levels to form X lead frame configurations, wherein X=M N .

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Certain embodiments of the present invention generally relate to improvements in electrical connectors and more particularly relate to multi-sequenced electrical connectors that include lead frames.  
           [0002]    Various electronic systems, such as computers, comprise a wide array of components mounted on printed circuit boards, such as daughtercards and motherboards, which are interconnected to transfer signals and power throughout the systems. The circuit boards are joined through electrical connectors. Typical connector assemblies include a plug connector and a receptacle connector, each of which may house a plurality of electrical contacts or wafers. An electrical wafer may be a thin printed circuit board or a series of laminated contacts within a plastic carrier. The electrical wafers within one connector may allow a daughter card to communicate with another daughter card through a backplane. Alternatively, the wafers may be mated in an orthogonal orientation obviating the need for a backplane.  
           [0003]    Typically, electrical traces are etched onto the electrical wafers. The electrical traces permit high-speed transmission of data signals. However, when it comes to carrying power, distinct power blade contacts are utilized within a connector. Power blade contacts are often configured as lead frames. The lead frames typically include a plurality of contact points. For various reasons, the contact points of the lead frames may be sequenced such that one or more contact points in one assembly of the connector, such as a plug assembly, interface with corresponding contact points in the other assembly of the connector, such as a receptacle assembly, before other points of contact. For example, typically it is desirable to have ground contacts contact each other before signal contacts.  
           [0004]    Electrical connectors have been proposed with sequenced lead frames, that is, lead frames with different mating levels of contacts. For example, one contact point may be at a first mating level or depth within the connector, while other contact points may be at different mating levels. Typically, each different lead frame sequence is manufactured separately. Therefore, if a lead frame having three mating levels of contacts is used within a connector, a total of twenty-seven different lead frame sequences are possible. Consequently, twenty-seven different lead frames typically must be stamped, blanked or otherwise formed and inventoried to accommodate the total number of lead frame possibilities. Additionally, twenty-seven lead frames require additional stamping, die tooling and set-ups, resulting in a higher cost of production.  
           [0005]    Thus, a need exists for a more efficient system and method of manufacturing lead frames of varying contact sequences. Additionally, a need exists for an efficient, interchangeable lead frame configured for use within an electrical connector. Further, a need exists for a flexible lead frame design configured to create multiple mating levels for an electrical connector from a single or reduced number of lead frames.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    Certain embodiments of the present invention provide an electrical connector system comprising a plug assembly and a receptacle assembly. At least one of the plug and receptacle assemblies comprises an interior cavity defining a lead frame plane; and first and second lead frame elements located in the lead frame plane. At least one of the first and second lead frame elements are positioned at one of a plurality of mating levels along the lead frame plane.  
           [0007]    The plurality of mating levels define different distances between a contact portion of the lead frame elements and a reference point of said plug or receptacle assembly. The lead frame elements are adjustable between shallow, intermediate and deep mating levels with respect to a mating face of either the plug or receptacle assembly. Overall, if there are N lead frame elements, each of which is adjustable between M levels to form X lead frame element configurations, the equation X=M N  defines the number of lead frame configurations, combination, sequences, etc., that are possible. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0008]    [0008]FIG. 1 illustrates a lead frame carrier strip attached to multiple plug lead frame elements formed in accordance with an embodiment of the present invention.  
         [0009]    [0009]FIG. 2 is an isometric view of a plug lead frame element formed in accordance with an embodiment of the present invention.  
         [0010]    [0010]FIG. 3 is an isometric cross sectional view of a plug assembly formed in accordance with an embodiment of the present invention.  
         [0011]    [0011]FIG. 4 illustrates an exemplary plug lead frame sequence according to an embodiment of the present invention.  
         [0012]    [0012]FIG. 5 illustrates an exemplary plug lead frame sequence according to an embodiment of the present invention.  
         [0013]    [0013]FIG. 6 illustrates an exemplary plug lead frame sequence according to an embodiment of the present invention.  
         [0014]    [0014]FIG. 7 illustrates an exemplary plug lead frame sequence according to an embodiment of the present invention.  
         [0015]    [0015]FIG. 8 is an isometric cross sectional view of the plug assembly including each plug lead frame element positioned at a first mating level, formed in accordance with an embodiment of the present invention.  
         [0016]    [0016]FIG. 9 is an isometric exploded view of a receptacle assembly formed in accordance with an embodiment of the present invention.  
         [0017]    [0017]FIG. 10 is an isometric view of the first receptacle lead frame element according to an embodiment of the present invention.  
         [0018]    [0018]FIG. 11 is an isometric exploded view of a receptacle assembly formed in accordance with an embodiment of the present invention.  
         [0019]    [0019]FIG. 12 is an isometric view of the first receptacle lead frame element according to an embodiment of the present invention.  
         [0020]    [0020]FIG. 13 is an isometric exploded view of a plug assembly according to an embodiment of the present invention.  
         [0021]    [0021]FIG. 14 is an isometric view of plug lead frame elements orthogonally mated with receptacle lead frame elements according to an embodiment of the present invention.  
         [0022]    [0022]FIG. 15 is a flow chart of a method of manufacturing an electrical connector according to an embodiment of the present invention. 
     
    
       [0023]    The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    [0024]FIG. 1 illustrates a lead frame strip  10  attached to multiple plug lead frame elements  14 ,  16  and  18 , formed in accordance with an embodiment of the present invention. A set of plug lead frame elements includes the plug lead frame elements  14 ,  16  and  18 . During the stamping or manufacturing process, the plug lead frame elements  14 ,  16  and  18  are formed integrally with a carrier strip  12  of the lead frame strip  10 . Identical sets of plug lead frame elements  14 ,  16  and  18  are formed. The lead frame strip  10  includes the carrier strip  12  connected to plug lead frame elements  14 ,  16 , and  18 , respectively, at breaking points  13 . The breaking points  13  may be perforated, or otherwise weakened, to facilitate removal of the plug lead frame elements  14 ,  16  and  18  from the carrier strip  12 .  
         [0025]    The plug lead frame element  14  includes an extension portion  28  formed integrally with, and connecting at a right angle to, a board transition portion  34 . The plug lead frame element  16  includes an extension portion  30  formed integrally with, and connecting at a right angle to, a board transition portion  36 . The lead frame element  18  includes an extension portion  32  formed integrally with, and connecting at a right angle to, a board transition portion  38 . Alternatively, the extension portions  28 ,  30  and  32  may connect to the board transition portions  34 ,  36  and  38 , respectively, at angles other than right angles. As shown in FIG. 1, the length of the extension portion  28  is shorter than that of the extension portion  30 , which in turn is shorter than that of the extension portion  32 . Similarly, the height of the board transition portion  34  is shorter than that of the board transition portion  36 , which in turn is shorter than that of the board transition portion  38 .  
         [0026]    Each of the plug lead frame elements  14 ,  16  and  18  include a contact portion  20  extending outwardly from each respective extension portion  28 ,  30  and  32 . Additionally, each of the plug lead frame elements  14 ,  16  and  18  may include flex slots  22 , which may provide added flexibility for the lead frame elements  14 ,  16  and  18 . Pins  26 , which may be received by receptacles, such as through-holes, in a printed circuit board (not shown), extend downwardly from the board transition portions  34 ,  36  and  38 . Also, each plug lead frame element  14 ,  16  and  18  may include positioning tabs  24 , which may be used to position the plug lead frame elements  14 ,  16  and  18  within a plug housing (as discussed below). The positioning tabs  24  may be removed depending on the desired level (discussed below) of the plug lead frame elements  14 ,  16  and  18  within a plug connector. Alternatively, the plug lead frame elements  14 ,  16  and  18  may include more or less than two positioning tabs  24 . Also, alternatively, the plug lead frame elements  14 ,  16  and  18  may not include positioning tabs  24 . Additionally, the plug lead frame elements  14 ,  16  and  18  may not include flex slots  22 .  
         [0027]    Before the plug lead frame elements  14 ,  16  and  18  are inserted, or positioned, within a plug housing, the plug lead frame elements  14 ,  16  and  18  are removed from the supporting body  12  of the carrier strip  10 .  
         [0028]    [0028]FIG. 2 is an isometric view of a plug lead frame element  14  formed in accordance with an embodiment of the present invention.  
         [0029]    [0029]FIG. 3 is an isometric cross sectional view of a plug assembly  40  formed in accordance with an embodiment of the present invention. The plug assembly  40  includes a cover  42 , a lead frame organizer  47  having a plurality of organizer walls  48 , which define channels therebetween, spacers  49 ,  51  and  53 , and an interface housing  50 . The cover  42  includes walls  44  and  46 . The cover  42  may also include lateral walls (not shown). Alternatively, lateral walls may be formed integrally with, and extending upwardly from, the organizer  47 . The interface housing  50  includes latch features  52  that engage latch members formed within the cover  42 . The interface housing  50  also includes a top wall  56 , a bottom wall  57 , a back wall  59  and side walls  58  (only one side wall shown) that define an interface cavity  54 , in which a set of plug lead frame elements, including the plug lead frame elements  14 ,  16  and  18 , and plug circuit boards (not shown) mate with corresponding set of receptacle lead frame elements (discussed below) and receptacle circuit boards (not shown), respectively. Also, the interface housing  50  may include guide slots  60  that receive and retain edges of electrical wafers.  
         [0030]    [0030]FIG. 3 shows a plug assembly  40  that houses both electrical wafers and plug lead frame elements. Optionally, sets of plug lead frame elements, including the plug lead frame elements  14 ,  16  and  18 , may be housed within a separate lead frame housing (discussed below). The plug assembly  40  shown in FIG. 3 is a floating interface assembly. Floating interface connectors are described in U.S. patent application Ser. No. 10/042,635, entitled, “Floating Interface for Electrical Connector,” which is incorporated herein by reference in its entirety. Alternatively, however, the plug assembly  40  may be a conventional, non-floating interface assembly.  
         [0031]    The spacer  49  may be formed integrally with the organizer  48 , lateral walls of the plug assembly  40 , or the interface housing  50 . The spacer  49  extends across the plug assembly  40  perpendicular to the orientation of the plug lead frame element  14 . The spacer  49  may extend from one lateral wall of the plug assembly  40  to the other lateral wall of the plug assembly  40 . Alternatively, the spacer  49  may extend from one lateral wall of the plug assembly  40  to a dividing wall within the plug assembly  40 . Also, alternatively, the spacer  49  may extend from one dividing wall within the plug assembly  40  to another dividing wall. Also, the spacers  49 ,  51  and  53  may be included within a separate plug lead frame housing (as discussed below).  
         [0032]    The spacer  51  may be formed integrally with the interface housing  50  or lateral walls of the plug assembly  40 . The spacer  51  extends across the plug assembly  40  perpendicular to the orientation of the lead frame element  16 . The spacer  51  may extend from one lateral wall of the plug assembly  40  to the other lateral wall of the plug assembly  40 . Alternatively, the spacer  51  may extend from one lateral wall of the plug assembly  40  to a dividing wall within the plug assembly  40 . Also, alternatively, the spacer  51  may extend from one dividing wall within the plug assembly  40  to another dividing wall.  
         [0033]    The spacer  53  may be formed integrally with the interface housing  50  or lateral walls of the plug assembly  40 . The spacer  53  extends across the plug assembly  40  perpendicular to the orientation of the lead frame element  18 . The spacer  53  may extend from one lateral wall of the plug assembly  40  to the other lateral wall of the plug assembly  40 . Alternatively, the spacer  53  may extend from one lateral wall of the plug assembly  40  to a dividing wall within the housing. Also, alternatively, the spacer  53  may extend from one dividing wall within the plug assembly  40  to another dividing wall.  
         [0034]    As shown in FIG. 3, the spacer  49  is positioned below the spacer  51 , which in turn is positioned below the spacer  53 . The spacer  49  contacts the plug lead frame element  14 . The spacer  51  is positioned to allow for proper clearance of the plug lead frame element  14 . Likewise, the spacer  53  is positioned to allow for proper clearance of the lead frame element  16  between the spacer  51  and the spacer  53 . The spacer  51  contacts the lead frame element  16 . The spacer  53  contacts the lead frame element  18 .  
         [0035]    Each plug lead frame element  14 ,  16  and  18  is positioned within the plug assembly  40  such that the pins  26  extend downwardly from the plug assembly  40 . Each pin  26  is received and retained by a pin receptacle (not shown) located on a printed circuit board. Each printed circuit board includes a plurality of pin receptacles aligned in rows. One row of pin receptacles is aligned to receive a row of pins  26  of a longitudinally aligned set of plug lead frame elements  14 ,  16  and  18 . Each row of pin receptacles may include more receptacles than the number of pins  26  of the longitudinally aligned set of plug lead frame elements  14 ,  16  and  18 . For example, a printed circuit board may include rows of 15-20 pin receptacles (if, for example, each plug lead frame  14 ,  16  and  18  includes four pins  26 , respectively). Thus, the plug lead frame elements  14 ,  16  and  18  may be installed at different depths, or mating levels, to accommodate different contact levels. That is, a set of three non-identical plug lead frame elements  14 ,  16  and  18  may be sequenced to accommodate different contact mating level configurations.  
         [0036]    As mentioned above, the plug lead frame elements  14 ,  16  and  18  may include positioning tabs  24 , which may assist in proper positioning of the plug lead frame elements  14 ,  16  and  18 . The plug lead frame elements  14 ,  16  and  18  are retained within the plug assembly  40  by retaining features, channels, and the like. The positioning tabs  24  of the plug lead frame elements  14 ,  16  and  18  (or the plug lead frame elements  14 ,  16  or  18  themselves) abut against the spacers  49 ,  51  and  53 , respectively. If, for example, a plug lead frame element  14 ,  16  or  18  is to be positioned such that it extends at the furthest possible length (“first mating level”) from a reference point within the plug assembly  40  (such as the back wall of the plug assembly  40 ), all of the positioning tabs  24  may be removed. If however, the plug lead frame element  14 ,  16  or  18  is to be positioned such that it extends at an intermediate length (“second mating level”), a portion of the positioning tabs  24  (such as one positioning tab  24 ) may be removed. On the other hand, if the plug lead frame element  14 ,  16  or  18  is to be positioned such that it extends at a shortest length (“third mating level”), none of the positioning tabs  24  may be removed. Thus, varying the mating levels of the plug lead frame elements  14 ,  16  and  18  allows for a plurality of different lead frame sequences from one lead frame. Thus, various lead frame sequences may be achieved through the use of lead frame elements, such as plug lead frame elements  14 ,  16  and  18 . As shown in FIG. 3, for example, the plug lead frame element  14  is at the third mating level, the lead frame element  16  is at the second mating level and the lead frame element  18  is at the first mating level. However, plug lead frame elements  14 ,  16  and  18  positioned behind the plug lead frame elements  14 ,  16  and  18  are positioned at different mating levels. As mentioned above, the plug lead frame elements  14 ,  16  and  18  may not include the positioning tabs  24 . That is, the positioning tabs  24  are used to assist in properly positioning the plug lead frame elements  14 ,  16  and  18 , but are not required for proper positioning.  
         [0037]    FIGS.  4 - 7  illustrate exemplary plug lead frame sequences  62 ,  64 ,  66  and  68 , according to an embodiment of the present invention. FIGS.  4 - 7  show the plug lead frames  14 ,  16  and  18  as each would be positioned within the plug assembly  40  (or other such plug assemblies). However, for clarity, the plug assembly  40  is not shown. It is noted that identical sets of plug lead frame elements  14 ,  16  and  18  are used to form each of the plug lead frame sequences  62 ,  64 ,  66  and  68 .  
         [0038]    Lead frame sequence  62  includes the first and second plug lead frame elements  14  and  16  at the third mating level (L 3 ) and the lead frame element  18  at the first mating level (L 1 ). Each mating level is measured from a reference point within the plug assembly  40 , such as the back wall of the plug assembly, or from a terminal end of a positioning channel of a lead frame element organizer. Lead frame sequence  64  includes the plug lead frame element  14  at the third mating level (L 3 ), the lead frame element  16  at the second mating level (L 2 ), and the lead frame element  18  at the first mating level (L 1 ). Lead frame sequence  66  includes the plug lead frame elements  14 ,  16  and  18  at the second mating level (L 2 ). Lead frame sequence  68  includes the plug lead frame element  14  at the first mating level (L 1 ), while the plug lead frame elements  16  and  18  are at the third mating level (L 3 ). FIGS.  4 - 7  are examples, which by no mean limit the invention to the sequences  62 ,  64 ,  66  and  68  shown. That is, each plug lead frame element  14 ,  16  and  18  may be positioned at first, second or third mating levels. Further, the plug lead frame elements  14 ,  16  and  18  may be combined in twenty-seven different lead frame sequence combinations if three different plug lead frame elements  14 ,  16  and  18  are used. Thus, twenty-seven different lead frame sequences may be produced using three different lead frame elements. However, more or less than three different plug lead frame elements  14 ,  16  and  18  may be used with certain embodiments of the present invention. Thus, certain embodiments of the present invention may accommodate more or less than twenty-seven different lead frame sequence combinations.  
         [0039]    [0039]FIG. 8 is an isometric cross sectional view of the plug assembly  40  including each plug lead frame element  14 ,  16  and  18  positioned at the first mating level, formed in accordance with an embodiment of the present invention. As shown in FIG. 8, the positioning tabs  24  of each plug lead frame element  14 ,  16  and  18  have been removed such that each plug lead frame element  14 ,  16  and  18  extends to its fullest extent into the cavity  54 .  
         [0040]    [0040]FIG. 13 is an isometric exploded view of a plug assembly  40  according to an embodiment of the present invention. As mentioned above, the plug assembly  40  may house electrical wafers (such as electrical wafer  204 ) and plug lead frame elements  14 ,  16  and  18  in a common housing, or in separate housings included within the plug assembly. Plug assembly  200  includes an interface housing  202 , a plug lead frame housing  208 , a wafer organizer  211  and a cover  206 . The interface housing  202  includes a wafer section  203  having slots  207  (that receive and retain electrical wafers  204 ) and a lead frame section  205  within a cavity  209  formed by walls of the interface housing  202 . The interface housing  202  also includes latch receptacles  224 . The cover  206  includes latch members  226  that engage the latch receptacles  224  and latch members  222  that engage latch receptacles  220  of the lead frame housing  208 . The lead frame housing  208  includes passages  214 ,  216  and passages  218 . The plug lead frame element  14  is received and retained within the passage  214 . The lead frame element  16  is received and retained within the passage  216 . The lead frame element  18  is received and retained within the passage  218 . It is to be noted that the lead frame housing  208  includes spacers (as discussed above) within the lead frame housing  208  for proper positioning of the plug lead frame elements  14 ,  16  and  18 . The electrical wafers  204  are positioned within channels (not shown) of the wafer organizer  211 . Upon assembly of the plug assembly  200 , contact portions  20  of the plug lead frame elements  14 ,  16  and  18  extend outwardly from the back wall of the interface housing  202  into the cavity  209 . Also, contact edges  206  of the electrical wafers  204  (and/or signal and ground terminals connected to the electrical wafers  204 ) likewise extend into the cavity  209  of the interface housing  202 .  
         [0041]    [0041]FIG. 9 is an isometric exploded view of a receptacle assembly  70  formed in accordance with an embodiment of the present invention. The receptacle assembly  70  includes a wafer housing  71  having a wafer organizer  74 , an intermediate floating member  78 , a plurality of signal and ground terminals  82  and  80  and a terminal interface housing  84 . The organizer  74  includes channels  75 , each of which receive and retain an electrical wafer  72 . Each electrical wafer  72  is connected to contact pins  76  extending downwardly therefrom. Each electrical wafer  72  is connected to a row of ground terminals  80  or signal terminals  82 , or a row of alternating ground and signal terminals  80  and  82 . The signal and ground terminals  82  and  80  are retained within the intermediate floating member  78  and the terminal interface housing  84 , which includes contact passages  85 . The contact passages  85  allow contact portions of the signal and ground terminals  82  and  80  of the receptacle assembly  70  to mate with corresponding wafers housed within a compatible plug assembly. The housing  86  is positioned over the electrical wafers  72  and snapably engages the board organizer  74 . The cover  86  also latchably engages the terminal interface housing  84  through the mating of the latch members  87  with the latch receptacles  89 . Also, because the intermediate floating member  78  is positioned between the cover  86  and the terminal interface housing  84 , the latch members  87  are also retained by the latch channels  91  of the intermediate floating member  78 .  
         [0042]    As shown in FIG. 9, the receptacle assembly  70  also includes a lead frame housing  88 , which is separate and distinct from the wafer housing  71 . In the embodiment shown in FIG. 9, lead frame housing  88  mounts to the wafer housing  71  through an interaction, or mating, of the mounting surface  102  with a corresponding mating surface on the wafer housing  71 . Alternatively, however, the wafers  72  and lead frame elements may be housed within the same housing. The lead frame housing  88  includes a cavity  96  for a receptacle lead frame element  90 , a cavity  98  for a receptacle lead frame element  92  and a cavity  100  for a receptacle lead frame element  94 . Each set of receptacle lead frame elements, including, the receptacle lead frame elements  90 ,  92  and  94  is configured similarly to a set of plug lead frame elements, including the plug lead frame elements  14 ,  16  and  18  except that the contact portions  104  of the receptacle lead frame elements  90 ,  92  and  94  are configured to mate with the contact portions  20  of the plug lead frame elements  14 ,  16  and  18 . The receptacle lead frame elements  90 ,  92  and  94  may be positioned at different mating levels in a similar fashion as that of the plug lead frame elements  14 ,  16  and  18 .  
         [0043]    [0043]FIG. 10 is an isometric view of the receptacle lead frame element  90  according to an embodiment of the present invention. The receptacle lead frame element  90  includes an extension portion  128  and a board transition portion  134 . The contact portion  104  of the receptacle lead frame element  90  includes a first member  108  and a second member  106  extending outwardly from the first extension portion  128 . A plug contact channel  110  is defined between the first member  108  and the second member  106 . During mating, the contact portion  20  of the plug lead frame element  14  is positioned within the plug contact channel  110  between the members  108  and  106 , such that the contact portion  20  is sandwiched between the members  108  and  106 . The members  108  and  106  contact the contact portion  20  of the plug lead frame element  14  thereby establishing an electrical connection between the plug lead frame element  14  and the receptacle lead frame element  90 .  
         [0044]    The receptacle lead frame elements  92  and  94  are configured similar to the receptacle lead frame element  90 . Further, the mating between the receptacle lead frame elements  92  and  94  and the plug lead frame elements  16  and  18  occurs in a similar fashion to that described above with respect to the receptacle lead frame element  90  and the plug lead frame element  14 .  
         [0045]    Referring again to FIG. 9, the receptacle assembly  70  may mate in a parallel, or in-line, fashion with the plug assembly  40 . That is, a sequence of plug lead frame elements  14 ,  16  and  18  mate with a sequence of receptacle lead frame elements  90 ,  92  and  94 . For example, a plug lead frame element  14  may mate with a receptacle lead frame element  90 , a plug lead frame element  16  may mate with a receptacle lead frame element  92 , while a plug lead frame element  18  may mate with a receptacle lead frame element  94 . The receptacle lead frame elements  90 ,  92  and  94  may be positioned at the same mating level such that, during mating, certain plug lead frame elements  14 ,  16  or  18 , which may be at varying mating levels, may contact the corresponding receptacle lead frame elements  90 ,  92  and  94  before other plug lead frame elements  14 ,  16  or  18  contact their corresponding receptacle lead frame elements  90 ,  92  and  94 . For example, the plug lead frame element  14  may contact the receptacle lead frame element  90  before the plug lead frame elements  16  and  18  contact the receptacle lead frame elements  92  and  94 , respectively.  
         [0046]    Alternatively, the receptacle lead frame elements  90 ,  92  and  94  may be positioned at varying mating levels while the plug lead frame elements  14 ,  16  and  18  may all be positioned at the same mating level. Also, alternatively, the receptacle lead frame elements  90 ,  92  and  94  may be positioned at different mating levels, while the plug lead frame elements  14 ,  16  and  18  are also positioned at different mating levels.  
         [0047]    For example, a plug lead frame element  14  may be positioned at a first mating level (while a lead frame element  16  may be positioned at a different mating level than that of the plug lead frame element  14 ), while a corresponding receptacle lead frame element  90  may be positioned at a first mating level, second mating level or third mating level (while the second receptacle lead frame element  92  is positioned at a different mating level than that of the receptacle lead frame element  90 ). Overall, certain plug lead frame elements  14 ,  16  or  18  may contact certain receptacle lead frame elements  90 ,  92  and  94  at different times during mating. For example, it may be desired to have a ground lead frame  14 ,  16  or  18  contact a corresponding ground receptacle lead frame  90 ,  92  or  94  before signal lead frames contact each other. Because of the multi-sequence nature of the plug lead frame elements  14 ,  16  and  18  and the receptacle lead frame elements  90 ,  92  and  94 , a variety of different mating sequences may be used such that certain plug lead frame elements  14 ,  16  or  18  contact certain receptacle lead frame elements  90 ,  92  or  94 , respectively, before others.  
         [0048]    [0048]FIG. 11 is an isometric exploded view of a receptacle assembly  136  formed in accordance with an embodiment of the present invention. The receptacle assembly  136  differs from the receptacle assembly  70  in that the receptacle assembly  136  aligns ground and signal terminals  138  in rows (as opposed to the column configuration shown with respect to the receptacle assembly  70 ). The receptacle assembly  70  and the receptacle assembly  136  may mate with a plug assembly in an orthogonal or in-line manner, depending on the orientation of the terminals and plug lead frame elements of the compatible plug assembly.  
         [0049]    The receptacle assembly  136  includes terminals  138 , a terminal interface housing  140 , an intermediate member  144  mounted over a lead frame housing  142 , a cover  154  and an organizer  148  for receiving and retaining electrical wafers  146  and receptacle lead frame elements  150  and  152 . The receptacle lead frame elements  150  and  152  are positioned in two rows. That is, a receptacle lead frame element  150  is positioned below a receptacle lead frame element  152 . A planar row of lead frame elements  150  is formed and a planar row of lead frame elements  152  is formed upon assembly of the receptacle assembly  136 . The receptacle assembly  136  may mate in an orthogonal fashion with the plug assembly  40 . That is, a sequence of plug lead frame elements  14 ,  16  and  18  mate with a sequence of three receptacle lead frame elements  150  or  152 .  
         [0050]    For example, a plug lead frame element  14  may mate with a receptacle lead frame element  150 , a lead frame element  16  may mate with another receptacle lead frame element  150 , while a lead frame element  18  may mate with another lead frame element  150 . The receptacle lead frame elements  150  and  152  may be positioned at the same mating level such that, during mating, certain plug lead frame elements  14 ,  16  or  18 , which may be at varying mating levels, may contact the receptacle lead frame elements  150  and  152  before other plug lead frame elements  14 ,  16  or  18  contact the receptacle lead frame elements  150  and  152 . Alternatively, the receptacle lead frame elements  150  and  152  may be positioned at varying mating levels while the plug lead frame elements  14 ,  16  and  18  may all be positioned at the same mating level. Overall, certain plug lead frame elements  14 ,  16  or  18  may contact certain receptacle lead frame elements  150  or  152  at different times during mating. For example, it may be desired to have a ground lead frame  14 ,  16  or  18  contact a corresponding ground receptacle lead frame  150  or  152  before signal lead frames contact each other.  
         [0051]    [0051]FIG. 12 is an isometric view of the receptacle lead frame element  150  according to an embodiment of the present invention. The receptacle lead frame element  150  includes an extension portion  156  and a board transition portion  158 . The contact portion  160  of the receptacle lead frame element  150  includes a member  162  and a member  164  extending outwardly from the extension portion  156 . A plug contact channel  166  is defined between the member  162  and the member  164 . During mating, the contact portion  20  of a plug lead frame element  14 ,  16  or  18  is positioned within the plug contact channel  166  between the members  162  and  164 , such that the contact portion  20  is sandwiched between the members  162  and  164 . The members  162  and  164  contact the contact portion  20  thereby establishing an electrical connection between the plug lead frame element  14 ,  16  or  18  and the receptacle lead frame element  150 .  
         [0052]    The receptacle lead frame element  152  is configured similar to the receptacle lead frame element  150 . Further, the mating between the receptacle lead frame elements  152  and the plug lead frame elements  14 ,  16  or  18  occurs in a similar fashion to that described above with respect to the receptacle lead frame element  150 .  
         [0053]    [0053]FIG. 14 is an isometric view of plug lead frame elements  300  and  302  orthogonally mated with receptacle lead frame elements  304 ,  306 ,  308 , and  310  according to an embodiment of the present invention. The plug lead frame elements  300  and  302  include pins  318  that are received and retained by receptacles  316  formed within a printed circuit board  312 . Similarly, the receptacle lead frame elements  304 ,  306 ,  308  and  310  include pins  320  that are received and retained by receptacles  317  formed within a printed circuit board  314 . Each plug lead frame element  300  and  302  includes a contact portion  324  similar to the contact portions  20  (discussed above). However, as shown in FIG. 14, the receptacle lead frame elements  304 ,  306 ,  308  and  310  include a contact portion  326  that includes two members on a first side of the contact portion  324  of the plug lead frame elements  300  and  302  and at least one member on the other side of the contact portion  324 .  
         [0054]    One sequence of plug lead frame elements  300  and  302  mate with a sequence of two receptacle lead frame elements  304 . A second sequence of plug lead frame elements  300  and  302  mate with two receptacle lead frame elements  306 . Similarly, a third sequence of plug lead frame elements  300  and  302  mate with two receptacle lead frame elements  306 . Also, a fourth sequence of plug lead frame elements  300  and  302  mate with two receptacle lead frame elements  308 .  
         [0055]    [0055]FIG. 15 is a flow chart of a method of manufacturing an electrical connector according to an embodiment of the present invention. At step  500 , lead frames (including plug and receptacle lead frame elements) are stamped, blanked or otherwise formed. At step  502 , the plug and receptacle interface, intermediate and lead frame housing are molded. At step  504 , lead frame elements are separated from the carrier strip. At step  506 , lead frame elements are inserted into the lead frame housings at varying depths relative to a reference point, thereby creating a plurality of mating levels.  
         [0056]    Thus, embodiments of the present invention provide an efficient, interchangeable and adaptable lead frame through the use of a plurality of lead frame elements. That is, a small number of lead frame elements may be used to form a wide variety of lead frames through various combinations of the lead frame elements. Additionally, embodiments of the present invention provide a more efficient method of manufacturing various lead frame sequences. Embodiments of the present invention also provide a more efficient method of manufacturing connectors with various lead frame element sequences where a single lead frame may be used to form a plurality of mating levels. The mating levels are created by varying the depth of insertion of the lead frame elements. Any lead frame element may form any mating level and unique lead frame elements are not required for each mating level. It is to be understood that the lead frame elements may be used with electrical connectors that utilize lead frames. That is, the lead frame elements may be used with orthogonal or in-line connectors.  
         [0057]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. 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. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.