Patent Publication Number: US-7909668-B2

Title: Contact with twist pin interface

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part of U.S. patent application Ser. No. 12/177,646 filed on Jul. 22, 2008, and claims priority to that application, which is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to electrical connectors and assemblies, and more particularly, to electrical connectors and assemblies that are configured to maintain an electrical connection while in extreme or inhospitable environments. 
     Electrical connectors provide communicative interfaces between electrical components where power and/or signals may be transmitted therethrough. For example, the electrical connectors may be used within telecommunication equipment, servers, and data storage or transport devices. Typically, electrical connectors are used in environments, such as in offices or homes, where the connectors are not subjected to constant shock, vibration, and/or extreme temperatures. However, in some applications, such as aerospace or military equipment, the electrical connector must be configured to withstand certain environmental conditions and still effectively transmit power and/or data signals. 
     For example, in one conventional connector assembly, an electrical connector includes a mating face that is configured to engage another connector. The electrical connector includes a plurality of conductors that extend through the electrical connector and into a cavity near the mating face. Each conductor is coupled to or forms into a spring beam that projects into the cavity of the connector. Each cavity and spring beam is configured to electrically couple to a corresponding pin from the other connector when the pin is inserted. However, while the conventional connectors may be effective for friendlier environments, such as in a home or office, the connectors have limited capabilities in maintaining the electrical connection in environments that include extreme temperatures or in environments that include constant shock or vibrations. 
     Accordingly, there is a need for an electrical connector that, during the connector&#39;s normal course of usage, can withstand conditions harsher than typically experienced in a home or office environment. Furthermore, there is also a need for electrical connectors that offer alternative means for maintaining an electrical connection. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, an electrical connector is provided and includes a housing that has a mating face configured to engage a mating connector. The electrical connector also includes a plurality of conductors that extend through the housing and a plurality of socket members that project from the mating face. Each socket member is electrically coupled to one of the conductors and includes a shaft that is configured to be inserted into a cavity of the mating connector. The shaft forms a passage that is configured to receive an associated mating contact held within the cavity for establishing an electrical connection. 
     Optionally, the shaft of the socket member is configured to receive a twist pin contact. The plurality of socket members may be configured into an array that includes rows and columns of socket members that project from the mating face in a common direction. Also, the mating face may be substantially planar. In addition, each conductor may include a mating tail that forms a compliant pin. The compliant pin may be configured to be inserted into a hole of the socket member such that the socket member and the compliant pin form an interference fit with each other and are mechanically and electrically coupled to each other. Also, the housing and the conductors of the electrical connector may be configured to transmit high-speed differential signals. 
     In another embodiment, an electrical connector assembly for interconnecting first and second electrical components is provided. The connector assembly includes a mating connector that has a housing having a mating face and a plurality of a cavities extending into the housing. Each cavity has a mating contact therein that is electrically coupled to the first electrical component. The connector assembly also includes a socket connector that is configured to engage the mating connector. The socket connector includes a socket housing having a mating face configured to engage the mating face of the mating connector and a plurality of conductors that extend through the socket housing and are electrically coupled to the second electrical component. The socket connector also includes a plurality of socket members that are electrically coupled to the conductors. Each socket member includes a shaft that projects from the mating face of the socket housing and is configured for insertion into one of the cavities. The shaft forms a passage that is configured to receive the corresponding mating contact held within the cavity and to establish an electrical connection. 
     Optionally, the mating contacts are configured to establish multiple points of electrical contact within the shaft of the socket member. 
     The electrical connector includes a contact which has a conductive portion, a wire-receiving portion and a bundle of wound wires. The conductive portion has a compliant portion extending from a first end thereof. The compliant portion is configured to be positioned in an opening of a panel, which includes, but is not limited to, a printed circuit board. The wire-receiving portion has a wire-receiving channel provided thereon. The bundle of wound wires is mounted in the wire-receiving channel and has a contact section which is configured to engage a mating connector. 
     The wire-receiving portion may be formed from the conductive portion proximate a second end thereof. The wire-receiving portion may have arcuate sections which define the wire-receiving channel. The wire-receiving channel may have a diameter which is less than the diameter of a mounting section of the bundle of helically wound wire, causing the mounting section of the bundle of helically wound wires to frictionally engage the inside surfaces of the arcuate sections to mechanically and electrically maintain the mounting section in the wire-receiving channel. Alternatively, the wire-receiving portion may be configured to be soldered to the mounting section of the bundle of helically wound wires or the wire-receiving portion may be configured to be displaced inward around a mounting section of the bundle of helically wound wires. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electrical connector assembly formed in accordance with one embodiment. 
         FIG. 2  is a partially exploded view of an electrical connector that may be used in the connector assembly shown in  FIG. 1 . 
         FIG. 3  is a perspective view of a contact module that may be used with the connector shown in  FIG. 2 . 
         FIG. 4  is a partially exploded view of a mating connector that may mate with the electrical connector shown in  FIG. 2 . 
         FIG. 5  is an isolated view of a mating contact that may be used with the mating connector shown in  FIG. 4 . 
         FIG. 6  is a perspective cross-sectional view of the connectors shown in  FIGS. 2 and 4  when the connectors are in a fully mated position. 
         FIG. 7  is an enlarged cross-sectional view of the connectors shown in  FIG. 6 . 
         FIG. 8  is an enlarged perspective view of a first alternate mating contact. 
         FIG. 9  is an enlarged perspective view of the first alternate mating contact of  FIG. 8  with a bundle of helically wound wires inserted therein. 
         FIG. 10  is an enlarged perspective view of a second alternate mating contact. 
         FIG. 11  is an enlarged perspective view of the second alternate mating contact of  FIG. 10  with a bundle of helically wound wires inserted therein. 
         FIG. 12  is an enlarged perspective view of a third alternate mating contact. 
         FIG. 13  is an enlarged perspective view of the third alternate mating contact of  FIG. 12  with a bundle of helically wound wires inserted therein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of an electrical connector assembly  100  formed in accordance with one embodiment. As shown, the connector assembly  100  includes a sub-assembly  102  that has an electrical component  104  (illustrated as a circuit board  106  in  FIG. 1 ) and an electrical connector  108  mounted to the circuit board  106 . The connector assembly  100  also includes another sub-assembly  110  having an electrical component  112 , which is illustrated as a circuit board  114 , and an electrical connector  116  mounted to the circuit board  114 . The sub-assemblies  102  and  110  (and corresponding connectors  108  and  116 ) are configured to mate with one another such that electrical signals and/or power may be transmitted therebetween. In the illustrated embodiment, the connectors  108  and  116  are configured to transmit differential signals. As will be discussed in greater detail below, the connector  108  includes a plurality of socket members  130  that are sized and shaped to be inserted into corresponding cavities  132  ( FIG. 4 ) of the connector  116 . The cavities  132  hold mating contacts  134  ( FIG. 4 ), which, in one embodiment, may be twist pin contacts  236  ( FIG. 5 ). When the connectors  108  and  116  are fully mated, the socket members  130 , cavities  132 , and twist pin contacts  236  facilitate maintaining a mechanical and electrical connection between the connectors  108  and  116 . However, although the following description is with specific reference to the illustrated connectors  108  and  116 , alternative embodiments of electrical connectors and assemblies may incorporate similar features and components as described herein. As such, the following description is provided for purposes of illustration, rather than limitation, and is but one potential application of the subject matter herein. 
     The connector  108  may be held and covered by a shield  109 , and the connector  116  may be held and covered by a shield  115 . Also, in addition to the connectors  108  and  116 , the sub-assemblies  102  and  110  may have additional parts and connectors mounted to the circuit boards  106  and  114 , respectively, such as another pair of mateable electrical connectors  117  and  118 , complementary guiding features  120  and  122 , and power connectors  124  and  126 , which are illustrated as DIN power connectors but may be any other type of connector. 
     The connector assembly  100  (and corresponding sub-assemblies  102  and  110 ) may be configured for many applications, such as high-speed telecommunications equipment, various classes of servers, and data storage and transport devices. Also, the connector assembly  100  may be configured to transmit high-speed differential signals. As used herein, the term “high-speed” includes transmission speeds of approximately one (1) gigabit/s or greater. In one embodiment, connectors  108  and  116  are configured to transmit approximately 10 gigabit/s or greater. Furthermore, the connector assembly  100  may perform at high speeds and maintain signal integrity while withstanding vibrations and shock that may be experienced during, for example, aerospace or military operations. As such, the connector assembly  100  may be configured to satisfy known industry standards including military specifications, such as MIL-DTL-83513. However, embodiments described herein are not limited to applications for extreme environments, but may also be used in other environments, such as in an office or home. 
       FIG. 2  is a partially exploded view of the connector  108 , and  FIG. 3  is an isolated perspective view of a contact module  150 A that is used by the connector  108 . As shown in  FIG. 2 , the connector  108  includes a housing assembly  147  that has a plurality of contact modules  150  and a front housing  160 . The contact modules  150  may be grouped together or arranged to form a contact module assembly  151  ( FIG. 2 ) that is held by the front housing  160 . The various features of the housing assembly  147  and the contact module(s)  150  may be designed to provide an electrical connector, such as the connector  108 , that is operable at frequencies, densities, and/or throughputs that are relatively higher than electrical connectors without some or all of the features described herein, by reducing crosstalk, reducing noise persistence, reducing impedance footprint mismatch and/or reducing intra-pair skew. 
     Also shown in  FIG. 2 , each contact module  150  may include a plurality of conductors  152  (shown in  FIG. 6 ) that extend between a mounting edge  154  and a mating edge  156  of the contact module  150 . The contact modules  150  also include the socket members  130  that project from the mating edge  156  in a common direction (i.e., parallel with respect to each other). When fully assembled, the contact modules  150  may be held by the front housing  160  and arranged side-by-side. Each contact module  150  may include one shield  158  on one side of the contact module  150 . Alternatively, the contact module  150  may have shields on both sides. Also shown, the front housing  160  may include a substantially rectangular and planar mating face  162  and a rear side  164  that engages the contact modules  150 . As shown, the front housing  160  may include a shroud  166  that covers a portion of the contact modules  150 . An outer surface  168  of the shroud  166  may have features (e.g., ridges, grooves, or keys) for mating with the shield  109 . The front housing  160  includes a dielectric front portion  170  that extends between the rear side  164  and the mating face  162 . A plurality of openings or passages  163  extend through the front portion  170  and are configured to receive the socket members  130  when the contact module assembly  151  (or individual contact modules  150 ) is inserted into the front housing  160 . Although not shown, the front housing  160  may form open slots that receive and hold the mating edges  156  of each contact module  150 . 
     The plurality of socket members  130  may project from the mating face  162  in a common direction and at a common distance D. The socket members  130  may form a forward-facing array  177 , which may take a grid-like form of rows and columns of socket members  130 . As will be discussed in greater detail below, in one embodiment, the array  177  of socket members  130  are received by a complementary array  204  ( FIG. 4 ) of cavities  132 . When the connectors  108  and  116  are fully mated, the socket members  130  and cavities  132  may cooperate with other features of the connectors  108  and  116  to facilitate mechanically and electrically coupling the connectors  108  and  116  together. 
       FIG. 3  illustrates the contact module  150  in greater detail. The contact module  150  includes an internal lead frame  180  (shown in  FIG. 6 ) that includes the conductors  152  ( FIG. 6 ) and is contained within a dielectric body  182 . The lead frame  180  is enclosed within the body  182 , but may be partially exposed by the body  182  in certain areas. In some embodiments, the body  182  is manufactured using an over-molding process. During the molding process, the lead frame  180  is encased in a dielectric material, which forms the body  182 . A plurality of mating tails  186  extend from the mating edge  156  and a plurality of mounting tails  184  extend from the edge  154 . In the illustrated embodiment, the mating edge  156  and the mounting edge  154  are generally perpendicular to one another (i.e., the connector  108  is a right-angle connector). Also shown, the body  182  includes opposite side portions  188  and  190  that extend substantially parallel to and along the lead frame  180 . 
     In the illustrated embodiment, the contact modules  150  include two different types of contact modules  150  (indicated as  150 A and  150 B in  FIG. 2 ) that include different arrangements of conductors  152  ( FIG. 6 ) or types of lead frames  180  ( FIG. 6 ). When fully assembled, the contact modules  150 A and  150 B are placed alongside each other such that side portion  190  of the contact module  150 A is adjacent to or abuts the side portion  188  of the contact module  150 B. 
     Also, the body  182  may include a plurality of openings  192 A and  192 B formed entirely through the body  182  between the side portions  188  and  190 . The openings  192 A and  192 B provide an air gap through the body  182  and may be provided between signal conductors of adjacent differential pairs. The openings  192 A and  192 B may have shapes and lengths that are selected to balance structural integrity of the contact module  150 . The openings  192 A and  192 B may provide an air gap between signal conductors, which may decrease the cross-talk of the contact module  150  by providing an air dielectric therebetween as opposed to only a plastic dielectric. Selecting the width and the length of the openings  192 A and  192 B may balance these factors. Optionally, the openings  192 A may be filled with a dielectric material having certain characteristics that may enhance at least one of the stability and the electrical performance of the contact modules  150  and/or module assembly  151 . 
     In the illustrated embodiment, the openings  192 B are substantially rectangular and arranged near the mounting edge  154  and the mating edge  156  of the contact module  150 . The openings  192 B may be configured to receive grips  193  from the shield  158 . The grips  193  may attach to and make electrical contact with a ground conductor. 
     In the illustrated embodiment, the mating tails  186  and  184  are compliant pins formed to have an eye-of-needle shape. The compliant pins may be configured to form an interference, gas-tight fit with a hole in a circuit board or with a hole  250  (shown in  FIG. 7 ) of the socket member  130 . As shown in  FIG. 3 , the socket members  130  may include a base portion  131  and a shaft  133 . The base portion  131  includes the hole  250  through which the mating tail  186  is received and the shaft  133  includes a passage  135  in which the mating contact  134  ( FIG. 4 ) is received. The diameter of base portion  131  is greater than a diameter of the shaft  133 . When the connector  108  ( FIG. 1 ) is fully assembled and the socket members  130  are inserted through the front housing  160 , the base portion  131  of each socket member  130  may be prevented from moving away from the mating edge  156  because the openings  163  of the front housing  160  are configured to prevent movement by the socket member  130 . 
       FIG. 4  is a partially exploded view of the connector  116  that includes a dielectric housing  200  that also has a mating face  202  configured to engage the mating face  162  ( FIG. 2 ) of the connector  108  ( FIG. 2 ). The connector  116  also includes a plurality of cavities  132  that extend through the housing  200 . In the illustrated embodiment, the cavities  132  extend linearly through the housing  200  and form a forward-facing array  204  of cavities  132 , which may take a complementary grid-like form of rows and columns of cavities  132  with respect to the array  177  of socket members  130 . The housing  200  may also have an outer surface that surrounds the mating face  202 . The outer surface and housing  200  may be configured to be surrounded or held by a shield  115  (shown in  FIG. 6 ). 
     The connector also includes a plurality of mating contacts  134  that are inserted into and held by the cavities  132 . The mating contacts  134  are configured to mate with the socket members  130  ( FIG. 1 ) when the socket members  130  are inserted into the cavities  132 . In one embodiment, the mating contact  134  is configured to form multiple points of electrical contact with the shaft  133  ( FIG. 3 ) of the socket member  130  ( FIG. 3 ). Each cavity  132  may have a rounded opening that initially directs the socket members  130  into the corresponding cavity  132 . Also, the connector  116  may be a vertical-type connector as shown in  FIG. 4  in that the paths of the mating contacts  134  are substantially linear. However, in alternative embodiments, the connector  116  may be another type of connector. 
       FIG. 5  is an isolated view of the mating contact  134  and includes a window showing an enlarged, exposed portion of the mating contact  134 . In the illustrated embodiment, the mating contact  134  includes a conductive portion or conductive beam  230  having two ends  232  and  234  shaped into compliant pins. The beam  230  may have any length or shape in order to transmit signals or power through the connector  116  ( FIG. 4 ). The compliant pin at the end  232  couples to, for example, the circuit board  114 , and the compliant pin at the end  234  is coupled to a twist pin contact  236 . The twist pin contact  236  includes a barrel  238  that is connected with a plurality of conductive wires  240  that are joined at a core  242 . In one embodiment, the wires  240  are made from a copper material and are helically wound and terminate at a hemispherical weld. The wires  240  may form several self wiping spring surfaces that are configured for a consistent continuity and a very low noise level. As shown, the barrel  238  is configured to form a gas-tight, interference fit with a compliant pin formed by the end  234  of the beam  230 . The barrel  238  and/or core  242  may also have guiding features on an outer surface thereof. When the mating contact  134  is inserted into the cavity  132  ( FIG. 4 ), the guiding features may direct the mating contact  134  into a predetermined position. 
     The contact  134  shown in  FIG. 5  has three components: the conductive beam  230 , the barrel  238  and the bundle of helically wound wires  240 , which are assembled together. The wires  240  are joined at the core  242  of the barrel by crimping the core  242  to the wires  240 , thereby forming the twist pin contact  236 . An end  234  of the beam  230  is inserted into the barrel  238  to form a gas-tight, interference fit therebetween, as was previously described. This allows the bundle of helically wound wires  240  to be connected via the barrel  238  and the conductive beam  230  to the circuit board  114  ( FIG. 1 ). 
     Referring to  FIGS. 8 and 9 , an alternate mating contact  300  ( FIG. 9 ) is shown. The mating contact  300  has a conductive portion or conductive beam  330  with a first end  332  and a second end  334 . The conductive beam  330  is stamped and formed from conventional spring metal such as copper alloy or tin-plated phosphor bronze or any other material that has the resilient and electrical characteristics required. The first end  332  has a compliant portion  333  which extends therefrom and is configured to be received in an opening of the panel or circuit board  114  ( FIG. 1 ). In the embodiment shown, the compliant portion has an eye-of-the-needle configuration, but other types of compliant portions can be used. The conductive beam  330  has a wire-receiving portion  350  formed therefrom proximate the second end  334 . The wire-receiving portion  350  has a first arcuate section  352 , a second arcuate section  354 , and a third arcuate section  356   
     The first and third arcuate sections  352 ,  356  are spaced from each other and are formed in essentially the same configuration to one side of the plane of the conductive beam  330 . The second arcuate section  354  is spaced between the first and third arcuate sections  352 ,  356  and is formed to the opposite side of the plane of the conductive beam  330  as the first and third arcuate sections  352 ,  356 . The first, second and third arcuate sections  352 ,  354 ,  356  define a wire-receiving channel  358 . The wire-receiving channel  358  extends from the second end  334  of the conductive beam to a stop surface  360  provided proximate the first arcuate section  352 . 
     Mounting projections  362  may be provided on the conductive beam  330 . The mounting projections  362  extend from the conductive beam  330  to engage a wall of an opening of connector  116  ( FIG. 1 ). The mounting projections  362  maintain and stabilize the mating contact  300  in the opening of the connector  116 . 
     As shown in  FIG. 9 , a bundle of helically wound wires  340  has a mounting section  370 , a bulge contact section  372  and a cap  374 . The mounting section  370  of the bundle of helically wound wires  340  is positioned in the wire-receiving channel  358 . The first and third arcuate sections  352 ,  356  extend below the mounting section  370  of the bundle of helically wound wires  340  (as shown in  FIG. 9 ) and the second arcuate section  354  extends above the mounting section  370 . In order to assure that the bundle of helically wound wires  340  are placed in electrical engagement with the first, second and third arcuate sections  352 ,  354 ,  356  and the conductive beam  330 , the first, second and third arcuate sections  352 ,  354 ,  356  are formed so that the wire-receiving channel  358  has a diameter which is slightly larger than the diameter of the mounting section  370  of the bundle of helically wound wires  340 , thereby allowing the mounting section  370  of the bundle of helically wound wires  340  to be easily inserted into the wire receiving channel  358 . With the mounting section  370  positioned in the wire receiving channel  358 , the first, second and third arcuate sections  352 ,  354 ,  356 , or any one or two of the sections, may be displaced inward or crimped, such that the mounting section  370  is distorted to prevent the bundle of helically wound wires  340  from being removed. In addition, the inside surfaces of the first, second and third arcuate sections  352 ,  354 ,  356  may be plated with a highly conductive material, i.e. gold, to provide a better electrical connection to the bundle of helically wound wires  340 . The conductive beam  330  may have tapered surfaces at the second end  334 . The tapered surfaces and the cap  374  provide lead-in surfaces which facilitate the insertion of the mating contact  300  into a mating receptacle (not shown). 
     In the alternative, the first, second and third arcuate sections  352 ,  354 ,  356  may be formed so that the wire-receiving channel  358  has a diameter which is slightly less than the diameter of the mounting section  370  of the bundle of helically wound wires  340 , thereby causing the mounting section  370  of the bundle of helically wound wires  340  to frictionally engage the inside surfaces of the first, second and third arcuate sections  352 ,  354 ,  356  causing the mounting section  370  of the bundle of helically wound wires  340  to wipe or clean the inside surfaces of the first, second and third arcuate sections  352 ,  354 ,  356  as insertion occurs. This wiping action removes any contamination or corrosion on the mounting section  370  and the inside surface of the first, second and third arcuate sections  352 ,  354 ,  356 , thereby providing a reliable electrical connection between the mounting section  370  and the first, second and third arcuate sections  352 ,  354 ,  356 . As the mounting section  370  of the bundle of helically wound wires  340  has a slightly larger diameter than that of the wire-receiving channel  358 , the bundle of helically wound wires  340  will be mechanically and electrically maintained in the wire-receiving channel  358  over time. 
     Mating contacts  300  can be stamped and formed on a carrier strip to allow the mating contacts  300  to be spaced in alignment with the contact-receiving cavities of the connector  116  ( FIG. 1 ). This allows for mass insertion of the mating contacts  300  into the connector  116 . As the wire-receiving portions  350  are stamped and formed from the conductive beams  330 , no extra material is required to form the wire-receiving portions  350 . Therefore, the mating contacts  300  can be stamped to the spacing required and mass inserted into the connector  116 . 
     Referring to  FIGS. 10 and 11 , a second alternate mating contact  400  ( FIG. 11 ) is shown. The mating contact  400  has a conductive portion or conductive beam  430  with a first end  432  and a second end  434 . The conductive beam  430  is stamped and formed from conventional spring metal such as copper alloy or tin-plated phosphor bronze or any other material that has the resilient and electrical characteristics required. The first end  432  has a compliant portion  433  which extends therefrom and is configured to be received in an opening of the panel or circuit board  114  ( FIG. 1 ). In the embodiment shown, the compliant portion has an eye-of-the-needle configuration, but other types of compliant portions can be used. 
     A wire-receiving portion  450  extends from the second end  434  of the conductive beam  430 . The wire-receiving portion  450  has a transition section  452 , an arcuate retention section  454  and an arcuate alignment section  456 . The transition section  452  is slightly inclined relative to the plane of the conductive beam  430 . The arcuate retention section  454  extends from the transition section  452  in a direction away from the conductive beam  430 . The arcuate alignment section  456  extends from the arcuate retention section  454  in a direction away from the transition section  430 . The arcuate retention section  454  and the arcuate alignment section  456  have a wire-receiving channel  458  which extends thereacross. Mounting projections  462  may be provided on the conductive beam  430 . The mounting projections  462  extend from the conductive beam  430  to engage a wall of an opening of connector  116  ( FIG. 1 ). The mounting projections  462  maintain and stabilize the mating contact  400  in the opening of the connector  116 . 
     As shown in  FIG. 11 , the bundle of helically wound wires  440  has a mounting section  470 , a bulge contact section  472  and a cap  474 . The mounting section  470  of the bundle of helically wound wires  440  is positioned in the wire-receiving channel  458 . The arcuate alignment section  456  extends below the mounting section  470  of the bundle of helically wound wires  440  (as shown in  FIG. 11 ) and helps to align the bundle of helically wound wires  440  upon insertion. The mounting section  470  of the bundle of helically wound wires  440  is positioned in the arcuate retention section  454 . In order to assure that the mounting section  470  of the bundle of helically wound wires  440  is placed in electrical engagement with the arcuate retention section  454 , the arcuate retention section  454  is formed so that the wire-receiving channel  458  has a diameter which is slightly larger than the diameter of the mounting section  470  of the bundle of helically wound wires  440 , thereby allowing the mounting section  470  of the bundle of helically wound wires  440  to be easily inserted into the wire receiving channel  458 . With the mounting section  470  positioned in the wire receiving channel  458 , the mounting section  470  of the bundle of helically wound wires  440  may be soldered to the arcuate retention section  454  and/or the arcuate alignment section  456  using known soldering techniques. Alternately, with the mounting section  470  positioned in the wire receiving channel  458 , the arcuate retention section  454  may be displaced inward or crimped, such that the mounting section  470  is distorted to prevent the bundle of helically wound wires  440  from being removed. The inside surface of the arcuate retention section  454  may be plated with a highly conductive material, i.e. gold, to provide a better electrical connection to the bundle of helically wound wires  440 . 
     In the alternative, the arcuate retention section  454  may be formed so that the wire-receiving channel  458  has a diameter which is slightly less than the diameter of the mounting section  470  of the bundle of helically wound wires  440 , thereby causing the mounting section  470  of the bundle of helically wound wires  440  to frictionally engage the inside surfaces of the arcuate retention section  454  causing the mounting section  470  of the bundle of helically wound wires  440  to wipe or clean the inside surfaces of the arcuate retention section  454  as insertion occurs. This wiping action removes any contamination or corrosion on the mounting section  470  and the inside surface of the arcuate retention section  454 , thereby providing a reliable electrical connection between the mounting section  470  and the arcuate retention section  454 . As the mounting section  470  of the bundle of helically wound wires  440  has a slightly larger diameter than that of the wire-receiving channel  458 , the bundle of helically wound wires  440  will be frictionally maintained in the wire-receiving channel  458  over time. 
     The slight inclination of the transition section  452  allows the longitudinal axis of the conductive beam  430  and the longitudinal axis of the bundle of helically wound wires  440  to be in essentially the same plane. The cap  474  provides a lead-in surface which facilitates the insertion of the mating contact  400  into a mating receptacle (not shown). 
     Referring to  FIGS. 12 and 13 , a third alternate mating contact  500  ( FIG. 13 ) is shown. The mating contact  500  has a conductive portion or conductive beam or mounting section  530  with a first end  532  and a second end  534 . The conductive beam  530  is stamped and formed from conventional spring metal such as copper alloy or tin-plated phosphor bronze or any other material that has the resilient and electrical characteristics required. The first end  532  has a compliant portion  533  which extends therefrom and is configured to be received in an opening of the panel or circuit board  114  ( FIG. 1 ). In the embodiment shown, the compliant portion has an eye-of-the-needle configuration, but other types of compliant portions can be used. 
     A wire-receiving portion  550  extends from the second end  534  of the conductive beam  530 . The wire-receiving portion  550  has a transition section  552  and a wire retention section  554 . The transition section  552  is slightly inclined relative to the plane of the conductive beam  530 . The wire retention section  554  extends from the transition section  552  in a direction away from the conductive beam  530 . The wire retention section  554  is initially provided in an open position ( FIG. 12 ). Mounting projections  562  may be provided on the conductive beam  530 . The mounting projections  562  extend from the conductive beam  530  to engage a wall of an opening of connector  116  ( FIG. 1 ). The mounting projections  562  maintain and stabilize the mating contact  500  in the opening of the connector  116 . 
     As shown in  FIG. 13 , a bundle of helically wound wires  540  has a mounting section  570 , a bulge contact section  572  and a cap  574 . The mounting section  570  of the bundle of helically wound wires  540  is positioned in the wire retention section  554 . The wire retention section  554  is displaced inward or crimped around the mounting section  570  of the bundle of helically wound wires  540  using known crimping techniques. This maintains the mounting section  570  of the bundle of helically wound wires  540  is position relative to the wire retention section  554  and places the mounting section  570  of the bundle of helically wound wires  540  in electrical engagement with the wire retention section  554 . 
     The slight inclination of the transition section  552  allows the longitudinal axis of the conductive beam  530  and the longitudinal axis of the bundle of helically wound wires  540  to be in essentially the same plane. The cap  574  provides a lead-in surface which facilitates the insertion of the mating contact  500  into a mating receptacle (not shown). 
       FIG. 6  is a perspective cross-sectional view of the connectors  108  and  116  in a fully mated position with each other, and  FIG. 7  is a cross-sectional view of the engaged connectors  108  and  116  in  FIG. 6 . As discussed above, when the connectors  108  and  116  are engaged, the connectors  108  and  116  form a mechanical coupling that may withstand extreme temperature, shock, and/or vibrations while maintaining an effective electrical connection. As shown, in the fully mated position, the housing assembly  147  and the housing  200  are adjacent to or directly abutting each other. The shafts  133  of the socket members  130  are inserted into the corresponding cavities  132  of the connector  116  the distance D ( FIG. 2 ). In turn, the mating contact  134  of the connector  116  are inserted into and covered by the shaft  133  such that the twist pin contact  236  ( FIG. 5 ) is electrically connected to the inner surface  252  ( FIG. 7 ) of the shaft  133 . As such, the wires  240  of the twist pin contact  236  form multiple points of electrical contact with the shaft  133  of the socket member  130 . 
       FIG. 7  also illustrates electrical interconnecting portions P 1  and P 2  formed by the connectors  108  and  116 . When fully engaged, the mating faces  162  ( FIG. 2) and 202  ( FIG. 4 ) of the connectors  108  and  116 , respectively, may directly abut each other along an interface I C . As shown, the mating tail  186  is coupled to and forms an interference fit with the socket member  130 , and the end  234  of the beam  230  ( FIG. 5 ) is coupled to and forms an interference fit with the twist pin contact  236 . The shaft  133  of the socket member  130  is inserted into a corresponding cavity  132  of the connector  116 . In some embodiments, the shaft  133  may form an interference or compressive fit within the corresponding cavity  132 . In the illustrated embodiment, as the socket member  130  is inserted into the corresponding cavity  132 , the wires  240  are deflected into and slide along an inner surface  252  of the socket member  130 . The wires  240  form multiple points of electrical contact with the inner surface  252 . 
     The interconnecting portions P 1  and P 2  (and other interconnecting portions not shown) cooperate with each other such that the connectors  108  and  116  are mechanically and electrically coupled together. For example, the abutting mating faces  162  and  202 , along with the shafts  133  within the cavities  132 , prevent rotational movement about a vertical axis  390  (shown in  FIG. 6 ). Also, the multiple shafts  133  within corresponding cavities  132  may prevent the connectors  108  and  116  from being inadvertently separated along a longitudinal axis  392  (shown in  FIG. 6 ). In addition, the multiple points of contact formed by the wires  240  and the shafts  133  facilitate maintaining an electrical connection while the connectors  108  and  116  are sustaining shock and/or vibrations. As such, each interconnecting portion P 1  and P 2  forms an electrical and mechanical coupling. 
     As shown above, embodiments described herein may include electrical connectors that are ruggedized (i.e., built to sustain shock and vibrations and still maintain an effective electrical connection). However, embodiments herein are not limited to such applications. Also, although the illustrated embodiment shows a right-angle connector  108  coupling to a vertical connector  116 , the connectors  108  and  116  may take many forms and shapes and the connectors  108  and  116  may couple to each other in many orientations. For example, the connectors  108  and  116  may be incorporated into backplane electrical connector assemblies where the connectors  108  and  116  mate with each other in an orthogonal, coplanar, or mezzanine (stacking) manner. 
     In one alternative embodiment, the socket members  130  ( FIG. 1 ) are not separately coupled to the conductors  152  ( FIG. 6 ) but are formed with or are an integral part of the conductors  152 . 
     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. 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.