Patent ID: 8904633

Claim:
A method of manufacturing an electronic device, said method comprising the steps of: molding a header from a plastic header material to form passages in the header to receive a plurality of compliant pins, each passage of the header being at least partially defined by a substantially flat datum surface and an opposed passage surface disposed opposite the substantially flat datum surface; forming each of the compliant pins from electrically conductive material to have a substantially flat pin surface and an opposed pin surface disposed opposite the substantially flat pin surface, the opposed pin surface including a raised portion; inserting each compliant pin into a corresponding passage of the header to form a compliant pin header assembly, the raised portion of the opposed pin surface of the compliant pin engaging the opposed passage surface of the corresponding passage and thereby pressing the substantially flat pin surface of the compliant pin against the datum surface of the corresponding passage; engaging the compliant pin header assembly with a housing so that a first end of each compliant pin is presented outwardly of the housing and a second end of each compliant pin is disposed within the housing; and placing a printed circuit board within the housing so that the printed circuit board engages the second end of each compliant pin.