DE2302429A1 - METHOD OF MAKING AN ELECTRICAL CONNECTOR ARRANGEMENT - Google Patents

Description

PATENT LAWYERS
Dr. phil. GB HAGEN Dipl.-Phys. W. KALKOFF y q Q JIJ Q

800OMUNCHENZl (SoIIn) £ <5 U 4 H 4 ίί

Franz-Hals-Strasse 21
Tel. (0811) 796213

AMP 3117 Munich, January 16, 1973

NS

AMP Incorporated
Eisenhower Boulevard
Harrisburg " Pa., V. St. A.

Method of making an electrical connector assembly

Priority; Jan. 29, 1972; Great Britain; No. 4327/72

The invention relates to electrical connector assemblies and methods of making them.

In general, electrical connectors include nestable ones metallic contact parts, each of which has means for connecting to a conductor wire and releasable in can be mounted in an insulating housing. The housing can have a number of contacts for the corresponding connection are arranged with complementary contacts in a second housing. Result in such connector assemblies certain disadvantageous limitations. Due to the existing trend towards miniaturization of arrangements that widespread use of integrated circuits and the construction of complex arrangements such. B. Computer off small switching modules there is also the need to create an alternative to the conventional connector forms, the alternative solution should be economical and versatile in use.

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1302429

In the publication "Automotive Industries" from lg. On December 1, 1997 , a contact material was proposed consisting of a conductive elastomer which may be porous or semi-rigid. In one application proposal, conductor ends are arranged in respective plastic sheaths and are pressed against a membrane which has an elastomeric frame which contains cells of the conductive elastomer in a compressed state. The cells are larger than the conductor ends that are pressed against the respective cells. The cells offer the conductor ends a large number of contact points as well as a large number of parallel current conduction paths through the cell »

The contact material consists of a mass of fine metallic or conductive particles which are suspended in the elastomer matrix in such a way that when they are acted upon with pressure, particles are printed along pressure lines in contact with one another, thus forming conductive paths.

The invention relates to another form of material, consisting of a base body of an elastomeric insulating matrix which has a plurality of spaced apart elastic conductors which extend between spaced apart surface parts of the base body through non-straight paths. An example of such a material is disclosed in DOS 2 119 5 & 7 of November 25, 1971. , - -. ^r ■

According to the invention a method for '_ features. * Manufacturing such a connector material characterized in that a metal wire is wound into a coil with axially spaced-apart turns, that the coil is encapsulated in a mass of elastomeric insulating material, that the resulting body is cut through the coil turns to form a

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Body section with cut surface parts on which a plurality of corresponding segment ends of the coil turns exposed.

Suitably the wire is made of metal with good spring properties as well as good electrical performance and high resistance to energy loss, for example made of phosphor bronze or brass · The wire should be referenced on the contact areas with which it is intended to be used, so that a large one within a contact area Number of contact points is exposed.

The coil can be wound in a suitable shape to give the wire segments the desired resilient shape, for example, the segments may be curved in a coil of circular section or in a coil of polygonal cross-section be V-shaped.

To facilitate the electrical separation of neighboring windings, the coil can be wound from pre-insulated wire will. For example, the insulation can be a lacquer so that a thin coating is maintained and adjacent wire windings can lie close to one another, or the insulation can be a slippery insulating material, for example polytetrafluoroethylene, to allow relative movement between adjacent segments in a cut off body part as well as between the wire segments and the insulation surrounding them.

The invention also relates to a body made of contact material, which is manufactured according to the method described above and a matrix of elastomeric insulating material has a mass of spaced apart

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lichen segment-shaped resilient insulated conductors, which extend between spaced apart surface portions of the body.

In one embodiment of the invention, each wire segment is in a separate sheath or cover comprised of a fine insulating material, and the mass of the insulated conductors in the elastomeric matrix is one encapsulated second insulating material.

Embodiments of the invention are described below under Described with reference to the figures. From the figures show:

FIG. 1 is a perspective view of a wire coil of circular cross-section, which is shown in FIG encapsulated a block of elastomeric insulating material;

Figure 2 is a perspective view of one from

The connector piece 1 cut out of the encapsulated coil of FIG

Figure 3 is an end view of an alternative connector piece, cut out of the encapsulated coil of Figure 1 |

Figure k is an end view of a connector cut out of an encapsulated coil similar to Figure 1, but this coil is polygonal in cross-section}

Figure 5 is a partial sectional view of one of the Figure 1 similar connector piece with a coil of relatively strong insulated wire j

FIG. 6 shows a partial illustration of part of a contact surface of a coil-like wound Connector piece with separate contact zones 1

FIG. 7 shows a perspective illustration of a coil J wound according to a first method

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figure 8th 15th figure 9 16 figure 10 figure 11 figure 12th characters
13, l'i figure figure

Figure17

Figure 18
Figure 19
Figure 20

a partial section along the line 8-8 of Figure 7 5

a perspective view of a wound according to a second method Kitchen sink;

a section along the line 10-10 of Figure 9 5

a perspective view of a coil wound according to a third method}

a partial section along the line 12-12 of Figure 11 |

Partial sections similar to FIG. 12 of coils which, according to a fourth or fifth method are wound up;

a perspective view of a wound with a polygonal cross-section coil |

a partial section similar to FIGS. 12-14 of a wound according to a sixth method Kitchen sink}

a partial section of a coil that is used to form separate contact zones is wound on a stencil}

a partial end view of the coil template from Figure 17}

a sectional view of a coil wound according to a further method; and

FIG. 19 is an end view of a connector made from the coil of FIG a pair of back-to-back printed circuit boards is applied.

According to Figure 1, a cylindrical coil 1 is made of fine insulated Wire encapsulated in a block 2 of elastomeric insulating material so that the wire turns of the coil individually at a distance from each other in a matrix of elasto-

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contain and are supported by other insulating material * Various coil winding and encapsulation processes for this purpose are described below.

The encapsulated coil 1 is cut into one or more connector pieces 3, e.g. B. Figure 2 shows, in which the coil has been cut through in the planes 4, 5 extending axially and radially to the coil to form a pair of mutually perpendicular contact surfaces 4, 5 arranged, which are arranged at a small distance from each other in the elastomeric matrix. After the cutting process, the contact surfaces A, 5 are expediently cleaned in order to remove conductive chips and surface unevenness, and then the conductor ends 6 are expediently coated with contact material, e.g. B. gold or tin, plated so that there are contact tips that protrude from the elastomeric matrix surface 4, 5 and serve to facilitate the electrical contact with the conductor ends 6 and improve. The cut wire windings 7 form arched springs held in the elastomeric matrix and extend between the contact surfaces 4, 5.

In the connector 8 according to Figure 3, a coil is in two spaced axially extending planes 9j 10 cut, which are parallel to and at the same distance from a radial plane of the. Coil extend so that the connector piece 8 is formed. This connector piece results in a pair of parallel contact surfaces 9 »10, at which the conductor ends 11 in opposite one another are arranged in an identical pattern

In the embodiment according to FIG. 4, a coil has been wound around a polygonal template that each cut away Conductor segment 12 V-shaped is with a pair

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of rectilinear sections 13-14 inclined relative to one another in contrast to the curved segments in figures 2 and 3.

In the embodiment according to FIG. 5, the conductor turns exist 15 made of insulated conductor wire, which is a relatively strong sheath 16 of insulating material for example made of polytetrafluoroethylene, and / in a surrounding matrix 17 made of a more flexible elastomer, e.g. B. silicone rubber, encapsulated,

In the embodiment according to FIG. 6, a coil with im Spaced turns 18 provided, which are encapsulated in a matrix of elastomeric material, and the connector part is cut away so that mutually separate contact zones 19 at a distance from each other lying areas within the elastomeric matrix 20 result in »

While the technology of coil winding is sophisticated, it is however, some practical difficulties in encapsulating a tightly wound coil into a cohesive one can arise Matrix made of elastomeric material, which is free from air pockets, result. An elastomer such as Silicone rubber can be prepared from liquid components and during a curing time in the remain liquid phase so that it is suitable for injection or vacuum forming purposes} through the flow paths however, a tightly wound coil made particularly of fine wire can provide satisfactory encapsulation in which coil turns are individually contained in the matrix, difficult to make.

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In the coil winding method of Figure 7, a Number of wires 21 in flat turns 22 at intervals 23 from each other axially with respect to a cylindrical template 24 wrapped, being tabular elastomeric material 25 is interposed. As Figure 8 shows, the Wire turns 22 to embed themselves in the elastomeric layer 25 lying below them in the coil, and elastomeric Material is pressed or deformed into the spaces between the wires in such a way that successive Coils of the elastomeric layer 25 come into contact with one another through these interspaces, for example at 29. After winding, the elastomeric layers can be converted into a cohesive matrix by means of a process that depends on the properties of the elastomer used.

In general, an adhesive bond can be obtained between mutually abutting surfaces of the elastomer by that a surface or surfaces of the elastomeric layer 25 prior to winding in coil form with a suitable adhesive to be coated; after winding, the adhesive can harden. The one resulting from the coil winding radial pressure is sufficient to cause sufficient coalescence of the adhesive and the coil can be subjected to a heat treatment which brings about the hardening or increases the hardening speed.

When the elastomeric layer 25 is silicone rubber, their surfaces can be wetted with uncured silicone rubber in a liquid state, and the curing is effected by a heat treatment after the coiling, the one continuous weld between the contacting layers in the · interstices 23 between the turns of wire 22 has the consequence.

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When the elastomeric layer is a partially cured butyl rubber, the coil winding pressure is combined sufficient with the application of heat to produce a coherent weld during curing. One similar effect can be achieved with other partially cured rubbers that contain a linking agent, so that the welding under the action of the coil winding pressure and the application of heat he follows. Polyurethane in the resitol state (B-resin) can be welded in the same way.

Another option is to use a suitable solvent to use to make the surfaces of the elastomeric layer pliable before winding and after winding to volatilize the solvent by heating.

In the embodiment according to Figures 9 and 10 is a Double layer spool 30 in a manner similar to the single layer spool according to FIGS. 7 and 8, but with groups 31 »32 of spaced apart wires and associated layers 33 »3 ^ wound of elastomeric material, wherein the wire and elastomer groups begin at diametrically opposite positions on the spool template 35. Like Figure 10 shows, the wires 31 are of alternating layers of the composite Winding offset in the longitudinal direction of the coil with respect to the wires 32 from intermediate layers, so that in section one wire of each layer is radial with respect to the coil with the free space between adjacent wires is in alignment in the adjacent layer or layers. This increases the tendency of the elastomer layers 33 »3 ^» to extrude into the spaces between the wires and to fill this completely under the action of the coil winding pressure, so that the formation of a coherent, void-free matrix of elastomeric material enclosing the wire windings is facilitated.

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In the embodiment according to FIGS. 11 and 12 is a multilayer coil 35 wound spirally from a single wire 36 and an elastomeric strip 37, the so are arranged side by side, that adjacent turns of the wire 36 through the Elastomerötreifen 37 axially in with respect to the coil lie at a distance from each other. As FIG. 12 shows, successive turns are 38 »391 40, 4l arranged axially offset with respect to the coil, so that wire turns 36 in one position on the elastomer strip 37 adjacent layers are in contact. The elastomer strip 37 is expediently wider than the wire diameter, so that the interstices receiving the wire between adjacent turns of the elastomeric strip in a layer entirely from the elastomeric strip 37 in the neighboring layer are bridged »

In the embodiment according to FIG. 13, that of those of FIGS. 11 and 12 are similar, layers 44 are made between coil layers or successive turns 42, 43 Arranged elastomer plates, which are wound in a concentric coil. In this case, the intermediate turns need made of elastomer strips 37 do not have a larger diameter than the wire and allow a narrower one WideIn the turns of wire.

FIG. 17 shows a further embodiment of the invention in which a coil is formed in a manner similar to that in the figures and 12 wound with successive layers 45, 46, 47 however, the elastomeric strip 48 is circular in cross-section and larger in diameter than the intermediate one Wire 49 · This allows the between The interstices between the wires by the alternating layers of the elastomeric strip 48, which extend under the Deform coil winding pressure so that it substantially fills gaps and insulates the wires from one another keep at a distance from each other.

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FIG. 15 shows the winding technology disclosed in FIG. applied to the winding of a polygonal coil 50 on a polygonal template 51

FIG. 16 shows a partial section through a coil in which the insulated wire 52 is wound in the form of a multi-layer coil, the turns of adjacent layers 53 »54 and 54, 35 leading in opposite directions. Adjacent turns 56, 57 in each layer are at a distance from one another, so that a multi-layer braid is formed when viewed radially to the coil. With windings of this shape, there is sufficient flow space 58,59,6O through the coil so that windings 52 can be effectively encapsulated by injection or vacuum molding processes using an uncured elastomeric resin. In order to facilitate encapsulation, the coil core can be designed with flow channels (not shown) through which the synthetic resin penetrates, which then flows radially through the coil braid and fills the spaces 58, 59,6O.

In the embodiment of FIGS. 17 and 18, there is a coil core 62 with radially protruding spacer elements 63 are provided, which are arranged in axially spaced groups 64, the spacer elements 63 of each group 64 are distributed circumferentially around the core 62. First, using one of the above Movement between the adjacent groups 64 of spacer elements 63 of spaced-apart pairs of groups 64 coils 65 wound. Spaces 66 between adjacent first coils 65 are filled with elastomer, namely by winding or potting up to radial level of the first coils 65 then second coils 67 are wound over these elastomeric filling compounds, and the corresponding spaces 68 above the first coils 65 are filled with elastomer. That way will

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a composite coil formed with groups 65 »67 of closely im. Distance from each other wire turns are arranged at a distance from one another in the elastomer matrix for the purpose of producing a connector of the type shown in FIG shown art.

When a connector matrix from the encapsulated coil according to 17 and 18 is cut out, the contact surfaces in the spaces 69 between adjacent Cut out spacers 63 of the groups. As a result, each spacer element 63 can "that within a connector matrix remains away from the contact surfaces be included in the matrix.

When winding a composite coil by means of this Technique it is possible to shield the groups of wire windings from one another / by arranging metal foils in the elastomer. For example, a tape film wound over and under each layer of bobbins, and annular Foil spacers are provided at axially spaced locations between coils. The annular Foil spacers can be the groups of spacers replace according to Figure l8.

In the embodiment according to FIGS. 19 and 20, a coil 70 (FIG. 19) wound by means of one of the methods described above is provided with an outer coil layer 71 of spring wire with increased spring properties compared to the inner coil windings 72 electrical connector is formed by removing the coil core 73 and cutting a segment out of the coil along the dash-dotted lines 7k, so that the electrical connector is designed as a C-shaped spring with a pair of spaced apart contact surfaces 751 76 » from

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where the ends 77 of the outer spring wire windings are expediently cut back. As Figure 20 shows,
becomes a pair of when using this connector
Back-to-back printed circuit boards 78 with current conducting paths 79 on their distal sides clamped together between pads 75; the mechanical tensioning effect results essentially from the outer spring windings 71, which press the contact surfaces against the plates 78 and the current conducting paths 79.

In the embodiments described above, for
the coil winding uses a core that can be molded from cured elastomer for the purpose of welding ^ in the
Matrix in encapsulating the coil turns. However, it can
a rigid core can also be used, which is removed after the coil has been encapsulated.

Although conventional round wire was used for the winding in the exemplary embodiments, wire of any cross section can be used. If a wire with elongated
Cross-section is used, it can be arranged so
that its longer axis extends radially to the coil, so that the winding segments are bent against their maximum rigidity.

Claims a

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Claims (15)

AMP 3117 - * - Claims l.i Method of making an electrical connector with a plurality of spaced apart elastic conductive springs, which in one of elastomeric Isolating material existing matrix are arranged, .which a body with spaced apart surface parts defined, between which the springs extend in non-linear paths and at which ends of the Feathers exposed, marked thereby -t that at least one wire (l) (figure l) to one Coil is wound with spaced turns that the coil in a mass (2) made of elastomeric Insulating material is encapsulated and that the resulting body cut by the coil turns (7) is to form the connector (Figure 2), the cut parts (4, 5) being the spaced apart surface parts form. 2. The method according to claim 1, characterized in that several wires (21) (Figure 7) in flat turns at a distance from each other axially on a cylindrical template (24) are wound with one of the Plurality of wires common intermediate layer of plate-shaped! elastomers «! Material (25) and that the resulting coil formed into a coherent matrix is made by welding adjacent layers of the elastomeric material (25) through the spaces (23) between the wires. 3 »Method according to claim 2, characterized in that that two groups of several wires each (33. »32) (Figure 9), each with a layer of elastomeric insulating material (33 $ 3 ^) are assigned, as alternating 1 / il Q Ί ■ 1
ι ι y 3 o i AMP 3117 - $ - Layers are wound to form a composite coil, the wires (3I) of one group in the longitudinal direction of the Coil with respect to the wires (32) of the other group are offset so that one wire (31 »Figure 10) in each position between adjacent wires (32) in the adjacent or the neighboring layers. 4. The method according to claim 1, characterized draws that a coil (Figure 11) made of a wire (36) and an elastomeric strip (37) »lying next to each other are arranged, is wound, wherein coil turns of the elastomeric strip (37) with coil turns of the wire (36) alternate. 5. The method according to claim 4, characterized in that successive layers (38 »39> 40, 4l) (Figure 12) are offset in the longitudinal direction of the coil so that wires (36) in one layer on the elastomer Strips (37) rest in the adjacent layer or layers and the strip (37) bridges the spaces between the wires of the adjacent layer or layers. 6. The method according to claim 4, characterized in that between successive layers (42, 43; Figure I3) the coil is plate-shaped elastomer Material (44) is arranged. 7. The method according to claim 1, characterized in that a coil (Figure l6) from axially at a distance from one another turns (56, 57) of insulated wire is wound and that successive layers (53 »54, 55) are wound opposite to previous layers to form themselves radially through the coil extending flow passages (58, 59 »60), wherein the 309831/093 1 AMP 3117 - f - Coil encapsulated by injection or vacuum molding of liquid elastomer through the passages (58, 59 »6O) will. 8. The method according to claim 1, characterized in that lying axially at a distance from one another Place coils (65? Figure 17) on a template (62) that are wound between adjacent coils (65) Interstices (66) are filled with elastomeric material that another group of coils (67) over the with Elastomer-filled spaces (66) are wound so that the spaces (68) between adjacent coils (67) are also filled with elastomer and that the coils (65j 67) are encapsulated in elastomeric insulating material and with the elastomeric material in the spaces (66, 68) between the coils one of all turns of the coils form a common matrix. 9. The method according to claim 8, characterized in that that around adjacent coils metal foils are wound and arranged between adjacent coils. 10. The method according to claim 8, characterized draws that coils (65, 67) are wound on a template (62) which has radially extending spacer elements (63) which are axially spaced from one another lying groups are arranged, the Ab was seleniente (63) of each group over the circumference of the template (62) are distributed, and that after encapsulation, the resulting body is cut out so that the spaced mutually located surface parts defined at locations between adjacent spacer elements (63) of each group are. 3 0 9 8 3 1/0931 AMP 3117 - # - 11. The method according to claim 1, characterized in that that uncured or partially cured elastomer is wound into the coil and that the curing is then completed for the purpose of welding between adjacent layers of the elastomer. 12. The method according to claim 1, characterized in that strip-shaped or plate-shaped Elastomer, desasn surface covered with an adhesive or wetted with a solvent, wrapped in the coil and then cured or volatilized is used for the purpose of welding adjacent layers. 13 · Method according to claim 1, characterized in that a vulcanizable elastomer is wrapped in the coil and then vulcanized for the purpose of welding adjacent layers. 14. The method according to claim 1, characterized in that that a second wire (71? Figure 19) in or around the coil, spaced from other turns (72) of the coil is wound, the second wire (7I) having stronger spring properties than the wire (72) and that both wires are encapsulated in a common elastomer matrix. 15. According to the method according to any one of claims 1 to electrical connector made thereby characterized in that the surfaces (75ι 76) extending between the spaced apart surfaces Spring wires (71, 72J Figures 19, 20) one Minority (71) with considerably higher spring properties than a majority (72) with considerably weaker ones Have spring properties. 309831/093 1