Contact for pin grid array connector and method of forming same

#Certain embodiments of the present invention relate to a pin grid array contact, and more particularly to an pin grid array contact that provides more efficient assembly into an electrical connector.

#Connectors are known for interconnecting various electrical media components, such as printed circuit boards (PCB), discrete circuit components, flex circuits and the like. Many printed circuit boards are connected to pin grid substrates by way of ZIF (zero insertion force) connectors. Typically, ZIF connectors include single or double point contacts that connect conductive pins, which extend from the pin grid substrate, to traces on the printed circuit board. Typically, the pin grid substrate, the connector, and printed circuit board are compressed together in order to ensure a conductive path between the pins, contacts and the traces on the printed circuit board.

#FIG. 1 is an isometric view of a conventional connector including pin grid substrate 10, a printed circuit board 16 and ZIF electrical connector 20. The pin grid substrate 10 includes a member 12 from which pins 14 outwardly extend. The circuit board 16 includes circuitry connected to plated through holes 18. The connector 20 includes a housing 22, contact elements 24, a cover 26 and a lever 28. The housing 22 carries a number of regularly spaced cavities (not shown), positioned below the pins 14. A groove 54 is open at one end 60 to accommodate the lever 28.

#FIG. 1 is an isometric view of a conventional connector with a pin grid substrate, a printed circuit board and a ZIF (zero insertion force) electrical connector.

#FIG. 2 is an isometric view of a conventional two point contact.

#FIG. 3 illustrates a conventional preformed, blanked two point contact attached to a carrier strip.

#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 instrumentality shown in the attached drawings.

#FIG. 4 is a front view of a carrier strip 240 carrying a plurality of flat blanked contacts 202 formed in accordance with an embodiment of the present invention. FIG. 5 is an end view of a carrier strip 240 carrying a plurality of flat blanked contacts 202 formed in accordance with an embodiment of the present invention. The carrier strip 240 and the flat blanked contacts 202 are formed from a unitary, planar piece of conductive material, such as a copper alloy having a suitable plating, such as tin, lead or nickel. The carrier strip 240 includes cavities 236 and connection joints 234 that join the carrier strip 240 to the flat blanked contacts 202. The connection joints 234 may be perforated to facilitate the release of the individual contacts 202 from the carrier strip 240.

#Each flat blanked contact 202 is coplanar with the carrier strip 240. Each contact 202 includes a paddle 204, first radial positioners 208, second radial positioners 210, a main body 206, a first spring beam 212, a second spring beam 214, a first contacting portion 216 connected to the first spring beam 212, and a second contacting portion 218 connected to the second spring beam 214. The main body 206 has opposed side edges 246, 247 and opposed end edges 248, 249. The first and second spring beams 212 and 214 are stamped integral with, and extend outward from end edge 249. The first spring beam 212 extends a length 250 from the end edge 249, while the second spring beam 214 extends a length 251 from the same end edge 249. The first and second spring beams 212 and 214 are shifted laterally in the direction of arrow 213 from one another on opposite sides of the center line 230. The lateral shift is parallel to the primary contact plane. The center line of each contact 202 is denoted by reference line 230 that is contained within a primary contact plane. The width of the carrier strip 240 and the contacts 202 in the preformed blanked state, as shown in FIG. 5, is denoted by WS. The distance (DC) represents the distance between the center lines 230 of adjacent contacts 202. The contacts 202 may be flat blanked such that the distance (DC) between their center lines 230 is less than or equal to 1.27 mm, or 0.05″ apart from one another.