High density connector and method of manufacture

An electrical connector adapted to be mounted on a substrate that includes a conductive element, the electrical connector comprising:

• an insulative housing, the housing having an exterior housing side adapted to face the substrate;
• an electrical contact that extends from the insulative housing, wherein the electrical contact defines a tab with a free end that does not engage the insulative housing and an exterior side that defines a contact recess;
• and
• a body of reflowable, electrically conductive material disposed at least partially in the contact recess,
• wherein the exterior housing side of the insulative housing and the exterior side of the electrical contact each face the same direction.

An electrical connector adapted to be mounted on a substrate that includes a conductive element, the electrical connector comprising:

• an insulative housing, the housing having an exterior side adapted to face the substrate;
• a contact partially positioned in the insulative housing and partially extending from the insulative housing, wherein the contact comprises a tab that defines a free end and the tab defines an exterior side that defines a recess;
• an anti-solder wicking material attached to the tab;
• and
• a solder ball disposed at least partially in the recess.

A high density electrical connector mountable to a substrate having conductive elements therein and having a substrate mounting side and a mating side comprising:

• a housing having an exterior and interior side, and having a plurality of adjacent parallel rows of openings therein the receive contacts, wherein the openings extend between the interior side and the exterior side thereof;
• a contact positioned in at least one of the openings, wherein the contact defines a free mounting tab end that extends substantially to the exterior side of the housing and defines an exterior side;
• a recess disposed in the exterior side of the contact at the substrate mounting side of the connector, the recess adapted to receive and position a solder ball;
• and
• an electrically conductive solder ball adapted to mount the connector to the substrate, the solder ball being disposed in the recess.

A high density electrical connector mountable to a substrate having conductive elements therein comprising:

• a housing having a plurality of adjacent parallel rows of openings therein extending in one direction for receiving contacts and transverse parallel rows of openings for receiving contacts therein, wherein the housing has an exterior side and interior side and the openings extend between the interior side and the exterior side;
• a contact that extends through the opening and defines a substrate mounting end that extends substantially to the exterior side of the housing, the substrate mounting end being adapted to be connected to a solder ball, wherein the substrate mounting end of the contact has an angled connection portion and a free end;
• and
• a conductive solder ball adapted to fuse the connector to the substrate, the solder ball being disposed in a recess defined by the angled connection portion of the contact.

A method of making an electrical connector adapted to be mounted to a substrate and having a substrate mounting side and a mating side comprising:

• providing an insulative member that defines a first surface that corresponds to the mating side of the connector and a second surface that corresponds to the substrate mounting side of the connector;
• providing an electrically conductive contact on the insulative member with a section of the contact extending into the insulative member and with a portion of the contact positioned adjacent to the second surface;
• providing a recess at the substrate mounting side of the connector on the portion of the contact that is positioned adjacent to the second surface;
• positioning a substantially spherical electrically conductive element in the recess;
• and
• reflowing the electrically conductive element to the portion of the contact that extends toward the second surface.