Electrical connector and method of making it

An electrical connector comprising:

• a substrate having a first surface and a second surface and carrying electrical contacts on at least one surface and a plurality of apertures extending between the first surface and the second surface, said electrical contacts including an elastic portion;
• an electrically-conductive material which extends through at least one of the plurality of apertures and electrically couples the first surface and the second surface;
• and
• an additional material in addition to the conductive material which is included within at least one of the plurality of apertures, said additional material sealing at least a portion of the electrically-conductive material from exposure to the environment outside the substrate, said additional material chosen to have a coefficient of thermal expansion approximating the coefficient of thermal expansion of at least one of the substrate and the electrically-conductive material.

A method of making an electrical connector comprising the steps of:

• providing a connector substrate with a plurality of apertures;
• defining a plurality of electrically-conductive contacts on a flat sheet of conductive material, forming the flat sheet into a three-dimensional form with a plurality of elastic electrical contacts, attaching the three-dimensional conductive sheet with a plurality of electrical contacts to the substrate and singulating the electrical contacts;
• providing an electrically-conductive path through at least one of the apertures and attaching at least one of the electrical contacts to the electrically-conductive path through the substrate;
• choosing an additional material which has a coefficient of thermal expansion approximating the coefficient of thermal expansion of at least one of the substrate, the electrical contact and the electrically-conductive path;
• and
• inserting the chosen additional material into the aperture to protect the electrically-conductive path by providing a sealing of at least part of the electrically-conductive path.

An electrical connector comprising:

• a substrate including an insulating body, at least one mounting surface and a plurality of apertures extending at least partially through the substrate;
• a set of electrical contacts carried on the mounting surface of the substrate and at least some of the electrical contacts being proximate at least some of the apertures, the electrical contacts including at least one elastic spring contact;
• a first conductive material within at least some of the apertures and in contact with at least one of the electrical contacts providing an electrical path coupling the one electrical contact with a second surface of the substrate, said first conductive material only partially filling the apertures into which the first conductive material is within;
• and
• a second material in the same aperture in which the first conductive material has been inserted, said second material covering at least part of the first conductive material and filling at least part of the aperture, said second material having a coefficient of thermal expansion which approximates the coefficient of thermal expansion of at least one of the substrate and the first conductive material.

An electrical connector comprising:

• a substrate having a first surface and a second surface and carrying electrical contacts on both surfaces and a plurality of apertures extending between the first surface and the second surface, said electrical contacts including an elastic portion;
• an electrically-conductive material which extends through at least one of the plurality of apertures and electrically couples the first surface and the second surface;
• and
• an additional material in addition to the conductive material which is included within each of the plurality of apertures, said additional material sealing the apertures to prevent ingress of fluid materials through the apertures;
• a sealing mechanism around the perimeter of at least the connector first surface, said sealing mechanism comprising a compliant material, said sealing mechanism providing a fluid ingress-inhibiting seal around the perimeter of the connector area containing the electrical contacts when compressed against a mating surface of an electrical component, such as a printed circuit board.

An electrical connector comprising:

• a substrate including an insulating body, at least one mounting surface and a plurality of apertures extending at least partially through the substrate;
• a set of electrical contacts carried on the mounting surface of the substrate and at least some of the electrical contacts being adjacent to or on top of at least some of the apertures, the electrical contacts including at least one elastic spring contact;
• a first conductive material within at least some of the apertures and in contact with at least one of the electrical contacts providing an electrical path coupling the one electrical contact with a second surface of the substrate, said first conductive material only partially filling the apertures into which the first conductive material is within;
• and
• a second material in the same aperture in which the first conductive material has been inserted, said second material covering completely filling the apertures;
• and
• a sealing mechanism around at least the perimeter of at least the connector first surface, said sealing mechanism comprising a compliant material, said sealing mechanism providing a seal which inhibits the ingress of liquids from around the perimeter of the connector area containing the electrical contacts when compressed against a mating surface of an electrical component, such as a printed circuit board.