Woven multiple-contact connector

• US 6,942,496 B2
• Filed: 10/17/2002
• Issued: 09/13/2005
• Est. Priority Date: 01/15/2002
• Status: Expired due to Term

• Current Assignee: Methode Electronics Incorporated
• Original Assignee: Tribotek, Inc. (Methode Electronics Incorporated)
• Inventors: Suh, Nam P., Sweetland, Matthew
• Primary Examiner(s): DUVERNE, JEAN F
• Application Number:
  US10/273,241
• Publication Number:
  US 20030134525A1
• Time in Patent Office: 1,062 Days
• Field of Search: 439/66, 439/91, 439/591, 439/482, 439/329, 439/493, 439/496, 439/930
• US Class Current: 439/67
• CPC Class Codes: H01R 12/714 with contacts abutting directly the printed circuit; Button contacts therefore provided on the printed circuit
• CPC Class Codes: H01R 13/2407 characterized by the resilient means
• CPC Class Codes: H01R 13/2492 multiple contact points

Abstract

A multiple-contact woven connector including a weave arranged to provide a plurality of tensioned fibers and a conductor woven with the plurality of tensioned fibers so as to form a plurality of peaks and valleys along a length of the conductor. The conductor has a plurality of contact points positioned along the length of the conductor, such that when the conductor engages a conductor of a mating connector element, at least some of the plurality of contact points provide an electrical connection between the conductor of the multiple-contact woven connector and the conductor of the mating connector element. The tensioned fibers of the weave provide a predetermined contact force between the at least some of the plurality of contact points of the conductor of the multiple-contact woven connector and the conductor of the mating connector element.

Claims

1. A multiple-contact woven connector comprising:

a weave having a plurality of fibers and at least one conductor woven with the plurality of fibers, the at least one conductor having a plurality of peaks and valleys along a length thereof;

wherein the at least one conductor has a plurality of contact points positioned along the length of the at least one conductor, such that when the at least one conductor engages a conductor of a mating connector element, at least some of the plurality of contact points provide an electrical connection between the at least one conductor of the multiple-contact woven connector and the conductor of the mating connector element; and

wherein, upon sliding the conductor of the mating connector element relative to the weave during engagement of the woven connector and the mating connector element, at least some of the plurality fibers are tensioned, thereby providing a contact force between at least some of the plurality of contact points of the at least one conductor of the multiple-contact woven connector and the conductor of the mating connector element.

2. The multiple-contact woven connector as claimed in claim 1, wherein the plurality of contact points are formed by the plurality of peaks and valleys of the at least one conductor.

3. The multiple-contact woven connector as claimed in claim 1, wherein the plurality of fibers are elastic.

4. The multiple-contact woven connector as claimed in claim 1, wherein the plurality of fibers are non-conductive.

5. The multiple-contact woven connector as claimed in claim 1, wherein the at least one conductor comprises a first conductor and a second conductor, and further comprising a non-conductive housing member adapted to hold the first conductor in a substantially fixed relationship with the second conductor.

6. The multiple-contact woven connector as claimed in claim 1, wherein the at least one conductor comprises a first conductor and a second conductor, and further comprising a first connector pin, wherein the first and second conductors are connected to an end of the first connector pin and provide a first electrical contact.

7. The multiple-contact woven connector as claimed in claim 1, wherein the weave comprises a woven tube.

8. The multiple-contact woven connector as claimed in claim 1, further comprising the mating connector element, wherein the mating connector element comprises a rod member.

9. The multiple-contact woven connector as claimed in claim 8, wherein the rod member comprises a conductive core having a circular cross-section and at least one conductive strip separated from the conductive core by an insulating layer.

10. The multiple-contact woven connector as claimed in claim 9, further comprising an electrical shield connected to the conductive core.

11. The multiple-contact woven connector as claimed in claim 10, wherein the conductive core defines a cavity therein, and further comprising a drain wire located in the cavity and connected to the electrical shield.

12. The multiple-contact woven connector as claimed in claim 8, wherein the rod member comprises first and second conductors and an insulating member disposed between the first and second conductors.

13. The multiple-contact woven connector as claimed in claim 8, wherein the rod member includes a dielectric core having a substantially circular cross-section, and a plurality of conductors spaced circumferentially along an outer surface of the dielectric core and extending along a length of the dielectric core.

14. The multiple-contact woven connector as claimed in claim 13, wherein the dielectric core has an annular cross-section defining a cavity therethrough, and further comprising one of an optical fiber, a strength member, or a thermal transfer member located in the cavity.

15. The multiple-contact woven connector as claimed in claim 1, further comprising a housing having a base wall and first and second end walls, wherein the at least one conductor is mounted to the base wall.

16. The multiple-contact woven connector as claimed in claim 15, wherein the plurality of fibers are disposed between the first and second end walls of the housing.

17. The multiple-contact woven connector as claimed in claim 16, wherein the first and second end walls of the housing comprise tensioning mounts to tension the plurality of fibers.

18. The multiple-contact woven connector as claimed in claim 16, further comprising the mating connector element, wherein the mating connector element includes an insulating member and a mating conductor mounted to the insulating member.

19. An electrical connector comprising:

a first connector element comprising a weave including a plurality of non-conductive fibers and at least one conductor woven with the plurality of non-conductive fibers, the at least one conductor having a plurality of contact points along a length of the at least one conductor; and

a mating connector element including a rod member;

wherein the first connector element and the mating connector element are adapted to engage such that at least some of the plurality of contact points of the first connector element contact the rod member of the mating connector element to provide an electrical connection between the first connector element and the mating connector element; and

wherein the plurality of non-conductive fibers are tensioned so as to provide contact force between the at least some of the plurality of contact points of the first connector element contact and the rod member of the mating connector.

20. The electrical connector as claimed in claim 19, wherein the rod member comprises a conductive core having a circular cross-section and at least one conductor separated from the conductive core by an insulating layer.

21. The electrical connector as claimed in claim 19, wherein the rod member comprises a core having a circular cross-section and a plurality of conductors spaced circumferentially along an outer surface of the rod member and extending along a length of the rod member.

22. The electrical connector as claimed in claim 21, wherein the core is a conductive core and wherein the each of plurality of conductors is separated from the conductive core by a respective insulator.

23. The electrical connector as claimed in claim 22, wherein the conductive core has an annular cross-section defining a central cavity within the conductive core.

24. The electrical connector as claimed in claim 21, wherein the core has an annular cross-section defining a central cavity therein, and further including any one of an optical fiber, a drain wire, a thermal transfer element and a strength member located within the central cavity.

25. The electrical connector as claimed in claim 19, wherein the rod member comprises a core of a dielectric material.

26. The electrical connector as claimed in claim 19, wherein the plurality of non-conductive fibers include an elastomer.

27. The electrical connector as claimed in claim 19, wherein the plurality of non-conductive fibers are elastic and provide a predetermined contact force between the plurality of contact points of the at least one conductor and the rod member of the mating connector element.

28. The electrical connector as claimed in claim 19, wherein the at least one conductor of the first connector element comprises a first conductor and a second conductor, and wherein the rod member of the mating connector element comprises a first mating conductor, a second mating conductor, and an insulating strip positioned between the first mating conductor and the second mating conductor to electrically isolate the first mating conductor from the second mating conductor.

29. The electrical connector as claimed in claim 19, wherein the first connector element further comprises a housing having a base member and two opposing end walls connected to the base member, and wherein the at least one conductor is connected to the base member.

30. The electrical connector as claimed in claim 29, wherein the plurality of non-conductive fibers are disposed between the two opposing end walls of the housing.

31. The electrical connector as claimed in claim 30, wherein the two end walls include tensioning mounts that provide tension in the plurality of non-conductive fibers.

32. An electrical connector comprising:

a base member;

first and second conductors mounted to the base member and having an undulating form along a length of the first and second conductors so as to include a plurality of contact points along the length of the first and second conductors;

at least one elastomeric band that encircles the first and second conductors; and

a mating connector element comprising third and fourth conductors separated by an insulator, the electrical connector and mating connector element constructed such that the third and fourth conductors contact at least some of the plurality of contact points of the first and second conductors when the mating connector element is engaged with the electrical connector.

33. The electrical connector as claimed in claim 32, wherein each of the first and second conductors has a plurality of peaks and valleys positioned along the length of the first and second conductors, provided by the undulating form of the first and second conductors, and wherein the at least one elastomeric band passes over a first valley of the first conductor and under a first peak of the second conductor.

34. The electrical connector as claimed in claim 33 wherein the at least one elastomeric band is elastic and is tensioned so as to provide a contact force between the third and fourth conductors and the at least some of the plurality of contact points of the first and second conductors.

35. An array of connector elements comprising:

at least one power connector element; and

a plurality of signal connector elements, each signal connector element comprising a weave including a plurality of non-conductive fibers and first and second conductors woven with the plurality of non-conductive fibers so as to form a plurality of peaks and valleys along a length of each of the first and second conductors;

wherein the second conductor is located adjacent the first conductor, and a first one of the plurality of non-conductive fibers passes under a first peak of the first conductor and over a first valley of the second conductor;

wherein the first and second conductors have a plurality of contact points positioned along the length of the first and second conductors, the plurality of contact points adapted to provide an electrical connection between the first and second conductors of the signal connector element and a conductor of a mating signal connector element; and

wherein a contact force between the plurality of contact points of the first and second conductors of the signal connector element and the conductor of a mating signal connector element is provided by a tension of the weave.

36. The array of connector elements as claimed in claim 35 wherein the power connector element includes a woven conductive fabric including a plurality of conductive strands and at least one power conductor woven with the plurality of conductive strands, the at least one power conductor having a plurality of power contact points along a length of the at least one power conductor.

37. An electrical connector comprising:

a housing including a base member and two opposing end walls;

a plurality of non-conductive fibers mounted between the opposing end walls of the housing such that a predetermined tension is provided in the plurality of non-conductive fibers;

a first termination contact mounted to the base member and having a first plurality of conductors connected to a first end of the first termination contact, wherein the first plurality of conductors are woven with the plurality of non-conductive fibers to form a woven structure such that each conductor of plurality of conductors has a plurality of contact points along a length of each conductor; and

a second termination contact mounted to the base member and including a second plurality of conductors woven with the plurality of non-conductive fibers, and an insulating strand positioned between the first plurality of conductors and the second plurality of conductors to electrically isolate the first plurality of conductors from the second plurality of conductors.

38. The electrical connector as claimed in claim 37, wherein the plurality of non-conductive fibers are elastic and include an elastomeric material.

39. The electrical connector as claimed in claim 37, wherein the first termination contact and the second termination contact together comprise a differential signal pair of contacts.

40. The electrical connector as claimed in claim 37, further comprising:

a third termination contact mounted to the base member of the housing and including a third plurality of conductors woven with the plurality of non-conductive fibers;

a fourth termination contact mounted to the base member of the housing and including a fourth plurality of conductors woven with the plurality of non-conductive fibers;

a second insulating strand positioned between the third and fourth pluralities of conductors; and

an electrical shield mounted to the base member of the housing and located between the first plurality of conductors and the third plurality of conductors to electrically isolate the first plurality of conductors from the third plurality of conductors.

41. The electrical connector as claimed in claim 37, further comprising a mating termination contact having at least one mating conductor adapted to contact at least some of the plurality of contact points along the length of each conductor of the first plurality of conductors, wherein a contact force between the at least some of the plurality of contact points and the mating conductor is provided by the tension of the plurality of non-conductive fibers.

42. The electrical connector as claimed in claim 41, further comprising a mating housing, wherein the mating termination contact is mounted to the mating housing, the mating housing being adapted to provide a predetermined contact force between the at least one mating conductor and the at least some of the plurality of contact points of the first plurality of conductors.

43. An electrical connector array comprising:

a first housing element including a base portion and two opposing end walls;

a plurality of non-conductive fibers mounted between the opposing end walls;

a first conductor woven with the plurality of non-conductive fibers to provide a first electrical contact;

a second conductor woven with the plurality of non-conductive fibers to provide a second electrical contact; and

at least one insulating strand woven with the plurality of non-conductive fibers and positioned between the first and second conductors to electrically isolate the first electrical contact from the second electrical contact.

44. The electrical connector array as claimed in claim 43, wherein the plurality of non-conductive fibers are tensioned so as to provide contact force between the first conductor and a mating conductor and between the second conductor and the mating conductor.

45. The electrical connector array as claimed in claim 43, wherein the first conductor includes a first plurality of conductors and the second conductor includes a second plurality of conductors.

46. The electrical connector array as claimed in claim 45, further comprising at least one electrical shield positioned between the first and second plurality of conductors to further electrically isolate the first electrical contact from the second electrical contact.

47. The electrical connector array as claimed in claim 45, wherein the first and second pluralities of conductors are woven in an undulating manner with the plurality of non-conductive fibers so as to form a plurality of peaks and valleys along a length of each conductor, such that each of the first and second electrical contacts includes a plurality of contact points along the length of each conductor.

48. The electrical connector array as claimed in claim 43, further comprising a second housing element and first and second mating conductors mounted to the second housing element, wherein the second housing element is adapted to mate with the first housing element so as to bring the first and second conductors into contact with the first and second mating conductors.

49. The electrical connector array as claimed in 48, wherein each of the first and second conductors are woven in an undulating manner with the non-conductive fibers so as to form a plurality of peaks and valleys along a length of each conductor, such that each of the first and second electrical contacts includes a plurality of contact points along the length of each conductor;

and wherein at least some of the contact points provide an electrical connection between the first and second conductors and the first and second mating conductors when the second housing element is mated with the first housing element.

50. A multiple-contact woven connector comprising:

a weave including a plurality of tensioned, non-conductive fibers and first and second conductors woven with the plurality of tensioned, non-conductive fibers so as to form a plurality of peaks and valleys along a length of each of the first and second conductors;

wherein the second conductor is located adjacent the first conductor, and a first one of the plurality of tensioned non-conductive fibers passes under a first peak of the first conductor and over a first valley of the second conductor; and

wherein the first and second conductors have a plurality of contact points positioned along the length of the first and second conductors, such that when the first and second conductors engage a conductor of a mating connector element, at least some of the plurality of contact points provide an electrical connection between the first and second conductors of the multiple-contact woven connector and the conductor of the mating connector element; and

wherein the plurality of tensioned, non-conductive fibers of the weave provide a contact force between the at least some of the plurality of contact points of the first and second conductors and the conductor of the mating connector element.

51. The multiple-contact woven connector as claimed in claim 50, further comprising a third conductor and a fourth conductor woven with the plurality of tensioned, non-conductive fibers, wherein the first and second conductors together comprise a first electrical contact and wherein the third and fourth conductors together comprise a second electrical contact.

52. The multiple-contact woven connector as claimed in claim 51, further comprising an insulating fiber woven with the plurality of tensioned, non-conductive fibers and positioned between the first electrical contact and the second electrical contact.

53. An array of electrical connector the first and second multiple-contact woven connectors as claimed in claim 52.

54. The array of electrical connectors as claimed in claim 53, further comprising an electrical shield positioned between the first and second multiple-contact woven connectors.

55. The array of electrical connectors as claimed in claim 54, wherein the first and second electrical contacts of the first multiple-contact woven connector together comprise a differential signal contact.

56. An electrical connector comprising:

a weave having a plurality of fibers and at least one conductor woven with the plurality of fibers, the at least one conductor having a plurality of peaks and valleys and a plurality of contact points along a length thereof, the contact points adapted to engage a corresponding conductor of a mating connector element in sliding contact as the electrical connector is engaged with the mating connector;

wherein, upon sliding the conductor of the mating connector element relative to the weave, at least some of the plurality of fibers are tensioned, thereby providing a contact force between at least some of the plurality of contact points and the corresponding conductor of the mating connector element.

57. The electrical connector as claimed in claim 56, wherein the at least one conductor of the weave comprises multiple conductors of the weave, each having a corresponding conductor in the mating element.

58. The electrical connector as claimed in claim 56, wherein the plurality of fibers are elastic.

59. The electrical connector as claimed in claim 56, wherein the plurality of fibers are non-conductive.

63. The electrical connector as claimed in claim 56, wherein the plurality of fibers are tensioned prior to engagement of the electrical connector with the mating connector element, and wherein upon sliding the conductor of the mating connector element against the weave, the at least some of the plurality of fibers are tensioned further so as to provide the contact force between the at least some of the plurality of contact points and the corresponding conductor of the mating element.

64. The electrical connector as claimed in claim 56, wherein the at least one conductor of the weave comprises two or more conductors, each having at least two contact points adapted to engage a corresponding conductor of the mating connector.

65. The multiple-contact woven connector as claimed in claim 56, wherein the plurality of contact points are formed by the plurality of peaks and valleys of the at least one conductor.

60. The electrical connector as claimed in clam 56, further comprising a housing having a base wall and first and second end walls, wherein the at least one conductor is mounted to the base wall.

61. The electrical connector as claimed in claim 60, wherein the plurality of fibers are disposed between the first and second end walls of the housing.

62. The electrical connector as claimed in claim 61, wherein the first and second end walls of the housing comprise tensioning mounts to tension the plurality of fibers.

66. An electrical connector comprising:

a weave having a plurality of fibers and at least one conductor woven with the plurality of fibers, at least some of the plurality of fibers adapted to provide a contact force at contact points between the at least one conductor of the woven connector and a conductor of a mating connector element as at least some of the plurality of fibers are tensioned, wherein the contact force is substantially dependent upon the force applied from the tensioned fibers and substantially independent of any bending or compression of the at least one conductor.

67. The electrical connector as claimed in claim 66, wherein the plurality of contact points are formed by a plurality of peaks and valleys along a length of the at least one conductor.

68. The electrical connector as claimed in claim 66, wherein the at least one conductor of the weave comprises multiple conductors of the weave, each having a corresponding conductor in the mating element.

69. The electrical connector as claimed in claim 66, wherein the plurality of fibers are elastic.

70. The electrical connector as claimed in claim 66, wherein the plurality of fibers are non-conductive.

71. The electrical connector as claimed in claim 66, further comprising a housing having a base wall and first and second end walls, wherein the at least one conductor is mounted to the base wall.

72. The electrical connector as claimed in claim 71, wherein the plurality of fibers are disposed between the first and second end walls of the housing.

73. The electrical connector as claimed in claim 72, wherein the first and second end walls of the housing comprise tensioning mounts to tension the plurality of fibers.

74. The electrical connector as claimed in claim 66, wherein the plurality of fibers are tensioned prior to engagement of the electrical connector with the mating connector element, and wherein upon sliding the conductor of the mating connector element against the weave, the at least some of the plurality of fibers are tensioned further so as to provide the contact force between the at least some of the plurality of contact points and the conductor of the mating element.

75. The electrical connector as claimed in claim 66, wherein the at least one conductor of the weave comprises two or more conductors, each having at least two contact points adapted to engage a corresponding conductor of the mating connector.

76. An electrical connector comprising:

a weave having a plurality of fibers each anchored at a first and a second anchor point and at least one conductor woven with the plurality of fibers to form the weave;

wherein at least some of the plurality of fibers are adapted to provide contact forces at contact points between the at least one conductor of the woven connector and a conductor of a mating connector element as the fibers are tensioned substantially evenly from the first anchor point to the second anchor point upon displacement of the fibers during engagement of the woven connector and the mating connector element.

77. The electrical connector as claimed in claim 76, wherein the plurality of contact points are formed by a plurality of peaks and valleys along a length of the at least one conductor.

78. The electrical connector as claimed in claim 76, wherein the at least one conductor of the weave comprises multiple conductors of the weave, each having a corresponding conductor in the mating element.

79. The electrical connector as claimed in claim 76, wherein the plurality of fibers are elastic.

80. The electrical connector as claimed in claim 76, wherein the plurality of fibers are non-conductive.

81. The electrical connector as claimed in claim 76, further comprising a housing having a base wall and first and second end walls, wherein the at least one conductor is mounted to the base wall.

82. The electrical connector as claimed in claim 80, wherein the plurality of fibers are disposed between the first and second end walls of the housing.

83. The electrical connector as claimed in claim 81, wherein the first and second end walls of the housing comprise the first and second anchor points of each of the plurality of fibers and also act as tensioning mounts to tension the plurality of fibers.

84. The electrical connector as claimed in claim 76, wherein the plurality of fibers are tensioned prior to engagement of the electrical connector with the mating connector element, and wherein upon sliding the conductor of the mating connector element against the weave, the at least some of the plurality of fibers are tensioned further so as to provide the contact forces between the at least some of the plurality of contact points and conductors of the mating element.

85. The electrical connector as claimed in claim 76, wherein the at least one conductor of the weave comprises two or more conductors, each having at least two contact points adapted to engage a corresponding conductor of the mating connector.

86. The electrical connector as claimed in claim 76, wherein each of the plurality of fibers comprise circular bands woven with the at least one conductor.

88. The electrical connector as claimed in claim 81, wherein the plurality of contact points are formed by a plurality of peaks and valleys along a length of the at least one conductor.

89. The electrical connector as claimed in claim 81, wherein the at least one conductor of the weave comprises multiple conductors of the weave, each having a corresponding conductor in the mating element.

90. The electrical connector as claimed in claim 81, wherein the plurality of fibers are substantially inelastic and are each connected to a spring element to tension the fibers.

87. An electrical connector comprising:

a weave having a plurality of fibers and at least one conductor woven with the plurality of fibers to form the weave, the at least one conductor having multiple contact points along a length thereof, the plurality of fibers of the weave being exposed within the electrical connector;

wherein at least some of the plurality of fibers are adapted to provide contact forces between at least some of the contact points of the at least one conductor of the woven connector and a conductor of a mating connector element as the fibers are tensioned upon displacement of the at least some fibers during engagement of the woven connector and the mating connector element.

91. The electrical connector as claimed in claim 87, wherein the plurality of fibers are non-conductive.

92. The electrical connector as claimed in claim 87, further comprising a housing having a base wall and first and second end walls, wherein the at least one conductor is mounted to the base wall.

93. The electrical connector as claimed in claim 87, wherein the plurality of fibers are disposed between the first and second end walls of the housing.

94. The electrical connector as claimed in claim 93, wherein the first and second end walls of the housing comprise the first and second anchor points of each of the plurality of fibers and also act as tensioning mounts to tension the plurality of fibers.

95. The electrical connector as claimed in claim 87, wherein the plurality of fibers are tensioned prior to engagement of the electrical connector with the mating connector element, and wherein upon sliding the conductor of the mating connector element against the weave, the at least some of the plurality of fibers are tensioned further so as to provide the contact forces between the at least some of the plurality of contact points and conductors of the mating element.

96. The electrical connector as claimed in claim 93, wherein the at least one conductor of the weave comprises two or more conductors, each having at least two contact points adapted to engage a corresponding conductor of the mating connector.

97. The electrical connector as claimed in claim 93, wherein each of the plurality of fibers comprise circular bands woven with the at least one conductor.