Electrical connector apparatus and method

• US 7,287,987 B2
• Filed: 05/31/2005
• Issued: 10/30/2007
• Est. Priority Date: 05/31/2005
• Status: Expired due to Fees

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Heisen, Peter T, Navarro, Julio A
• Primary Examiner(s): Harvey; James R.
• Application Number:
  US11/140,799
• Publication Number:
  US 20060270279A1
• Time in Patent Office: 882 Days
• Field of Search: 439/67, 439492-499
• US Class Current: 439/67
• CPC Class Codes: H01Q 1/1207 for fastening a rigid aerial element
• CPC Class Codes: H01Q 21/0025 Modular arrays
• CPC Class Codes: H01Q 21/0087 Apparatus or processes specially adapted for manufacturing antenna arrays manufacturing waveguides H01P11/00
• CPC Class Codes: H01R 12/62 connecting to rigid printed circuits or like structures

Abstract

An electrical connector apparatus and method for connecting circuit traces on two or more independent circuit board assemblies. A compressible elastomeric member is wrapped with a flexible circuit assembly having a plurality of independent circuit traces, with each circuit trace including a pair of raised electrical contacts. The compressible member with the electrical circuit wrapped over it is supported by a holder assembly. The holder assembly is secured to one of a pair of adjacently positioned independent printed circuit assemblies. The compressible member is held by the holder assembly so that it is compressed against both of the printed circuit board assemblies. The raised electrical contacts electrically contact traces on each of the printed circuit assemblies to complete the electrical connections between the circuit assemblies. The apparatus is especially useful in applications where a large plurality of electrical connections need to be made between independent circuit board assemblies in a very limited space.

Claims

1. An electrical interconnect apparatus for forming an electrical connection between spaced apart first and second electrical contact points of a pair of adjacent electrical components, the apparatus comprising:

a compressible substrate having at least one hole formed therethrough;

a flexible electrical circuit having at least one circuit trace electrically coupling spaced apart first and second electrical contact portions, said flexible electrical circuit having at least one hole and being laid over at least a portion of said compressible substrate; and

a holder structure securable to one of the pair of adjacent electrical components for securing said compressible substrate in a compressed state against each of said pair of electrical components such that said first and second electrical contact portions are compressed into contact with said first and second electrical contact points;

said holder structure including an alignment member extending from said holder structure, through said holes in said compressible substrate and said flexible electrical circuit, and engageable with a surface portion of said one electrical component, to thus key said flexible electrical circuit in a position relative to said one electrical component.

2. The apparatus of claim 1, wherein said compressible substrate comprises an elastomeric, cylindrical substrate.

3. The apparatus of claim 1, wherein said flexible electrical circuit is wrapped completely around a circumference of said compressible substrate.

4. The apparatus of claim 1, wherein said flexible electrical circuit has a plurality of holes formed therein and said holder structure has a corresponding plurality of pins that engage said holes and surface portions of said one electrical component to hold said flexible compressible circuit in a desired alignment relative to said electrical contact portions.

5. The apparatus of claim 4, wherein said holder structure includes a frame for supporting a pair of securing members that secure said compressible substrate to said one adjacent electrical component.

6. An electrical interconnect apparatus for forming an electrical connection between spaced apart independent, electrical components having first and second spaced apart electrical contact points, the apparatus comprising:

a compressible member having a hole;

a sheet-like, flexible electrical circuit having at least one circuit trace electrically coupling spaced apart first and second electrical contact portions formed thereon, said flexible electrical circuit having a hole and being wrapped over and secured to said compressible member to form a compressible electrical coupling subassembly; and

a holder structure for receiving said compressible electrical coupling subassembly and for compressing said subassembly against said electrical components such that electrical coupling is formed between said first and second electrical contact portions and said first and second electrical contact points;

said holder structure further including an alignment member extending through said holes in said compressible member and said flexible electrical circuit, and engaging with a surface portion of one of said electrical components, to thus hold said flexible electrical circuit in a precisely registered orientation with said one electrical component.

7. The apparatus of claim 6, wherein said holder structure includes fastening elements adapted to be secured to supporting structure used to support at least one of said electrical components.

8. The apparatus of claim 6, wherein said compressible member comprises a cylindrical elastomeric member.

9. The apparatus of claim 6, wherein said holder structure includes a plurality of said alignment members, each said alignment member forming an alignment pin, and wherein said sheet-like, flexible electrical circuit includes a corresponding plurality of holes for receiving said alignment pins;

and

wherein said alignment pins are adapted to engage with a corresponding plurality of surface portions of said supporting structure to maintain engagement between said electrical contact portions and said electrical contact points.

10. An electrical signal coupling apparatus for coupling electrical signals between a pair of spaced apart electrical contact points on independent electrical assemblies, the apparatus comprising:

an elastomeric member;

a flexible circuit layer defining a plurality of circuit traces, with each said circuit trace having a pair of spaced apart electrical contact pads;

the flexible circuit layer being wrapped onto the elastomeric member and secured thereto to form a compressible signal coupling subassembly;

the electrical contact pads being arranged to align with said electrical contact points on said independent circuit assemblies to effect a plurality of electrical signal coupling paths between said independent electrical assemblies when said compressible signal coupling subassembly is compressed into contact with each of said independent electrical assemblies; and

a holder structure including at least one alignment pin that extends through a hole in said flexible circuit layer and a hole in said elastomeric member to key said flexible circuit layer to one of said electrical circuit assemblies.

11. The apparatus of claim 10, wherein said elastomeric member comprises a cylindrical elastomeric member.

12. The apparatus of claim 10, wherein the holder structure includes a frame and a plurality of fastening components for fastening the holder frame to one of the independent electrical assemblies.

13. The apparatus of claim 10, wherein the holder includes a plurality of alignment elements adapted to engage with one of the independent electrical assemblies to align the electrical contact pads with the electrical contact points.

14. A method for forming signal coupling between first and second spaced apart electrical contact points on first and second electrical assemblies, the method comprising:

forming a compressible member;

forming a flexible circuit layer having at least one circuit trace having a pair of spaced apart electrical contact elements; and

wrapping said flexible circuit layer onto said compressible member;

using a holder having an alignment member extending through said flexible substrate and said flexible layer to engage a surface portion of one of said electrical assemblies; and

using said holder to secure said compressible member relative to said first and second assemblies such that said spaced apart electrical contact elements are compressed against said first and second contact points on said first and second assemblies, and held in a position relative to at least said one electrical assembly.

15. The method of claim 14, wherein forming a compressible member comprises forming an elastomeric member.

16. The method of claim 14 further comprising forming said compressible member as a cylindrically shaped, elongated elastomeric member.

17. The method of claim 14 further comprising forming said flexible substrate with a plurality of circuit traces each having a pair of electrical contact elements.

18. The method of claim 14 further comprising forming said flexible substrate such that said electrical contact points form raised, electrically conductive pads.