Low profile electrical interconnect with fusion bonded contact retention and solder wick reduction
First Claim
1. A method of making an electrical interconnector, the method comprising the steps of:
- positioning a plurality of discrete contact members in through holes in a substrate so distal portions of the contact members extend above a first surface of the substrate in a cantilevered configuration and proximal portions of the contact members are accessible along a second surface of the substrate;
locating a flowable polymeric on the second surface of the substrate adjacent the through holes;
subjecting the substrate and the contact members to sufficient energy and/or pressure so the flowable polymeric layer flows into engagement with the proximal portions of the contact members and fuses the contact members to the substrate;
positioning distal portions of the contact members in through holes in an insulator housing; and
bonding the first surface of the substrate to a first surface of the insulator housing so the distal portions are accessible from a second surface of the insulator housing.
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Accused Products
Abstract
An electrical interconnect and a method of making the same. A plurality of contact members are located in through holes in a substrate so distal portions of the contact members extend above a first surface of the substrate in a cantilevered configuration and proximal portions of the contact members are accessible along a second surface of the substrate. A flowable polymeric material located on the second surface of the substrate is fusion bonded to the proximal portions of the contact members so the flowable polymeric material substantially seals the through holes in the substrate. An insulator housing is bonded to the first surface of the substrate with the distal portions of the contact members located in through holes in an insulator housing, so the distal portions are accessible from a second surface of the insulator housing.
436 Citations
19 Claims
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1. A method of making an electrical interconnector, the method comprising the steps of:
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positioning a plurality of discrete contact members in through holes in a substrate so distal portions of the contact members extend above a first surface of the substrate in a cantilevered configuration and proximal portions of the contact members are accessible along a second surface of the substrate; locating a flowable polymeric on the second surface of the substrate adjacent the through holes; subjecting the substrate and the contact members to sufficient energy and/or pressure so the flowable polymeric layer flows into engagement with the proximal portions of the contact members and fuses the contact members to the substrate; positioning distal portions of the contact members in through holes in an insulator housing; and bonding the first surface of the substrate to a first surface of the insulator housing so the distal portions are accessible from a second surface of the insulator housing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. An electrical interconnector comprising:
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a plurality of discrete contact members located in through holes in a substrate so distal portions of the contact members extend above a first surface of the substrate in a cantilevered configuration and proximal portions of the contact members are accessible along a second surface of the substrate; a flowable polymeric material located on the second surface of the substrate is fusion bonded to the proximal portions of the contact members so the flowable polymeric material substantially seals the through holes in the substrate; and an insulator housing bonded to the first surface of the substrate with the distal portions of the contact members located in through holes in an insulator housing, so the distal portions are accessible from a second surface of the insulator housing. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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Specification