US20020111069A1
Expired / Lapsed
US
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Connector molding method and shielded waferized connector made therefrom
Assignee: Amphenol Corp
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Filing: 2002-04-24
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Granted: —
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Expires: 2022-04-24
Abstract
Abstract A high speed, high density electrical connector. The connector is assembled from wafers. Each wafer is formed by molding a first dielectric housing over a shield plate. Signal contacts are inserted into the first dielectric housing and a second housing is overmolded on the first housing. Features are employed to lock the first and second housings together with the shield plate to provide a mechanically robust subassembly. The connector as formed has a good electrical properties, including precise impedance control and low cross talk.
Inventors
- 👤 Allan Astbury
- 👤 Thomas Cohen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 23:18
CPC Classifications
H; H01; H01R; H01R13/00; H01R13/648; H01R13/658; H01R13/6581; H01R13/6585; H01R13/6586; H01R13/6587
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
219 words
1 . A method of manufacturing an electrical connector assembled from wafers, including a process of manufacturing wafers comprising: a) providing a shield plate having an upper surface and a lower surface, the shield plate having a plurality of contact tails extending therefrom, the contact tails connected to the shield plate through a portion bent to raise the contact tail above the plane of the shield plate; b) molding a first dielectric housing on the shield plate, the first dielectric housing having a cavity and a plurality of openings extending from the cavity and encapsulating the bent portions attaching the contact tails to the shield plate; c) providing a plurality of signal contacts, each of the signal contacts having a contact tail, a contact region and an intermediate portion joining the contact tail and the contact region; d) inserting the plurality of signal contacts into the first dielectric housing, with the intermediate portions in the cavity, the contact regions in one of the plurality of openings and the contact tails extending from the first dielectric housing; e) molding a second dielectric housing within the cavity, thereby securing the shield, the first dielectric housing and the signal contacts together as a wafer, whereby the contact tails of the shield plate and the signal contacts are secured to the insulative housing.
Claim 2
Dependent Claim
219 words
1 . A method of manufacturing an electrical connector assembled from wafers, including a process of manufacturing wafers comprising: a) providing a shield plate having an upper surface and a lower surface, the shield plate having a plurality of contact tails extending therefrom, the contact tails connected to the shield plate through a portion bent to raise the contact tail above the plane of the shield plate; b) molding a first dielectric housing on the shield plate, the first dielectric housing having a cavity and a plurality of openings extending from the cavity and encapsulating the bent portions attaching the contact tails to the shield plate; c) providing a plurality of signal contacts, each of the signal contacts having a contact tail, a contact region and an intermediate portion joining the contact tail and the contact region; d) inserting the plurality of signal contacts into the first dielectric housing, with the intermediate portions in the cavity, the contact regions in one of the plurality of openings and the contact tails extending from the first dielectric housing; e) molding a second dielectric housing within the cavity, thereby securing the shield, the first dielectric housing and the signal contacts together as a wafer, whereby the contact tails of the shield plate and the signal contacts are secured to the insulative housing.
Claim 3
Dependent Claim
39 words
2 . The electrical connector of claim 1 wherein the shield plate additionally comprises a first plurality of tabs bent above the upper surface of the shield plate and wherein the tabs are encapsulated in the first dielectric housing.
Claim 4
Dependent Claim
53 words
3 . The electrical connector of claim 2 wherein the shield plate includes a second plurality of tabs extending above the upper surface and molding the first dielectric housing includes molding a window around the second plurality of tabs and molding the second dielectric housing encapsulates the tabs in the second dielectric housing.
Claim 5
Dependent Claim
43 words
4 . The electrical connector of claim 1 wherein the cavity is molded to have areas to receive mating portions of the signal contacts and the signal contacts are inserted into the first dielectric housing in a direction perpendicular to the first surface.
Claim 6
Dependent Claim
75 words
5 . The electrical connector of claim 1 wherein the shield plate has a raised portion forming a recess below the upper surface, the raised portion having a hole therein and molding the first dielectric housing includes providing a first portion of the first dielectric housing above the raised portion providing a second portion of the first dielectric housing in the recess and in the hole, thereby securing the first portion and the second portion.
Claim 7
Dependent Claim
35 words
6 . The electrical connector of claim 5 wherein the connector has a face adapted to mate to a second connector and the raised portion is along the edge of the plate at the face.
Claim 8
Dependent Claim
47 words
7 . The electrical connector of claim 1 wherein the shield plate has a raised portion and the first dielectric housing includes recessed areas in the floor of the cavity whereby air spaces are provided between the signal contacts and the raised portion of the shield plate.
Claim 9
Dependent Claim
57 words
8 . The electrical connector of claim 1 wherein the connector has a face adapted to mate to a second connector and the shield plate has a plurality of slots in the edge adjacent the face, with the front housing having an opening therein exposing the slot and portion of the shield plate away from the face.
Claim 10
Dependent Claim
26 words
9 . The method of claim 1 wherein inserting the plurality of signal contacts comprises pressing the signal contacts into channels in the first dielectric housing.
Claim 11
Dependent Claim
18 words
10 . The method of claim 1 wherein inserting the plurality of signal contacts comprises inserting signal contacts
Claim 12
Dependent Claim
199 words
11 . An electrical connector having a first piece and a second intermateable piece, the first connector piece comprising: a) a first housing having opposing side walls; b) a plurality of blades disposed in rows parallel to the opposing side walls; c) a plurality of first shield plates disposed between adjacent rows of blades, each of the shield plates having a flat portion and a plurality of slots; the second connector piece comprising: a) a second housing having a mating face with a plurality of openings therein, each of the openings aligned with one of the blades from the first connector piece; b) a plurality of signal contacts each having a mating portion accessible within one of the openings; c) a plurality of second shield plates disposed within the second housing perpendicular to the shield plates in the first connector piece, each of the shield plates having a slot formed therein, the slots positioned to engage one of the plurality of first shield plates; d) wherein the second housing is shaped to expose portions of the second shield plates adjacent the slots in the second shield plate, whereby the slots of the first shield plates engage the exposed portions.
Claim 13
Dependent Claim
199 words
11 . An electrical connector having a first piece and a second intermateable piece, the first connector piece comprising: a) a first housing having opposing side walls; b) a plurality of blades disposed in rows parallel to the opposing side walls; c) a plurality of first shield plates disposed between adjacent rows of blades, each of the shield plates having a flat portion and a plurality of slots; the second connector piece comprising: a) a second housing having a mating face with a plurality of openings therein, each of the openings aligned with one of the blades from the first connector piece; b) a plurality of signal contacts each having a mating portion accessible within one of the openings; c) a plurality of second shield plates disposed within the second housing perpendicular to the shield plates in the first connector piece, each of the shield plates having a slot formed therein, the slots positioned to engage one of the plurality of first shield plates; d) wherein the second housing is shaped to expose portions of the second shield plates adjacent the slots in the second shield plate, whereby the slots of the first shield plates engage the exposed portions.
Claim 14
Dependent Claim
38 words
12 . The electrical connector of claim 11 wherein the second connector piece is assembled from a plurality of wafers, each wafer comprising a shield plate, a portion of the second housing and a column of signal contacts.
Claim 15
Dependent Claim
47 words
13 . The electrical connector of claim 12 wherein the portion of the second housing in each wafer comprises a first portion molded around the shield plate to leave a cavity with the signal contacts disposed within the cavity and a second portion molded in the cavity.
Claim 16
Dependent Claim
29 words
14 . The electrical connector of claim 11 wherein each of the second shield plates has a contact adjacent each slot, the contact member engaging the first shield plate.
Claim 17
Dependent Claim
20 words
15 . The electrical connector of claim 14 wherein the second housing has a tapered surface opposing each contact member.
Claim 18
Dependent Claim
166 words
16 . A method of manufacturing an electrical connector from a plurality of wafers by manufacturing wafers according to the method of: a) providing a shield plate with an upper surface and a lower surface, the plate having raised portions in the upper surface thereby forming a recesses in the lower surface; b) molding a first insulative housing on the upper surface of the shield plate and the lower surface of the shield plate in the recesses, the insulative housing having a cavity therein; c) inserting signal contacts into the cavity, each having a mating portion, a tail and an intermediate portion joining the mating portion and the contact tail; d) placing insulative material in the cavity to secure the signal contacts to the first housing, leaving the mating portions and the tails exposed; e) stacking the wafers side by side with the first insulative housing molded in the recess of one wafer adjacent the exposed mating portions of the signal contacts in an adjacent wafer.
Claim 19
Dependent Claim
166 words
16 . A method of manufacturing an electrical connector from a plurality of wafers by manufacturing wafers according to the method of: a) providing a shield plate with an upper surface and a lower surface, the plate having raised portions in the upper surface thereby forming a recesses in the lower surface; b) molding a first insulative housing on the upper surface of the shield plate and the lower surface of the shield plate in the recesses, the insulative housing having a cavity therein; c) inserting signal contacts into the cavity, each having a mating portion, a tail and an intermediate portion joining the mating portion and the contact tail; d) placing insulative material in the cavity to secure the signal contacts to the first housing, leaving the mating portions and the tails exposed; e) stacking the wafers side by side with the first insulative housing molded in the recess of one wafer adjacent the exposed mating portions of the signal contacts in an adjacent wafer.
Claim 20
Dependent Claim
29 words
17 . The method of manufacturing an electrical connector of claim 16 wherein the method of stacking the wafers side by side includes attaching the wafers to metal stiffener.
Claim 21
Dependent Claim
56 words
18 . The method of claim 16 wherein the shield plate has a plurality of attachment features therein and molding the first insulative housing comprises molding insulation over a first portion of the attachment features and placing insulative material in the cavity comprises molding a second insulative housing around a second portion of the attachment features.
Claim 22
Dependent Claim
35 words
19 . The method of claim 16 wherein providing a shield plate includes bending portions of the shield plate at right angles to the plate to form slots and a contact elements adjacent the slots.
Claim 23
Dependent Claim
21 words
20 . The method of claim 19 wherein the molding a first insulative housing leaves each of the contact elements exposed.
Claim 24
Dependent Claim
40 words
21 . The method of claim 16 wherein inserting signal contacts into the cavity comprises inserting signal contacts joined by tie bars and molding a first insulative housing comprises leaving holes in the housing to leave the tie bars exposed.
Claim 25
Dependent Claim
96 words
22 . A connector having a mating interface comprising: a) a shield plate having a front edge, the shield plate having a plurality of ribs formed therein and a plurality of beams formed at right angles to the shield plate adjacent a slot therein; b) housing affixed to the shield plate, the housing having a plurality of openings formed therein; c) a plurality of signal contacts, each signal contact having a mating contact portion disposed within one of the plurality of openings, with one of the plurality of beams between adjacent ones of the signal contacts.
Claim 26
Dependent Claim
96 words
22 . A connector having a mating interface comprising: a) a shield plate having a front edge, the shield plate having a plurality of ribs formed therein and a plurality of beams formed at right angles to the shield plate adjacent a slot therein; b) housing affixed to the shield plate, the housing having a plurality of openings formed therein; c) a plurality of signal contacts, each signal contact having a mating contact portion disposed within one of the plurality of openings, with one of the plurality of beams between adjacent ones of the signal contacts.
Claim 27
Dependent Claim
18 words
23 . The connector of claim 22 wherein each of the signal contacts comprises a dual beam contact.
Claim 28
Dependent Claim
23 words
24 . The connector of claim 23 wherein the signal contacts are disposed in pairs and there is a beam between adjacent pairs.
Claim 29
Dependent Claim
26 words
25 . The connector of claim 22 wherein the housing has a plurality of surfaces, each surface opposing a beam, said surfaces having tapers formed therein.
Claim 30
Dependent Claim
14 words
26 . The connector of claim 22 wherein the connector is a cable connector.
Claim 31
Dependent Claim
85 words
27 . An electrical connector of the type having a plurality of contacts disposed in multiple rows, comprising: a) a conducting housing having a first surface having a plurality of rows of holes, with contacts extending through the holes; b) a plurality of strips of insulative material, each of the strips running along a row of holes and each strip comprising insulative plugs disposed within the holes and insulative material joining the plugs into a strip; c) wherein the contacts are anchored in the plugs.
Claim 32
Dependent Claim
85 words
27 . An electrical connector of the type having a plurality of contacts disposed in multiple rows, comprising: a) a conducting housing having a first surface having a plurality of rows of holes, with contacts extending through the holes; b) a plurality of strips of insulative material, each of the strips running along a row of holes and each strip comprising insulative plugs disposed within the holes and insulative material joining the plugs into a strip; c) wherein the contacts are anchored in the plugs.
Claim 33
Dependent Claim
20 words
28 . The connector of claim 27 wherein the contacts are disposed in pairs within the holes in the housing.
References Cited (Backward Citations)
No citation records indexed.
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