Miniature small pitch connection element and a process for manufacturing such a connection element

Claim 2

A miniature small pitch connection element comprising an insulating elastomer body associated with conducting strips, wherein said strips are spaced from each other an amount sufficient to prevent electrical intercontact, and are continuously disposed about and in contact with said body over the greatest part of its circumference and having their outer surfaces overmolded by and fully enclosed by the insulating elastomer body over the rest of said strips so as to provide a strong mechanical connection between said strips and said body, and with said strips emerging from said body, at a single substantially flat surface of the body at their two ends to be flush with the single surface of the body whereby said strips define electrical contacts for said connection element to interconnect electrical components and whereby as a result of the two ends of the strip emerging at and being flush with the single surface the connection between the body and the strips is enhanced.

Claim 3

The connection element as in claim 1, wherein the insulating elastomer is made of silicone.

Claim 4

The connection element is in claim 1, wherein said strips are formed from copper or copper alloy.

Claim 5

The connection element as in claim 1, wherein said strips are coated with a conductive metal coating for ensuring reliability of electrical contact whenin use as a connector.

Claim 6

The connection element as in claim 1, wherein said insulating body is shaped like a parallelepiped having a rectangular cross-section.

Claim 7

The connection element as in claim 5 wherein the parallelepiped shaped body has a square cross-section.

Claim 8

The connection element as in claim 6 wherein the length of the sides of the square is about 3 mm, the strips have a width of about 0.2 mm, are spaced from each other by about 0.4 mm and have a thickness of about 0.1 mm.

Claim 9

The connection element as in claim 1 wherein the strips are made of copper coated with a layer of gold.

Claim 10

The connection element as in claim 1 wherein the strips are made of copper coated with, in sequence, two nickel layers with a gold layer superimposed thereon.

Claim 11

The connection element as in claim 1 wherein the strips are made of copper coated with a layer of tin-lead alloy.

Claim 12

The connection element as in claim 1 wherein the strips are made of copper coated with a layer of palladium.

Claim 13

The connection element as in claim 9 wherein the thickness of the nickel coating is about 2 and the thickness of the gold coating is about 1.

Claim 14

A process for manufacturing a connection element which comprises an insulating elastomer body associated with conductive strips, each of which have two ends, wherein said strips are spaced from each other and are disposed about and in contact with said body over the greatest part of its circumference and overmolded by and inside the insulating elastomer body over the rest of said strips so as to provide a strong mechanical connection between said strips and said body, and with said strips emerging from said body at their two ends whereby said strips define electrical contacts for said connection element to interconnect electrical components, said method comprising the steps of: cutting out a band of conducting material in a manner such as to obtain a series of strips which are parallel to each other, are separated by gaps and are interconnected together at ends thereof by two continuous borders; transversely folding said band, while holding it by its two continuous borders to form rings with said strips which are almost closed; introducing said band into a mold in a position such that the outer faces of the strips bear against walls of said mold; introducing and polymerizing an elastomer in said mold in a manner such that this upper level of the elastomer below the attachment location of said strips to said continuous bands; and cutting off the bands at said attachment location at a point flush with the elastomer body.

Claim 15

A process for manufacturing a connection element which comprises an insulating elastomer body associated with conductive strips, each of which have two ends, wherein said strips are spaced from each other and are disposed about and in contact with said body over the greatest part of its circumference and overmolded by and inside the insulating elastomer body over the rest of said strips so as to provide a strong mechanical connection between said strips and said body, and with said strips emerging from said body at their two ends whereby said strips define electrical contacts for said connection element to interconnect electrical components, said method comprising the steps of: cutting out a band of conducting material in a manner such as to obtain a series of strips which are parallel to each other, are separated by gaps and are interconnected together at ends thereof by two continuous borders; transversely folding said band, while holding it by its two continuous borders to form rings with said strips which are almost closed; introducing said band into a mold in a position such that the outer faces of the strips bear against walls of said mold; introducing and polymerizing an elastomer in said mold in a manner such that this upper level of the elastomer below the attachment location of said strips to said continuous bands; and cutting off the bands at said attachment location at a point flush with the elastomer body.

Claim 16

The process as in claim 13, further comprising an electrolytic coating step for coating said strips with a conductive material.

Claim 17

The process as in claim 14, wherein said electrolytic coating step is carried out before the folding step.

Claim 18

The process is in claim 14, wherein said electrolytic coating step is carried out before the step of introducing the band into a mold.

Claim 19

The process as in claim 14, wherein said electrolytic coating step is carried out before the step of cutting the borders of the band.

Claim 20

The process is in claim 14, wherein said electrolytic coating step comprises a step of depositing a layer of nickel then a step of depositing a layer of gold.

Claim 21

A process as in claim 13, further comprising before introducing the band into the mold, inserting a prepolymerized elastomer parallelepiped in the rings formed by the strips of the band, and then introducing the ring and parallelepiped assembly into the mold.

Claim 22

The process as in claim 13 wherein said mold is coated on the interior surfaces thereof with a rubber which is nonadherent to said elastomer introduced and polymerized therein.