High-density electrical interconnect system

Claim 2

An electrical interconnect system comprising: a first insulative substrate; a first array of groups of multiple electrically conductive contacts arranged in rows and columns on the first substrate, each of the contacts of the first array having a contact section extending from a surface of the first insulative substrate, wherein the groups from adjacent rows of the first array are staggered as are the groups from adjacent columns of the first array, and the groups of the first array are interleaved among one another in a nested configuration such that a portion of each group of the first array overlaps into an adjacent row of the groups of the first array or an adjacent column of the groups of the first array; a second insulative substrate; and a second array of groups of multiple electrically conductive contacts arranged in rows and columns on the second substrate, each of the contacts of the second array having a contact section extending from a surface of the second insulative substrate, wherein the groups from adjacent rows of the second array are staggered as are the groups from adjacent columns of the second array, the groups of the second array are interleaved among one another in a nested configuration such that a portion of each group of the second array overlaps into an adjacent row of the groups of the second array or an adjacent column of the groups of the second array, each of the contact section of the first and second arrays has a contact surface side of the contact section and an opposing surface located opposite the contact surface on an opposing side of the contact section, the nested configurations of the groups of contacts maintain the contacts in close proximity to one another while allowing adequate clearance between the contacts so that each group of contacts from the first array is received within a corresponding single one of the groups of contacts from the second array when the first and second arrays are mated, the contact surface of each contact section of the first array contacts a corresponding one of the contact surfaces of the contact sections of the second array when the first and second arrays are mated, and each contact section of at least the second array is laterally unsupported on the opposing surface of the contact section both before and after mating of the first and second arrays.

Claim 3

An electrical interconnect system according to claim 1, wherein the contacts of each group form the shape of a cross.

Claim 4

An electrical interconnect system according to claim 1, wherein each group of the second array includes a plurality of contacts each for electrically connecting to a contact of one of the groups of contacts of the first array.

Claim 5

An electrical interconnect system according to claim 1, wherein the contacts of different ones of the groups from the first array are different in height.

Claim 6

An electrical interconnect system according to claim 1, wherein the contacts of different ones of the groups from the second array are different in height.

Claim 7

An electrical interconnect system according to claim 1, wherein each of the groups of contacts from the first array includes an insulative buttress positioned between the contacts of that group.

Claim 8

An electrical interconnect system according to claim 1, further comprising alignment means for aligning each group of contacts from the first array with a corresponding one of the groups of contacts from the second array upon contact between at least one of the groups of contacts from the first array and its corresponding group of contacts from the second array.

Claim 9

An electrical interconnect system according to claim 1, wherein each group of the first array is a projection-type interconnect component, each group of the second array is a receiving-type interconnect component, each projection-type interconnect component is configured for receipt within a single one of the receiving-type interconnect components, and each projection-type interconnect component comprises: a buttress attached to the first substrate and comprising an electrically insulative material; and a plurality of electrically conductive contacts positioned around the buttress in electrical isolation from one another.

Claim 10

An electrical interconnect system according to claim 8, wherein, for each protection-type interconnect component, all of the conductive contacts are in close proximity to the buttress.

Claim 11

An electrical interconnect system according to claim 8, wherein the first substrate is also formed of electrically insulative material and the contacts for each projection-type interconnect component of the first array are electrically isolated from one another by the insulative material of the first substrate and the buttress for that component.

Claim 12

An electrical interconnect system according to claim 8, wherein the buttress for each group of the first array and the first substrate are adjacent components of an integrally formed unit made of the electrically insulative material.

Claim 13

An electrical interconnect system according to claim 8, wherein the electrically insulative material is a liquid crystal polymer.

Claim 14

An electrical interconnect system according to claim 8, wherein the buttress for each group of the first array is substantially perpendicular with respect to the first substrate.

Claim 15

An electrical interconnect system according to claim 8, wherein each of the plurality of contacts of each projection-type interconnect component comprises: a contact portion for contacting a contact of a corresponding receiving-type interconnect component when the projection-type interconnect component is received within the corresponding receiving-type component; a stabilizing portion, anchored within the first substrate, for preventing displacement of the contact portion; and a foot portion, located below the first substrate and attached to the stabilizing portion, for performing a circuit interface function.

Claim 16

An electrical interconnect system according to claim 14, wherein the contact portion, the stabilizing portion, and the foot portion of each contact of each projection-type interconnect component are centered around a single axis of that contact.

Claim 17

An electrical interconnect system according to claim 14, wherein at least the stabilizing portion of each contact of each projection-type interconnect component is centered around a single axis of that contact, and the contact portion of that contact is offset from the axis toward a control portion of the interconnect component including that contact.

Claim 18

An electrical interconnect system according to claim 14, wherein each foot portion has a flattened end for interfacing with one of a wire, a flat flexible cable, a round cable, or a surface mount interface surface.

Claim 19

An electrical interconnect system according to claim 14, wherein each foot portion has a rounded end for interfacing with a plated hole in a printed wiring board.

Claim 20

An electrical interconnect system according to claim 8, wherein each of the plurality of contacts of each projection-type interconnect component comprises: a conductive post; and conductive plating, formed on only a portion of a surface of the post, for contacting a contact of a corresponding receiving-type interconnect component when that projection-type interconnect component is received within the corresponding receiving-type component.

Claim 21

An electrical interconnect system according to claim 19, wherein each conductive post comprises at least one of beryllium copper, phosphor bronze, brass, or a copper alloy.

Claim 22

An electrical interconnect system according to claim 19, wherein the conductive plating comprises at least one of palladium, tin, gold, or another conductive metal.

Claim 23

An electrical interconnect system according to claim 19, wherein the conductive plating is formed only on the portion of the surface of the post used for contacting a contact of the corresponding receiving-type interconnect component.

Claim 24

An electrical interconnect system according to claim 1, wherein each group of the first array is a projection-type interconnect component, each group of the second array is a receiving-type interconnect component, each receiving-type interconnect component is configured to receive therein a single one of the projection-type interconnect components, and each of the contacts of each receiving-type interconnect component comprises: a flexible beam portion having a contact surface facing a position located between a plurality of contacts of that receiving-type interconnect component and contacting an electrically conductive contact of a corresponding projection-type interconnect component when the corresponding projection-type interconnect component is received within the receiving-type interconnect component.

Claim 25

An electrical interconnect system according to claim 23, wherein the contacts of each receiving-type interconnect component are deflected toward one another prior to receipt of a corresponding projection-type interconnect component within that receiving-type interconnect component.

Claim 26

An electrical interconnect system according to claim 23, wherein the contacts of each receiving-type interconnect component are deflected away from one another after receipt of a corresponding projection-type interconnect component within that receiving-type interconnect component.

Claim 27

An electrical interconnect system according to claim 23, wherein the contacts of each receiving-type interconnect component each comprise force exerting means for exerting a normal force against one of the contacts of a corresponding projection-type interconnect component when the corresponding projection-type interconnect component is received within that receiving-type interconnect component.

Claim 28

An electrical interconnect system according to claim 23, wherein the flexible beam portions of each receiving-type interconnect component are initially in close proximity to one another and separate in response to insertion of a corresponding projection-type interconnect component into that receiving-type interconnect component, and the force exerting means each exert a normal force against a respective one of the contacts of the corresponding projection-type interconnect component in response to the separation of the flexible beam portions.

Claim 29

An electrical interconnect system according to claim 23, when each receiving-type interconnect component comprises further zero force inserting means for separating the flexible beam portions prior to insertion of a corresponding projection-type interconnect component into that receiving-type interconnect component, and for releasing the flexible beam portions after insertion of the corresponding projection-type interconnect component into that receiving-type interconnect component.

Claim 30

An electrical interconnect system according to claim 28, wherein the zero force inserting means of each receiving-type interconnect component comprises a member, located between the flexible beam portions of that component, for separating the flexible beam portions in response to relative movement between the member and the flexible beam portions.

Claim 31

An electrical interconnect system according to claim 29, wherein the member is a bulbous member.

Claim 32

An electrical interconnect system according to claim 23, wherein each of the plurality of contacts of each receiving-type interconnect component comprises: a contact portion for contacting a contact of a corresponding projection-type interconnect component when the corresponding projection-type interconnect component is received within the receiving-type interconnect component; a stabilizing portion, anchored within the second substrate, for preventing displacement of the contact portion; and a foot portion, located below the second substrate and attached to the stabilizing portion, for performing a circuit interface function.

Claim 33

An electrical interconnect system according to claim 31, wherein the contact portion, the stabilizing portion, and the foot portion of each contact of each receiving-type interconnect component are centered around a single axis of that contact.

Claim 34

An electrical interconnect system according to claim 31, wherein at least the stabilizing portion of each contact of each receiving-type interconnect component is centered around a single axis of that contact, and the contact portion of that contact is offset from the axis away from a central portion of the interconnect component including that contact.

Claim 35

An electrical interconnect system according to claim 31, wherein each foot portion has a flattened end for interfacing with one of a wire, a flat flexible cable, a round cable, or a surface mount interface surface.

Claim 36

An electrical interconnect system according to claim 31, wherein each foot portion has a rounded end for interfacing with a plated hole in a printed wiring board.

Claim 37

An electrical interconnect system according to claim 8, wherein each of the plurality of contacts of each receiving-type interconnect component comprises: a conductive post; and conductive plating, formed on only a portion of a surface of the post, for contacting a contact of a corresponding projection-type interconnect component when the corresponding projection-type interconnect component is received within that receiving-type component.

Claim 38

An electrical interconnect system according to claim 36, wherein each conductive post comprises at least one of beryllium copper, phosphor bronze, brass, or a copper alloy.

Claim 39

An electrical interconnect system according to claim 36, wherein the conductive plating comprises at least one of palladium, tin, gold, or another conductive material.

Claim 40

An electrical interconnect system according to claim 36, wherein the conductive plating is formed only on the portion of the surface of the post used for contacting a contact of the corresponding projection-type interconnect component.

Claim 41

An electrical interconnect system comprising: a first insulative substrate; a first array of groups of multiple electrically conductive contacts arranged in rows and columns on the first substrate, wherein the groups from adjacent rows of the first array are staggered as are the groups from adjacent columns of the first array, and the groups of the first array are interleaved among one another in a nested configuration such that a portion of each group of the first array overlaps into an adjacent row of the groups of the first array or an adjacent column of the groups of the first array; a second insulative substrate; a second array of groups of multiple electrically conductive contacts arranged in rows and columns on the second substrate, wherein the groups from adjacent rows of the second array are staggered as are the groups from adjacent columns of the second array, the groups of the second array are interleaved among one another in a nested configuration such that a portion of each group of the second array overlaps into an adjacent row of the groups of the second array or an adjacent column of the groups of the second array, and the nested configurations of the groups of contacts maintain the contacts in close proximity to one another while allowing adequate clearance between the contacts so that each group of contacts from the first array may be received within a corresponding single one of the groups of contacts from the second array; wherein each group of the first array is a projection-type interconnect component, each group of the second array is a receiving-type interconnect component, each projection-type interconnect component is configured for receipt within a single one of the receiving-type interconnect components, and each projection-type interconnect component comprises a buttress attached to the first substrate and comprising an electrically insulative material, and a plurality of electrically conductive contacts positioned around the buttress in electrical isolation from one another; and wherein each receiving-type interconnect component includes a plurality of electrically conductive contacts having flexible beam portions adjustable in position; and wherein the buttress for each projection-type interconnect component comprises an elongated portion surrounded by the contacts of the projection-type interconnect component, the elongated portion having a first end fixed to the first substrate, and positional adjustment means, located at a second end of the elongated portion opposite the first end, for adjusting the position of the flexible beam portions to enable receipt of the projection-type interconnect component between the contacts of a corresponding one of the receiving-type interconnect components.

Claim 42

An electrical interconnect system comprising: a first insulative substrate; a first array of groups of multiple electrically conductive contacts arranged in rows and columns on the first substrate, wherein the groups from adjacent rows of the first array are staggered as are the groups from adjacent columns of the first array, and the groups of the first array are interleaved among one another in a nested configuration such that a portion of each group of the first array overlaps into an adjacent row of the groups of the first array or an adjacent column of the groups of the first array; a second insulative substrate; a second array of groups of multiple electrically conductive contacts arranged in rows and columns on the second substrate, wherein the groups from adjacent rows of the second array are staggered as are the groups from adjacent columns of the second array, the groups of the second array are interleaved among one another in a nested configuration such that a portion of each group of the second array overlaps into an adjacent row of the groups of the second array or an adjacent column of the groups of the second array, and the nested configurations of the groups of contacts maintain the contacts in close proximity to one another while allowing adequate clearance between the contacts so that each group of contacts from the first array may be received within a corresponding single one of the groups of contacts from the second array; wherein each group of the first array is a projection-type interconnect component, each group of the second array is a receiving-type interconnect component, each projection-type interconnect component is configured for receipt within a single one of the receiving-type interconnect components, and each projection-type interconnect component comprises a buttress attached to the first substrate and comprising an electrically insulative material, and a plurality of electrically conductive contacts positioned around the buttress in electrical isolation from one another; and wherein each receiving-type interconnect component includes a plurality of electrically conductive contacts having flexible beam portions adjustable in position; and wherein the buttress for each projection-type interconnect component comprises an elongated portion surrounded by the contacts of the projection-type interconnect component, the elongated portion having a first end fixed to the first substrate, and positional adjustment means, located at a second end of the elongated portion opposite the first end, for adjusting the position of the flexible beam portions to enable receipt of the projection-type interconnect component between the contacts of a corresponding one of the receiving-type interconnect components.

Claim 43

An electrical interconnect system according to claim 40, wherein the elongated portion of the buttress for each projection-type interconnect component is at least as long as the contacts of the projection-type interconnect component.

Claim 44

An electrical interconnect system according to claim 40, wherein the positional adjustment means of the buttress for each projection-type interconnect component comprises first separating means, responsive to relative movement between the projection-type interconnect component and a corresponding one of the receiving-type interconnect components, for separating the flexible beam portions of the contacts of the corresponding receiving-type interconnect component to cause the flexible beam portions to separate from one another by a first distance.

Claim 45

An electrical interconnect system according to claim 42, wherein the plurality of contacts for each projection-type interconnect component comprises second separating means, responsive to further relative movement between the projection-type interconnect component and a corresponding one of the receiving-type interconnect components, for separating the flexible beam portions of the contacts of the receiving-type interconnect component to cause the flexible beam corresponding portions to separate from one another by a second distance.

Claim 46

An electrical interconnect system according to claim 43, wherein the second separating means associated with each projection-type interconnect component comprises sloped surfaces of contacts located on opposite sides of the buttress for that interconnect component.

Claim 47

An electrical interconnect system according to claim 43, wherein the first separating means associated with each protection-type interconnect component comprises at least one sloped surface of the buttress for that interconnect component, and the second separating means associated with each projection-type interconnect component comprises at least one sloped surface of the plurality of contacts of that projection-type interconnect component.

Claim 48

An electrical interconnect system according to claim 17, wherein the first separating means associated with each protection-type interconnect component comprises at least one sloped surface of the buttress for that interconnect component, the second separating means associated with each protection-type interconnect component comprises at least a first and a second sloped surface of the plurality of contacts of that projection-type interconnect component, and for each projection-type interconnect component the first sloped surface is positioned closer to the first separating means than is the second sloped surface.

Claim 49

An electrical interconnect system according to claim 46, wherein, for each protection-type interconnect component, the first and second sloped surfaces are sloped surfaces of different ones of the plurality of contacts of that projection-type interconnect component.

Claim 50

An electrical interconnect system according to claim 40, wherein the elongated portion of each buttress has a substantially rectangular, four-sided cross-section, and at least one of the plurality of contacts of the projection-type interconnect component for that buttress is located at one of the four sides of the buttress.

Claim 51

An electrical interconnect system according to claim 40, wherein the elongated portion of each buttress has a substantially cross-shaped cross-section, and at least one of the plurality of contacts of the projection-type interconnect component for that buttress is located at one of the sides of the buttress.

Claim 52

An electrical interconnect system according to claim 40, wherein the elongated portion of each buttress has a substantially rectangular, four-sided cross-section, and at least one of the plurality of contacts of the projection-type interconnect component for that buttress is located at each of two opposing sides of the buttress.

Claim 53

An electrical interconnect system according to claim 40, wherein the elongated portion of each buttress has a substantially cross-shaped cross-section, and at least one of the plurality of contacts of the projection-type interconnect component for that buttress is located at each of two opposing sides of the buttress.

Claim 54

An electrical interconnect system comprising: a first insulative substrate; a first array of groups of multiple electrically conductive contacts arranged in rows and columns on the first substrate, wherein the groups from adjacent rows of the first array are staggered as are the groups from adjacent columns of the first array, a portion of each group of the first array overlaps into an adjacent row of the groups of the first array or an adjacent column of the groups of the first array, each group of the first array is a protection-type interconnect component, and each contact of each protection-type interconnect component has a section extending out of the first substrate; a second insulative substrate; and a second array of groups of multiple electrically conductive contacts arranged in rows and columns on the second substrate, wherein the groups from adjacent rows of the second array are staggered as are the groups from adjacent columns of the second array, each group of the second array is a receiving-type interconnect component configured to receive a corresponding single one of the projection-type interconnect components, each contact of each receiving-type interconnect component has a section extending out of the second substrate, the extending sections of the contacts of the projection-type interconnect components extend in a vertical direction both prior to and after receipt within a corresponding receiving-type interconnect component, and the extending sections of the contacts of the receiving-type interconnect components have portions bent toward a horizontal direction prior to receiving a corresponding projection-type interconnect component and straightened to extend in a vertical direction after receiving the corresponding projection-type interconnect component.

Claim 55

An electrical interconnect system comprising: a first insulative substrate; a first array of groups of multiple electrically conductive contacts arranged in rows and columns on the first substrate, wherein the groups from adjacent rows of the first array are staggered as are the groups from adjacent columns of the first array, a portion of each group of the first array overlaps into an adjacent row of the groups of the first array or an adjacent column of the groups of the first array, each group of the first array is a protection-type interconnect component, and each contact of each protection-type interconnect component has a section extending out of the first substrate; a second insulative substrate; and a second array of groups of multiple electrically conductive contacts arranged in rows and columns on the second substrate, wherein the groups from adjacent rows of the second array are staggered as are the groups from adjacent columns of the second array, each group of the second array is a receiving-type interconnect component configured to receive a corresponding single one of the projection-type interconnect components, each contact of each receiving-type interconnect component has a section extending out of the second substrate, the extending sections of the contacts of the projection-type interconnect components extend in a vertical direction both prior to and after receipt within a corresponding receiving-type interconnect component, and the extending sections of the contacts of the receiving-type interconnect components have portions bent toward a horizontal direction prior to receiving a corresponding projection-type interconnect component and straightened to extend in a vertical direction after receiving the corresponding projection-type interconnect component.

Claim 56

An electrical interconnect system according to claim 52, wherein each of the groups of conductive contacts from the first array includes an insulative buttress positioned between the contacts of that group, and, for each group of the first array, all of the contacts are positioned around the buttress in close proximity to the buttress.

Claim 57

An electrical interconnect system according to claim 53, wherein each group of the second array comprises a plurality of electrically conductive contacts each having a flexible beam portion for contacting a respective one of the contacts of a corresponding projection-type interconnect component.

Claim 58

An electrical interconnect system according to claim 53, wherein each buttress is substantially perpendicular with respect to the first substrate.

Claim 59

An electrical interconnect system according to claim 54, wherein for each projection-type interconnect component the buttress comprises: an elongated portion surrounded by the contacts of the projection-type interconnect component, the elongated portion having a first end fixed to the first substrate; and positional adjustment means, located at a second end of the elongated portion opposite the first end, for adjusting the position of the flexible beam portions to enable receipt of the projection-type interconnect component between the contacts of a corresponding one of the receiving-type interconnect components.

Claim 60

An electrical interconnect component according to claim 56, wherein the elongated portion of the buttress for each projection-type interconnect component is at least as long as the contacts of the projection-type interconnect component.

Claim 61

An electrical interconnect system according to claim 56, wherein the positional adjustment means of the buttress for each projection-type interconnect component comprises first separating means, responsive to relative movement between the projection-type interconnect component and a corresponding one of the receiving-type interconnect components, for separating the flexible beam portions of the contacts of the corresponding receiving-type interconnect component to cause the flexible beam portions to separate from one another by a first distance.

Claim 62

An electrical interconnect system according to claim 58, wherein the plurality of contacts for each projection-type interconnect component comprises second separating means, responsive to further relative movement between the projection-type interconnect component and a corresponding one of the receiving-type interconnect components, for separating the flexible beam portions of the contacts of the corresponding receiving-type interconnect component to cause the flexible beam portions to separate from one another by a second distance.

Claim 63

An electrical interconnect component according to claim 59, wherein the second separating means associated with each protection-type interconnect component comprises sloped surfaces of contacts located on opposite sides of the buttress for that interconnect component.

Claim 64

An electrical interconnect system according to claim 59, wherein the first separating means associated with each projection-type interconnect component comprises at least one sloped surface of the buttress for that interconnect component, and the second separating means associated with each projection-type interconnect component comprises at least one sloped surface of the plurality of contacts of that projection-type interconnect component.

Claim 65

An electrical interconnect system of claim 59, wherein the first separating means associated with each projection-type interconnect component comprises at least one sloped surface of the buttress for that interconnect component, the second separating means associated with each projection-type interconnect component comprises at least a first and a second sloped surface of the plurality of contacts of that projection-type interconnect component, and for each projection-type interconnect component the first sloped surface is positioned closer to the first separating means than is the second sloped surface.

Claim 66

An electrical interconnect system according to claim 62, wherein, for each projection-type interconnect component, the first and second sloped surfaces are sloped surfaces of different ones of the plurality of contacts of that projection-type interconnect component.

Claim 67

An electrical interconnect system according to claim 52, wherein the contacts of each receiving-type interconnect component each comprise force exerting means for exerting a normal force against one of the contacts of a corresponding projection-type interconnect component when the corresponding projection-type interconnect component is received within that receiving-type interconnect component.

Claim 68

An electrical interconnect system according to claim 64, wherein flexible beam portions of each receiving-type interconnect component are initially in close proximity to one another and separate in response to insertion of a corresponding projection-type interconnect component into that receiving-type interconnect component, and the force exerting means each exert a normal force against a respective one of the contacts of the corresponding projection-type interconnect component in response to the separation of the flexible beam portions.

Claim 69

An electrical interconnect system according to claim 54, wherein within each group of the second array at least two of the flexible beam portions differ in length.