US6164983A
Expired / Lapsed
US
⏱️ 0.0 years remaining
High density connector
Assignee: FCI Americas Technology LLC
•
Filing: 1996-12-31
•
Granted: 2000-12-26
•
Expires: 2016-12-31
Abstract
Abstract Electrical connectors capable of being mounted on circuit substrates by BGA techniques are disclosed. Also disclosed is a method for manufacturing such connectors. There is at least one recess on the exterior side of the connector elements. A conductive contact extends from adjacent the interior side of the into the recess on the exterior side of the housing. A controlled volume of solder paste is introduced into the recess. A fusible conductive element, in the form of solder balls is positioned in the recess. The connector is subjected to a reflow process to fuse the solder ball to the portion of the contact extending into said recess. Contacts are secured in the insulative housing of the connector by deformable sections that minimize stress imposed on the housing, thereby reducing warpage. Solder resist areas are formed on central portions of the contacts to promote uniformity of solder volume. As a result of these features, substantial coplanarity of the BGA array along the mounting interface of the connector is achieved.
Inventors
- 👤 Timothy A. Lemke
- 👤 Timothy W. Houtz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 13:12
CPC Classifications
H; H01; H01R; H01R12/00; H01R12/70; H01R12/71; H01R12/712; H01R12/716; H01R43/00; H01R43/02; H01R43/0256; H01R43/20; H01M; H01M50/00; H01M50/50; H01M50/543; H01M50/564; H01M50/566; H05; H05K; H05K3/00; H05K3/30; H05K3/32; H05K3/34; H05K3/341; H05K3/3421; H05K3/3426; H05K3/3465; H05K3/3478; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117
Claims Analysis
Total Claims: 63
Claim 1
Independent Claim
92 words
An electrical connector adapted to be mounted on a substrate having a conductive element, comprising: an insulative housing, the housing having an exterior side adapted to face the substrate; a stamped contact formed from a sheet of conductive material, adapted to mate with a mating component and extending substantially to the exterior side of the housing, the contact having an angled connection portion adapted to be electrically connected to said conductive element; and a body of reflowable, electrically conductive material disposed on the connection portion adjacent the exterior side of the housing.
Claim 2
Dependent Claim
92 words
An electrical connector adapted to be mounted on a substrate having a conductive element, comprising: an insulative housing, the housing having an exterior side adapted to face the substrate; a stamped contact formed from a sheet of conductive material, adapted to mate with a mating component and extending substantially to the exterior side of the housing, the contact having an angled connection portion adapted to be electrically connected to said conductive element; and a body of reflowable, electrically conductive material disposed on the connection portion adjacent the exterior side of the housing.
Claim 3
Dependent Claim
20 words
The electrical connector of claim 1, wherein the reflowable material is also fused to the conductive element of the substrate.
Claim 4
Dependent Claim
30 words
The electrical connector as recited in claim 1, wherein said reflowable material body has a shape different than a shape of said connection portion to which said reflowable material secures.
Claim 5
Dependent Claim
29 words
The electrical connector as recited in claim 1, wherein said reflowable material is disposed on said connection portion of said contact prior to the connector mounting to the substrate.
Claim 6
Dependent Claim
37 words
The electrical connector of claim 1, wherein said exterior side has a recess, the connection portion of the contact is disposed within the recess, and the reflowable material is fused to the connection portion in said recess.
Claim 7
Dependent Claim
20 words
The electrical connector as recited in claim 5, wherein said connection portion of said contact resides entirely within said recess.
Claim 8
Dependent Claim
15 words
The electrical connector of claim 5, wherein the reflowable material is a body of solder.
Claim 9
Dependent Claim
15 words
The electrical connector of claim 7, wherein the body of solder is a solder ball.
Claim 10
Dependent Claim
117 words
An electrical connector mountable to a substrate and comprising: an insulative housing having a base wall with an interior side and an exterior side, a plurality of recesses on said exterior side; a plurality of contact receiving slots, each of said slots extending from the interior side of said base wall to one of said recesses; a contact extending through each of said slots and having a mounting end residing substantially within said recess, but not substantially beyond said recess in a direction towards the substrate; and a plurality of bodies of reflowable, electrically conductive material, each body being associated with a recess and having a portion thereof disposed in the recess and fused to the contact.
Claim 11
Dependent Claim
117 words
An electrical connector mountable to a substrate and comprising: an insulative housing having a base wall with an interior side and an exterior side, a plurality of recesses on said exterior side; a plurality of contact receiving slots, each of said slots extending from the interior side of said base wall to one of said recesses; a contact extending through each of said slots and having a mounting end residing substantially within said recess, but not substantially beyond said recess in a direction towards the substrate; and a plurality of bodies of reflowable, electrically conductive material, each body being associated with a recess and having a portion thereof disposed in the recess and fused to the contact.
Claim 12
Dependent Claim
13 words
The electrical connector of claim 9, wherein the reflowable elements are solder balls.
Claim 13
Dependent Claim
30 words
The electrical connector of claim 9, wherein the housing includes at least one contact support extension carried by the insulative housing for retaining at least one contact on the housing.
Claim 14
Dependent Claim
30 words
The electrical connector of claim 11, wherein the contact support extension extends into at least one of said contact receiving slots to bear against a contact inserted in the slot.
Claim 15
Dependent Claim
20 words
The electrical connector as recited in claim 9, wherein said mounting end of said contact resides entirely within said recess.
Claim 16
Dependent Claim
16 words
The electrical connector of claim 9, wherein the plurality of contacts are arranged in an array.
Claim 17
Dependent Claim
15 words
The electrical connector of claim 14, wherein the contacts are positioned in a staggered array.
Claim 18
Dependent Claim
16 words
The electrical connector of claim 14, wherein said contacts are aligned in a plurality of rows.
Claim 19
Dependent Claim
23 words
The electrical connector of claim 16, wherein at least one elongated power/ground contact is positioned along one side of the array of contacts.
Claim 20
Dependent Claim
19 words
The electrical connector of claim 16, wherein an elongated power/ground contact is positioned along each side of the array.
Claim 21
Dependent Claim
16 words
The electrical connector of claim 18, wherein the ground/power contact carries at least one solder ball.
Claim 22
Dependent Claim
44 words
The electrical connector of claim 16, wherein at least one elongated ground/power contact is disposed between two of said rows of contacts and at least one reflowable electrically conductive element is carried by the ground/power contact on the exterior side of the base wall.
Claim 23
Dependent Claim
19 words
The electrical connector of claim 20, wherein the at least one reflowable electrically conductive element comprises a solder ball.
Claim 24
Dependent Claim
31 words
The electrical connector of claim 21, in combination with a substrate having at least one conductive element, and wherein the solder balls are fused to the conductive element of the substrate.
Claim 25
Dependent Claim
31 words
The electrical connector as recited in claim 22, wherein said solder balls are fused to the conductive element of the substrate subsequent to said solder ball being fused to said contact.
Claim 26
Dependent Claim
142 words
An electrical connector comprising: an insulative member having a mating side adapted to face a mating component, a mounting side adapted to face a substrate, and an opening extending from the mating side towards the mounting side, and a recess in said mounting side; an electrical terminal insertable into the opening in the insulative member, the terminal having a contact portion disposed on the contact bearing side of the insulative member and a mounting portion, the mounting portion having a securing section extending at least partially through the insulative member and a distal region disposed in the recess; and an electrically conductive heat fusible section secured to the distal region, extending from the securing section and adjacent the mounting side of the insulative body, with a portion of the fusible section disposed in the recess and a portion disposed outside the recess.
Claim 27
Dependent Claim
142 words
An electrical connector comprising: an insulative member having a mating side adapted to face a mating component, a mounting side adapted to face a substrate, and an opening extending from the mating side towards the mounting side, and a recess in said mounting side; an electrical terminal insertable into the opening in the insulative member, the terminal having a contact portion disposed on the contact bearing side of the insulative member and a mounting portion, the mounting portion having a securing section extending at least partially through the insulative member and a distal region disposed in the recess; and an electrically conductive heat fusible section secured to the distal region, extending from the securing section and adjacent the mounting side of the insulative body, with a portion of the fusible section disposed in the recess and a portion disposed outside the recess.
Claim 28
Dependent Claim
22 words
The electrical connector of claim 24, wherein the portion of the fusible member disposed outside the recess includes a substantially spherical surface.
Claim 29
Dependent Claim
20 words
The electrical connector as recited in claim 24, wherein the distal region of the terminal resides entirely within the recess.
Claim 30
Dependent Claim
29 words
An electrical connector as in claim 24, comprising a plurality of terminals insertable into a plurality of openings in the insulative member, said terminals being arranged in an array.
Claim 31
Dependent Claim
19 words
The electrical connector of claim 27, wherein the number of terminals in each dimension of the array exceeds 2.
Claim 32
Dependent Claim
12 words
The electrical connector of claim 24, wherein the fusible section comprises solder.
Claim 33
Dependent Claim
17 words
The electrical connector of claim 29, wherein the solder is substantially in the form of a ball.
Claim 34
Dependent Claim
22 words
The electrical connector as recited in claim 24, wherein an end of the distal region of the terminal resides within the recess.
Claim 35
Dependent Claim
19 words
The electrical connector as recited in claim 31, wherein the end of the terminal resides entirely within the recess.
Claim 36
Dependent Claim
144 words
An electrical component adapted to be surface mounted to a major surface of a circuit substrate, comprising: a body formed of an insulative material, the body having a mounting surface adapted to be disposed in facing relationship to the circuit substrate and an opening therein extending toward said mounting surface; an electrically conductive member insertable into the opening in the body, the conductive member including a terminal portion extending toward the mounting surface and adapted to be positioned adjacent the major surface of the circuit substrate, and a mass of heat fusible material extending from the terminal portion to the mounting surface for establishing electrical continuity between the circuit substrate and the conductive member and adapted to secure to the major surface of the circuit substrate; wherein, when the mass engages the circuit substrate, the body remains a distance away from the circuit substrate.
Claim 37
Dependent Claim
144 words
An electrical component adapted to be surface mounted to a major surface of a circuit substrate, comprising: a body formed of an insulative material, the body having a mounting surface adapted to be disposed in facing relationship to the circuit substrate and an opening therein extending toward said mounting surface; an electrically conductive member insertable into the opening in the body, the conductive member including a terminal portion extending toward the mounting surface and adapted to be positioned adjacent the major surface of the circuit substrate, and a mass of heat fusible material extending from the terminal portion to the mounting surface for establishing electrical continuity between the circuit substrate and the conductive member and adapted to secure to the major surface of the circuit substrate; wherein, when the mass engages the circuit substrate, the body remains a distance away from the circuit substrate.
Claim 38
Dependent Claim
18 words
An electrical component as in claim 33, wherein the mass is substantially in the form of a ball.
Claim 39
Dependent Claim
36 words
An electrical component as in claim 33, wherein the mass comprises a plurality of solder bodies, each having an outermost surface that is presented substantially in a plane and have a coplanarity within about 0.004 inch.
Claim 40
Dependent Claim
16 words
The electrical component as recited in claim 33, wherein said conductive member is a stamped contact.
Claim 41
Dependent Claim
27 words
The electrical component as recited in claim 33, wherein said mass has a shape different than a shape of said terminal portion to which said mass secures.
Claim 42
Dependent Claim
31 words
The electrical connector as recited in claim 33, wherein the body further comprises a recess in communication with the opening and the conductive member has an end residing within the recess.
Claim 43
Dependent Claim
16 words
The electrical connector as recited in claim 38, wherein the end resides entirely within the recess.
Claim 44
Dependent Claim
14 words
An electrical component as in claim 33, wherein the mass presents a curved surface.
Claim 45
Dependent Claim
30 words
An electrical component as in claim 40, wherein the curved surface comprises a plurality of curved surfaces presented substantially in a plane and having a coplanarity within about 0.004 inch.
Claim 46
Dependent Claim
14 words
An electrical component as in claim 40, wherein said curved surface is generally spherical.
Claim 47
Dependent Claim
31 words
An electrical component as in claim 42, wherein the curved surface comprises a plurality of generally spherical surfaces presented substantially in a plane and having a coplanarity within about 0.004 inch.
Claim 48
Dependent Claim
143 words
An electrical connector comprising: an insulative housing having a mating interface for facing a mating component, a mounting interface for facing a substrate including conductive elements, and a plurality of openings extending from the mating interface towards the mounting interface; a plurality of contacts, each insertable into a respective one of said openings in the housing from one of the mating interface and the mounting interface, each contact having a mating portion associated with the mating interface and adapted for engaging the mating component and a connector portion associated with the mounting interface, extending generally parallel to the opening and adapted to be secured to one of the conductive elements on the substrate, the connector portion having an end, and a plurality of fusible elements, each fusible element secured to one of said contacts so that the ends reside within the fusible elements.
Claim 49
Dependent Claim
143 words
An electrical connector comprising: an insulative housing having a mating interface for facing a mating component, a mounting interface for facing a substrate including conductive elements, and a plurality of openings extending from the mating interface towards the mounting interface; a plurality of contacts, each insertable into a respective one of said openings in the housing from one of the mating interface and the mounting interface, each contact having a mating portion associated with the mating interface and adapted for engaging the mating component and a connector portion associated with the mounting interface, extending generally parallel to the opening and adapted to be secured to one of the conductive elements on the substrate, the connector portion having an end, and a plurality of fusible elements, each fusible element secured to one of said contacts so that the ends reside within the fusible elements.
Claim 50
Dependent Claim
19 words
The electrical connector of claim 44, wherein the fusible elements are fused to the conductive elements on the substrate.
Claim 51
Dependent Claim
20 words
The electrical connector as recited in claim 44, wherein the ends of the contacts reside entirely within the fusible elements.
Claim 52
Dependent Claim
17 words
An electrical connector as in claim 44, wherein the contacts are arranged in a two dimensional array.
Claim 53
Dependent Claim
28 words
An electrical connector as in claim 44, wherein said connector portions of said contacts are spaced from the mounting interface, and the fusible elements form the mounting interface.
Claim 54
Dependent Claim
34 words
An electrical connector as in claim 48, wherein each fusible element is located to provide electrical continuity between the contact on which the fusible element is secured and a conductive element on the substrate.
Claim 55
Dependent Claim
30 words
An electrical component as in claim 33, wherein the terminal portion of each conductive member includes a transversely extending part and the mass is secured on the transversely extending part.
Claim 56
Dependent Claim
36 words
An electrical component as in claim 50, wherein the body includes a mandrel surface adjacent each conductive member and the transversely extending part of the conductive member is a bent portion formed about the mandrel surface.
Claim 57
Dependent Claim
13 words
The electrical connector of claim 44, wherein the fusible elements are substantially spherical.
Claim 58
Dependent Claim
15 words
The electrical connector of claim 52, wherein the fusible elements are soldered on the contacts.
Claim 59
Dependent Claim
36 words
The electrical connector as recited in claim 44, wherein the housing comprises a plurality of recesses at the mounting interface and in communication with respective openings, wherein the ends of the contacts reside within respective recesses.
Claim 60
Dependent Claim
19 words
The electrical connector as recited in claim 54, wherein the ends of the contacts reside entirely within the recesses.
Claim 61
Dependent Claim
23 words
The electrical connector of claim 44, wherein the melting temperature of the fusible elements is less than the melting temperature of the contacts.
Claim 62
Dependent Claim
13 words
The electrical connector of claim 56, wherein the fusible elements are a solder.
Claim 63
Dependent Claim
13 words
The electrical connector of claim 57, wherein the fusible elements are solder balls.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2003-12-26 | 2004-06-26 | 2004-12-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2007-12-26 | 2008-06-26 | 2008-12-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2011-12-26 | 2012-06-26 | 2012-12-26 | $7700.00 | Window Closed / Lapsed |