Self-aligning electrical connector

Claim 2

An electrical connector comprising: a) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; b) a first housing, with the intermediate portion of each of the plurality of electrical conductors attached to the first housing; c) a second housing, with the contact portions of each of the plurality electrical conductors attached to the second housing; d) a compliant coupling between the first housing and the second housing; e) a plurality of insulative portions, wherein portions of the plurality of electrical conductors are attached to each of the insulative portions to form a plurality of subassemblies; and f) a first plurality of conductive plates, each conductive plate having: i) an intermediate portion attached to the insulative portion of a subassembly; ii) a plurality of contact tails extending from the intermediate portion of the plate; iii) a plurality of compliant portions having distal ends extending from the intermediate portion of the plate; iv) a plurality of contacts electrically connected to the distal ends of the plurality of compliant portions, wherein the plurality of contacts is attached to the second housing.

Claim 3

The electrical connector of claim 1 wherein the first housing is an insulative housing.

Claim 4

The electrical connector of claim 1 wherein each of the compliant portions comprises an elongated segment with bends therein.

Claim 5

The electrical connector of claim 3 wherein each of the compliant portions includes a curve.

Claim 6

The electrical connector of claim 3 wherein each of the compliant portions includes a plurality of curves.

Claim 7

The electrical connector of claim 5 wherein each of the compliant portions includes two curves, curving in opposite directions.

Claim 8

The electrical connector of claim 1 wherein the second housing has gathering features formed therein.

Claim 9

The electrical connector of claim 7 wherein the gathering feature comprises at least one tapered surface.

Claim 10

The electrical connector of claim 1 wherein the second housing has a plurality of side walls bounding a mating area and the contact portions of each of the plurality of electrical conductors is disposed within the mating area.

Claim 11

The electrical connector of claim 9 wherein the contact portions are disposed in the mating area in a rectangular array having rows and columns and the electrical connector further comprises a plurality of conducting plates disposed in parallel, each plate being disposed between adjacent rows of contact portions.

Claim 12

The electrical connector of claim 10 wherein the second housing is an insulator.

Claim 13

The electrical connector of claim 1 additionally comprising a second plurality of conductive plates, each of the second plurality of conductive plates attached to the second housing and at least one of the plurality of contacts on one of the first plurality of conductive plates.

Claim 14

The electrical connector of claim 12 wherein each of the second plurality of conductive plates is attached to one of the plurality of contacts on each of the first plurality of conductive plates.

Claim 15

An electrical connector comprising: a) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; b) a first housing, with the intermediate portion of each of the plurality of electrical conductors attached to the first housing; c) a second housing, with the contact portions of each of the plurality electrical conductors attached to the second housing; and d) a compliant coupling between the first housing and the second housing; e) wherein the compliant coupling comprises means for allowing motion in the plane between the first housing and the second housing while restraining motion along the line between the first housing and the second housing.

Claim 16

An electrical connector comprising: a) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; b) a first housing, with the intermediate portion of each of the plurality of electrical conductors attached to the first housing; c) a second housing, with the contact portions of each of the plurality electrical conductors attached to the second housing; and d) a compliant coupling between the first housing and the second housing; e) wherein the compliant coupling comprises means for allowing motion in the plane between the first housing and the second housing while restraining motion along the line between the first housing and the second housing.

Claim 17

The electrical connector of claim 14 wherein the compliant coupling comprises at least one recess in the first housing with a lip extending into the recess and a tab projecting from the second housing, with the tab engaging the lip.

Claim 18

The electrical connector of claim 15 wherein the compliant coupling further comprises a stop spaced apart from the tab.

Claim 19

An electrical connector comprising: a) a plurality of subassemblies disposed side-by side, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the compliant portions extending from the insulative portion, wherein each of the subassemblies holds the intermediate portions in a plane; b) a cap receiving the contact portions of the plurality of subassemblies and holding the contact portions, with the compliant portions extending from the insulative portion, whereby the cap may move relative to the insulative portions of the subassemblies; and c) a shield member attached to the insulative portion parallel to the plane of the intermediate portions, wherein the shield member comprises an intermediate portion adjacent the insulator, a plurality of compliant portions extending from the intermediate portion and a forward portion attached to the cap.

Claim 20

An electrical connector comprising: a) a plurality of subassemblies disposed side-by side, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the compliant portions extending from the insulative portion, wherein each of the subassemblies holds the intermediate portions in a plane; b) a cap receiving the contact portions of the plurality of subassemblies and holding the contact portions, with the compliant portions extending from the insulative portion, whereby the cap may move relative to the insulative portions of the subassemblies; and c) a shield member attached to the insulative portion parallel to the plane of the intermediate portions, wherein the shield member comprises an intermediate portion adjacent the insulator, a plurality of compliant portions extending from the intermediate portion and a forward portion attached to the cap.

Claim 21

The electrical connector of claim 17 wherein the forward portion has a plurality of contacts thereon.

Claim 22

The electrical connector of claim 18 additionally comprising a plurality of second type shields disposed within the cap, each of the second type shields connected to at least one contact on a forward member of at least one subassembly.

Claim 23

The electrical connector of claim 17 wherein the compliant portions comprises an elongated segment with bends formed therein.

Claim 24

The electrical connector of claim 20 wherein the bends comprise smooth curves.

Claim 25

The electrical connector of claim 21 wherein the bends comprise two smooth curves, curving in opposite directions.

Claim 26

The electrical connector of claim 17 additionally comprising a housing receiving at least a portion of the insulative portions of the plurality of subassemblies.

Claim 27

The electrical connector of claim 23 additionally comprising a compliant coupling between the housing and the cap.

Claim 28

The electrical connector of claim 24 wherein the compliant coupling comprises means for allowing motion in the plane between the housing and the cap.

Claim 29

The electrical connector of claim 24 wherein the compliant coupling comprises means for allowing motion in the plane between the housing and the cap and inhibiting motion along a line between the cap and the housing.

Claim 30

The electrical coupling of claim 24 wherein the compliant coupling comprises a tab engaged under a lip.

Claim 31

A matrix assembly comprising: a first connector comprising: a) a plurality of subassemblies disposed side-by side, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the compliant portions extending from the insulative portion; b) a cap receiving the contact portions of the plurality of subassemblies and holding the contact portions, with the compliant portions extending from the insulative portion, whereby the cap may move relative to the insulative portions of the subassemblies connector comprising: a) a second plurality of subassemblies, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, and intermediate portion and a contact portion, the contact portion shaped to mate with a contact portion of an electrical conductors in the first electrical connector; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the contact portions extending from the insulative portion; and b) a housing receiving at least the contact portions of the plurality of subassemblies, the housing having a mating face adapted to engage the cap of the first connector.

Claim 32

A matrix assembly comprising: a first connector comprising: a) a plurality of subassemblies disposed side-by side, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, an intermediate portion, a compliant portion and a contact portion; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the compliant portions extending from the insulative portion; b) a cap receiving the contact portions of the plurality of subassemblies and holding the contact portions, with the compliant portions extending from the insulative portion, whereby the cap may move relative to the insulative portions of the subassemblies connector comprising: a) a second plurality of subassemblies, each subassembly comprising: i) a plurality of electrical conductors, each electrical conductor having a contact tail, and intermediate portion and a contact portion, the contact portion shaped to mate with a contact portion of an electrical conductors in the first electrical connector; ii) an insulative portion encapsulating the intermediate portions of the electrical conductors with the contact portions extending from the insulative portion; and b) a housing receiving at least the contact portions of the plurality of subassemblies, the housing having a mating face adapted to engage the cap of the first connector.

Claim 33

The electrical connector of claim 28 wherein the cap comprises gathering features whereby the mating face of the housing is guided into mating position relative to the cap.

Claim 34

An electrical connector, adapted for use in a matrix assembly comprising: a) a first plurality of wafers, each wafer comprising a column of signal contacts, each signal contact having an intermediate portion, a contact tail, and a mating portion, each of the wafers further having a insulative portion encapsulating the intermediate portions of the signal contacts; b) a first housing holding the wafers in parallel with the mating portions held in a first planar array; c) a second plurality of wafers, each wafer comprising a column of signal contacts, each signal contact having an intermediate portion, a contact tail, a mating portion and curved portion having at least two opposing curves joining the intermediate portion to the mating portion, each of the wafers further having a insulative portion encapsulating the intermediate portions of the signal contacts and leaving the curved portion un-encapsulated; d) a second housing holding the insulative portion of the second plurality of wafers in parallel; e) a cap connected to the contact portions of the second plurality of wafers, the cap holding the contact potions in a second planar array of dimensions matching the first planar array.

Claim 35

An electrical connector, adapted for use in a matrix assembly comprising: a) a first plurality of wafers, each wafer comprising a column of signal contacts, each signal contact having an intermediate portion, a contact tail, and a mating portion, each of the wafers further having a insulative portion encapsulating the intermediate portions of the signal contacts; b) a first housing holding the wafers in parallel with the mating portions held in a first planar array; c) a second plurality of wafers, each wafer comprising a column of signal contacts, each signal contact having an intermediate portion, a contact tail, a mating portion and curved portion having at least two opposing curves joining the intermediate portion to the mating portion, each of the wafers further having a insulative portion encapsulating the intermediate portions of the signal contacts and leaving the curved portion un-encapsulated; d) a second housing holding the insulative portion of the second plurality of wafers in parallel; e) a cap connected to the contact portions of the second plurality of wafers, the cap holding the contact potions in a second planar array of dimensions matching the first planar array.