High speed modular connector for printed circuit boards

Claim 2

Electrical connector of the type comprising an electrically conductive housing having at least one row of passages therein, each passage extending between a first face and a second face of said housing, each connector further comprising a plurality of electrical terminals lying in respective passages, each terminal having a first end at said first face and a second end at said second face, each terminal being surrounded by a dielectric sleeve lying in the respective passage, said sleeves insulating said terminals from said housing, said connector being characterized in that said first face and said second face are substantially planar and lie in substantially perpendicular planes, said passages having substantially right angle bends therein, said sleeves and said terminals likewise having substantially right angle bends therein.

Claim 3

An electrical connector as in claim 1 characterized in that said housing is die cast metal.

Claim 4

An electrical connector as in claim 1 characterized in that said dielectric sleeve is injection molded plastic.

Claim 5

An electrical connector as in claim 1 characterized in that said terminals are die cast metal.

Claim 6

An electrical connector as in claim 2 or claim 4 characterized in that said metal is zinc.

Claim 7

An electrical connector as in claim 1 characterized in that said first end of said terminal is a pin which extends beyond said first face, said sleeve being flush with said first face.

Claim 8

An electrical connector as in claim 6 characterized in that said second end of said terminal is a socket which is flush with said second face of said connector, said sleeve being flush with said second face. .Iadd.

Claim 9

Apparatus for high speed signal transmission and for interconnecting high speed circuits without appreciable degradation of electrical transmission characteristics, the apparatus comprising: conductive housing means having plural apertures, dielectric sleeves within each aperture and a plurality of terminals, each disposed within a dielectric sleeve, the dielectric sleeves each comprising a molded structure and the housing means comprising a cast structure, the dielectric sleeves and the housing means being formed by sequential molding and casting processes, the one of said structures formed in an initial one of said processes forming a part of the mold for the subsequent one of said structures. .Iaddend. .Iadd.9. A high density, high speed connector apparatus for interconnecting corresponding circuits on printed circuit boards comprising first and second intermatable connectors, each connector having a plurality of terminals, each intermatable with corresponding terminals in the other connector, each terminal being located within a separate dielectric sleeve, each connector having a unitary electrically conductive outer housing having internal walls separating adjacent terminals, the dielectric sleeves being positioned within cavities extending between opposite sides of the outer housing formed by the internal walls of the unitary housing, the outer housing and the dielectric sleeves being formed by the sequential steps of casting an outer housing of a conductive material and injection molding a plurality of dielectric sleeves located in the housing, the housing or dielectric sleeve formed in the first of said sequential steps forming a portion of the mold defining the subsequently formed housing or dielectric sleeves followed by the step of positioning conductive terminals within the dielectric sleeves. .Iaddend.

Claim 10

Apparatus for high speed signal transmission and for interconnecting high speed circuits without appreciable degradation of electrical transmission characteristics, the apparatus comprising: conductive housing means having plural apertures, dielectric sleeves within each aperture and a plurality of terminals, each disposed within a dielectric sleeve, the dielectric sleeves each comprising a molded structure and the housing means comprising a cast structure, the dielectric sleeves and the housing means being formed by sequential molding and casting processes, the one of said structures formed in an initial one of said processes forming a part of the mold for the subsequent one of said structures. .Iaddend. .Iadd.9. A high density, high speed connector apparatus for interconnecting corresponding circuits on printed circuit boards comprising first and second intermatable connectors, each connector having a plurality of terminals, each intermatable with corresponding terminals in the other connector, each terminal being located within a separate dielectric sleeve, each connector having a unitary electrically conductive outer housing having internal walls separating adjacent terminals, the dielectric sleeves being positioned within cavities extending between opposite sides of the outer housing formed by the internal walls of the unitary housing, the outer housing and the dielectric sleeves being formed by the sequential steps of casting an outer housing of a conductive material and injection molding a plurality of dielectric sleeves located in the housing, the housing or dielectric sleeve formed in the first of said sequential steps forming a portion of the mold defining the subsequently formed housing or dielectric sleeves followed by the step of positioning conductive terminals within the dielectric sleeves. .Iaddend.

Claim 11

.Iadd.10. A method of manufacturing an electrical connector having a plurality of terminals separated from a conductive outer housing by dielectric sleeves between the housing and the terminals to define the electrical signal transmission characteristics of the connector, comprising the sequential steps of: a step of casting an outer housing of a conductive material and a step of injection molding a plurality of dielectric sleeves in the housing, the housing or dielectric sleeves formed initially, forming a portion of the mold defining the subsequently formed dielectric sleeves or housing respectively; followed by the step of positioning conductive terminals within the dielectric sleeves. .Iaddend.

Claim 12

.Iadd.10. A method of manufacturing an electrical connector having a plurality of terminals separated from a conductive outer housing by dielectric sleeves between the housing and the terminals to define the electrical signal transmission characteristics of the connector, comprising the sequential steps of: a step of casting an outer housing of a conductive material and a step of injection molding a plurality of dielectric sleeves in the housing, the housing or dielectric sleeves formed initially, forming a portion of the mold defining the subsequently formed dielectric sleeves or housing respectively; followed by the step of positioning conductive terminals within the dielectric sleeves. .Iaddend.

Claim 13

.Iadd.11. The method of claim 10 wherein the outer housing is cast of a metallic material and the dielectric sleeves are injection molded within apertures in the outer housing. .Iaddend.