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Electrical contact and connector and method of manufactureRelated Patent Categories: Electrical Connectors, Preformed Panel Circuit Arrangement, E.g., Pcb, Icm, Dip, Chip, Wafer, Etc., With Provision To Conduct Electricity From Panel Circuit To Another Panel Circuit, Conductor Is Compressible And To Be Sandwiched Between Panel CircuitsElectrical contact and connector and method of manufacture description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060141814, Electrical contact and connector and method of manufacture. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/503,007, filed Sep. 15, 2003. [0002] This application is a continuation in part of U.S. patent application Ser. No. 10/736,280, filed Dec. 15, 2003, which claims the benefit of U.S. Provisional Patent Application No. 60/457,076, filed Mar. 24, 2003, U.S. Provisional Patent Application No. 60/457,258, filed Mar. 25, 2003, and U.S. Provisional Patent Application No. 60/462,143, filed Apr. 8, 2003. FIELD OF THE INVENTION [0003] The present invention generally relates to electrical interconnection devices, and more particularly to electrical contacts that are at the interface between a first electronic device and a substrate or between an electrical connector and the same. BACKGROUND OF THE INVENTION [0004] Referring to FIG. 1, prior art LGA assemblies are used to interconnect an IC package A having a plurality of flat contact pads or solder bumps B formed on a bottom surface, to contact pads C arranged in a regular pattern on a surface of PCB D. [0005] Prior art LGA assemblies are known which include an insulative housing E and a plurality of resilient conductive contacts F received in passageways formed in housing E. Resilient conductive contacts F typically have exposed portions at the upper and lower surfaces of insulative housing E for engaging flat contact pads B,C. When IC package A is accurately positioned in overlying aligned engagement with PCB D, such that conductive pads B engage conductive pads C, a normal force is applied to the exposed portions of each resilient conductive contact F to electrically and mechanically engage the respective contact pads B,C. [0006] The resilient conductive contacts associated with prior art LGA's have had a variety of shapes. A commonly used form of resilient conductive contact includes two free ends connected by a curved, resilient portion which provides for the storage of elastic energy during engagement with the IC package and PCB. Prior art resilient conductive contacts may be a single metal structure in the form of a spring to provide the required elastic response during service while also serving as a conductive element for electrical connection. Alternatively, contact buttons have been developed in which a connector is wound around, embedded, or otherwise engaged with a dielectric core, which often provides for elastic energy storage during operation with the conductor merely providing an electrical conduction pathway. Typically, a combination of barrier metal and noble metal platings are applied to the surface of the spring for corrosion prevention and for electrical contact enhancement. It is often the case that these platings are not of sufficient thickness for electrical conduction along only the surface of the spring. Examples of such prior art resilient conductive contacts may be found in U.S. Pat. Nos. 2,153,177; 3,317,885; 3,513,434; 3,795,884; 4,029,375; 4,810,213; 4,820,376; 4,838,815; 4,922,376; 5,030,109; 5,061,191; 5,101,553; 5,127,837; 5,215,472; 5,228,861; 5,232,372; 5,308,252; 5,350,308; 5,385,477; 5,403,194; 5,427,535; 5,441,690;5,473,510; 5,495,397; 5,599,193; 5,653,598; 5,791,914; 5,800,184; 5,806,181; 5,810,607; 5,817,986; 5,823,792; 5,833,471; 5,949,029; 6,074,219; and 6,264,476. The foregoing patents are hereby incorporated herein by reference. [0007] A problem in the art exists in that, a conductive contact in the form of a single conductor spring for attaining high compliance, has a high resistance and a high inductance. Further, a contact, in the form of multiple conductors in a bunched wire bundle, or in the form of a conductor structure embedded in a polymer core, is made with lower resistance and inductance than a single conductor spring, but requires a high contact force for deflection, and is unable to attain high compliance. Further, one problem in the art exists in that a good material for the construction of a spring, such as a high strength steel, is not a very good electrical conductor. On the other hand, a good electrical conductor, such as a copper alloy or precious metal, often does not provide adequate spring properties. There is a need for a more resilient conductive contact which incorporates the seemingly opposing requirements of good spring properties, temperature resistance, and high conductivity, but without the need for any integral supporting structure. Therefore, an improved electrical contact for use in an LGA socket or electrical connector is needed which can overcome the drawbacks of conventional electrical contacts. [0008] Thus, it is desirable that a good electrical contact element possesses the following attributes: (a) usable for both a production socket, as well as, test and burn-in sockets, where the latter use requires high durability; (b) a large elastic compliance range and low contact forces; (c) capable of transmitting high frequency signals and high currents; (d) capable of withstanding high operating temperatures; and (e) exhibiting high durability, i.e. >500K repeated deflections [0009] The prior art has been devoid of at least one of the foregoing attributes necessary for a universally applicable electrical contact. A problem in the art exists in that, a conductive contact in the form of a single conductor spring for attaining high compliance, has a high resistance and a high inductance. Further, a contact, in the form of multiple conductors in a bunched wire bundle, or in the form of a conductor structure embedded in a polymer core, is made with lower resistance and inductance than a single conductor spring, but requires a high contact force for deflection, and is unable to attain high compliance. Further, one problem in the art exists in that a good material for the construction of a spring, such as a high strength steel, is not a very good electrical conductor. On the other hand, a good electrical conductor, such as a copper alloy or precious metal, often does not provide adequate spring properties. There is a need for a more resilient conductive contact which incorporates the seemingly opposing requirements of good spring properties, temperature resistance, and high conductivity, but without the need for any integral supporting structure. Therefore, an improved electrical contact for use in an LGA socket or electrical connector is needed which can overcome the drawbacks of conventional electrical contacts. SUMMARY OF THE INVENTION [0010] The present invention provides an electrical contact. The terminology, electrical contact, is used herein interchangeably with the terminology, electrical contact element. An embodiment of an electrical contact in accordance with the present invention is an electrically conducting, interlaced mesh, wherein the mesh comprises an unsupported electrical contact substantially free of elastic strain, and the mesh is hardened. According to another embodiment of an electrical contact in accordance with the present invention, when a more compact form of electrical contact is desired, the contact is compressed to a compact form, and is annealed while constrained in the compact form to substantially relieve only the internal elastic strain. According to another embodiment of the invention, when added hardening is desired, the annealed structure is compressed to a more compact form of the individual electrical contacts, wherein a controlled amount of inelastic deformation results in added hardening. [0011] In one embodiment, the present invention provides an electrical contact formed from a plurality of interlaced and annealed wires. The electrical contact is often formed by weaving or braiding a plurality of wires together to form a mesh, annealing the mesh, and cutting the annealed mesh so as to form a plurality of individual electrical contacts that each have an extended elastic range as a result of the annealing process. When a more compact form of electrical contact is desired, the contact is compressed to a compact form, and is annealed while constrained in the compact form to substantially relieve only the internal elastic strain. According to another embodiment of the invention, when added hardening is desired, the annealed structure is compressed to a more compact form of the individual electrical contacts, wherein a controlled amount of inelastic deformation results in added hardening. [0012] A connector system may be formed in accordance with the invention including a housing defining a plurality of openings that are each filled with an electrical contact of the present invention. In one embodiment, a connector system may be formed including a housing defining a plurality of openings that are each filled with an electrical contact comprising a plurality of interlaced and annealed wires. The connector system may also include electrical contacts comprising a plurality of interlaced and annealed wires arranged in a unitary mesh having at least one pleat or formed in a tube structure, including, a square tube, a rectangular tube or a round tube. BRIEF DESCRIPTION OF THE DRAWINGS [0013] These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein: [0014] FIG. 1 is a perspective exploded view of a prior art land grid array assembly; [0015] FIG. 1A is an isometric view of a cage configuration, including a tubular configuration; [0016] FIG. 1B is an isometric view of a cage configuration, including a square; [0017] FIG. 1C is an isometric view of a cage configuration, including a rectangle; [0018] FIG. 1D is an isometric view of a mandrel and a mesh shaped over the mandrel; [0019] FIG. 2A is an edgewise view of an interlaced sheet during shaping thereof in a die to a shape of one or more electrical contacts; Continue reading about Electrical contact and connector and method of manufacture... 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