Electrical connector with continuous strip contacts

1. An electrical connector contact set adapted for insertion into an electrical connector housing to form an electrical connector, the contact set comprising:

a plurality of electrical contacts fixedly connected to each other, wherein each contact comprises a main section and a tab section extending from an end of the main section;

fusible elements on the tab sections; and

an overmolded body comprising dielectric material molded onto the contacts,

wherein the contact set with the electrical contacts and fusible elements is adapted to be inserted into the electrical connector housing after the fusible elements are attached to the contacts, and

wherein, after the contacts are inserted into the electrical connector housing, the fusible elements are adapted to be at least partially located outside of the electrical connector housing.

2. A contact set as in claim 1 wherein each tab section has an outwardly flared shape.

3. A contact set as in claim 1 wherein the fusible elements have portions located in pocket areas of the contacts to retain the fusible elements on the tab sections.

4. A contact set as in claim 1

wherein the contacts are connected to each other in series, wherein the body forms a seal between the tab sections and the main sections to prevent wicking of the fusible elements along the contacts between tab sections and second end sections of the contacts.

5. A contact set as in claim 1 wherein the body comprises polymer material connecting the electrical contacts to one another, wherein the tab sections extend from a first side of the body and a second end section of the contacts extend from an opposite second side of the body.

6. A contact set as in claim 5 wherein the second sections comprise male contact tab sections.

7. A contact set as in claim 5 wherein the second sections comprise deflectable contact sections.

8. A contact set as in claim 5 wherein the tab sections comprise a pocket area, and wherein the fusible elements have portions located in the pocket areas of the contacts to retain the fusible elements on the tab sections.

9. An electrical connector contact group adapted for insertion into an electrical connector housing to form an electrical connector, the contact group comprising:

a plurality of electrical contacts connected to each other in a group;

fusible elements connected to the contacts, wherein the fusible elements comprise solder balls with the contacts extending into the solder balls to thereby attach the solder balls with the contacts; and

an overmolded body connecting the contacts to each other,

wherein the electrical connector contact group provides the contacts as connected fusible element mountable electrical contacts, and wherein the contacts are sized and shaped to be inserted into the electrical connector housing with the fusible elements attached and with the fusible elements being located at least partially outside of the electrical connector housing.

10. An electrical connector contact group as in claim 9 wherein the overmolded body comprising main sections surrounding portions of the contacts and interconnect sections connecting the main sections to each other, wherein the body forms a seal at the middle sections of the contacts between first and second ends of the contacts to prevent wicking of the fusible elements along the contacts between first and second ends of the contacts.

11. An electrical connector contact group as in claim 9 wherein first ends of the contacts each comprise a dual beam contact section.

12. An electrical connector contact group as in claim 9 wherein the contacts comprise stamped sheet metal.

13. An electrical connector contact group as in claim 12 wherein second ends of the contacts each form a tab section which has an outwardly flared shape.

14. An electrical connector contact group as in claim 13 wherein the tab section comprises a general flat dovetail shape.

15. An electrical connector contact group as in claim 13 wherein the contacts comprise a flat shape.

16. A method of assembling an electrical connector contact set comprising steps of:

providing a group of connected electrical contacts; and

attaching solder balls to the connected contacts, the contacts extending into the solder balls to thereby attach the solder balls with the contacts, wherein the contacts and solder balls are provided as a group of connected, fusible element mountable electrical contacts which is adapted to be subsequently connected to a housing to form an electrical connector.

17. A method as in claim 16 wherein the step of providing the contacts comprises overmolding a body onto the contacts to connect the contacts to each other, the body forming a seal on the contacts to prevent wicking of the fusible elements along the contacts.

18. A method of assembling an electrical connector comprising steps of:

assembling an electrical connector contact set as in claim 16 ,

inserting the contact set, with the solder balls attached to the contacts, into an electrical connector housing with the solder balls being located at least partially outside of the housing, wherein the solder balls are attached to the contacts before the contacts are inserted into the electrical connector housing.

19. A method as in claim 16 wherein the contacts are stamped from sheet metal to form the contacts with a substantially flat shape.

20. A method as in claim 19 wherein the contacts are stamped from the sheet metal to form the contacts with dual contact beams at first ends of the contacts.

21. A method of assembling an electrical connector contact set comprising steps of:

providing a group of connected electrical contacts; and attaching fusible elements to the connected contacts, the contacts extending into the fusible elements to thereby attach the fusible elements with the contacts, wherein the contacts and fusible elements are provided as a group of connected, fusible element mountable electrical contacts which is adapted to be subsequently connected to a housing to form an electrical connector.