Hermetic edge-connect headers and corresponding connectors
A hermetically-sealed edge-connect header that can withstand high temperatures, high pressures (or high vacuum levels), and high vibration environments, along with two corresponding connectors are disclosed. After brazing the edge-connect header components, the assembly is machined to form a slot with a portion of each of a plurality of electrical conductors removed in the machining process, resulting in a header with a high pin density. During the process of mating the first connector design to the edge-connect header, a plurality of wipers in the connector deflect, thereby causing the wipers to extend from the connector and contact the corresponding electrical conductors in the header. During the process of mating the second connector design to the edge-connect header, each of a plurality of wipers formed of low-mass, compliant metal wool, forms multiple contact points with a corresponding electrical conductor in the header.
1. An edge-connect header comprising:
a shell;
a core located within an opening in the shell;
a core braze filler located between the shell and the core, the core braze filler adapted to form a first hermetic seal;
a plurality of electrical conductors, each of the plurality of electrical conductors located within a corresponding one of a plurality of openings within the core, the plurality of electrical conductors includes a first set of the plurality of electrical conductors and a second set of the plurality of electrical conductors; and
a plurality of electrical conductor braze fillers, each of the plurality of electrical conductor braze fillers located between a corresponding one of the plurality of electrical conductors and the core, the plurality of electrical conductor braze fillers adapted to form a corresponding second plurality of hermetic seals;
wherein the edge-connect header includes a slot, the slot exposing a machined surface of the core and a corresponding plurality of machined surfaces of the plurality of electrical conductors.
2. The edge-connect header of claim 1 ,
wherein the slot is a linear slot, and
wherein the first set of the plurality of electrical conductors are located adjacent a first side of the linear slot, and
wherein the second set of the plurality of electrical conductors are located adjacent a second side of the linear slot facing the first side of the linear slot.
3. The edge-connect header of claim 1 ,
wherein the slot is a ring-shaped slot, thereby forming a boss surrounded by the ring-shaped slot, and
wherein the first set of the plurality of electrical conductors are located adjacent a first side of the boss, and
wherein the second set of the plurality of electrical conductors are located adjacent a second side of the boss opposite the first side of the boss.
4. The edge-connect header of claim 1 ,
wherein the slot is a ring-shaped slot, thereby forming a boss surrounded by the ring-shaped slot,
wherein the first set of the plurality of electrical conductors are located adjacent an inner perimeter of the ring-shaped slot, and
wherein the second set of the plurality of electrical conductors are located adjacent an outer perimeter of the ring-shaped slot.
5. The edge-connect header of claim 1 , further comprising at least a second slot, the second slot exposing a second machined surface of the core and a corresponding second plurality of machined surfaces of the plurality of electrical conductors.