Filter insert for an electrical connector assembly

Abstract

A filter insert for a terminal connector includes a rigid substrate and low-cost interference fit connections between the filter insert circuitry and the connector terminals. In a first embodiment, the insert includes a flexible circuit bonded to the rigid substrate, and the substrate is provided with over-sized openings that the terminals pass through without interference. A second embodiment is like the first, except that the filter circuit traces are formed directly on the rigid substrate, and the substrate material backing the terminal connection sites is removed to form the over-sized openings.

1 . A filter insert for insertion on at least one electrical terminal in a connector assembly, the filter insert comprising: 
 a rigid substrate having a first opening through which said electrical initially passes when said filter is inserted on said electrical terminal, said first opening being over-sized relative to said electrical terminal so that said electrical terminal passes through said first opening without interference; and    filter circuitry for filtering electrical signals carried by said electrical terminal, including at least one conductor trace having a coefficient of thermal expansion substantially equal to a coefficient of thermal expansion of said rigid substrate, said conductor trace being formed on a flexible film bonded to a surface of said rigid substrate facing away from said connector assembly, said conductor trace also having a second opening that is concentric with said first opening and aligned with concentric openings in said flexible film, said second opening being under-sized relative to said electrical terminal so that said conductor trace deforms away from said rigid substrate when said electrical passes through said second opening, forming interference fit electrical connections between said conductor trace and said electrical terminal.    
   
   
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