Flexible connector

Abstract

A flexible connector includes a unitary connector block having first and second board-facing areas. The first and second board-facing areas are longitudinally spaced from each other on a chosen surface of the connector block. The connector block includes a block body transversely separating the chosen surface from an opposing surface oppositely facing from the chosen surface. The connector block includes a flexible connector bridge longitudinally interposed between the first and second board-facing areas. A first connector port is located within the first board-facing area. A second connector port is located within the second board-facing area. A connector trace extends through at least a portion of the block body between the first and second board-facing areas. The connector trace electrically connects the first and second connector ports. Methods of making and using the flexible connector are also included.

I claim: 
     
         1 . A flexible connector, comprising:
 a unitary connector block having first and second board-facing areas, the first and second board-facing areas being longitudinally spaced from each other on a chosen surface of the connector block, the connector block including a block body transversely separating the chosen surface from an opposing surface oppositely facing from the chosen surface, and the connector block including a flexible connector bridge longitudinally interposed between the first and second board-facing areas;   a first connector port located within the first board-facing area;   a second connector port located within the second board-facing area; and   a connector trace extending through at least a portion of the block body between the first and second board-facing areas, the connector trace electrically connecting the first and second connector ports.   
     
     
         2 . The flexible connector of  claim 1 , wherein the connector bridge and the first and second board-facing areas are all made from the same material. 
     
     
         3 . The flexible connector of  claim 1 , wherein the connector bridge is made from a different material from the first and second board-facing areas. 
     
     
         4 . The flexible connector of  claim 2 , wherein the connector bridge and the first and second board-facing areas are concurrently and unitarily formed as a monolithic component of the connector block. 
     
     
         5 . The flexible connector of  claim 1 , wherein a selected one of the chosen surface and the opposing surface of the connector block is contoured at differing distances from the other one of the chosen surface and the opposing surface along a longitudinal dimension of the connector block. 
     
     
         6 . The flexible connector of  claim 1 , wherein the connector block has a first transverse thickness at at least one of the first and second board-facing areas and a second transverse thickness at the connector bridge, and the second transverse thickness is a minority of the first transverse thickness. 
     
     
         7 . The flexible connector of  claim 1 , wherein the chosen surface faces first and second circuit boards for creating an electrical connection therebetween, and the block body is interposed between the chosen surface and the opposing surface. 
     
     
         8 . The flexible connector of  claim 1 , wherein the block body includes at least one increased-thickness portion and at least one reduced-thickness portion, and each connector trace includes at least one via extending transversely through an increased-thickness portion of the block body. 
     
     
         9 . The flexible connector of  claim 1 , including at least one connector orientation feature for selectively engaging a corresponding board orientation feature on a circuit board. 
     
     
         10 . The flexible connector of  claim 1 , wherein the block body includes a plurality of laminated substrate layers, with a selected substrate layer forming the chosen surface having a significantly varied transverse thickness along a longitudinal dimension thereof. 
     
     
         11 . A method comprising:
 providing a planar chosen substrate having transversely spaced top and bottom chosen substrate surfaces;   defining first and second board-facing areas longitudinally spaced from each other on a selected one of the top and bottom chosen substrate surfaces;   providing a planar opposing substrate having transversely spaced top and bottom opposing substrate surfaces;   attaching the chosen and opposing substrates together to at least partially form a unitary connector block including a block body with the first and second board-facing areas on an outward-facing surface thereof;   depositing a conductive material to generate a first connector port located within the first board-facing area;   depositing a conductive material to generate a second connector port located within the second board-facing area;   depositing a conductive material on at least one of the chosen and opposing substrate surfaces to generate a connector trace extending through at least a portion of the block body between the first and second board-facing areas;   electrically connecting the first and second connector ports with the connector trace; and   selectively reducing a thickness of one of the chosen and opposing substrate surfaces to define a flexible connector bridge longitudinally interposed between the first and second board-facing areas;   facilitating relative angular motion of the first and second board-facing areas with the connector bridge.   
     
     
         12 . The method of  claim 11 , wherein selectively reducing a thickness of one of the chosen and opposing substrate surfaces to define a flexible connector bridge longitudinally interposed between the first and second board-facing areas includes selectively reducing a thickness of the selected one of the chosen and opposing substrate surfaces upon which the first and second board-facing areas are defined. 
     
     
         13 . The method of  claim 11 , wherein selectively reducing a thickness of one of the chosen and opposing substrate surfaces to define a flexible connector bridge longitudinally interposed between the first and second board-facing areas includes selectively reducing a thickness of the other one of the chosen and opposing substrate surfaces upon which the first and second board-facing areas are defined. 
     
     
         14 . The method of  claim 11 , wherein depositing a conductive material on at least one of the chosen and opposing substrate surfaces to generate a connector trace includes creating at least one via extending transversely through an increased-thickness portion of the block body. 
     
     
         15 . The method of  claim 11 , including electrically connecting first and second mutually angularly arranged circuit boards with a flexible connector including the connector block. 
     
     
         16 . The method of  claim 15 , wherein electrically connecting first and second mutually angularly arranged circuit boards with a flexible connector including the connector block includes selectively engaging a board orientation feature on a circuit board with a corresponding connector orientation feature on the flexible connector. 
     
     
         17 . An apparatus for electrically connecting pairs of pads on mutually angularly arranged circuit boards, the apparatus comprising:
 a planar chosen substrate having transversely spaced top and bottom chosen substrate surfaces, and first and second board-facing areas being longitudinally spaced from each other on a selected one of the top and bottom chosen substrate surfaces;   a planar opposing substrate having transversely spaced top and bottom opposing substrate surfaces, a selected one of the chosen and opposing substrates having a significantly varied transverse thickness along a longitudinal dimension thereof;   a unitary connector block at least partially formed by the chosen and opposing substrates, the connector block including a block body;   a first connector port located within the first board-facing area;   a second connector port located within the second board-facing area;   a connector trace extending through at least a portion of the block body between the first and second board-facing areas, the connector trace electrically connecting the first and second connector ports; and   a flexible connector bridge longitudinally interposed between the first and second board-facing areas for facilitating relative angular motion of the first and second board-facing areas.   
     
     
         18 . The apparatus of  claim 17 , wherein the connector bridge and the first and second board-facing areas are all made from the same material. 
     
     
         19 . The apparatus of  claim 17 , wherein the connector bridge is made from a different material from the first and second board-facing areas. 
     
     
         20 . The apparatus of  claim 18 , wherein the connector bridge and the first and second board-facing areas are concurrently and unitarily formed as a monolithic component of the connector block. 
     
     
         21 . The apparatus of  claim 17 , wherein the connector block has a first transverse thickness at at least one of the first and second board-facing areas and a second transverse thickness at the connector bridge, and the second transverse thickness is a minority of the first transverse thickness. 
     
     
         22 . The apparatus of  claim 17 , wherein the block body includes at least one increased-thickness portion and at least one reduced-thickness portion, and each connector trace includes at least one via extending transversely through an increased-thickness portion of the block body. 
     
     
         23 . The apparatus of  claim 17 , including at least one connector orientation feature for selectively engaging a corresponding board orientation feature on a circuit board.