Electrical connectors

Abstract

An electrical connector is provided that meets the requirements for miniaturization and thinness of electronic devices, suppresses the resistance of conductive terminals to a low level, and can cope with the increase in current flowing in the conductive terminals. In an electrical connector such as a plug connector (100), an insulating housing (110) and conductive terminals (120, 130) fixed to the housing (110) are provided. Each terminal (120, 130) includes a mounting portion (121, 131, 132) connected to a substrate (500) and a contact portion (122, 133) protruding from the mounting portion (121, 131, 132) in a mating direction (Z1 direction). The plate thickness (t1) of the contact portion (122, 133) is greater than the plate thickness (t2) of the mounting portion (121, 131, 132) in a direction orthogonal to the substrate (500) (Z1Z2 direction).

Description

Technical Field

[0001] This invention relates to electrical connectors, and more particularly to electrical connectors mounted on a substrate. Background Technology

[0002] Conventionally, substrate-to-substrate electrical connectors have been used as connectors to connect the surfaces of substrates to each other. In substrate-to-substrate electrical connectors, a plug connector and a socket connector form a set. The plug connector is inserted into the socket connector, causing the conductive terminals (contacts) to make contact, thereby forming an electrical connection. As for technologies related to such substrate-to-substrate electrical connectors, examples include those described in Patent Document 1 (Japanese Patent Application Laid-Open No. 2017-16897).

[0003] Patent Document 1: Japanese Patent Application Publication No. 2017-16897

[0004] In recent years, with the increasing demand for miniaturization and thinness in electronic devices such as smartphones, mobile phones, and portable information terminals, the components used in them have become increasingly smaller and lighter. However, along with the increasing functionality of these electronic devices, the current used in them has also increased. Furthermore, these electronic devices typically use rechargeable batteries as their power source and require short charging times, resulting in situations where large currents flow through small electrical connectors. Summary of the Invention

[0005] The present invention was made to solve the problems mentioned above, and its object is to provide a technology that meets the requirements of miniaturization and thinness of electronic devices in electrical connectors, and suppresses the resistance of conductive terminals to a low level, and can cope with the increase of current flowing in conductive terminals.

[0006] The above and other objects and novel features of the present invention will become clear from the description and drawings herein.

[0007] If we were to briefly describe a summary of representative content from the embodiments disclosed in this application, it would be as follows.

[0008] That is, in a representative embodiment, the electrical connector has an insulating housing and a conductive terminal fixed to the housing. The terminal includes a mounting portion connected to a substrate and a contact portion protruding from the mounting portion in a mating direction. The thickness of the contact portion is greater than the thickness of the mounting portion in a direction orthogonal to the substrate.

[0009] The effects obtained through representative embodiments disclosed in this application will be briefly described as follows.

[0010] (1) The plate thickness t1 of the contact part is thick, so the conductor resistance of the terminal can be reduced, thereby allowing more current to flow in the terminal.

[0011] (2) The metal volume of the terminals increases, thereby increasing the strength of the connector.

[0012] (3) The plate thickness t2 of the mounting part is thinner than the plate thickness t1 of the contact part, thus enabling the connector to be made shorter. Attached Figure Description

[0013] Figure 1 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 1 of the present invention.

[0014] Figure 2 This is a front view showing the structure of the electrical connector (plug connector) according to Embodiment 1 of the present invention.

[0015] Figure 3 yes Figure 2 A cross-sectional view of the AA section.

[0016] Figure 4 This is a perspective view showing the structure of the electrical connector according to Embodiment 1 of the present invention, with only the terminals removed from the housing portion.

[0017] Figure 5 This is a perspective view showing the structure of the first terminal in the electrical connector according to Embodiment 1 of the present invention.

[0018] Figure 6 This refers to the electrical connector according to Embodiment 1 of the present invention. Figure 5 A side view of the structure of the terminal shown.

[0019] Figure 7 This is a perspective view showing the structure of the second terminal in the electrical connector according to Embodiment 1 of the present invention.

[0020] Figure 8 This refers to the electrical connector according to Embodiment 1 of the present invention. Figure 7 A side view of the structure of the terminal shown.

[0021] Figure 9 This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0022] Figure 10 This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0023] Figure 11This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0024] Figure 12 This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0025] Figure 13 This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0026] Figure 14 This is a perspective view showing the manufacturing process of the terminals in the electrical connector according to Embodiment 1 of the present invention.

[0027] Figure 15 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 2 of the present invention.

[0028] Figure 16 This is a front view showing the structure of the electrical connector (plug connector) according to Embodiment 2 of the present invention.

[0029] Figure 17 It means Figure 16 A sectional view of the BB section.

[0030] Figure 18 This is a perspective view showing the structure of the electrical connector (socket connector) according to Embodiment 3 of the present invention.

[0031] Figure 19 This is a perspective view showing the structure of the electrical connector according to Embodiment 3 of the present invention, with only the terminals removed from the housing portion.

[0032] Figure 20 This is a perspective view showing the structure of the terminals in the electrical connector according to Embodiment 3 of the present invention.

[0033] Figure 21 This refers to the electrical connector according to Embodiment 3 of the present invention. Figure 20 A side view of the structure of the terminal shown.

[0034] Figure 22 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 4 of the present invention.

[0035] Figure 23 This is a perspective view showing the structure of the terminals in the electrical connector according to Embodiment 4 of the present invention, with the housing portion removed.

[0036] Figure 24This is a perspective view showing the structure of the terminals in the electrical connector according to Embodiment 4 of the present invention.

[0037] Explanation of reference numerals in the attached figures

[0038] 100...Plug connector; 101...Matching recess; 110...Housing; 111...Bottom wall; 112...Side wall; 113...Terminal fixing part; 120...First terminal; 121...Mounting part; 122...Contact part; 123...Recess; 124...Side side; 125...Side side; 126...Matching surface; 130...Second terminal; 131...Mounting part; 132...Mounting part; 133...Contact part; 134...Recess; 135...Side side; 136...Side side; 137...Matching surface; 140...Metal plate; 141...Wall thickness portion; 142...Part; 143...Pin; 144...End portion; 145...Wall thickness portion; 200...Plug connector; 201... 210...Matching recess; 211...Housing; 212...Bottom wall; 213...Side wall; 213...Terminal fixing part; 220...First terminal; 221...Mounting part; 222...Contact part; 223...Locking part; 230...Second terminal; 231...Mounting part; 232...Mounting part; 233...Contact part; 300...Socket connector; 310...Housing; 311...Side wall; 320...First terminal; 330...Second terminal; 331...Mounting part; 332...Mounting part; 333...Mounting part; 334...Contact part; 340...Third terminal; 400...Plug connector; 410...Housing; 420...Terminal; 421...Mounting part; 422...Contact part; 500...Substrate. Detailed Implementation

[0039] Hereinafter, embodiments of the present invention will be described in detail based on the accompanying drawings. Furthermore, in all the drawings used to describe the embodiments, the same reference numerals are used to label the same components, and repeated descriptions are omitted.

[0040] In the following embodiments, for convenience, the description is divided into multiple blocks or implementation methods as needed. Unless otherwise explicitly stated, these are not unrelated to each other; one embodiment may be part or all of another embodiment, or may be related as details or supplementary descriptions. Furthermore, in the following embodiments, when referring to the quantity of elements (including number, value, quantity, range, etc.), the description is not limited to that specific quantity, except where specifically stated or limited to a quantity that is clearly understood in principle. The quantity may be greater than or less than that specific quantity.

[0041] (Implementation Method 1)

[0042] Figure 1 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 1 of the present invention. Figure 2 This is the main view. Figure 3 yes Figure 2 A cross-sectional view of the AA section. Figure 4 It means in Figure 1 A perspective view of the terminals only, excluding the housing portion, of an electrical connector. Figure 5 This is a three-dimensional diagram showing the structure of the first terminal. Figure 6 It means Figure 5 A side view of the structure of the terminal shown. Figure 7 This is a three-dimensional diagram showing the structure of the second terminal. Figure 8 It means Figure 7 A side view of the structure of the terminal shown.

[0043] First, according to Figures 1-4 The structure of the electrical connector according to Embodiment 1 will be described. The electrical connector of Embodiment 1 is a plug connector 100 mounted on a substrate 500 such as a printed circuit board, and includes an insulating housing 110, four conductive first terminals 120 (a-d) fixed to the housing 110, and two conductive second terminals 130 (a-b). The four terminals 120 (a-d) each have the same shape. The two terminals 130 (a-b) each have the same shape. The second terminals 130 (a-b) are disposed at both ends of the long side direction (X1X2 direction) of the first terminals 120 (a-d). In this embodiment, an example of four first terminals 120 and two second terminals 130 is shown, but this is not a limitation, and their number can be arbitrary. Furthermore, the first terminals 120 and second terminals 130 are mainly used as signal terminals or power terminals, but this is not a limitation; they can also be used in other applications such as reinforcing metal parts, frames, and shielding parts.

[0044] The substrate 500 is, for example, connected to a rechargeable battery for a mobile phone, portable information terminal, etc., and its control circuit. The housing 110 is formed of an insulating resin or the like. The terminals 120 and 130 are formed of a conductive metal such as a copper alloy. The plug connector 100 is formed by, for example, integral molding of the housing 110 by arranging the terminals 120 and 130 in a mold and injecting resin, or insert molding.

[0045] The housing 110 is composed of a bottom wall 111 forming the bottom surface of the mating recess 101 of the connector, a side wall 112 filling between the terminals and standing upright from the bottom wall 111, and a terminal fixing part 113 forming a portion covering the terminals 120 and 130. In addition, the terminal fixing part 113 is formed by filling the recesses 123 and 134 between the mounting portions 121, 131, and 132 of the terminals 120 and 130 and the contact portions 122 and 133 with a portion of the housing.

[0046] like Figures 4-6 As shown, the first terminal 120 has a mounting portion 121 connected to a substrate 500 such as a printed circuit board, and a contact portion 122 extending from the mounting portion 121 in the mating direction (Z1 direction). The mounting portions 121 of the terminals 120 are arranged opposite to each other in the Y1Y2 direction. Furthermore, for the terminals 120, the thickness t1 of the contact portion 122 in the direction parallel to the substrate 500 (Y1Y2 direction) is greater than the thickness t2 of the mounting portion 121 in the direction orthogonal to the substrate 500 (Z1Z2 direction). For example, the thickness t1 of the contact portion is more than twice the thickness t2 of the mounting portion. Additionally, the interior of the contact portion 122 (the lower part of the mating surface 126 (Z2 direction)) is filled with a conductive metal. The mating surface 126 at the end (Z1 direction) of the contact portion 122 has rounded corners.

[0047] Furthermore, a portion of the surface of the mounting portion 121 of the first terminal 120 on the mating side (Z1 direction) is partially covered by a portion of the housing 110 (terminal fixing portion 113). Additionally, the terminal 120 has a recess 123 between the mounting portion 121 and the contact portion 122, and a portion of the housing 110 is filled within the recess 123. This secures the terminal to the housing and prevents it from detaching. Furthermore, the two opposing side surfaces 124 and 125 of the contact portion 122 in the long-side direction (X1X2 direction) are in close contact with a portion of the housing 110 (side wall 112).

[0048] The first terminals 120 are positioned opposite each other in the width direction (Y1Y2 direction) of the connector. The mounting portion 121 extends outward in the width direction (Y1Y2 direction) from below the bottom wall 111, and its thickness direction (Z1Z2 direction) intersects the surface (XY plane) of the printed circuit board 500. The mounting portion 121 is soldered to each circuit pattern on the printed circuit board during installation.

[0049] like Figure 4 , Figure 7 and Figure 8As shown, the second terminal 130 has two mounting portions 131 and 132 that are respectively connected to a substrate 500 such as a printed circuit board; and a contact portion 133 that protrudes and extends from the mounting portions 131 and 132 in a mating direction (Z1 direction). The contact portion 133 extends in a direction parallel to the substrate 500 (XY plane) and electrically connects the mounting portions 131 and 132. The mounting portions 131 and 132 of the second terminal 130 are arranged opposite each other in the Y1Y2 direction. In addition, for the terminal 130, the thickness t1 of the contact portion 133 in the direction parallel to the substrate 500 (Y1Y2 direction) is greater than the thickness t2 of the mounting portions 131 and 132 in the direction orthogonal to the substrate 500 (Z1Z2 direction). For example, the thickness t1 of the contact portion is more than twice the thickness t2 of the mounting portion. The mating surface 137 at the end (Z1 direction) of the contact portion 133 has rounded corners. The interior of the lower part (Z2 direction) of the mating surface 137 is filled with metal.

[0050] Furthermore, a portion of the mounting portions 131 and 132 of the second terminal 130 on the mating side (Z1 direction) is partially covered by a portion of the housing 110 (terminal fixing portion 113). Additionally, the terminal 130 has a recess 134 between the mounting portions 131 and 132 and the contact portion 133, and a portion of the housing 110 is filled within the recess 134. This secures the terminal to the housing and prevents it from detaching. Furthermore, the two side surfaces 135 and 136 of the contact portion 133 in the same direction along its long side (X1X2 direction) are in close contact with a portion of the housing 110 (side wall 112). The two terminals 130 are positioned on either side of the terminal 120, and when viewed from the mating direction (Z1 direction), the two terminals 130 have a U-shaped form. In this embodiment, the terminal 130 has two mounting portions, but it is not limited to this; a terminal may have one or more mounting portions.

[0051] Mounting portions 131 and 132 are separately configured in the width direction (Y1Y2 direction) of the connector, extending outward in the width direction (Y1Y2 direction) from below the bottom wall 111, with the thickness direction (Z1Z2 direction) intersecting the surface (XY plane) of the printed circuit board 500. Mounting portions 131 and 132 are respectively soldered to various circuit patterns on the printed circuit board during installation.

[0052] In addition, in order to allow a large current to flow, the contact portion of the terminal 130 that contacts the terminal of the socket connector is lengthened in the long side direction (X1X2 direction) to ensure sufficient contact area between the terminals.

[0053] In this embodiment, terminals 120a and 120b are arranged adjacent to each other in the long side direction (X1X2 direction) and are disposed between terminals 130a and 130b. Similarly, terminals 120c and 120d are arranged adjacent to each other in the long side direction (X1X2 direction) and are disposed between terminals 130a and 130b. For example, terminal 120 is used as a signal terminal and terminal 130 is used as a power supply terminal.

[0054] Next, according to Figures 9-14 The manufacturing method of the electrical connector (plug connector) according to Embodiment 1 of the present invention will be described. Figures 9-14 This is a perspective view showing the manufacturing process of terminals 120 and 130 of the plug connector 100.

[0055] First, such as Figure 9 As shown, a wall thickness portion 141 is formed on the metal plate 140 by forging. The thickness of this wall thickness portion 141 is equivalent to the plate thickness t1 of the contact portions 122 and 133. In addition, the thickness of the metal plate 140 is equivalent to the plate thickness t2 of the mounting portions 121, 131, and 132.

[0056] Next, as Figure 10 As shown, the part 142 and the pin 143 are left as terminals after being punched.

[0057] Next, as Figure 11 As shown, the end portion 144 of the terminal is flattened to form a rounded corner (forming R). The end portion 144 becomes the mating surfaces 126 and 137.

[0058] Next, as Figure 12 As shown, the wall thickness portion 145 is bent at approximately 90 degrees to form contact portions 122 and 133. At this time, there is a height difference between the surface of the wall thickness portion 145 and the surface of the pin 143, therefore, recesses 123 and 134 are formed on the inner side of the bent portion.

[0059] Next, as Figure 13 As shown, a portion of pin 143 is punched to cut the mounting portion 132 away from pin 143.

[0060] Next, as Figure 14 As shown, the wall thickness portion 145 is bent in a U-shape to form the contact portion 133 of the terminal 130. At this time, two first terminals 120 and one second terminal 130 are formed.

[0061] Next, make with Figure 14 The two first terminals 120 and one second terminal 130 shown are arranged in an identical configuration with a 180-degree rotation, fitted into a mold, and integrally molded by resin injection. Finally, the pins 143 are cut off, and the connector is complete.

[0062] (Implementation Method 2)

[0063] Figure 15 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 2 of the present invention. Figure 16 This is the main view. Figure 17 yes Figure 16 A sectional view of the BB section.

[0064] Compared to Embodiment 1 described above, Embodiment 2 of the present invention does not have a recessed portion of the housing 210 filled between the contact portion of terminals 220 and 230 and the mounting portion. Instead, as an anti-detachment component for the terminals, a portion of the housing (terminal fixing portion 213) closely adheres to and covers the mating direction (Z1 direction) surface of the mounting portion. The structure of other parts is the same as that of Embodiment 1 described above, therefore, repeated descriptions are omitted.

[0065] The electrical connector of this embodiment 2 is a plug connector 200 mounted on a substrate 500 such as a printed circuit board, and includes an insulating housing 210 and four conductive first terminals 220 and two conductive second terminals 230 fixed to the housing 210. Furthermore, for the terminals 220, the thickness t1 of the contact portion 222 in the direction parallel to the substrate 500 (Y1Y2 direction) is greater than the thickness t2 of the mounting portion 221 in the direction orthogonal to the substrate 500 (Z1Z2 direction). For example, the thickness t1 of the contact portion is more than twice the thickness t2 of the mounting portion. Similarly, for the terminals 230, the thickness t1 of the contact portion 233 in the direction parallel to the substrate 500 (Y1Y2 direction) is greater than the thickness t2 of the mounting portions 231 and 232 in the direction orthogonal to the substrate 500 (Z1Z2 direction). For example, the thickness t1 of the contact portion is more than twice the thickness t2 of the mounting portion. In addition, a locking part 223 is provided at the end of the contact part 222 to prevent it from disengaging from the connector on the object side.

[0066] The housing 210 is composed of a bottom wall 211 forming the bottom surface of the mating recess 201 of the connector, a side wall 212 filling between the terminals and standing upright from the bottom wall 211, and a terminal fixing part 213 formed in close contact with and covering a portion of the terminals 220 and 230.

[0067] In order to manufacture the plug connector 200, the method described in Embodiment 1 above is as follows: Figure 9 In the forging process, a wall thickness portion 141 is formed on the back side of the metal plate 140. Subsequent processes are the same as in Embodiment 1 described above. Figure 12 In the bending process, the wall thickness portion 141 exists on the back side, i.e. the outer side of the bent portion. Therefore, the inner side of the bent portion is flat, and thus, no concave portion is formed.

[0068] (Implementation Method 3)

[0069] Figure 18 This is a perspective view showing the structure of the electrical connector (socket connector) according to Embodiment 3 of the present invention. Figure 19 This is a perspective view showing the structure of only the terminals, excluding the housing portion.

[0070] Figure 20 It is a three-dimensional diagram showing the structure of the terminal. Figure 21 It is a side view. Figure 20 and Figure 21 The terminals are used as reinforcing metal parts. In this embodiment 3, the invention is used in a socket connector. The parts other than the terminals 330 (reinforcing metal parts) are the same as those in a typical socket connector.

[0071] The electrical connector of this embodiment 3 is a socket connector 300 mounted on a substrate 500 such as a printed circuit board, and includes an insulating housing 310, four conductive first terminals 320 fixed to the housing 310, four conductive second terminals 330, and two metal third terminals 340. For example, the first terminals 320 are used as signal terminals, the second terminals 330 are used as power terminals, and the third terminals 340 are used as ground (GND) terminals, power terminals, or reinforcing metal parts. The housing 310 has sidewalls 311 surrounding the first terminals 320, second terminals 330, and third terminals 340. The strength of the connector is increased by filling the third terminals 340 with metal.

[0072] like Figure 20 and Figure 21 As shown, the third terminal 340 has: mounting portions 331, 332, and 333 respectively connected to a substrate 500 such as a printed circuit board; and contact portions 334 extending from the mounting portions 331, 332, and 333 in the mating direction (Z1 direction). For the terminal 340, the thickness t1 of the contact portion 334 in the direction parallel to the substrate 500 (Y1Y2 direction) is greater than the thickness t2 of the mounting portions 331, 332, and 333 in the direction orthogonal to the substrate 500 (Z1Z2 direction). For example, the thickness t1 of the contact portion is more than twice the thickness t2 of the mounting portion.

[0073] (Implementation Method 4)

[0074] Figure 22 This is a perspective view showing the structure of the electrical connector (plug connector) according to Embodiment 4 of the present invention. Figure 23 This is a perspective view showing the structure of the terminals excluding the housing portion. Figure 24This is a side view showing the structure of the terminals. In this embodiment 4, the invention is used in a plug connector that engages in a direction parallel to the substrate. The engagement direction in this embodiment 4 is not the Z1 direction as in embodiments 1-3 described above, but rather a direction parallel to the substrate 500 (X2 direction).

[0075] The electrical connector in this embodiment 4 is a plug connector 400 mounted on a substrate 500 such as a printed circuit board, and includes an insulating housing 410 and three conductive terminals 420 fixed to the housing 410. Additionally, as... Figure 24 As shown, for terminal 420, the plate thickness t1 of contact portion 422 in the direction orthogonal to substrate 500 (Z1Z2 direction) is greater than the plate thickness t2 of mounting portion 421 in the direction orthogonal to substrate 500 (Z1Z2 direction). For example, the plate thickness t1 of contact portion is more than twice the plate thickness t2 of mounting portion. For example, terminal 420 is used as a signal terminal or a power terminal.

[0076] As mentioned above, in this embodiment 1 to 4, the terminals are not formed by bending a plate-shaped metal to create a contact portion as in the past, but rather the contact portion is filled with metal.

[0077] Therefore, in the electrical connectors according to embodiments 1 to 4, the plate thickness t1 of the contact portion is thick, thus reducing the conductor resistance of the terminal, thereby enabling more current to flow in the terminal.

[0078] In addition, the increased metal volume of the terminals improves the strength of the connector.

[0079] In addition, the thickness t2 of the mounting part is thinner than the thickness t1 of the contact part, thus enabling the connector to be made smaller.

[0080] The invention made by the inventor has been specifically described above based on the embodiments, but the invention is not limited to the above embodiments, and it is self-evident that various modifications can be made without departing from its spirit. In addition, the above embodiments 1 to 4 can be appropriately combined.

[0081] In the above embodiments 1 to 4, the connector mounted on the substrate was described, but it is not limited to this and other connectors can also be applied.

[0082] Industrial availability

[0083] The electrical connector described in this embodiment can be widely used in industrial, commercial, and household applications.

Claims

1. An electrical connector comprising an insulating housing and conductive terminals fixed to the housing, The electrical connector is characterized in that... The terminal includes a mounting portion that connects to the substrate and a contact portion that protrudes from the mounting portion in a mating direction orthogonal to the substrate. The thickness of the contact portion in the direction parallel to the surface direction of the substrate is greater than the thickness of the mounting portion in the direction orthogonal to the substrate. The contact portion is solid and is formed to protrude in one direction relative to the mounting portion in a direction parallel to the surface direction of the substrate. When viewed from the mating direction, the contact portion has a U-shaped shape.

2. The electrical connector according to claim 1, characterized in that, A portion of the surface of the mounting part on the mating side is partially covered by a portion of the housing.

3. The electrical connector according to claim 1 or 2, characterized in that, The terminal has a recess between the mounting portion and the contact portion, and a portion of the housing is filled in the recess.

4. The electrical connector according to claim 1 or 2, characterized in that, The two sides of the contact portion are in close contact with a portion of the housing.

5. The electrical connector according to claim 1 or 2, characterized in that, The interior of the mating surface at the end of the contact portion is filled with the metal that forms the terminal.

6. The electrical connector according to claim 1 or 2, characterized in that, The terminal has multiple mounting portions. The contact portion extends in a direction parallel to the substrate, and the plurality of mounting portions are electrically connected to each other.

7. The electrical connector according to claim 1 or 2, characterized in that, The contact portion is formed by forging.

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