connector

Abstract

The present invention provides a connector that prevents the flexible conductor from breaking when the adhesive used for waterproofing is heated, and enables a highly reliable electrical connection. A protective sheet (18) is configured to at least cover a surface portion of a flexible substrate (21) on which the flexible conductor (23) is formed, and is bonded to the flexible substrate (21) by an adhesive layer. A first insulator (14) has a flat surface (14C) opposite to the flexible substrate (21), and a first adhesive layer (17A) composed of an adhesive that bonds the first insulator (14) and the protective sheet (18) is disposed between the flat surface (14C) and the protective sheet (18).

Description

Technical Field

[0001] This invention relates to a connector, and more particularly to a connector for connecting to a flexible conductor. Background Technology

[0002] As a connector for connecting to a flexible conductor, for example, a type disclosed in Patent Document 1 Figure 32 The connector shown is, for example, a wearable connector that is mounted on clothing, and includes a first insulator 2 and a second insulator 3 that sandwich a flexible substrate 1 between them and are positioned opposite each other. A contact insertion hole 2A is formed in the first insulator 2, and an annular receiving member 4 is embedded in an annular stepped portion 2B formed at the periphery of the contact insertion hole 2A.

[0003] The cylindrical portion 5A of the contact 5 is inserted into the contact insertion hole 2A of the first insulator 2 and protrudes from the first insulator 2. The flange 5B of the contact 5 is sandwiched between the first insulator 2 and the second insulator 3, thereby the contact 5 is held by the first insulator 2 and the second insulator 3.

[0004] The flexible substrate 1 is disposed between the first insulator 2 and the second insulator 3 with its surface facing the first insulator 2 and its back side facing the second insulator 3. The open end of the flexible substrate 1 is bent in the protruding direction of the contact 5 and is sandwiched between the large diameter portion 5C formed at the base end of the cylindrical portion 5A of the contact 5 and the receiving member 4. Thus, the flexible conductor 6 disposed on the back side of the flexible substrate 1 contacts the large diameter portion 5C of the contact 5 and is electrically connected to the contact 5.

[0005] The second insulator 3 is bonded to the back of the flexible substrate 1 with an adhesive, and the surface of the flexible substrate 1 is also bonded to the first insulator 2 with an adhesive. In addition, by providing an annular waterproof component 7 between the contact insertion hole 2A of the first insulator 2 and the cylindrical portion 5A of the contact 5, water can be prevented from seeping from the outside of the connector into the contact area between the flexible conductor 6 and the large diameter portion 5C of the contact 5.

[0006] Existing patent literature

[0007] Patent documents

[0008] Patent Document 1: Japanese Patent Application Publication No. 2021-57294 Summary of the Invention

[0009] The technical problem that the invention aims to solve

[0010] As an adhesive for bonding the first insulator 2 and the second insulator 3 to the flexible substrate 1, for example, an adhesive made of thermosetting resin or thermoplastic resin that cures through heat treatment can be used. Thermosetting resin adhesives cure through a chemical reaction upon heating, while thermoplastic resin adhesives soften upon heating and then cure upon cooling.

[0011] Furthermore, the flexible substrate 1 has a flexible substrate on which flexible conductors 6 are formed by printing on the surface of a substrate body made of resin film. By heating the flexible substrate 1 while it is placed on the fabric of clothing, the resin film of the substrate body is melted and fused to the fabric of the clothing, and wiring made of flexible conductors 6 can be formed on the surface of the clothing.

[0012] However, if we proceed with... Figure 32 In the assembly process where the connector shown is installed onto a flexible substrate 1 having a flexible conductor 6 formed by printing as described above, the resin film forming the substrate body of the flexible substrate 1 may melt during heat treatment performed to cure the adhesive applied to the bonding area in order to bond the first insulator 2 and the second insulator 3 to the flexible substrate 1. In this case, since the adhesive is in direct contact with the flexible substrate 1, when the adhesive flowing through the heat fills the bonding area, the flexible conductor 6 located on the molten resin film may deform under the force of the flowing adhesive, resulting in a breakage.

[0013] If the flexible conductor 6 breaks, it will impair its function as a connector.

[0014] This invention was made to solve this existing problem, and its object is to provide a connector that can prevent the breakage of the flexible conductor when the adhesive used for waterproofing is heated, and to provide a highly reliable electrical connection.

[0015] Means for solving technical problems

[0016] The connector of the present invention is mounted on a sheet-like flexible substrate, wherein a flexible conductor is formed on the surface of the substrate body, and the connector comprises:

[0017] At least one contact is formed of a conductive material and connected to a flexible conductor;

[0018] Housing, mounted on a flexible substrate and holding the contacts; and

[0019] The protective sheet is composed of an insulating film having an adhesive layer formed on one side, and is disposed between the housing and the flexible substrate with the adhesive layer facing each other.

[0020] The protective sheet is configured to at least cover the surface portion of the flexible substrate on which the flexible conductor is formed, and is bonded to the flexible substrate by an adhesive layer.

[0021] The housing has a flat surface opposite to the flexible substrate.

[0022] An adhesive layer is provided between the flat surface and the protective sheet to bond the housing and the protective sheet.

[0023] Preferably, the housing has a first insulator disposed on one side of the flexible substrate and holding the contact, and a second insulator disposed on the other side of the flexible substrate, the first insulator and the second insulator each having a flat surface.

[0024] In this configuration, a flexible conductor can be formed on one side of a flexible substrate, a protective sheet can be disposed between a first insulator and one side of the flexible substrate, the protective sheet can be bonded to one side of the flexible substrate by an adhesive layer, and a first adhesive layer serving as an adhesive layer can be disposed between the flat surface of the first insulator and the protective sheet.

[0025] Preferably, a fixing piece is provided, which is made of an insulating film and is disposed between the second insulator and the other side of the flexible substrate in such a way that the adhesive layer is opposite to the other side of the flexible substrate. The fixing piece is bonded to the other side of the flexible substrate by the adhesive layer, and a second adhesive layer for bonding the second insulator and the fixing piece is disposed between the flat surface of the second insulator and the fixing piece.

[0026] Alternatively, a second adhesive layer for bonding the second insulator and the flexible substrate may be disposed between the flat surface of the second insulator and the other surface of the flexible substrate.

[0027] It can be configured such that the contact has a concave protrusion receiving portion, the second insulator has a protrusion protruding towards the other side of the flexible substrate, the flexible substrate is sandwiched in the middle by the protrusion and received in the protrusion receiving portion, and the contact is electrically connected to the flexible conductor.

[0028] In this case, it is preferable that the protective sheet has a protrusion insertion hole disposed at a position corresponding to the protrusion receiving portion of the contact, and the protrusion and the flexible substrate are received in the protrusion receiving portion through the protrusion insertion hole.

[0029] Furthermore, preferably, the protruding insertion hole has a smaller size than the contact size of the portion that contacts the protective sheet, along the surface of the protective sheet.

[0030] Preferably, the contact has a cylindrical portion extending in a direction perpendicular to the flexible substrate, the protrusion receiving portion is disposed inside the cylindrical portion, and the contact is configured such that the protrusion receiving portion is aligned with the protrusion insertion hole.

[0031] Furthermore, preferably, the contact has a flange extending from one end of the cylindrical portion in a direction parallel to the flexible substrate, and the contact is configured such that the flange repeatedly contacts the protective sheet throughout the entire circumference.

[0032] The first insulator may have a contact insertion hole that penetrates the first insulator, and the contact is held in the first insulator while the cylindrical portion is inserted into the contact insertion hole.

[0033] Preferably, the first adhesive layer covers the entire circumferentially closed cylindrical portion of the contact between the contact insertion hole and the cylindrical portion of the contact.

[0034] Alternatively, the flexible substrate can be sandwiched between two insulators and assembled onto the first insulator, with the contacts electrically connected to the flexible conductor.

[0035] Furthermore, it can be configured to include a reinforcing sheet disposed between one side of the first insulator and the flexible substrate, the reinforcing sheet having an opening located inward from the outer periphery of the protective sheet, the protective sheet being bonded to the flat surface of the first insulator via the opening through a first adhesive layer, and also bonded to the edge of the opening.

[0036] Preferably, the first adhesive layer is disposed inward from the outer periphery of the protective sheet.

[0037] In this case, it is preferable that the first adhesive layer is disposed in an area above the specified area.

[0038] Preferably, the adhesive layer is composed of an adhesive that is cured by heat treatment, and the insulating film and the adhesive layer have a heat resistance temperature higher than the heat treatment temperature of the adhesive.

[0039] It can be used as an adhesive, an adhesive made of thermosetting or thermoplastic resin.

[0040] The effects of the invention

[0041] According to the present invention, the protective sheet is disposed between the housing and the flexible substrate in such a way that it at least covers the surface portion of the flexible substrate on which the flexible conductor is formed, and is bonded to the flexible substrate by an adhesive layer. An adhesive layer for bonding the housing and the protective sheet is disposed between the flat surface of the housing and the protective sheet, thereby preventing the flexible conductor from breaking when the adhesive used for waterproofing is heated, and enabling a highly reliable electrical connection. Attached Figure Description

[0042] Figure 1 This is a perspective view of the connector of Embodiment 1 of the present invention, viewed from an obliquely upward angle.

[0043] Figure 2 This is a perspective view of the connector of Embodiment 1 viewed from a slightly lower angle.

[0044] Figure 3 This is an assembly diagram of the connector in Embodiment 1, viewed from an oblique top.

[0045] Figure 4 This is an assembly diagram of the connector in Embodiment 1, viewed from a slightly lower angle.

[0046] Figure 5 This is a perspective view of the first insulator used in the connector of Embodiment 1, viewed from an obliquely upward angle.

[0047] Figure 6 This is a perspective view of the first insulator used in the connector of Embodiment 1, viewed from a slightly lower angle.

[0048] Figure 7 This is a perspective view of the second insulator used in the connector of Embodiment 1, viewed from an obliquely upward angle.

[0049] Figure 8 This is a perspective view of the second insulator used in the connector of Embodiment 1, viewed from a slightly lower angle.

[0050] Figure 9 This is a perspective view showing the reinforcing sheet used in the connector of Embodiment 1.

[0051] Figure 10 This is a perspective view showing the protective sheet used in the connector of Embodiment 1.

[0052] Figure 11 This is a perspective view showing the fixing plate used in the connector of Embodiment 1.

[0053] Figure 12 This is a perspective view of the contacts used in the connector of Embodiment 1, viewed from an obliquely upward angle.

[0054] Figure 13 This is a perspective view of the contacts used in the connector of Embodiment 1, viewed from a slightly lower angle.

[0055] Figure 14 This is a perspective view of the flexible substrate on which the connector of Embodiment 1 is installed, viewed from an obliquely upward angle.

[0056] Figure 15 This is a perspective view of the flexible substrate on which the connector of Embodiment 1 is installed, viewed from a slightly lower angle.

[0057] Figure 16 This is a partial three-dimensional sectional view showing the state in which a reinforcing sheet is installed on the first insulator.

[0058] Figure 17 It is a partial three-dimensional sectional view showing the state in which adhesive has been applied to the first insulator.

[0059] Figure 18 It is a partial three-dimensional sectional view showing the state in which the contacts are assembled in the first insulator.

[0060] Figure 19 It is a partial three-dimensional view showing the relationship between the adhesive and the contact, omitting the first insulator.

[0061] Figure 20 It is a partial three-dimensional sectional view showing the state in which the protective sheet is assembled on the first insulator and the contact.

[0062] Figure 21 This is a partial three-dimensional cross-sectional view showing the state in which a flexible substrate is assembled on a protective sheet.

[0063] Figure 22 It is a partial three-dimensional cross-sectional view showing the state of a fixed piece assembled on a flexible substrate.

[0064] Figure 23 It is a partial three-dimensional sectional view showing the state of adhesive being applied to the fixing plate.

[0065] Figure 24 It is a partial three-dimensional sectional view showing the state of the second insulator being assembled.

[0066] Figure 25 This is a cross-sectional view showing the state of the second insulator assembled.

[0067] Figure 26 This is a partially enlarged cross-sectional view showing the main part of the connector in Embodiment 1.

[0068] Figure 27 This is a perspective view of the contacts used in the connector of Embodiment 2, viewed from a slightly lower angle.

[0069] Figure 28 This is an assembly diagram of the connector in Embodiment 2, viewed from a slightly lower angle.

[0070] Figure 29 This is a cross-sectional view of the connector of Embodiment 2, showing the state in which the second insulator is assembled.

[0071] Figure 30 This is a partially enlarged cross-sectional view showing the main part of the connector in Embodiment 2.

[0072] Figure 31 This is a cross-sectional view showing the connector of embodiment 3.

[0073] Figure 32 This is a partial cross-sectional view showing an existing connector.

[0074] Figure Labels

[0075] 1 Flexible substrate, 2 First insulator, 2A Contact insertion hole, 2B Stepped portion, 3 Second insulator, 4 Receiving component, 5 Contact, 5A Cylindrical portion, 5B Flange, 5C Large diameter portion, 6 Flexible conductor, 11, 31, 41 Connector, 12 Housing, 13, 33, 43 Contact, 13A, 33A Cylindrical portion, 13B Flange, 13C, 33C Protrusion receiving portion, 14, 34, 44 First insulator, 14A, 44A Recess, 14B, 34B Contact insertion hole, 14C, 15C Flat surface, 14D, 15D Surrounding surface, 14E Fixing post, 15, 45 Second Insulator, 15A base, 15B protrusion, 15E, 16B, 18B, 19B, 22A through holes, 16, 46 reinforcing pieces, 16A opening, 17, 20 adhesive, 17A, 47A first adhesive layer (adhesive layer), 18, 48 protective pieces, 18A, 19A protrusion insertion holes, 18C, 19C cutouts, 19, 49 fixing pieces, 20A, 50A second adhesive layer, 21, 51 flexible substrate, 21A surface, 21B back side, 22, 52 substrate body, 23, 53 flexible conductor, 45A protrusion, D1 inner diameter, D2, D3 outer diameter. Detailed Implementation

[0076] The embodiments of the present invention will now be described with reference to the accompanying drawings.

[0077] Implementation Method 1

[0078] Figure 1 and Figure 2 The connector 11 is shown in Embodiment 1. The connector 11 is used, for example, as a clothing-side connector for fitting a wearable device and is mounted on a sheet-like flexible substrate 21.

[0079] The connector 11 has a housing 12 made of insulating material. In the housing 12, four contacts 13 are held in a manner that protrudes perpendicularly relative to the flexible substrate 21, arranged in two parallel columns.

[0080] The housing 12 has a first insulator 14 disposed on the surface 21A of the flexible substrate 21, and a second insulator 15 disposed on the back surface 21B of the flexible substrate 21 and opposite to the first insulator 14. The first insulator 14 and the second insulator 15 have an elongated oval planar shape that is substantially the same size as each other.

[0081] The first insulator 14 is disposed on the surface 21A of the flexible substrate 21 through the reinforcing sheet 16, and has a recess 14A that opens in the opposite direction to the flexible substrate 21. Four contacts 13 protrude vertically from the planar bottom surface of the recess 14A of the first insulator 14.

[0082] For convenience, the bottom surface of the recess 14A of the first insulator 14 extends along the XY plane. The arrangement direction of the two columns of four contacts 13 is referred to as the X direction, and the direction in which the four contacts 13 protrude is referred to as the +Z direction. The Z direction is the mating direction of the connector 11 and the mating of the other side connector (not shown). The recess 14A of the first insulator 14 constitutes a mating connector receiving portion that accommodates a part of the other side connector (not shown).

[0083] Figure 3 and Figure 4 This diagram shows the assembly of connector 11. A reinforcing piece 16 is disposed on the -Z direction side of the first insulator 14. Four contacts 13 are disposed on the -Z direction side of the reinforcing piece 16, separated by an adhesive 17. A flexible substrate 21 is disposed on the -Z direction side of the four contacts 13, separated by a protective piece 18. Furthermore, a fixing piece 19 is disposed on the -Z direction side of the flexible substrate 21, and a second insulator 15 is disposed on the -Z direction side of the fixing piece 19, separated by an adhesive 20.

[0084] like Figure 5 and Figure 6 As shown, the first insulator 14 has four contact insertion holes 14B that penetrate the bottom surface of the recess 14A in the Z direction. The four contact insertion holes 14B correspond to four contacts 13. Furthermore, a flat surface 14C extending along the XY plane and facing the -Z direction is formed at the center of the first insulator 14 on the -Z direction side. A surrounding surface 14D is formed at the periphery of the flat surface 14C, surrounding its entire circumference. This surrounding surface 14D is located closer to the +Z direction side than the flat surface 14C, extending along the XY plane and facing the -Z direction.

[0085] Furthermore, a plurality of fixed posts 14E protruding in the -Z direction are formed on the flat surface 14C and the surrounding surface 14D of the first insulator 14.

[0086] like Figure 7 and Figure 8 As shown, the second insulator 15 has a flat base 15A and four protrusions 15B protruding from the base 15A in the +Z direction. The four protrusions 15B correspond to the four contacts 13. A flat surface 15C extending along the XY plane and facing the +Z direction is formed at the center of the base 15A, and the four protrusions 15B protrude from the flat surface 15C in the +Z direction. A surrounding surface 15D extending along the XY plane and facing the +Z direction is formed at the periphery of the flat surface 15C in a manner that surrounds the entire circumference of the flat surface 15C.

[0087] Furthermore, a plurality of through holes 15E extending through the base 15A in the Z direction are formed on the flat surface 15C and the surrounding surface 15D of the second insulator 15. The plurality of through holes 15E correspond to a plurality of fixing posts 14E of the first insulator 14.

[0088] The reinforcing sheet 16 reinforces the flexible substrate 21 and has an outer periphery larger than the first insulator 14 when viewed from the Z direction, such as... Figure 9 As shown, an opening 16A is formed in the center of the reinforcing sheet 16, penetrating the reinforcing sheet 16. The opening 16A has a size and shape corresponding to the flat surface 14C of the first insulator 14. Furthermore, the reinforcing sheet 16 has a thickness corresponding to the height difference in the Z direction between the flat surface 14C of the first insulator 14 and the surrounding surface 14D.

[0089] A plurality of through holes 16B are formed around the opening 16A, through the reinforcing sheet 16. The plurality of through holes 16B correspond to a plurality of fixing posts 14E of the first insulator 14.

[0090] Such reinforcing sheet 16 is formed, for example, from a resin with excellent elasticity, such as polyurethane.

[0091] like Figure 10 As shown, the protective sheet 18 is made of an insulating film with an elongated oval shape, having a profile slightly smaller than the surrounding surface 14D of the first insulator 14 and larger than the opening 16A of the reinforcing sheet 16. Four protruding insertion holes 18A are formed in the center of the protective sheet 18, penetrating the protective sheet 18. These four protruding insertion holes 18A correspond to the four contacts 13 respectively.

[0092] The insulating film constituting the protective sheet 18 can be, for example, a PET (polyethylene terephthalate) film (heat resistance temperature: about 150°C), a polyimide film (heat resistance temperature: about 200°C), or a so-called retort pouch (heat resistance temperature: about 130°C) made by laminating a resin film such as polypropylene.

[0093] Three through holes 18B are formed along the center line of the protective sheet 18 in the Y direction, and four cuts 18C are formed at the edges of the protective sheet 18 in the +Y and -Y directions. These through holes 18B and cuts 18C correspond to a plurality of fixing posts 14E of the first insulator 14.

[0094] An adhesive layer is formed on the entire surface of the protective sheet 18 facing the -Z direction, that is, the surface opposite to surface 21A of the flexible substrate 21. The adhesive layer is not suitable for use with water, solvents, heat, etc.; it achieves bonding effect simply by applying pressure for a short time at room temperature. No adhesive layer is formed on the surface of the protective sheet 18 facing the +Z direction.

[0095] like Figure 11As shown, the fixing piece 19 has the same size, shape, and material as the protective piece 18. Specifically, the fixing piece 19 is made of an insulating film with an elongated oval shape having a profile slightly smaller than the surrounding surface 14D of the first insulator 14, and four protruding insertion holes 19A are formed in the center of the fixing piece 19. These four protruding insertion holes 19A correspond to the four contacts 13 respectively.

[0096] Three through holes 19B are formed on the center line of the fixing piece 19 in the Y direction, and four cuts 19C are formed on the edge portion in the +Y direction and the edge portion in the -Y direction of the fixing piece 19. These through holes 19B and cuts 19C correspond to the plurality of fixing posts 14E of the first insulator 14.

[0097] An adhesive layer is formed on the entire surface of the fixing sheet 19 facing the +Z direction, that is, the surface opposite to the back surface 21B of the flexible substrate 21. No adhesive layer is formed on the surface of the fixing sheet 19 facing the -Z direction.

[0098] like Figure 12 and Figure 13 As shown, the contact 13 is a plug-type contact made of a conductive material such as metal, and has a cylindrical portion 13A extending in the +Z direction, and a flange 13B integrally formed at the -Z end of the cylindrical portion 13A and extending outward along the XY direction towards the cylindrical portion 13A.

[0099] In addition, the cylindrical portion 13A of the contact 13 has an outer diameter smaller than the inner diameter of the contact insertion hole 14B of the first insulator 14, and the flange 13B of the contact 13 has an outer diameter larger than the inner diameter of the contact insertion hole 14B of the first insulator 14.

[0100] A concave protrusion receiving portion 13C with an opening in the -Z direction is formed inside the cylindrical portion 13A. The protrusion receiving portion 13C has an inner diameter that is slightly smaller than the outer diameter of the protrusion 15B of the second insulator 15 plus twice the thickness of the flexible substrate 21. Such a contact 13 can be manufactured, for example, by performing stamping, cutting, deep drawing, or other processes on the metal material.

[0101] like Figure 14 and Figure 15 As shown, the flexible substrate 21 has a structure in which a plurality of flexible conductors 23 are formed by printing on the surface of a substrate body 22 made of resin film. When the flexible substrate 21 is placed on the fabric of clothing, it is heated by an iron or the like, so that the resin film forming the substrate body 22 melts and is fused to the fabric of clothing, thereby forming a wiring composed of flexible conductors 23 on the surface of clothing.

[0102] Alternatively, the connector 11 can be installed on the surface of clothing with pre-formed wiring made of flexible conductor 23.

[0103] Two flexible conductors 23 extending parallel to each other in the +X direction and two flexible conductors 23 extending parallel to each other in the -X direction are disposed on the surface 21A of the flexible substrate 21. These flexible conductors 23 correspond to four contacts 13. No flexible conductors 23 are disposed on the back side 21B of the flexible substrate 21.

[0104] Furthermore, a plurality of through holes 22A are formed in the central portion of the substrate body 22 of the flexible substrate 21, penetrating the substrate body 22. These through holes 22A correspond to a plurality of fixing posts 14E of the first insulator 14.

[0105] Figure 3 and Figure 4 The adhesive 17 shown bonds the +Z-oriented surface of the protective sheet 18 to the flat surface 14C of the first insulator 14 and the edge of the opening 16A surrounding the opening 16A of the reinforcing sheet 16, and extends throughout the entire circumference of the cylindrical portion 13A of the contact 13, closing the cylindrical portion 13A between it and the contact insertion hole 14B of the first insulator 14.

[0106] In addition, adhesive 20 bonds the side of the fixing piece 19 facing the -Z direction to the flat surface 15C and the surrounding surface 15D of the second insulator 15.

[0107] These adhesives 17 and 20, for example, use adhesives made of thermosetting resins. Thermosetting resin adhesives, for example, are fluid at room temperature and cure by a chemical reaction upon heating.

[0108] Furthermore, the insulating film and adhesive layer constituting the protective sheet 18 and the fixing sheet 19, respectively, have a heat resistance temperature higher than the heat treatment temperature of the adhesives 17 and 20. That is, even in an atmosphere in which heat treatment is performed to cure the adhesives 17 and 20, the protective sheet 18 and the fixing sheet 19 will not melt, and the adhesive effect of the adhesive layer will not be substantially impaired.

[0109] Here, a method for mounting connector 11 onto flexible substrate 21 is described.

[0110] First, such as Figure 16As shown, by passing multiple fixing posts 14E of the first insulator 14 through multiple through holes 16B of the reinforcing piece 16, and moving the reinforcing piece 16 from the -Z direction toward the +Z direction toward the first insulator 14, the reinforcing piece 16 is installed on the first insulator 14. Consequently, the flat surface 14C of the first insulator 14 is inserted into the opening 16A of the reinforcing piece 16, and the edge of the opening 16A of the reinforcing piece 16 contacts the surrounding surface 14D of the first insulator 14.

[0111] Furthermore, the reinforcing sheet 16 has a thickness corresponding to the height difference in the Z direction between the flat surface 14C and the surrounding surface 14D of the first insulator 14, so that the reinforcing sheet 16 mounted on the first insulator 14 forms the same surface as the flat surface 14C of the first insulator 14.

[0112] Next, as Figure 17 As shown, adhesive 17 is applied to the flat surface 14C of the first insulator 14 facing the -Z direction and the edge of the opening 16A of the reinforcing piece 16. At the same time, adhesive 17 is also applied to the edges of the four contact insertion holes 14B of the opening on the flat surface 14C of the first insulator 14.

[0113] In addition, such as Figure 18 As shown, corresponding contacts 13 are assembled in the four contact insertion holes 14B of the first insulator 14. The cylindrical portion 13A of each contact 13 is inserted into the contact insertion hole 14B.

[0114] At this point, if the first insulator 14 is omitted and the view is taken from the +Z direction, then as follows: Figure 19 As shown, the adhesive 17, which is applied to the flat surface 14C of the first insulator 14, is located on the flange 13B of each contact 13.

[0115] Next, as Figure 20 As shown, the protective sheet 18 is mounted on a first insulator 14 coated with adhesive 17 and assembled with four contacts 13. The protective sheet 18 is mounted by passing multiple fixing posts 14E of the first insulator 14 through multiple through holes 18B and cutouts 18C of the protective sheet 18. At this time, the protective sheet 18 is configured such that the surface with the adhesive layer faces the -Z direction opposite to the first insulator 14, and the protruding insertion holes 18A of the protective sheet 18 are arranged on the -Z direction side of the corresponding contact 13.

[0116] In addition, such as Figure 21 As shown, by passing multiple fixing posts 14E of the first insulator 14 through multiple through holes 22A of the flexible substrate 21, and by moving the flexible substrate 21 from the -Z direction to the +Z direction, the flexible substrate 21 is assembled onto the -Z direction side of the protective sheet 18. At this time, the flexible substrate 21 is configured such that the surface 21A on which the flexible conductor 23 is formed faces the protective sheet 18.

[0117] After that, as Figure 22 As shown, multiple fixing posts 14E of the first insulator 14 pass through multiple through holes 19B of the fixing piece 19, and the fixing piece 19 is mounted on the back surface 21B of the flexible substrate 21. At this time, the fixing piece 19 is configured such that the side with the adhesive layer is facing the back surface 21B of the flexible substrate 21, and the protruding insertion hole 19A of the fixing piece 19 is disposed on the -Z direction side of the corresponding contact 13 across the flexible substrate 21.

[0118] Next, as Figure 23 As shown, after applying adhesive 20 to the surface of the fixing piece 19 facing the -Z direction, as... Figure 24 As shown, the plurality of fixing posts 14E of the first insulator 14 pass through the plurality of through holes 15E of the second insulator 15, and the second insulator 15 is assembled to the first insulator 14. At this time, the flat surface 15C and the surrounding surface 15D of the second insulator 15 are disposed on the adhesive 20 coated on the surface of the fixing piece 19, and the +Z direction end of the protrusion 15B is disposed in the protrusion insertion hole 19A of the fixing piece 19.

[0119] Therefore, as Figure 25 As shown, the second insulator 15, adhesive 20, fixing piece 19, flexible substrate 21, protective piece 18, four contacts 13, adhesive 17, reinforcing piece 16 and first insulator 14 are stacked sequentially from the -Z direction to the +Z direction.

[0120] In this state, in order to cure the adhesives 17 and 20 while pressing the second insulator 15 toward the first insulator 14, a heat treatment is performed.

[0121] By applying pressure to the second insulator 15 relative to the first insulator 14, adhesive 17 applied to the flat surface 14C of the first insulator 14 and the edge of the opening 16A of the reinforcing sheet 16 extends and expands in the XY plane between the flat surface 14C of the first insulator 14 and the reinforcing sheet 16 and the protective sheet 18. Adhesive 17 applied to the edge of the contact insertion hole 14B of the first insulator 14 fills the space between the contact insertion hole 14B and the cylindrical portion 13A of the contact 13. Similarly, adhesive 20 applied to the surface of the fixing sheet 19 extends and expands in the XY plane between the fixing sheet 19 and the second insulator 15.

[0122] Furthermore, by performing heat treatment, the adhesives 17 and 20, which are composed of thermosetting resins, undergo a chemical reaction and are cured.

[0123] Subsequently, the second insulator 15 is fixed to the first insulator 14 by heating and deforming the -Z direction ends of the multiple fixing posts 14E of the first insulator 14 that protrude from the multiple through holes 15E of the second insulator 15 in the -Z direction, and the four contacts 13 are held in the housing 12 composed of the first insulator 14 and the second insulator 15.

[0124] Thus, the installation of connector 11 onto flexible substrate 21 is completed.

[0125] thus, Figure 26 This indicates the main part of the connector 11 mounted on the flexible substrate 21. Adhesives 17 and 20 are cured to form a first adhesive layer (adhesive layer) 17A and a second adhesive layer 20A, respectively.

[0126] The protective piece 18, facing the +Z direction, is bonded to the flat surface 14C of the first insulator 14 and the edge of the opening 16A surrounding the reinforcing piece 16 by a first adhesive layer 17A. Furthermore, the cylindrical portion 13A of the contact 13, extending throughout its circumference, is sealed between the cylindrical portion 13A and the contact insertion hole 14B of the first insulator 14 by the first adhesive layer 17A. Additionally, the fixing piece 19, facing the -Z direction, is bonded to the flat surface 15C and the surrounding surface 15D of the second insulator 15 by a second adhesive layer 20A.

[0127] Furthermore, by pressing the second insulator 15 relative to the first insulator 14, the protrusion 15B of the second insulator 15 contacts the back surface 21B of the flexible substrate 21 within the protrusion insertion hole 19A of the fixing piece 19. The flexible substrate 21 is pushed in the +Z direction through the protrusion insertion hole 18A of the protective piece 18, and the flexible substrate 21 is sandwiched in the middle and accommodated in the protrusion receiving portion 13C of the contact 13. The protrusion receiving portion 13C has an inner diameter slightly smaller than the outer diameter of the protrusion 15B plus twice the thickness of the flexible substrate 21. Therefore, it is in a state where the flexible conductor 23 of the flexible substrate 21 is pressed against the inner surface of the protrusion receiving portion 13C of the contact 13 through the side of the protrusion 15B and contact pressure is applied, and the contact 13 is electrically connected to the flexible conductor 23.

[0128] Along the XY plane of the protective sheet 18, the protruding insertion hole 18A of the protective sheet 18 has an inner diameter D1 smaller than the size of the contact 13 that contacts the protective sheet 18, i.e., the outer diameter D2 of the flange 13B of the contact 13. Furthermore, the flange 13B of the contact 13 is located on the +Z direction side of the protective sheet 18, and the first adhesive layer 17A is located on the +Z direction side of the flange 13B of the contact 13. Moreover, the first adhesive layer 17A is positioned further inward than the outer periphery of the protective sheet 18. Therefore, the first adhesive layer 17A does not contact the surface 21A of the flexible substrate 21.

[0129] Similarly, the second adhesive layer 20A is configured to be positioned closer to the inner side than the outer periphery of the fixing sheet 19, and the second adhesive layer 20A does not contact the back surface 21B of the flexible substrate 21.

[0130] Furthermore, the insulating film and adhesive layer constituting the protective sheet 18 and the fixing sheet 19 have a heat resistance temperature that is higher than the specified heat treatment temperature of the adhesive constituting the adhesives 17 and 20.

[0131] Therefore, when the adhesives 17 and 20 are heated to a specified heat treatment temperature for the purpose of curing, it is possible to prevent the flowing adhesives 17 and 20 from contacting the flexible substrate 21, especially the flexible conductor 23 formed on the surface 21A of the flexible substrate 21, and generating force. As a result, deformation and breakage of the flexible conductor 23 caused by the flowing adhesives 17 and 20 can be prevented.

[0132] Furthermore, since adhesives 17 and 20 do not come into direct contact with the flexible conductor 23, the constituent materials of adhesives 17 and 20 can be selected with a high degree of freedom.

[0133] Furthermore, the protective sheet 18 is bonded to the surface 21A of the flexible substrate 21 by an adhesive layer, and to the first insulator 14 and the reinforcing sheet 16 by a first adhesive layer 17A. The fixing sheet 19 is bonded to the back surface 21B of the flexible substrate 21 by an adhesive layer, and to the second insulator 15 by a second adhesive layer 20A. Therefore, water can be prevented from seeping into the connector 11 from the outside along the surface 21A and back surface 21B of the flexible substrate 21.

[0134] Furthermore, the entire circumference of the cylindrical portion 13A covering the contact 13 is sealed between the cylindrical portion 13A and the contact insertion hole 14B of the first insulator 14 by the first adhesive layer 17A. Therefore, even without the use of waterproof components such as O-rings, water can be prevented from seeping into the interior of the connector 11 through the contact insertion hole 14B of the first insulator 14.

[0135] In addition, the first adhesive layer 17A and the second adhesive layer 20A are respectively disposed inward from the outer periphery of the protective sheet 18 and the fixing sheet 19. However, in order to prevent water from seeping into the connector 11 from the outside along the surface 21A and back surface 21B of the flexible substrate 21, it is preferable that the first adhesive layer 17A and the second adhesive layer 20A surround the four contacts 13 and are disposed in an area above a specified area.

[0136] Furthermore, since the flexible conductor 23 is formed only on the surface 21A of the flexible substrate 21 and is not exposed on the back side 21B of the flexible substrate 21, the fixing piece 19 bonded to the back side 21B of the flexible substrate 21 can be omitted. By simply bonding the protective piece 18 to the surface 21A of the flexible substrate 21, deformation and breakage of the flexible conductor 23 caused by the flowing adhesive 17 can be prevented.

[0137] However, since the presence of the fixing piece 19 prevents the substrate body 22 of the flexible substrate 21 from being directly subjected to force from the flowing adhesive 20, it is preferable to place the fixing piece 19 between the back side 21B of the flexible substrate 21 and the adhesive 20 coated on the second insulator 15.

[0138] In addition, the connector 11 of the above embodiment 1 has four contacts 13, but it is not limited to this, as long as it has at least one contact 13.

[0139] Implementation Method 2

[0140] In the above-described embodiment 1, as Figure 12 and Figure 13 As shown, the contact 13 has a flange 13B integrally formed at the -Z direction end of the cylindrical portion 13A and extending outward along the XY direction of the cylindrical portion 13A, but a contact without a flange may also be used.

[0141] Figure 27 The contact 33 used in Embodiment 2 is indicated. The contact 33 is formed of a conductive material such as metal and has a cylindrical portion 33A extending in the +Z direction. Inside the cylindrical portion 33A, a concave protrusion receiving portion 33C opening in the -Z direction is formed. The protrusion receiving portion 33C has an inner diameter slightly smaller than the outer diameter of the protrusion 15B of the second insulator 15 plus twice the thickness of the flexible substrate 21. No flange extending outward from the cylindrical portion 33A is formed at the -Z direction end of the cylindrical portion 33A.

[0142] Figure 28 This is an assembly diagram of the connector 31 according to Embodiment 2, which has such contacts 33. A reinforcing piece 16 is disposed on the -Z direction side of the first insulator 34, and four contacts 33 are disposed on the -Z direction side of the reinforcing piece 16 with an adhesive 17 in between. A flexible substrate 21 is disposed on the -Z direction side of the four contacts 33 with a protective piece 18 in between. Furthermore, a fixing piece 19 is disposed on the -Z direction side of the flexible substrate 21, and a second insulator 15 is disposed on the -Z direction side of the fixing piece 19 with an adhesive 20 in between.

[0143] That is, in embodiment 2, the connector 31 uses four contacts 33 instead of four contacts 13 in embodiment 1, and uses a first insulator 34 instead of a first insulator 14. The other structures are the same as those of the connector 11 in embodiment 1.

[0144] The method of mounting connector 31 onto flexible substrate 21 is the same as that of connector 11 in Embodiment 1, such as... Figure 29 As shown, the second insulator 15, adhesive 20, fixing piece 19, flexible substrate 21, protective piece 18, four contacts 33, adhesive 17, reinforcing piece 16, and first insulator 34 are stacked sequentially from the -Z direction to the +Z direction. In this state, in order to cure the adhesives 17 and 20 while pressing the second insulator 15 against the first insulator 34, a heat treatment is performed. This completes the mounting of the connector 31 onto the flexible substrate 21.

[0145] Figure 30 This indicates the main part of the connector 31 mounted on the flexible substrate 21. The first insulator 34, in the first insulator 14 of Embodiment 1, has a contact insertion hole 34B instead of a contact insertion hole 14B; the other structures are the same as the first insulator 14 of Embodiment 1. The contact insertion hole 34B has a shape corresponding to the outer shape of the cylindrical portion 33A of the contact 33.

[0146] Along the XY plane of the protective sheet 18, the protruding insertion hole 18A of the protective sheet 18 has an inner diameter D1 smaller than the size of the contact 33 in contact with the protective sheet 18, i.e., the outer diameter D3 of the cylindrical portion 33A. Furthermore, the -Z direction end of the cylindrical portion 33A of the contact 33 is located on the +Z direction side of the protective sheet 18, extending circumferentially across the entire -Z direction end of the cylindrical portion 33A. The cylindrical portion 33A and the contact insertion hole 34B of the first insulator 34 are sealed by a first adhesive layer 17A. Moreover, the first adhesive layer 17A is positioned further inward than the outer periphery of the protective sheet 18. Therefore, the first adhesive layer 17A does not contact the surface 21A of the flexible substrate 21.

[0147] Therefore, in the connector 31 of Embodiment 2, when heated to a predetermined heat treatment temperature, it is possible to prevent the flowing adhesives 17 and 20 from contacting the flexible substrate 21, and in particular the flexible conductor 23 formed on the surface 21A of the flexible substrate 21, and generating force. As a result, deformation and breakage of the flexible conductor 23 caused by the flowing adhesives 17 and 20 are prevented.

[0148] Furthermore, by pressing the second insulator 15 relative to the first insulator 34, the protrusion 15B of the second insulator 15 pushes the flexible substrate 21 in the +Z direction and sandwiches the flexible substrate 21 in the middle, accommodating it in the protrusion receiving portion 33C of the contact 33. The protrusion receiving portion 33C has an inner diameter slightly smaller than the outer diameter of the protrusion 15B plus twice the thickness of the flexible substrate 21, thus creating a state in which the flexible conductor 23 of the flexible substrate 21 is pressed against the inner surface of the protrusion receiving portion 33C of the contact 33 by the side of the protrusion 15B, and contact pressure is applied, and the contact 33 is electrically connected to the flexible conductor 23.

[0149] In the connector 31 of embodiment 2, the protective sheet 18 is bonded to the surface 21A of the flexible substrate 21 by an adhesive layer, and to the first insulator 34 and the reinforcing sheet 16 by a first adhesive layer 17A. The fixing sheet 19 is bonded to the back surface 21B of the flexible substrate 21 by an adhesive layer, and to the second insulator 15 by a second adhesive layer 20A. Therefore, it is also possible to prevent water from seeping into the interior of the connector 11 from the outside along the surface 21A and the back surface 21B of the flexible substrate 21.

[0150] Furthermore, the entire circumference of the cylindrical portion 33A extending to the -Z direction end of the contact 33 is sealed between the cylindrical portion 33A and the contact insertion hole 34B of the first insulator 34 by the first adhesive layer 17A. Therefore, even without the use of waterproof components such as O-rings, water can be prevented from seeping into the interior of the connector 31 through the contact insertion hole 34B of the first insulator 34.

[0151] Implementation Method 3

[0152] In embodiments 1 and 2 described above, the protrusion 15B of the second insulator 15 sandwiches the flexible substrate 21 in the middle and is accommodated in the concave protrusion accommodating portions 13C and 33C of the contacts 13 and 33, thereby electrically connecting the contacts 13 and 33 to the flexible conductor 23, but is not limited thereto.

[0153] Figure 31 The connector 41 is shown in embodiment 3. The connector 41 has a housing composed of a first insulator 44 and a second insulator 45, wherein a recess 44A is formed in the first insulator 44 and a protrusion 45A is formed in the second insulator 45.

[0154] A contact 43, consisting of a strip-shaped component made of a conductive material such as metal, is temporarily held in the recess 44A of the first insulator 44. In this state, the second insulator 45 is assembled to the first insulator 44 by sandwiching the flexible substrate 51 in between, and the connector 41 is mounted on the flexible substrate 51.

[0155] The flexible substrate 51 has a structure in which a flexible conductor 53 is formed by printing on the surface of a substrate body 52 made of resin film. A protective sheet 48 is disposed on the surface of the flexible substrate 51 where the flexible conductor 53 is exposed, and a fixing sheet 49 is disposed on the back side of the flexible substrate 51 where the flexible conductor 53 is not exposed. The protective sheet 48 and the fixing sheet 49 each have an adhesive layer formed on one side of the insulating film, and are bonded to the surface and back side of the flexible substrate 51 by the adhesive layer.

[0156] The flexible substrate 51, located within the recess 44A of the first insulator 44, has no protective sheet 48 on its surface, and the flexible conductor 53 is exposed. The exposed flexible conductor 53 contacts the contact 43 with a specified contact pressure. The contact 43 is temporarily held in the recess 44A of the first insulator 44 by the protrusion 45A in the second insulator 45, thereby electrically connecting the contact 43 and the flexible conductor 53.

[0157] In addition, the protective sheet 48 is bonded to the first insulator 44 and the reinforcing sheet 46 by the first adhesive layer 47A (adhesive layer), and the fixing sheet 49 is bonded to the second insulator 45 by the second adhesive layer 50A, to prevent water from seeping into the connection between the contact 43 and the flexible conductor 53.

[0158] Here, a protective sheet 48 and a fixing sheet 49 exist between the flexible substrate 51 and the first adhesive layer 47A and the second adhesive layer 50A, and the first adhesive layer 47A and the second adhesive layer 50A are configured not to directly contact the flexible substrate 51. Furthermore, the insulating film and adhesive layer constituting the protective sheet 48 and the fixing sheet 49 have a heat resistance temperature higher than the predetermined heat treatment temperature of the adhesive constituting the first adhesive layer 47A and the second adhesive layer 50A.

[0159] Therefore, when the adhesive constituting the first adhesive layer 47A and the second adhesive layer 50A is heated to a specified heat treatment temperature, it is possible to prevent the flowing adhesive from contacting the flexible substrate 51 and generating force. As a result, it is possible to prevent deformation and breakage of the flexible conductor 53 caused by the flowing adhesive.

[0160] Therefore, in the connector 41 where the second insulator 45 is assembled into the first insulator 44 by sandwiching the flexible substrate 51 in the middle, and the contact 43 is electrically connected to the flexible conductor 53, it is also possible to prevent the flexible conductor 53 from breaking when the waterproof adhesive is heated, and a highly reliable electrical connection can be made.

[0161] In embodiments 1-3, adhesives constituting the first adhesive layer 17A, the second adhesive layer 20A, and the first adhesive layer 47A and the second adhesive layer 50A are all made of thermosetting resins. However, any adhesive that cures through heat treatment can be used, and adhesives made of thermoplastic resins can also be used. For example, the thermoplastic resin adhesive is solid at room temperature, softens by heating, and then cures by cooling. Such a thermoplastic resin adhesive is disposed corresponding to the bonding area and subjected to heat treatment. Thus, after the softened and flowing adhesive is filled into the bonding area by pressure, it is cooled and cured to form the first adhesive layers 17A, 47A and the second adhesive layers 20A, 50A.

[0162] Furthermore, in embodiments 1-3, connectors 11, 31, and 41 are mounted together with reinforcing pieces 16 and 46 on flexible substrates 21 and 51. However, if it is not necessary to specially reinforce the flexible substrates 21 and 51, the reinforcing pieces 16 and 46 may be omitted.

Claims

1. A connector mounted on a sheet-like flexible substrate, wherein a flexible conductor is formed on the surface of the substrate body, characterized in that, The connector includes: at least one contact formed of an electrically conductive material and connected to the flexible conductor; a housing mounted to the flexible substrate and holding the contact; and a protective sheet composed of an insulating film having an adhesive layer formed on one face and disposed between the housing and the flexible substrate with the adhesive layer facing the flexible substrate, the protective sheet is disposed to cover at least a surface portion of the flexible substrate in which the flexible conductor is formed and is adhered to the flexible substrate by the adhesive layer, the housing has a flat face facing the flexible substrate, an adhesive layer adhering the housing and the protective sheet is disposed between the flat face and the protective sheet.

2. The connector according to claim 1, wherein the housing has a first insulator disposed on one face of the flexible substrate and holding the contact, and a second insulator disposed on the other face of the flexible substrate, the first and second insulators each have the flat face.

3. The connector according to claim 2, wherein the flexible conductor is formed on the one face of the flexible substrate, the protective sheet is disposed between the first insulator and the one face of the flexible substrate, the protective sheet is adhered to the one face of the flexible substrate by the adhesive layer, a first adhesive layer that is the adhesive layer is disposed between the flat face of the first insulator and the protective sheet.

4. The connector according to claim 3, wherein the connector includes a fixing sheet composed of the insulating film and disposed between the second insulator and the other face of the flexible substrate with the adhesive layer facing the other face of the flexible substrate, the fixing sheet is adhered to the other face of the flexible substrate by the adhesive layer, a second adhesive layer adhering the second insulator and the fixing sheet is disposed between the flat face of the second insulator and the fixing sheet.

5. The connector according to claim 3, wherein a second adhesive layer adhering the second insulator and the flexible substrate is disposed between the flat face of the second insulator and the other face of the flexible substrate.

6. The connector according to any one of claims 3 to 5, wherein the contact has a recessed projection accommodating portion, the second insulator has a projection projecting toward the other face of the flexible substrate, the flexible substrate is accommodated in the projection accommodating portion with the flexible substrate sandwiched by the projection, and the contact is electrically connected to the flexible conductor.

7. The connector according to claim 6, wherein the protective sheet has a projection insertion hole disposed at a position corresponding to the projection accommodating portion of the contact, the projection is accommodated in the projection accommodating portion together with the flexible substrate via the projection insertion hole.

8. The connector according to claim 7, wherein The protrusion insertion hole has a size smaller than a size of the contact portion of the contact in contact with the protective sheet in a plane of the protective sheet.

9. The connector according to claim 7, wherein the contact has a cylindrical portion extending in a direction perpendicular to the flexible substrate, the protrusion accommodation portion is disposed inside the cylindrical portion, the contact is disposed such that the protrusion accommodation portion is aligned with the protrusion insertion hole.

10. The connector according to claim 9, wherein the contact has a flange extending from one end of the cylindrical portion in a direction parallel to the flexible substrate, the contact is disposed such that the flange repeatedly contacts the protective sheet over the entire circumference.

11. The connector according to claim 9, wherein the first insulator has a contact insertion hole that penetrates the first insulator, the contact is held to the first insulator in a state where the cylindrical portion is inserted into the contact insertion hole.

12. The connector according to claim 11, wherein the first adhesive layer closes between the cylindrical portion of the contact and the contact insertion hole over the entire circumference of the cylindrical portion of the contact.

13. The connector according to any one of claims 3 to 5, wherein the flexible substrate is sandwiched by the second insulator to be assembled to the first insulator, and the contact is electrically connected to the flexible conductor.

14. The connector according to any one of claims 3 to 5, wherein the connector has a reinforcing sheet disposed between the first insulator and the one face of the flexible substrate, the reinforcing sheet has an opening portion located inward of an outer peripheral portion of the protective sheet, the protective sheet is adhered to the flat face of the first insulator and to an edge portion of the opening portion via the first adhesive layer through the opening portion.

15. The connector of any one of claims 3-5, wherein, the first adhesive layer is disposed at a position inward of an outer peripheral portion of the protective sheet.

16. The connector of claim 15, wherein, the first adhesive layer is disposed in an area of a prescribed area or more.

17. The connector according to any one of claims 1 to 5, wherein the adhesive layer is composed of an adhesive cured by heat treatment, the insulating film and the adhesive layer have a heat resistance temperature higher than a heat treatment temperature of the adhesive.

18. The connector of claim 17, wherein, the adhesive is composed of a thermosetting resin or a thermoplastic resin.

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