Connector, connector unit, and method for manufacturing connector unit

Abstract

To provide a connector capable of reducing the number of assembly steps in a post-process and restraining unintended light leakage.SOLUTION: A connector 1 includes a contact 2, an insulator 3 that holds the contact, a metal shell 4, and a light-guiding member 5. The metal shell 4 includes a cylindrical portion 40 that surrounds the insulator 3. One end 40d of the cylindrical portion 40 forms an insertion opening SS into which a mating connector is inserted in a mating direction X1. The light-guiding member 5 includes an annular light-guiding emission portion 6 that surrounds one end 40d of the cylindrical portion 40. The light-guiding member 5 is fixed integrally and in close contact with the periphery of the metal shell 4 by insert molding.SELECTED DRAWING: Figure 1A-1B

Description

[Technical field]

[0001] The present invention relates to a connector, a connector unit, and a method for manufacturing the connector unit. [Background technology]

[0002] In order to improve visibility of connectors installed in automobiles, there are connectors that emit light around the insertion / removal opening where the mating connector is inserted / removed. For example, in the connector described in Patent Document 1, a removable light guide that guides light from a light source is placed over a shielding member that is placed over an insulator. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4475543 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, after assembling the connector, the light guide needs to be attached to the shielding member, which increases the number of assembly steps after assembling the connector. Also, a gap is likely to occur between the light guide and the shielding member, and light can leak inadvertently through the gap.

[0005] An embodiment of the present invention provides a connector that can reduce the number of assembly steps in a later process and can suppress unintended light leakage. [Means for solving the problem]

[0006] One embodiment of the present invention provides a connector (1; 1P) comprising contacts (2), an insulator (3) for holding the contacts, a metal shell (4), and a light-guiding member (5; 5P). The metal shell includes a cylindrical portion (40) surrounding the insulator. One end (40d) of the cylindrical portion forms an insertion opening (SS) into which a mating connector is inserted in a mating direction (X1). The light-guiding member includes an annular light-guiding emission portion (6) surrounding the one end of the cylindrical portion, and is fixed integrally and intimately around the metal shell by insert molding.

[0007] According to this configuration, the connector and the light guide member can be unitized in a state where the light guide member is fixed tightly and integrally to the periphery of the metal shell by insert molding. Therefore, compared to the case of the prior art in which a separately molded light guide member is later assembled to the connector, the number of assembly steps in the post-assembly process after the connector is assembled can be reduced. In addition, since no gap is generated between the metal shell and the light guide member, unintended light leakage due to the gap can be suppressed.

[0008] In addition, alphanumeric characters in parentheses indicate corresponding components in the embodiments described below, but this does not, of course, mean that the present invention should be limited to those embodiments. The same applies hereinafter in this section.

[0009] In one embodiment, the light guiding member includes an extended light guiding portion (7; 7P) that extends from the light guiding output portion and guides light from a light source (10; 20) to the light guiding output portion. With this configuration, the extended light guiding portion can guide the light from the light source to the light guiding output portion.

[0010] In one embodiment, the extending light-guiding portion of the light-guiding member includes a light source accommodating hole (8) into which the light source can be inserted and held. With this configuration, a light source can be inserted and held in the light source accommodating hole of the extending light-guiding portion of the light-guiding member of the connector. The connector and the light source can be integrated into a single unit.

[0011] In one embodiment, the connector further comprises a light source held in the light source accommodating hole, and the connector is unitized with the light source.

[0012] In one embodiment, the light guide member includes a transparent or translucent silicone resin. According to this configuration, the silicone resin has high adhesion strength to the metal shell. In addition, since the silicone resin has high heat resistance, the connector can be mounted on the circuit board by using a reflow connection with the light guide member fixed to the metal shell of the connector.

[0013] In one embodiment, the end face of the one end of the cylindrical portion of the metal shell protrudes from the annular light guiding portion in a direction (X2) opposite to the fitting direction. With this configuration, when the mating connector is fitted in the fitting direction, it is possible to prevent the mating connector from colliding with the light guiding and emitting portion of the light guiding member, thereby protecting the light guiding and emitting portion.

[0014] One embodiment of the present invention provides a connector unit (U) including the connector and a circuit board (100) on which the connector and the light source are mounted. With this configuration, it is possible to obtain a connector unit that can reduce the number of assembly steps in a post-process after assembling the connector and that can suppress unintended light leakage.

[0015] One embodiment of the present invention provides a method for manufacturing a connector unit (UP) including the connector according to claim 3 and a circuit board on which the connector and the light source are mounted, the method including the steps of inserting and holding the light source in the light source accommodating hole of the light guide member of the connector, and mounting the light source inserted and held in the light source accommodating hole on the circuit board. According to this configuration, the light source can be inserted and held in the light guide member fixed integrally to the metal shell of the connector, and then the light source can be mounted on the circuit board.

[0016] One embodiment of the present invention provides a method for manufacturing a connector unit (U) including the connector according to claim 5 and a circuit board on which the connector and the light source are mounted, the method including a step of arranging and fixing the connector to the circuit board, and a reflow step of reflow-connecting the contact to the circuit board. According to this configuration, the reflow step can be performed in a state in which a light-guiding member containing a highly heat-resistant silicone resin is fixed to the connector. Effect of the Invention

[0017] According to the present invention, the number of assembly steps in the later processes can be reduced, and unintended light leakage can be suppressed. [Brief description of the drawings]

[0018] [Figure 1A-1B] FIG. 1A is a perspective view of a connector according to one embodiment of the present invention, and FIG. 1B is a perspective view of a second subassembly of the connector. [Diagram 2] FIG. 2 is a perspective view of the metal shell. [Figure 3A-3B] 3A and 3B are perspective views of the light-guiding member from different angles. [Figure 4A-4E] 4A, 4B, 4C, 4D and 4E are a front view, a rear view, a plan view, a bottom view and a side view of the light-guiding member, respectively. [Diagram 5] FIG. 5 is a perspective view of the connector unit. [Figure 6] FIG. 6 is a perspective view of the connector unit from a different angle. [Figure 7A-7B] FIG. 7A is a side view of the connector unit, and FIG. 7B is a side view of the connector unit when a mating connector is about to be mated at an angle. [Figure 8] FIG. 8 is a flowchart of a method for manufacturing the connector unit. [Figure 9] FIG. 9 is a perspective view of a connector and a light source according to another embodiment of the present invention. [Figure 10A-10E]10A, 10B, 10C, 10D and 10E are a front view, a rear view, a plan view, a bottom view and a side view, respectively, of a light-guiding member according to another embodiment. [Figure 11] FIG. 11 is a perspective view of a connector unit according to another embodiment. [Figure 12] FIG. 12 is a perspective view of a connector unit according to another embodiment, seen from a different angle. [Figure 13] FIG. 13 is a flowchart of a method for manufacturing a connector unit according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

[0020] Fig. 1A is a perspective view of a connector 1 according to an embodiment of the present invention, and Fig. 1B is a perspective view of a second subassembly SA2 of the connector 1.

[0021] 1A, the connector 1 is a receptacle connector including a plurality of conductive contacts 2, an insulator 3 that holds the contacts 2, a conductive metal shell 4, and a light-guiding member 5. A mating connector (a flag connector, not shown) is mated with the connector 1 in a mating direction X1. The connector 1 has a width direction W and a height direction H that are perpendicular to the mating direction X1.

[0022] 1A and 1B, the connector 1 includes a first subassembly SA1 including a contact 2 and an insulator 3, and a second subassembly SA2 including a metal shell 4 and a light-guiding member 5. In the second subassembly SA2, the light-guiding member 5 is integrally and closely fixed to the metal shell 4 by insert molding.

[0023] Fig. 5 is a perspective view of the connector unit U, and Fig. 6 is a perspective view from another angle of the connector unit U. As shown in Fig. 5 and Fig. 6, the connector unit U includes a connector 1, a light source 10, and a circuit board 100 on which the connector 1 and the light source 10 are mounted. The light source 10 is, for example, an LED (light emitting diode).

[0024] As shown in FIG. 1A, the contact 2 held by the insulator 3 includes a contact portion (not shown) that is connected to a contact of a mating connector, and a lead portion 2a (see FIG. 6) that is solder-connected to a conductor portion of the circuit board 100.

[0025] Next, the metal shell 4 will be described.

[0026] Fig. 2 is a perspective view of the metal shell 4. As shown in Fig. 2, the metal shell 4 includes a front half 4f (a half in the direction X2 opposite to the fitting direction X1) and a rear half 4r. The metal shell 4 includes a cylindrical portion 40 surrounding the insulator 3, an extended upper plate 41, a pair of extended side plates 42, a rear plate 43, a pair of locking plates 44, two pairs of side locking tabs 45, and a plurality of rear locking tabs 46.

[0027] The cylindrical portion 40 is disposed in a front half 4f of the metal shell 4. An extended top plate 41, a pair of extended side plates 42, a rear plate 43, two pairs of side locking tabs 45, and a plurality of rear locking tabs 46 are disposed in a rear half 4r of the metal shell 4.

[0028] The cylindrical portion 40 includes an upper plate 40a, a lower plate 40b, a pair of side plates 40c, one end 40d, and an outer peripheral surface 40e, which are continuous in the circumferential direction. When viewed in the fitting direction X1, the corners formed by the upper plate 40a and each side plate 40c are R-shaped, and the corners formed by the lower plate 40b and each side plate 40c are R-shaped. When viewed in the fitting direction X1, the four corners of the cylindrical portion 40 are R-shaped, and the cylindrical portion 40 forms an oval shape.

[0029] One end 40d of the cylindrical portion 40 forms an insertion opening SS into which the mating connector is inserted in the mating direction X1. When viewed in the mating direction X1, the insertion opening SS has an elliptical shape.

[0030] The extended upper plate 41 extends in the fitting direction X1 from the upper plate 40a of the cylindrical portion 40. The pair of extended side plates 42 extend in the fitting direction X1 from upper halves of the pair of side plates 40c. The rear plate 43 is bent perpendicularly from the rear end of the extended upper plate 41. The pair of locking plates 44 are bent perpendicularly from a pair of side edges of the rear plate 43 and are locked to the rear ends of the pair of extended side plates 42.

[0031] A pair of side locking tabs 45 are cut and raised downward from each side plate 40c of the cylindrical portion 40. In addition, a plurality of rear locking tabs 46 are extended downward from the rear plate 43.

[0032] Next, the light guide member 5 will be described.

[0033] Figures 3A and 3B are perspective views of light-guiding member 5 from different angles. Figures 4A, 4B, 4C, 4D, and 4E are a front view, a rear view, a plan view, a bottom view, and a side view, respectively, of light-guiding member 5. Light-guiding member 5 includes a light-guiding output section 6 and a pair of elongated light-guiding sections 7.

[0034] 1B, the light guide member 5 is tightly attached to the periphery of the metal shell 4 by insert molding and fixed thereto. The light guide output portion 6 is formed in an annular shape surrounding the outer periphery of one end 40d of the tubular portion 40 of the metal shell 4.

[0035] As shown in Figures 3A and 3B, 4A, 4B, 4C, 4D, and 4E, the light guide emitting unit 6 includes an outer peripheral surface 6a, an inner peripheral surface 6b, an annular front end surface 6c, and an annular rear end surface 6d. The front end surface 6c and the outer peripheral surface 6a of the light guide emitting unit 6 function as an emitting unit. The inner peripheral surface 6b of the light guide emitting unit is in close contact with and fixed to the outer peripheral surface 40e of the cylindrical portion 40 of the metal shell 4. An end surface 40f of one end 40d of the cylindrical portion 40 of the metal shell 4 protrudes from the front end surface 6c of the light guide emitting unit 6 in the direction X2 opposite to the fitting direction X1 (see Figure 7A).

[0036] The pair of extending light guiding portions 7 extend in the fitting direction X1 from the rear end surface 6d of the light guiding and emitting portion 6. The extending light guiding portion 7 includes a first portion 71, a second portion 72, a third portion 73, and a fourth portion 74.

[0037] The first portion 71 extends in the fitting direction X1 from the rear end surface 6d of the light guiding and emitting portion 6. The first portion 71 includes a front end 71a connected to the rear end surface 6d of the light guiding and emitting portion 6, a rear end 71b, an outer side surface 71c, and an inner side surface 71d. The inner side surface 71d of the first portion 71 is fixed in close contact with the outer side surface of the corresponding side plate 40c (see FIG. 2) of the cylindrical portion 40 of the metal shell 4.

[0038] The second portion 72 extends in the fitting direction X1 from the rear end 71b of the first portion 71. The second portion 72 includes a front end 72a connected to the rear end 71b of the first portion 71, a rear end 72b, an outer side surface 72c, and an inner side surface 72d. The inner side surface 72d of the second portion 72 is fixed in close contact with the outer side surface of the corresponding side plate 40c (see FIG. 2) of the cylindrical portion 40 of the metal shell 4.

[0039] The third portion 73 protrudes outward in a wing-like shape from the outer surface 72c of the second portion 72. The third portion 73 includes an upper surface 73a and a lower surface 73b. The fourth portion 74 extends downward from the lower surface 73b of the third portion 73. The fourth portion 74 includes a lower surface 74a that functions as an incident portion facing the light source 10 (see FIGS. 5 and 6). The incident portion may be a recess provided in the lower surface 74a.

[0040] Light from the light source 10 enters the light-guiding member 5 through the lower surface 74a of the fourth portion 74, is internally reflected within the light-guiding member 5, and is emitted from the front end surface 6c and the outer circumferential surface 6a of the light-guiding output portion 6.

[0041] FIG. 8 is a flowchart of a method for manufacturing the connector unit U.

[0042] First, a first subassembly SA1 (see FIG. 1A) including a contact 2 and an insulator 3 is manufactured (step S1).

[0043] Next, the light guide member 5 containing silicone resin is tightly attached and fixed integrally to the periphery of the metal shell 4 by insert molding to manufacture a second subassembly SA2 (see FIG. 1B) (step S2). Steps S1 and S2 may be performed in reverse order or simultaneously in parallel.

[0044] Next, the first subassembly SA1 and the second subassembly SA2 are combined to assemble the connector 1 (step S3; see FIG. 1A).

[0045] Next, the connector 1 is positioned and fixed to the surface 101 of the circuit board 100 using the side locking tabs 45 and rear locking tabs 46 of the metal shell 4 (step S4; see FIGS. 5 and 6).

[0046] Next, the connector 1 is reflow-mounted on the circuit board 100 by a reflow process using a reflow oven (step S5). That is, the lead portions 2a (see FIG. 6) of the contacts 2 of the connector 1 are reflow-connected to the conductor portions of the circuit board 100. This completes the connector unit U.

[0047] According to the connector 1 of the present embodiment, as shown in Fig. 1A, the connector 1 and the light guide member 5 can be unitized in a state where the light guide member 5 is fixed integrally and closely around the metal shell 4 by insert molding. Therefore, compared with the case of the prior art (Patent Publication No. 4475543) in which a separately molded light guide member is later assembled to the connector, the number of assembly steps in the post-process after the connector is assembled can be reduced, and the workability of the post-process can be improved. In addition, since no gap is generated between the metal shell 4 and the light guide member 5, unintended light leakage due to the gap can be suppressed.

[0048] 3A , the light-guiding member 5 includes an extended light-guiding portion 7 that extends from the light-guiding output portion 6 in the fitting direction X1 and guides light from the light source 10 (see FIGS. 5 and 6 ). With this configuration, the extended light-guiding portion 7 can guide the light from the light source 10 to the light-guiding output portion 6.

[0049] Furthermore, the light guide member 5 contains a transparent or translucent silicone resin. The light guide member 5 containing the silicone resin has high adhesion strength to the metal shell 4. Furthermore, since the silicone resin has high heat resistance, the connector 1 can be mounted on the circuit board 100 by using a reflow connection in a state where the light guide member 5 is closely and fixed to the metal shell 4 of the connector 1.

[0050] 1A and 7A, an end face 40f of one end 40d of the tubular portion 40 of the metal shell 4 protrudes from the light guiding and emitting portion 6 of the light guiding member 5 in the direction X2 opposite to the fitting direction X1. With this configuration, as shown in Fig. 7B, when an inserting portion of a mating connector (e.g., the inserting portion 201 of a USB plug 200) is fitted in the fitting direction X1, even if the inserting portion 201 is deviated from the correct position, the one end 40d of the tubular portion 40 of the metal shell 4 can prevent the inserting portion 201 from colliding with the light guiding and emitting portion 6 of the light guiding member 5. This makes it possible to protect the light guiding and emitting portion 6.

[0051] Furthermore, according to the connector unit U of the present embodiment, the number of assembly steps in the post-processing steps following the connector assembly can be reduced, and unintended light leakage can be suppressed.

[0052] Furthermore, according to the manufacturing method of the connector of this embodiment, the reflow process (see FIG. 8) can be performed in a state where the light guide member 5 containing a silicone resin with high heat resistance is tightly and integrally fixed to the metal shell 4 of the connector 1. Compared to the case of the prior art (Japanese Patent No. 4475543) in which a separately molded light guide member is later assembled, the number of assembly steps in the post-process after the connector is assembled can be reduced.

[0053] Next, Fig. 9 is a perspective view of a connector 1P and a light source 20 according to another embodiment of the present invention. Figs. 10A, 10B, 10C, 10D, and 10E are a front view, a rear view, a plan view, a bottom view, and a side view of a light guide member 5P according to another embodiment, respectively. Fig. 11 is a perspective view of a connector unit UP according to another embodiment. Fig. 12 is a perspective view of a connector unit UP according to another embodiment from another angle.

[0054] Connector 1P of the present embodiment in Fig. 9 differs from connector 1 of the embodiment in Fig. 1A mainly in the following respects. Connector 1P includes a light-guiding member 5P including a light-guiding output portion 6 and a pair of extending light-guiding portions 7P. The extending light-guiding portions 7P include a light source accommodating hole 8 capable of holding a light source 20 inserted therein. Light source 20 includes a main body 21 and two terminals 22.

[0055] The light source accommodating hole 8 opens to an upper surface 73a of the third portion 73 of the extended light guide portion 7P. Two terminal insertion holes 9 are formed extending from the bottom of the light source accommodating hole 8 to a lower surface 74a of the fourth portion 74. The main body 21 of the light source 20 is accommodated and held in the light source accommodating hole 8. The inner surface of the light source accommodating hole 8 functions as an entrance portion through which light from the light source 20 is incident. Two terminals 22 of the light source 20 are inserted into the two terminal insertion holes 9.

[0056] In the configurations shown in Figures 9, 10A, 10B, 10C, 10D and 10E, components common to the configurations shown in Figures 1, 4A, 4B, 4C, 4D and 4E are given common reference symbols.

[0057] FIG. 13 is a flowchart of a method for manufacturing the connector unit UP.

[0058] First, a first subassembly SA1 (see FIG. 9) including a contact 2 and an insulator 3 is manufactured (step S10).

[0059] Next, a second subassembly SA2 (see FIG. 9) including the metal shell 4 and the light guiding member 5P is manufactured by tightly and integrally fixing the light guiding member 5P including the silicone resin to the periphery of the metal shell 4 by insert molding (step S20). Steps S10 and S20 may be performed in reverse order or simultaneously in parallel.

[0060] Next, the first subassembly SA1 and the second subassembly SA2 are combined to assemble the connector 1P (step S30; see FIG. 9).

[0061] Next, the light source 20 is inserted and held in the light source accommodating hole 8 of the light guide member 5P of the connector 1P (step S40, see FIG. 9). Specifically, the main body 21 is accommodated and held in the light source accommodating hole 8. The two terminals 22 are inserted through the terminal insertion holes 9 and protrude downward from the light guide member 5P.

[0062] Next, the connector 1 is positioned and fixed to the surface 101 of the circuit board 100 using the side locking tabs 45 and rear locking tabs 46 of the metal shell 4 (step S50; see FIGS. 11 and 12).

[0063] Next, the connector 1P is reflow-mounted on the circuit board 100 by a reflow process using a reflow oven (step S60), thereby completing the connector unit UP.

[0064] In this embodiment, as in the embodiment of Figures 1A to 8, it is possible to provide a connector 1P and a connector unit UP that can reduce the number of assembly steps in the post-assembly process after the connector is assembled, and that can suppress unintended light leakage caused by the gap between the metal shell 4 and the light-guiding member 5P.

[0065] Furthermore, by inserting and holding the light source 20 in the light source accommodating hole 8 of the extending light guiding portion 7P of the light guiding member 5P of the connector 1P, it is possible to unitize the connector 1P, the light guiding member 5P, and the light source 20. In other words, since the connector 1P includes the light guiding member 5P and the light source 20, it is possible to significantly reduce the number of assembly steps in the post-process after assembling the connector, and improve the workability of the post-process.

[0066] The present invention is not limited to the above-described embodiment. For example, the material of the light guide member 5; 5P is not limited to silicone resin, but may be any transparent or translucent resin that can transmit light.

[0067] Furthermore, although not shown, when the connector or connector unit of the present invention is placed within the housing of an electronic device, the light-guiding member 5; 5P may be configured to be elastically compressed between the metal shell 4 and the housing, thereby improving the prying strength of the connector against external forces.

[0068] Although not shown, the extending light-guiding portion 7; 7P of the light-guiding member 5; 5P may include a portion extending in a direction intersecting the fitting direction X1. In that case, the metal shell 4 may include an extension plate extending outward from the cylindrical portion 40 of the metal shell 4 as a portion to which the portion extending in the intersecting direction is fixed in close contact with the metal shell 4 by insert molding.

[0069] The shape of the cylindrical portion 40 of the metal shell 4 is not limited to an oval shape, but may be a rectangular shape when viewed from the fitting direction X1. The connector is not limited to a USB connector, and may be another connector structure having a dedicated electrode for charging an electronic device.

[0070] The number of LEDs as the light source may be one or more than two. When multiple LEDs are used, the multiple LEDs may include LEDs with different color tones. In addition, the present invention can be modified in various ways within the scope of the claims. [Explanation of symbols]

[0071] 1 Connector 1P Connector 2. Contact 2a Lead part 3. Insulators 4 Metal Shell 5 Light guide member 5P Light guide material 6 Light guiding / emitting part 7 Extended light guide section 7P extended light guide 8 Light source housing hole 9 Terminal insertion hole 10 light source 20 light source 21 Main unit 22 Terminals 40 Cylindrical part 40d one end 40e Outer surface 40f end face 100 Circuit Board SA1 1st Sub-Assembly SA2 Second Sub-Assembly SS Insertion Aperture U Connector unit UP Connector Unit X1 Mating direction X2 opposite direction

Claims

1. Contacts and an insulator that holds the contact; a metal shell including a cylindrical portion surrounding the insulator, one end of the cylindrical portion forming an insertion opening into which a mating connector is inserted in a mating direction; a light-guiding member including an annular light-guiding and emitting portion surrounding the one end of the cylindrical portion and integrally and tightly fixed to the periphery of the metal shell by insert molding.

2. The connector according to claim 1 , wherein the light-guiding member further includes an extended light-guiding portion that extends from the light-guiding output portion and guides light from a light source to the light-guiding output portion.

3. The connector according to claim 2 , wherein the extending light-guiding portion of the light-guiding member includes a light source accommodating hole capable of inserting and holding the light source.

4. The connector according to claim 3 , further comprising a light source held in the light source receiving hole.

5. The connector according to claim 1 , wherein the light-guiding member comprises a transparent or translucent silicone resin.

6. The connector according to claim 1 , wherein the end face at the one end of the cylindrical portion of the metal shell protrudes from the light guiding and emitting portion in a direction opposite to the fitting direction.

7. A connector unit comprising: the connector according to any one of claims 1 to 6; and a circuit board on which the connector and the light source are mounted.

8. A method for manufacturing a connector unit including the connector according to claim 3 and a circuit board on which the connector and the light source are mounted, comprising the steps of: a step of inserting and holding the light source in the light source accommodating hole of the light guide member of the connector; and mounting the light source inserted and held in the light source accommodating hole on the circuit board.

9. A method for manufacturing a connector unit including the connector according to claim 5 and a circuit board on which the connector and the light source are mounted, comprising the steps of: locating and fixing the connector to the circuit board; and a reflow process of reflow-connecting the contacts to the circuit board.

Images