Connector

Abstract

To narrow the intervals between protrusions to which a plurality of terminals are attached, to facilitate manufacturing, enable miniaturization, and increase reliability.SOLUTION: A method for manufacturing a connector having a pair of half portions and a plurality of terminals attached to the pair of half portions includes a first insert molding step of placing one terminal carrier connected to the tail portions of the plurality of terminals and the other terminal carrier connected to the tail portions of the plurality of terminals set in a first molding die to mold the half portions opposite each other, a first cutting step of removing a terminal carrier from the tail portions of the terminals, a second insert molding step of placing the pair of half portions connected to the other terminal carrier opposite each other and setting the pair in a second molding die to mold the connector, and a second cutting step of removing the other terminal carrier from the tail portions of the terminals.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a connector.

Background Art

[0002] Conventionally, in order to electrically connect a pair of parallel circuit boards, a connector such as a board-to-board connector has been used. Such a connector is attached to each of the mutually facing surfaces of a pair of circuit boards and is adapted to be fitted to each other to conduct electricity (see, for example, Patent Document 1).

[0003] FIG. 11 is a perspective view showing a conventional connector.

[0004] In the figure, 811 is a housing of a connector mounted on a circuit board (not shown), and has a pair of elongated convex portions 812 extending in the longitudinal direction. A plurality of terminals 861 are attached side by side in the longitudinal direction of the connector to the convex portions 812.

[0005] When the connector is fitted to a mating connector (not shown), the convex portions 812 are inserted into each of a pair of concave grooves formed in the mating housing of the mating connector. Thereby, the terminals 861 come into contact with and conduct electricity with each of the mating terminals (not shown) attached side by side in the concave grooves.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, in the conventional connector, since the terminal 861 is formed to be integrated with the housing 811, when miniaturized, the interval between the convex portions 812 becomes narrow, and the pitch of the terminals 861 becomes narrow, making manufacturing difficult. Usually, since the terminal 861 is integrated with a pair of convex portions 812 of the housing 811 by a molding method called overmolding or insert molding, when the interval between the convex portions 812 becomes narrow and the pitch of the terminals 861 becomes narrow, it becomes difficult to accurately arrange a large number of terminals 861 at positions corresponding to the pair of convex portions 812 in the molding die of the housing 811.

[0008] Here, an object is to solve the problems of the conventional connector, enable the interval between the convex portions to which a plurality of terminals are attached to be narrowed, be easy to manufacture, be capable of miniaturization, and provide a highly reliable connector.

Means for Solving the Problem

[0009] Therefore, in the connector, each includes a half body portion including a connector body and a plurality of terminals attached to the connector body, a body end portion formed at both ends of the connector body of each half body portion, and a reinforcing metal fitting integrated with the body end portion. Each of the connector bodies extends in its longitudinal direction and includes a convex portion integrated with the terminal. Each of the terminals includes a wide contact extending in the vertical direction and an upper portion narrower than the contact connected to the upper end of the contact. The terminals arranged side by side in the longitudinal direction of the convex portion have adjacent ones oriented in opposite directions with respect to the width direction of the convex portion, and the upper portions of adjacent ones are arranged so as to overlap when viewed from the longitudinal direction of the convex portion.

[0010] In another connector, further, each of the terminals includes a tail portion protruding outward in the width direction of the connector body and connected to a substrate, and the terminals are arranged such that adjacent tail portions protrude in opposite directions with respect to the width direction of the connector body.

[0011] In still other connectors, each of the connector bodies further includes a bottom plate portion extending in its longitudinal direction, the convex portion is integrally formed on the upper surface of the bottom plate portion, and the tail portion protrudes outward in the width direction of the connector body from the bottom plate portion.

[0012] In still other connectors, further, the space between the left and right half-body portions is an elongated concave groove portion extending in the longitudinal direction of the connector, and the concave groove portion opens to the upper and lower surfaces of the connector.

[0013] In a connector pair, it has the connector of the present disclosure and a mating connector that fits with the connector.

[0014] Also, in a manufacturing method, it is a manufacturing method of a connector including a pair of half-body portions and a plurality of terminals attached to the pair of half-body portions. The method includes: a first insert molding step of setting the plurality of terminals in a first molding die to mold the half-body portions with the one terminal carrier connected to the tail portions of the plurality of terminals and the other terminal carrier connected to the tail portions of the plurality of terminals facing each other; a first cutting step of cutting off the one terminal carrier from the tail portion of the terminal; a second insert molding step of setting the pair of half-body portions in a second molding die with the other terminal carrier connected thereto facing each other to mold the connector; and a second cutting step of cutting off the other terminal carrier from the tail portion of the terminal.

[0015] In another manufacturing method, further, in the second insert molding step, a reinforcing metal fitting is integrated with the connector.

[0016] In still another manufacturing method, further, the plurality of terminals are arranged in a staggered pattern with opposite orientations alternately.

[0017] In yet another manufacturing method, further, the pitch of the tail portions on each of both sides of each half-body portion is twice the pitch of the terminals, and the tail portion inside the width direction of the connector in one half-body portion and the tail portion inside the width direction of the connector in the other half-body portion are shifted from each other by a half pitch.

[0018] In yet another manufacturing method, further, the tail portions inside the width direction of the connector are both visible from the fitting surface.

Advantages of the Invention

[0019] According to the present disclosure, the connector can narrow the interval between the convex portions to which a plurality of terminals are attached, is easy to manufacture, can be miniaturized, and can improve reliability.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Embodiments for Carrying Out the Invention

[0021] Hereinafter, embodiments will be described in detail with reference to the drawings.

[0022] Fig. 1 is a perspective view of the first connector in the present embodiment, Fig. 2 is an exploded view of the first connector in the present embodiment, and Fig. 3 is a perspective view of the left half body portion of the first connector in the present embodiment.

[0023] In the figure, reference numeral 1 denotes a first connector as one of a pair of board-to-board connectors which is a connector in the present embodiment. The first connector 1 is a surface-mount type connector mounted on the surface of a first board which is a board (not shown) serving as a mounting member, and is fitted to a second connector 101 as a mating connector described later. Further, the second connector 101 is the other of the pair of board-to-board connectors, and is a surface-mount type connector mounted on the surface of a second board which is a board (not shown) serving as a mounting member.

[0024] Note that the first connector 1 and the second connector 101 in the present embodiment are preferably used to electrically connect the first substrate and the second substrate as substrates, but can also be used to electrically connect other members. The first substrate and the second substrate are, for example, printed circuit boards, flexible flat cables (FFCs), flexible circuit boards (FPCs), etc. used in electronic devices, etc., but can be any type of substrate.

[0025] Also, in the present embodiment, the expressions indicating directions such as up, down, left, right, front, and rear used to explain the configuration and operation of each part of the first connector 1 and the second connector 101 are not absolute but relative. They are appropriate when each part of the first connector 1 and the second connector 101 is in the posture shown in the figure, but should be interpreted as being changed according to the change in posture when the posture changes.

[0026] And the first connector 1 is configured by coupling a pair of left and right half-body parts, that is, a left half-body part 10A and a right half-body part 10B, by a first reinforcing metal fitting 51 as a reinforcing metal fitting and a covering part 16 integrally formed by a molding method called overmolding, outsert molding, or insert molding (hereinafter referred to as "insert molding"). Since the left half-body part 10A and the right half-body part 10B are the same members arranged to face each other left and right, they will be described as the half-body part 10 when described integrally. The left half-body part 10A and the right half-body part 10B each have a substantially gate-shaped shape in plan view (the shape projected onto the X - Y plane), and the space between the combined left half-body part 10A and right half-body part 10B is an elongated concave groove part 13 extending in the longitudinal direction (X-axis direction) of the first connector 1. The concave groove part 13 is a through hole opened on the upper and lower surfaces of the first connector 1.

[0027] In addition, in the present embodiment, for convenience of explanation, the first connector 1 is described as having a pair of half-body portions 10, that is, two half-body portions 10 arranged in parallel. However, three or more half-body portions 10 may be arranged in parallel. Further, the half-body portion 10 does not necessarily have a substantially gate-shaped configuration, and may have any shape as long as both ends in the longitudinal direction can be coupled by the first reinforcing metal fitting 51 and the covering portion 16.

[0028] The half-body portion 10 has a first housing 11 as a connector body integrally formed of an insulating material such as synthetic resin and having a substantially gate-shaped configuration in plan view. Each first housing 11 includes an elongated strip-shaped bottom plate portion 17 extending in the longitudinal direction (X-axis direction) of the first housing 11, and a first convex portion 12 as an elongated convex portion extending in the longitudinal direction of the first housing 11 integrally formed on the upper surface of the bottom plate portion 17. The first convex portion 12 is a member having a shape in which the cross-sectional shape is an upside-down U shape, and has a curved fitting surface 12a located on the upper side (Z-axis positive direction side), and outer side surfaces 12b and inner side surfaces 12c connected to both left and right sides of the fitting surface 12a. The outer side surface 12b and the inner side surface 12c are a pair of parallel and opposing planes extending in the longitudinal direction of the first housing 11. Since the dimension of the first convex portion 12 in the width direction (Y-axis direction) is shorter than the dimension of the bottom plate portion 17 in the width direction, at the lower end (Z-axis negative direction end) of the first convex portion 12, the bottom plate portion 17 protrudes outward in the width direction from the outer side surface 12b and the inner side surface 12c. Further, the lower surface of the bottom plate portion 17 is a mounting surface 17a of the first housing 11 facing the surface of the first substrate.

[0029] And a first terminal 61 as a terminal is disposed on each of the first convex portions 12. The first terminals 61 are arranged at a predetermined pitch and in a plurality (32 in the example shown in the figure) at a time. The first terminal 61 is a member integrally formed by punching, bending, etc. a conductive metal plate, and includes a main body portion 63 extending in the width direction of the first convex portion 12, a tail portion 62 connected to one end of the main body portion 63, a contact portion 65 extending in the vertical direction and bent approximately 90 degrees and connected to the other end of the main body portion 63, and an upper end portion 64 bent approximately 90 degrees and connected to the upper end of the contact portion 65.

[0030] The main body portion 63 is a portion embedded and held in the bottom plate portion 17. Further, the tail portion 62 extends outward in the width direction from the bottom plate portion 17 and is connected to a connection pad connected to a conductive trace of the first substrate by soldering or the like. The conductive trace is typically a signal line. Furthermore, the contact portion 65 is a portion that contacts a second terminal 161, which will be described later, provided in the second connector 101 when the first connector 1 and the second connector 101 are fitted, and desirably includes a contact recess 65a recessed from the surface.

[0031] The first terminal 61 is integrated with the first housing 11 by insert molding. That is, the first housing 11 is molded by filling an insulating material into a cavity of a mold in which the first terminal 61 is set in advance inside. Thereby, the first terminal 61 is integrally attached to the first housing 11 in a state where the lower surfaces of the main body portion 63 and the tail portion 62 are exposed on the mounting surface 17a of the bottom plate portion 17, and the surfaces of the contact portion 65 and the upper end portion 64 are exposed on the outer surface 12b or the inner surface 12c of the first convex portion 12 and the fitting surface 12a.

[0032] In addition, the first terminals 61 attached to the respective first convex portions 12 are oriented such that the postures of adjacent ones are opposite to each other with respect to the width direction of the first convex portion 12. In the example shown in the figure, among the first terminals 61 attached to the first convex portion 12 of the left half body portion 10A, the posture of the first terminal 61 located at the front end (the positive X-axis end) is oriented such that the tail portion 62 protrudes outward (toward the positive Y-axis side), while the posture of the first terminal 61 located second from the front end is oriented such that the tail portion 62 protrudes inward (toward the negative Y-axis side). In this way, the first terminals 61 are attached to the first convex portions 12 arranged so as to be alternately opposite in direction, so that the pitch of the tail portions 62 protruding on each of both sides of the first convex portion 12 is twice the pitch of the first terminals 61. Therefore, connection work such as soldering to the connection pads of the first substrate can be easily performed. Also, the pitch of the contact portions 65 exposed on the outer surface 12b of the first convex portion 12 and the pitch of the contact portions 65 exposed on the inner surface 12c are also twice the pitch of the first terminals 61.

[0033] Note that since the first terminal 61 is a member integrated with the first housing 11 by insert molding, it does not exist separated from the first housing 11. However, for convenience of explanation, note that in FIG. 2, it is drawn as if separated from the first housing 11.

[0034] And at both longitudinal ends of the first convex portion 12, first protruding ends 18 which are main body ends functioning as fitting guides are respectively provided. The first protruding end 18 is a member connected to both longitudinal ends of each first convex portion 12 and is formed to couple the left half body portion 10A and the right half body portion 10B. And the first protruding end 18 functions as an insertion convex portion to be inserted into a fitting concave portion 122 of a second protruding end 121, which will be described later, provided in the second connector 101 when the first connector 1 and the second connector 101 are in a fitted state.

[0035] In addition, the first protruding end 18 is composed of extension ends 14 and embedded portions 15 of the left and right half body portions 10, and the covering portion 16 and the first reinforcing metal fitting 51.

[0036] At both longitudinal ends of the first convex portion 12 of each half body portion 10, extension end portions 14 extending in the longitudinal direction are integrally connected respectively. At each extension end portion 14, embedding portions 15 further extending in the longitudinal direction of the first convex portion 12 are integrally connected respectively. Note that the extension end portions 14 extend obliquely inward, and the embedding portions 15 extend in the longitudinal direction from a position eccentric inward at the tip of the extension end portion 14 and are located inside the outer surface 12b of the first convex portion 12. That is, the extension end portion 14 in the left half body portion 10A extends obliquely rightward (negative Y-axis direction), and the embedding portion 15 extends in the longitudinal direction from a position eccentric rightward at the tip of the extension end portion 14. Also, the extension end portion 14 in the right half body portion 10B extends obliquely leftward (positive Y-axis direction), and the embedding portion 15 extends in the longitudinal direction from a position eccentric leftward at the tip of the extension end portion 14.

[0037] And at least a part of the extension end portions 14 and the whole of the embedding portions 15 in the left and right half body portions 10 are covered by a covering portion 16 formed of an insulating material such as synthetic resin. Specifically, the embedding portions 15 in the left and right half body portions 10 are brought close to each other and insert molding is performed in a state of being covered by the first reinforcing metal fitting 51, whereby the covering portion 16 is formed. Thereby, a first protruding end portion 18 in which the extension end portions 14 and the embedding portions 15 of the left and right half body portions 10, as well as the covering portion 16 and the first reinforcing metal fitting 51 are integrated is formed, and the left and right half body portions 10 are joined. By the way, the covering portion 16 does not necessarily need to cover the whole of the embedding portion 15, and it is sufficient to cover the embedding portion 15 to such an extent that it is sufficient to join the left and right half body portions 10, but in order to make the joining force the strongest, it is desirable to cover the whole of the embedding portion 15. Note that the covering portion 16 is a member formed to be integrated with other members by insert molding and does not exist alone in a state separated from other members, but for the convenience of explanation, it should be noted that in FIG. 2, it is drawn as existing alone.

[0038] As shown in FIG. 3, the extension end portion 14 has an upper surface 14a located on the upper side, outer surfaces 14b and inner surfaces 14c connected to both the left and right sides of the upper surface 14a, and a lower surface 14d located on the lower side. The lower surface 14d is located above the mounting surface 17a, and at least a part thereof is covered by the covering portion 16. The upper surface 14a is substantially flush with the fitting surface 12a of the first convex portion 12. Further, the inner surface 14c is a surface that is obliquely inclined inward with respect to the inner surface 12c of the first convex portion 12. And the outer surface 14b includes an inclined outer surface 14b1 that is obliquely inclined inward with respect to the outer surface 12b of the first convex portion 12 and a parallel outer surface 14b2 that is substantially parallel to the outer surface 12b of the first convex portion 12. The parallel outer surface 14b2 is substantially flush with the outer surface of the covering portion 16 and forms a part of the outer surface of the first protruding end portion 18.

[0039] Also, the embedding portion 15 is a member having a substantially rectangular parallelepiped overall shape, and has an upper surface 15a located on the upper side, outer surfaces 15b and inner surfaces 15c on both the left and right sides, a lower surface 15d located on the lower side, and end surfaces 15e at both longitudinal ends of the first connector 1. The upper surface 15a and the lower surface 15d are parallel planes to each other, and the distance between the upper surface 15a and the lower surface 15d, that is, the thickness of the embedding portion 15, is thinner than the thicknesses of the extension end portion 14 and the first convex portion 12. Note that the upper surface 15a is located below the fitting surface 12a, and the lower surface 15d is located above the mounting surface 17a. Also, the outer surface 15b is a plane substantially parallel to the outer surface 12b of the first convex portion 12 but is located inside the outer surface 12b, that is, closer to the center in the width direction of the first housing 11. And the inner surface 15c includes a parallel inner surface 15c1 that is a plane substantially parallel to the inner surface 12c of the first convex portion 12 and an inclined inner surface 15c2 that is substantially parallel to the inner surface 14c of the extension end portion 14. Further, the end surface 15e is a plane orthogonal to the longitudinal direction of the first connector 1. And the entire embedding portion 15 is covered by the covering portion 16, that is, is embedded in the covering portion 16.

[0040] Thus, since the extension end portion 14 extends obliquely inwardly and the embedding portion 15 is located inside the outer surface 12b of the first convex portion 12, the width of the first protruding end portion 18 (dimension in the Y-axis direction) can be made smaller than the width of the first connector 1 (distance between the outer surfaces 12b of the left and right first convex portions 12). When it is not necessary to make the width of the first protruding end portion 18 smaller than the width of the first connector 1, the extension end portion 14 does not necessarily have to be obliquely inclined inwardly and can be extended straight. Further, by directly extending the embedding portion 15 from both longitudinal ends of the first convex portion 12, the extension end portion 14 can be omitted. In that case, the longitudinal dimension of the first connector 1 can be shortened. Furthermore, when arranging three or more half body portions 10 in parallel, the extension end portion 14 can be extended in a Y-shape from both longitudinal ends of the first convex portion 12.

[0041] The first reinforcing fitting 51 is a member integrally formed by performing processes such as punching and bending on a metal plate, and includes a substantially rectangular upper plate 54 extending in the width direction of the first housing 11, substantially rectangular leg portions 55 connected to the left and right side edges of the upper plate 54 and extending downward, and an end wall outer surface covering portion 52 and an end wall inner surface covering portion 53 connected to the front and rear side edges of the upper plate 54 and extending downward. A tail portion 52a is connected to the lower end of the end wall outer surface covering portion 52. Also, the width of the end wall outer surface covering portion 52 is larger than the width of the end wall inner surface covering portion 53.

[0042] As described above, the first reinforcing fitting 51 is integrated with the covering portion 16 and constitutes the first protruding end portion 18. The upper plate 54 is embedded in the upper surface of the first protruding end portion 18, and the upper surface of the upper plate 54 is flush with the upper surface of the covering portion 16 and constitutes the majority of the upper surface of the first protruding end portion 18. Further, the left and right leg portions 55 are embedded in the left and right outer side surfaces of the first protruding end portion 18, and the outer side surfaces of the leg portions 55 are flush with the outer side surfaces of the covering portion 16 and constitute the majority of the outer side surfaces of the first protruding end portion 18. Furthermore, the end wall outer surface covering portion 52 and the end wall inner surface covering portion 53 are embedded in the end wall outer surface and the end wall inner surface of the first protruding end portion 18, and the outer surfaces of the end wall outer surface covering portion 52 and the end wall inner surface covering portion 53 are flush with the end wall outer surface and the end wall inner surface of the covering portion 16 and constitute the majority of the end wall outer surface and the end wall inner surface of the first protruding end portion 18.

[0043] Note that the tail portion 52a is bent and connected to the lower end of the end wall outer surface covering portion 52 at about 90 degrees, extends outward in the longitudinal direction of the first housing 11, and is connected to a connection pad connected to the conductive trace of the first substrate by soldering or the like. The conductive trace is typically a power line. If necessary, the lower end of the leg portion 55 can be made to approach or contact the surface of the first substrate. In this case, by connecting the lower end of the leg portion 55 to the connection pad of the first substrate by soldering or the like, the connection strength of the first reinforcing fitting 51 to the first substrate is improved.

[0044] Next, a method for manufacturing the first connector 1 having the above configuration will be described.

[0045] FIG. 4 is a perspective view showing one step of manufacturing the left half part of the first connector in the present embodiment, FIG. 5 is a front view showing the first step of manufacturing the first protruding end of the first connector in the present embodiment, FIG. 6 is a front view showing the second step of manufacturing the first protruding end of the first connector in the present embodiment, FIG. 7 is an enlarged view showing the main part of the first and second steps of manufacturing the first protruding end of the first connector in the present embodiment, and FIG. 8 is a cross-sectional view of the first and second steps of manufacturing the first protruding end of the first connector in the present embodiment. In FIGS. 5 and 6, (a) is a top view and (b) is a bottom view. In FIG. 7, (a) is an enlarged view of part E in FIG. 5, and (b) is an enlarged view of part F in FIG. 6. In FIG. 8, (a) is a cross-sectional view taken along line A-A in FIG. 5, (b) is a cross-sectional view taken along line B-B in FIG. 5, (c) is a cross-sectional view taken along line C-C in FIG. 6, and (d) is a cross-sectional view taken along line D-D in FIG. 6.

[0046] The first terminal 61 is a member made of a metal plate bent in the plate thickness direction, and is manufactured by performing processes such as punching and bending on the metal plate. As shown in FIG. 4, a plurality of them are supplied in a state of being connected to a flat terminal carrier 68 as a carrier. Each first terminal 61 has its tail portion 62 connected to the terminal carrier 68 via an elongated connecting arm 68a, and the tail portion 62 is separated from the connecting arm 68a at the cutting portion 68b, thereby becoming a member as shown in FIG. 2.

[0047] And in the process of being integrated with the first housing 11 by insert molding, as shown in FIG. 4, a plurality of the first terminals 61 are supplied in a state of being connected to a terminal carrier 68. FIG. 4 shows an example of manufacturing the left half body 10A. In this case, the first terminals 61 whose tail portions 62 are directed to protrude outward (in the positive Y-axis direction) are connected to the terminal carrier 68 on the right side in FIG. 4, and the first terminals 61 whose tail portions 62 are directed to protrude inward (in the negative Y-axis direction) are connected to the terminal carrier 68 on the left side in FIG. 4 and are set in a first-stage molding die (not shown). By holding and operating the terminal carrier 68 to which a plurality of the first terminals 61 are connected, the plurality of the first terminals 61 can be simultaneously positioned and set in the molding die.

[0048] Subsequently, the cavity of the molding die is filled with an insulating material such as synthetic resin in a molten state. That is, the first insert molding is performed. The insulating material may be any type of material, but here it is assumed to be LCP (liquid crystal polymer). In the first insert molding, it is desirable to select the material with emphasis on fluidity. Then, when the filled insulating material is cooled and solidified to form the first housing 11, the molding die is opened, and the left half body 10A with the terminal carrier 68 still connected to the first terminal 61 as shown in FIG. 4 is taken out. Similarly, the right half body 10B with the terminal carrier 68 still connected to the first terminal 61 is also manufactured.

[0049] Subsequently, only the terminal carrier 68 connected to the tail portion 62 protruding inward from the left half body portion 10A with the terminal carrier 68 connected to the first terminal 61 as shown in FIG. 4 (the left terminal carrier 68 in FIG. 4) is cut off, and the terminal carrier 68 connected to the tail portion 62 protruding outward (the right terminal carrier 68 in FIG. 4) is left as it is. Similarly, only the terminal carrier 68 connected to the tail portion 62 protruding inward is cut off from the right half body portion 10B with the terminal carrier 68 connected to the first terminal 61, and the terminal carrier 68 connected to the tail portion 62 protruding outward is left as it is.

[0050] Subsequently, as shown in FIG. 5, with the left half body portion 10A and the right half body portion 10B in which the terminal carrier 68 is connected only to the tail portion 62 protruding outward facing each other, they are set in a second molding die (not shown). Specifically, the inner sides of the left and right half body portions 10 face each other, the first housings 11 of the left and right half body portions 10 are parallel to each other, the mounting surfaces 17a of the first housings 11 of the left and right half body portions 10 and the end faces 15e at both longitudinal ends are flush with each other, respectively, and the embedded portions 15 of the left and right half body portions 10 are close to each other but not in contact. As shown in FIG. 7(a), the left and right half body portions 10 facing each other are positioned so that the distance between the parallel inner surfaces 15c1 of the embedded portions 15 facing each other is a predetermined distance L2, and then set in the second molding die.

[0051] Furthermore, the first reinforcing fitting 51 is set in the secondary molding die so as to cover at least a part of the extended end portions 14 of the left and right half body portions 10 and the entire embedded portion 15. In this case, the first reinforcing fitting 51 is set in a state where the tip of its tail portion 52a is connected to the fitting carrier 58 serving as a carrier. Note that, at the cutting portion 58b, when the tail portion 52a is separated from the fitting carrier 58, the first reinforcing fitting 51 becomes a member as shown in FIG. 2. Specifically, as shown in FIGS. 7(a), 8(a) and (b), etc., a gap is formed between the upper plate 54 of the first reinforcing fitting 51 and the upper surface 15a of the embedded portion 15, a gap is formed between the leg portion 55 of the first reinforcing fitting 51 and the outer side surface 15b of the embedded portion 15, a gap is formed between the end wall outer surface covering portion 52 of the first reinforcing fitting 51 and the end surface 15e of the embedded portion 15, a gap is formed between the end wall inner surface covering portion 53 of the first reinforcing fitting 51 and the inclined inner side surface 15c2 of the embedded portion 15, and the lower end of the leg portion 55 is set to be below the lower surface 15d of the embedded portion 15 and at substantially the same height as the mounting surface 17a.

[0052] Subsequently, the cavity of the molding die is filled with a molten insulating material such as synthetic resin. That is, secondary insert molding is performed. Note that the insulating material may be any type of material, but here, similar to the first insert molding, LCP is used with emphasis on fluidity. In the secondary insert molding, the insulating material can also be selected with emphasis on strength and melt bonding properties with the insulating material of the first insert molding. Then, when the filled insulating material is cooled and solidified to form the coating portion 16, the molding die is opened, and the left and right half body portions 10 whose longitudinal ends are joined by the first protruding end portions 18 as shown in FIG. 6 are taken out.

[0053] In this case, the left and right half body parts 10 are integrated with the covering part 16 in a state where at least a part of the extension end part 14 and the entire embedding part 15 are covered by the covering part 16, and the first reinforcing fitting 51 is integrated with the covering part 16 so as to cover at least a part of the outer surface of the covering part 16. Specifically, as shown in FIGS. 7(b), 8(c), and 8(d), etc., between the upper plate 54, the leg part 55, the end wall outer surface covering part 52, and the end wall inner surface covering part 53 of the first reinforcing fitting 51 and the upper surface 15a, the outer side surface 15b, the end surface 15e, and the inclined inner side surface 15c2 of the embedding part 15, the voids are filled with the insulating material of the covering part 16. Also, the voids between the parallel inner side surfaces 15c1 of the embedding part 15 facing each other are filled with the insulating material of the covering part 16. Further, the lower part of the lower surface 15d of the embedding part 15 is filled with the insulating material of the covering part 16, and the lower surface of the covering part 16 is substantially flush with the mounting surface 17a. Further, the parallel outer side surface 14b2 of the extension end part 14 is substantially flush with the outer side surface of the covering part 16 and becomes a part of the outer side surface of the first protruding end part 18.

[0054] As shown in FIG. 7(a), since there is a void between the end wall inner surface covering part 53 of the first reinforcing fitting 51 and the inclined inner side surface 15c2 of the embedding part 15 and the inclined inner side surface 15c2 is inclined, the molten insulating material filled in the cavity of the molding die in the second insert molding smoothly flows between the end wall inner surface covering part 53 and the left and right inclined inner side surfaces 15c2 and between the parallel inner side surfaces 15c1 of the embedding part 15 facing each other, and the cavity is filled without any gaps. Further, since the space between the end wall inner surface covering part 53 and the left and right inclined inner side surfaces 15c2 becomes larger, the filling amount of the insulating material increases.

[0055] Also, as shown in FIG. 7(a), the dimension of the first connector 1 in the width direction of the end wall inner surface covering portion 53 of the first reinforcing metal fitting 51 facing the gap between the parallel inner surfaces 15c1 of the embedded portion 15, that is, the width L1, is desirably set to be larger than the distance L2 which is the interval between the parallel inner surfaces 15c1. That is, it is desirably set such that L1 > L2. Note that the width of the end wall outer surface covering portion 52 is larger than the width of the end wall inner surface covering portion 53. Thereby, the boundary between the parallel inner surface 15c1 of the embedded portion 15 formed by the first insert molding and the covering portion 16 formed by the second insert molding is covered by the end wall outer surface covering portion 52 and the end wall inner surface covering portion 53 when viewed from the front-rear direction (X-axis direction), so it is difficult to separate, and thus the strength of the first protruding end portion 18 is improved.

[0056] Furthermore, as shown in FIG. 7(a), the dimension of the first connector 1 in the longitudinal direction of the leg portion 55 of the first reinforcing metal fitting 51, that is, the length L3, is desirably set to be larger than the length L4 of the outer surface 15b of the embedded portion 15. That is, it is desirably set such that L3 > L4. And, the end closer to the longitudinal center of the first connector 1 on the outer surface 15b is desirably positioned closer to both ends in the longitudinal direction of the first connector 1 than the end from the longitudinal center of the first connector 1 in the leg portion 55. Thereby, the boundary between the outer surface 15b of the embedded portion 15 formed by the first insert molding and the covering portion 16 formed by the second insert molding is covered by the leg portion 55 when viewed from the width direction (Y-axis direction), so it is difficult to separate, and thus the strength of the first protruding end portion 18 is improved.

[0057] Furthermore, the embedded portion 15 overlaps at least a part of any one of the upper plate 54, the end wall outer surface covering portion 52, the end wall inner surface covering portion 53, and the leg portion 55 of the first reinforcing metal fitting 51 when viewed from the up-down direction, the front-rear direction (longitudinal direction), and the left-right direction (width direction), that is, it is arranged to overlap. Therefore, the strength of the first protruding end portion 18 is improved.

[0058] Finally, the remaining terminal carrier 68 and bracket carrier 58 are removed from the left and right half bodies 10 whose longitudinal ends are joined by the first protruding end portions 18 as shown in FIG. 6. Thereby, the first connector 1 as shown in FIG. 1 can be obtained.

[0059] Next, the configuration of the second connector 101 that forms a connector pair together with the first connector 1 and the operation of fitting the first connector 1 and the second connector 101 will be described.

[0060] FIG. 9 is a perspective view seen from the first connector side showing the state immediately before fitting between the first connector and the second connector in the present embodiment.

[0061] The second connector 101 as the mating connector in the present embodiment has a second housing 111 as a mating connector body integrally formed of an insulating material such as synthetic resin. As shown in the figure, the second housing 111 has a substantially rectangular thick plate shape that is substantially a rectangular parallelepiped. And on the side where the first connector 1 is inserted into the second housing 111, that is, on the fitting surface 111a side (Z-axis negative direction side), there is a substantially rectangular recess 112 surrounded by the periphery, and a recess 112 that fits with the first housing 11 is formed. And in the recess 112, a second convex portion 113 as an island portion that fits with the concave groove portion 13 is integrally formed with the second housing 111, and side wall portions 114 that extend in parallel with the second convex portion 113 are integrally formed with the second housing 111 on both sides of the second convex portion 113.

[0062] The second convex portion 113 and the side wall portion 114 protrude upward (Z-axis negative direction) from the bottom surface of the recess 112 and extend in the longitudinal direction of the second connector 101. Thereby, on both sides of the second convex portion 113, as a part of the recess 112, elongated recesses 112a that extend in the longitudinal direction (X-axis direction) of the second connector 101 are formed.

[0063] On both side surfaces of the second convex portion 113 and on the inner side surface of the side wall portion 114, in order to accommodate the second terminal 161, a concave groove-shaped second terminal accommodation groove cavity 115a is formed. Further, in the second convex portion 113 and the side wall portion 114, in order to accommodate the second terminal 161, a hole-shaped second terminal accommodation hole cavity 115b is formed. And since the second terminal accommodation groove cavity 115a and the second terminal accommodation hole cavity 115b are connected and integrated with each other at the bottom surface of the concave groove portion 112a, when integrally explaining the second terminal accommodation groove cavity 115a and the second terminal accommodation hole cavity 115b, it is described as the second terminal accommodation cavity 115. The second terminal accommodation cavity 115 is arranged at a pitch corresponding to the first terminal 61 and in a corresponding number.

[0064] The second terminal 161 is a member integrally formed by performing processing such as punching on a conductive metal plate, and includes a main body portion (not shown), a tail portion 162 connected to the lower end of the main body portion, a connection portion (not shown) extending in the width direction (Y-axis direction) of the second connector 101 from the vicinity of the lower end of the main body portion, and a contact portion 165 extending upward (negative Z-axis direction) from the connection portion. It is desirable that a contact convex portion 165a protruding toward the main body portion is formed in the vicinity of the tip of the contact portion 165.

[0065] The main body portion is a portion that is press-fitted and held in the second terminal accommodation hole cavity 115b. The tail portion 162 is bent and connected to the lower end of the main body portion, extends in the width direction of the second housing 111, and is connected to a connection pad connected to a conductive trace of the second substrate by soldering or the like. The conductive trace is typically a signal line. Further, the contact portion 165 is a portion that contacts the first terminal 61 provided in the first connector 1 when the first connector 1 and the second connector 101 are fitted, and desirably, the contact convex portion 165a engages with a contact concave portion 65a formed in the contact portion 65 of the first terminal 61.

[0066] The second terminal 161 is inserted into the second terminal accommodation cavity 115 from below the second housing 111 and attached to the second housing 111. As a result, the main body portion of the second terminal 161 is press-fitted and held in the second terminal accommodation hole cavity 115b, the contact portion 165 is accommodated in the second terminal accommodation groove cavity 115a and exposed to the concave groove portion 112a, and the lower surface of the tail portion 162 is exposed to the mounting surface 111b which is the lower surface of the second housing 111.

[0067] Also, the second terminals 161 attached to the respective concave groove portions 112a are oriented such that the postures of adjacent ones are opposite to each other with respect to the width direction of the concave groove portion 112a, similar to the first terminals 61. In the example shown in FIG. 9, among the second terminals 161 attached to the concave groove portion 112a on the positive Y-axis side, the posture of the second terminal 161 located at the front end (positive X-axis end) is oriented such that the tail portion 162 protrudes toward the negative Y-axis direction, while the posture of the second terminal 161 located second from the front end is oriented such that the tail portion 162 protrudes toward the positive Y-axis direction. Thus, since the second terminals 161 are arranged in opposite directions alternately and attached to the concave groove portions 112a, the pitch of the tail portions 162 exposed to the mounting surface 111b on both sides of the concave groove portion 112a is twice the pitch of the second terminals 161. Therefore, the connection work such as soldering to the connection pads of the second substrate can be easily performed. Also, the pitch of the contact portions 165 exposed to the concave groove portion 112a is also twice the pitch of the second terminals 161.

[0068] Also, at both longitudinal ends of the second housing 111, second protruding end portions 121 as fitting guide portions are respectively provided. In each second protruding end portion 121, a fitting concave portion 122 is formed as a part of the concave portion 112. The fitting concave portion 122 is a substantially rectangular concave portion and is connected to both longitudinal ends of each concave groove portion 112a. And, in the fitting concave portion 122, when the first connector 1 and the second connector 101 are in a fitted state, the first protruding end portion 18 provided in the first connector 1 is inserted. Further, a second reinforcing metal fitting 151 as a mating reinforcing metal fitting is attached to the second protruding end portion 121. Note that the second reinforcing metal fitting 151 is integrated with the second housing 111 by insert molding.

[0069] The second reinforcing metal fitting 151 is a member integrally formed by performing processes such as punching and bending on a metal plate, and includes a second main body portion 152 extending in the width direction of the second housing 111, side covering portions 153 connected to both left and right ends of the second main body portion 152, contact side portions 154 disposed on the left and right inner walls of the fitting concave portion 122, and a tail portion 156 connected to the lower end of the second main body portion 152. The tail portion 156 extends toward the outside in the longitudinal direction of the second connector 101 and is connected and fixed to a connection pad (not shown) exposed on the surface of the second substrate by soldering or the like. Note that it is desirable that the connection pad is connected to, for example, a conductive trace which is a power line.

[0070] Next, the operation of fitting the first connector 1 and the second connector 101 having the above configuration will be described.

[0071] Here, the first connector 1 is surface-mounted on the first substrate by connecting the tail portion 62 of the first terminal 61 to a connection pad connected to a conductive trace of the first substrate (not shown) by soldering or the like, and connecting the tail portion 52a of the first reinforcing fitting 51 to a connection pad connected to the conductive trace of the first substrate by soldering or the like. It should be noted that the conductive trace connected to the connection pad to which the tail portion 62 of the first terminal 61 is connected is a signal line, and the conductive trace connected to the connection pad to which the tail portion 52a of the first reinforcing fitting 51 is connected is a power line.

[0072] Similarly, the second connector 101 is surface-mounted on the second substrate by connecting the tail portion 162 of the second terminal 161 to a connection pad connected to a conductive trace of the second substrate (not shown) by soldering or the like, and connecting the tail portion 156 of the second reinforcing fitting 151 to a connection pad connected to the conductive trace of the second substrate by soldering or the like. It should be noted that the conductive trace connected to the connection pad to which the tail portion 162 of the second terminal 161 is connected is a signal line, and the conductive trace connected to the connection pad to which the tail portion 156 of the second reinforcing fitting 151 is connected is a power line.

[0073] First, the operator places the mating surface 12a of the first convex portion 12 as the mating surface of the first housing 11 of the first connector 1 and the mating surface 111a of the second housing 111 of the second connector 101 in a facing state. When the position of the first convex portion 12 of the first connector 1 coincides with the position of the corresponding concave groove portion 112a of the second connector 101, and the position of the first protruding end portion 18 of the first connector 1 coincides with the position of the corresponding mating concave portion 122 of the second connector 101, the alignment of the first connector 1 and the second connector 101 is completed.

[0074] In this state, when the first connector 1 and / or the second connector 101 is moved in the direction approaching the mating side, that is, in the mating direction, the first convex portion 12 and the first protruding end portion 18 of the first connector 1 are inserted into the concave groove portion 112a and the mating concave portion 122 of the second connector 101. Thereby, the mating of the first connector 1 and the second connector 101 is completed. And the first terminal 61 and the second terminal 161 are in a conductive state.

[0075] Next, a modified example of the first connector 1 will be described.

[0076] FIG. 10 is an exploded view of the left half body portion of a modified example of the first connector in the present embodiment.

[0077] In the modified example shown in the figure, the first terminal 61 does not have a main body portion 63, and has a contact portion 65 extending in the vertical direction, a tail portion 62 connected to the lower end of the contact portion 65 by being bent approximately 90 degrees, and an upper end portion 64 connected to the upper end of the contact portion 65 by being bent approximately 90 degrees. Note that an embedding portion 64a extending downward by being bent approximately 90 degrees is connected to the tip of the upper end portion 64. The embedding portion 64a is a portion embedded in the first convex portion 12 downward from the mating surface 12a.

[0078] In the first terminal 61 shown in FIG. 2 and the like, the tail portion 62 extends in a direction opposite to the direction facing the contact portion 65, but in the first terminal 61 of the modified example shown in FIG. 10, the tail portion 62 extends in the same direction as the direction facing the contact portion 65. Therefore, it becomes easy to hold the terminal carrier 68 connected to the tip of the tail portion 62 via the elongated connection arm 68a and set the plurality of first terminals 61 from both the left and right sides in the first molding die so as to face in opposite directions.

[0079] Note that regarding the configuration, operation, and effects of other points of the first terminal 61 of the modified example shown in FIG. 10, they are the same as those of the first terminal 61 shown in FIG. 2 and the like, and thus the description thereof is omitted.

[0080] Thus, in this embodiment, the first connector 1 includes a half body portion 10 each including a first housing 11 and a plurality of first terminals 61 attached to the first housing 11, a first protruding end portion 18 formed at both ends of the first housing 11 where the first housings 11 of the respective half body portions 10 are butted against each other, and a first reinforcing metal fitting 51 attached to the first protruding end portion 18. Each of the first housings 11 is a member integrated with the first terminal 61 by first insert molding, extends in its longitudinal direction, and includes a first convex portion 12 that holds the first terminal 61, extension end portions 14 connected to both longitudinal ends of the first convex portion 12, and an embedded portion 15 extending from the extension end portions 14. The first protruding end portion 18 includes a covering portion 16 that covers at least a part of the extension end portions 14 and the entire embedded portion 15 of each first housing 11. The covering portion 16 is a member integrated with the extension end portions 14, the embedded portion 15, and the first reinforcing metal fitting 51 by second insert molding.

[0081] Thereby, the interval between the first convex portions 12 of the first housing 11 to which the plurality of first terminals 61 are attached can be narrowed, and the first connector 1 can be miniaturized. Also, the manufacturing of the first connector 1 becomes easy, and the reliability of the first connector 1 is improved.

[0082] Further, the first reinforcing metal fitting 51 includes an upper plate 54 extending in the width direction of the first housing 11, a pair of left and right leg portions 55 connected to the left and right side edges of the upper plate 54 and extending downward, and an end wall outer surface covering portion 52 and an end wall inner surface covering portion 53 connected to the front and rear side edges of the upper plate 54 and extending downward. The embedded portion 15 is arranged so that at least a part thereof overlaps with the upper plate 54, the leg portions 55, the end wall outer surface covering portion 52, and the end wall inner surface covering portion 53 when viewed from the vertical, front-rear, and left-right directions. Thereby, the embedded portion 15 of the left half body portion 10A and the embedded portion 15 of the right half body portion 10B are firmly joined by the covering portion 16 integrated with the first reinforcing metal fitting 51, the first protruding end portion 18 is reliably formed, and the left half body portion 10A and the right half body portion 10B are reliably joined.

[0083] Furthermore, the embedded portion 15 of each first housing 11 extends in the longitudinal direction of the first housing 11, includes parallel inner surfaces 15c1 facing the embedded portions 15 of the other first housings 11, and the distance L2 between the parallel inner surfaces 15c1 facing each other is smaller than the width L1 of the end wall inner surface covering portion 53 of the first reinforcing metal fitting 51 arranged so as to face the gap between the parallel inner surfaces 15c1 facing each other. Thereby, the boundary between the parallel inner surface 15c1 of the embedded portion 15 formed by the first insert molding and the covering portion 16 formed by the second insert molding overlaps the end wall inner surface covering portion 53 when viewed from the front-rear direction, making it difficult to separate and improving the strength of the first protruding end portion 18.

[0084] Furthermore, the end wall inner surface covering portion 53 faces the inclined inner surface 15c2 of the embedded portion 15 which is connected to each of the parallel inner surfaces 15c1 facing each other and is inclined with respect to the longitudinal direction of the first housing 11, and is arranged such that there is a gap between the end wall inner surface covering portion 53 and the inclined inner surface 15c2.

[0085] Furthermore, the embedded portion 15 of each first housing 11 extends in the longitudinal direction of the first housing 11, includes an outer surface 15b facing the leg portion 55 of the first reinforcing metal fitting 51, and the length L4 of the outer surface 15b is smaller than the length L3 of the leg portion 55. Thereby, the boundary between the outer surface 15b of the embedded portion 15 formed by the first insert molding and the covering portion 16 formed by the second insert molding is covered by the leg portion 55 when viewed from the left-right direction, making it difficult to separate and improving the strength of the first protruding end portion 18.

[0086] Furthermore, the extended end portion 14 of each first housing 11 inclines toward the inner side in the width direction of the first connector 1 and extends from both longitudinal ends of the first convex portion 12, and the width of the first protruding end portion 18 is smaller than the width of the first connector 1. In this way, since the width of the first protruding end portion 18 can be made smaller than the width of the first connector 1, when the first connector 1 and the second connector 101 are fitted, even if contact side portions 154 are provided on the left and right inner walls of the fitting concave portion 122 of the second housing 111 into which the first protruding end portion 18 is inserted and the width inside the fitting concave portion 122 is substantially reduced, it is possible to make corresponding arrangements.

[0087] It should be noted that the disclosure in this specification describes the features of preferred and exemplary embodiments. Various other embodiments, modifications, and variations within the scope and spirit of the appended claims will naturally occur to those skilled in the art upon reviewing the disclosure in this specification. For example, the staggered arrangement of the terminals may not be regular. Also, it is not necessary for the arrangement of the terminals to be the same in the left and right half-body portions. Furthermore, the left and right half-body portions may not be line-symmetric.

Industrial Applicability

[0088] This disclosure can be applied to connectors.

Explanation of Reference Numerals

[0089] 1 First connector 10A Left half-body portion 10B Right half-body portion 11 First housing 12 First convex portion 12a, 111a Fitting surface 12b, 14b, 15b Outer surface 12c, 14c, 15c Inner surface 13, 112a Groove portion 14 Extended end portion 14a, 15a Upper surface 14b1 Inclined outer surface 14b2 Parallel outer surface 14d, 15d Lower surface 15 Embedded portion 15c1 Parallel inner surface 15c2 inclined inner surface 15e end face 16 covering portion 17 bottom plate portion 17a, 111b mounting surface 18 first protruding end portion 51 first reinforcing fitting 52 outer surface covering portion of end wall 52a, 62, 156, 162 tail portion 53 inner surface covering portion of end wall 54 upper plate 55 leg portion 58 fitting carrier 58b, 68b cutting portion 61 first terminal 63 body portion 64 upper end portion 64a embedding portion 65, 165 contact portion 65a contact recess 68 terminal carrier 68a connecting arm 101 second connector 111 second housing 112 recess 113 second protruding portion 114 side wall portion 115 second terminal accommodating cavity 115a second terminal accommodating groove cavity 115b second terminal accommodating hole cavity 121 second protruding end portion 122 fitting recess 151 second reinforcing fitting 152 second body portion 153 side covering portion 154 contact side portion 161 second terminal 165a contact convex portion 811 housing 812 protruding portion 861 terminal

Claims

1. A method for manufacturing a connector comprising (a) a pair of half-body parts and a plurality of terminals attached to the pair of half-body parts, wherein (b) a first insert molding step is performed in which one terminal carrier connected to the tail portions of the plurality of terminals and the other terminal carrier connected to the tail portions of the plurality of terminals are opposed to each other, and the plurality of terminals are set in a first molding die to mold the half-body parts; wherein (c) a first cutting step is performed to cut off one terminal carrier from the tail portions of the terminals; wherein (d) a second insert molding step is performed in which the pair of half-body parts connected to the other terminal carrier are opposed to each other and set in a second molding die to mold the connector; and wherein (e) a second cutting step is performed to cut off the other terminal carrier from the tail portions of the terminals.

2. The manufacturing method according to claim 1, wherein a reinforcing metal fitting is integrated with the connector in the second insert molding step.

3. The manufacturing method according to claim 1 or 2, wherein the plurality of terminals are arranged in a staggered pattern in which they alternate in opposite directions.

4. The pitch of the tail portions on each side of each half-body part is twice the pitch of the terminals, and the tail portions on the inner side in the width direction of the connector in one half-body part and the tail portions on the inner side in the width direction of the connector in the other half-body part are offset from each other by a half pitch. The manufacturing method according to any one of claims 1 to 3.

5. The manufacturing method according to any one of claims 1 to 4, wherein the tail portions on the inner side in the width direction of the connector are all visible from the fitting surface.

Images