Connector and method of manufacturing the same

Abstract

To provide a new manufacturing method and a new structure of a connector in which a contact array and a housing holding the contact array are integrally formed by insert molding.SOLUTION: In the housing step, the plug contact assembly 70 is housed in the injection mold 73 such that both ends of the plug contact assembly 70 are supported in the injection mold 73 by using the two support portions 72. In the insert molding step, the plug housing 6 is molded integrally with the plug contact assembly 70 by insert molding so that the coupling beam 71 of the plug contact assembly 70 is located between the two width side surfaces 50 and away from the two width side surfaces 50 in the width direction. In the separation step, at least a part of the plug contact assembly 70 is removed so that the plurality of plug contacts 14 are separated.SELECTED DRAWING: Figure 13

Description

[Technical Field]

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

[0002] In Patent Document 1, as shown in Figure 39 of the present application, when a housing 1001 that holds a plurality of contacts 1000 is molded by insert molding, the plurality of contacts 1000 are held by a carrier 1002. After insert molding, the carrier 1002 is cut off. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-181803 Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present disclosure is to provide a new manufacturing method and a new structure for a connector in which a contact array and a housing that holds the contact array are integrally formed by insert molding. [Means for solving the problem]

[0005] A method for manufacturing a connector in which at least one contact array including a plurality of contacts and a housing for holding the at least one contact array are integrally formed by insert molding, and an outer peripheral surface of the housing includes two width side surfaces facing opposite to each other in a width direction perpendicular to a pitch direction of the at least one contact array, the method comprising: an assembly manufacturing step of manufacturing at least one contact assembly having the at least one contact array, a connecting beam for connecting the plurality of contacts of the at least one contact array to each other, and two support parts sandwiching the connecting beam in the pitch direction; The manufacturing method includes: a step of placing the at least one contact assembly in an injection molding mold so that both ends of the at least one contact assembly are supported within the injection molding mold using two support parts; an insert molding step of molding the housing integrally with the at least one contact assembly by insert molding so that the connecting beam of the at least one contact assembly is between the two width side surfaces and separated from the two width side surfaces in the width direction; and a separation step of removing at least a part of the at least one contact assembly so that the multiple contacts are separated. In the accommodation step, the at least one contact assembly may be supported at both ends within the injection molding mold by sandwiching the two support parts between the fixed side mold plate and the movable side mold plate in the direction of advancement and retreat of the movable side mold plate relative to the fixed side mold plate of the injection molding mold. In the insert molding step, the housing may be molded so that the two support portions of the at least one contact assembly are exposed outside the outer circumferential surface of the housing. The method may further include, after the insert molding step, a support part removing step of removing the two support parts of the at least one contact assembly. In the insert molding step, the housing may be molded so that the housing has at least one through hole that penetrates the housing in the vertical direction so that at least a portion of the at least one contact assembly is exposed in the vertical direction. The at least one contact assembly may include a plurality of contact assemblies, and in the assembly manufacturing step, the plurality of contact assemblies may be manufactured as separate parts from one another. Each contact may include a soldering portion, a buried portion, and a contact portion in this order, and each contact may protrude from the connecting beam in the order of the soldering portion, the buried portion, and the contact portion. Each contact may include a soldering portion, a buried portion, and a contact portion in this order, and each contact may protrude from the connecting beam in the order of the contact portion, the buried portion, and the soldering portion. In the insert molding step, the housing may be molded so that the contact portion is elastically displaceable relative to the housing. In the insert molding step, the housing may be molded so that the contact portion cannot be elastically displaced relative to the housing. A connector is provided which is formed integrally by insert molding of at least one contact array including a plurality of contacts and a housing which holds the at least one contact array, and the outer surface of the housing includes two pitch side surfaces which face opposite each other in the pitch direction of the at least one contact array, the housing having at least one through hole which penetrates the housing in the vertical direction and at least one pitch extension groove which extends from one of the two pitch side surfaces to the other, and the plurality of contacts of the at least one contact array protruding into the at least one through hole or having a cut surface which is flush with the inner surface of the at least one through hole. The at least one pitch extension groove may be formed to intersect with the at least one through hole. The at least one pitch extension groove may contain a metal piece of the same material as the plurality of contacts. The at least one through hole corresponding to the at least one contact array may include an extended through hole extending in the pitch direction, and the multiple contacts of the at least one contact array may protrude into the extended through hole or have a cut surface that is flush with the inner surface of the extended through hole. The at least one contact array includes two adjacent contact arrays in a width direction perpendicular to the pitch direction, and the extended through hole is formed between the two contact arrays, and the multiple contacts of one of the two contact arrays and the multiple contacts of the other of the two contact arrays may protrude into the extended through hole or have a cut surface that is flush with the inner surface of the extended through hole. The plurality of contacts in one of the two contact arrays and the plurality of contacts in the other of the two contact arrays may be arranged in a staggered manner. The at least one contact array may have a first contact array and a second contact array adjacent to each other in a width direction perpendicular to the pitch direction, the at least one through hole may include a first extended through hole and a second extended through hole extending in the pitch direction, the first contact array, the first extended through hole, the second contact array, and the second extended through hole may be arranged in the width direction in this order, the multiple contacts of the first contact array may protrude into the first extended through hole or have a cut surface that is flush with the inner surface of the first extended through hole, and the multiple contacts of the second contact array may protrude into the second extended through hole or have a cut surface that is flush with the inner surface of the second extended through hole. The at least one through hole corresponding to the at least one contact array may include a plurality of through holes arranged in the pitch direction, and the plurality of contacts of the at least one contact array may protrude into the interior of one of the plurality of through holes or have a cut surface that is flush with the inner surface of one of the plurality of through holes. The at least one contact array includes two contact arrays adjacent to each other in a width direction perpendicular to the pitch direction, and the plurality of through holes are formed between the two contact arrays, and the plurality of contacts of one of the two contact arrays and the plurality of contacts of the other of the two contact arrays may protrude into one of the plurality of through holes or have a cut surface that is flush with the inner surface of one of the plurality of through holes. Each contact may include a soldering portion, a buried portion, and a contact portion in this order, and the contact portion may be elastically displaceable relative to the housing. The soldering portion of each contact may protrude into the at least one through-hole or have a cut surface that is flush with the inner circumferential surface of the at least one through-hole. The contact portion of each contact may protrude into the at least one through hole or have a cut surface that is flush with an inner peripheral surface of the at least one through hole. Each contact may include a soldering portion, a buried portion, and a contact portion, in that order, and the contact portion may be non-elastically displaceable relative to the housing. The housing may have at least one width extension groove formed therein extending from the at least one pitch extension groove in a width direction perpendicular to the pitch direction, and the at least one width extension groove may accommodate a metal piece made of the same material as the plurality of contacts. [Effects of the Invention]

[0006] According to the present disclosure, a new manufacturing method and a new structure of a connector are provided in which a contact array and a housing that holds the contact array are integrally formed by insert molding. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a perspective view of a connector assembly (first embodiment); [Figure 2] 1 is a perspective view of the connector assembly as seen from another angle (first embodiment); [Figure 3] 1 is a perspective view of a plug connector (first embodiment). [Figure 4] 1 is a plan view of a plug connector (first embodiment). [Figure 5] 1 is a perspective view of a plurality of plug contact arrays arranged in the width direction (first embodiment). [Figure 6] 1 is a perspective view of a receptacle connector (first embodiment). [Figure 7] 1 is a plan view of a receptacle connector (first embodiment). [Figure 8] 1 is a perspective view of a plurality of receptacle contact arrays arranged in the width direction (first embodiment). [Figure 9] 1 is a cross-sectional perspective view of a plug connector (first embodiment). [Figure 10] 1 is a cross-sectional view of a plug connector (first embodiment). [Figure 11] 1 is a perspective view of a plug connector (first embodiment). [Figure 12] 1 is a bottom view of the plug connector (first embodiment). [Figure 13] 1 is a manufacturing flow of a plug connector (first embodiment). [Figure 14] 1 is a perspective view of a plug contact assembly (first embodiment); [Figure 15] 1 is a perspective view showing an injection molding die in which a plurality of plug contact assemblies are set (first embodiment). [Figure 16]1 is a front view of an injection molding die that houses a plurality of plug contact assemblies (first embodiment). [Figure 17] 1 is a perspective view of a molded product removed from an injection molding die (first embodiment). [Figure 18] 1 is a plan view of a molded product (first embodiment). [Figure 19] 1 is a plan view of a molded product, in which the areas to be removed are indicated by hatching (first embodiment). [Figure 20] 1 is a cross-sectional perspective view of a receptacle connector according to a first embodiment. [Figure 21] 1 is a cross-sectional view of a receptacle connector (first embodiment). [Figure 22] 1 is a perspective view of a receptacle contact assembly (first embodiment); [Figure 23] 10 is a cross-sectional perspective view of a plug connector (first modified example). [Figure 24] 10 is a partial plan view of a plug connector (second modified example). [Figure 25] 10 is a plan view of the plug contact assembly (second modified example). [Figure 26] 10 is a partial plan view of a plug connector (third modified example). [Figure 27] 10 is a plan view of the plug contact assembly (third modified example). [Figure 28] 10 is a partial plan view of a plug connector (fourth modified example). [Figure 29] 10 is an exploded perspective view of the plug connector (fourth modified example). [Figure 30] 10 is a partial plan view of a molded product (fourth modified example). [Figure 31] 10 is a partial plan view of a plug connector (fifth modified example). [Figure 32] 10 is an exploded perspective view of the plug connector (fifth modified example). [Figure 33] 10 is a partial plan view of a molded product (fifth modified example). [Figure 34] 10 is a partial plan view of a plug connector (sixth modified example). [Figure 35] 10 is a partial plan view of a molded product (sixth modified example). [Figure 36] 10 is an exploded perspective view of the plug connector (seventh modified example). [Figure 37] 13 is a partially cutaway perspective view of a receptacle connector (eighth modified example). [Figure 38] 10 is a partially cutaway perspective view of a molded product (eighth modified example). [Figure 39] This is a simplified diagram of FIG. 4 of Patent Document 1. DETAILED DESCRIPTION OF THE INVENTION

[0008] (First embodiment) Hereinafter, a first embodiment of the present disclosure will be described with reference to FIGS.

[0009] 1 and 2 show a connector assembly 1. As shown in FIGS. 1 and 2, the connector assembly 1 mechanically and electrically connects a lower substrate 2 (receptacle side substrate, first substrate, substrate) and an upper substrate 3 (plug side substrate, second substrate, substrate). The connector assembly 1 is composed of a receptacle 4 (receptacle connector, connector) surface-mounted on the connector mounting surface 2A of the lower substrate 2, and a plug 5 (plug connector, connector) surface-mounted on the connector mounting surface 3A of the upper substrate 3. The connector assembly 1 of this embodiment is a surface-mounted, fine-pitch, low-profile connector assembly with 60 cores.

[0010] The lower substrate 2 and the upper substrate 3 are rigid substrates such as paper phenolic substrates or glass epoxy substrates, or flexible substrates. When the plug 5 is fitted into the receptacle 4, the upper substrate 3 is parallel to the lower substrate 2.

[0011] As shown in FIGS. 3 to 5 , the plug 5 includes a plug housing 6 (housing) made of insulating resin and a plurality of plug contact arrays 7 (contact arrays) integrated into the plug housing 6 by insert molding. In this embodiment, the plurality of plug contact arrays 7 includes six plug contact arrays 7. The six plug contact arrays 7 include a first plug contact array 8, a second plug contact array 9, a third plug contact array 10, a fourth plug contact array 11, a fifth plug contact array 12, and a sixth plug contact array 13. However, the number of plug contact arrays 7 constituting the plug 5 is not limited as long as it is at least one. Typically, the plug 5 includes at least three plug contact arrays 7.

[0012] As shown in FIGS. 6 to 8 , the receptacle 4 includes a receptacle housing 20 (housing) made of insulating resin and a plurality of receptacle contact arrays 21 (contact arrays) integrated into the receptacle housing 20 by insert molding. In this embodiment, the plurality of receptacle contact arrays 21 includes six receptacle contact arrays 21. The six receptacle contact arrays 21 include a first receptacle contact array 22, a second receptacle contact array 23, a third receptacle contact array 24, a fourth receptacle contact array 25, a fifth receptacle contact array 26, and a sixth receptacle contact array 27. However, the number of receptacle contact arrays 21 constituting the receptacle 4 is not limited as long as it is at least one. Typically, the receptacle 4 includes at least three receptacle contact arrays 21. The plurality of receptacle contact arrays 21 all have the same shape.

[0013] In this embodiment, the "connector" corresponds to the plug 5 and the receptacle 4. Similarly, the "housing" corresponds to the plug housing 6 and the receptacle housing 20. Similarly, the "at least one contact array" corresponds to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, the fifth plug contact array 12, the second receptacle contact array 23, the third receptacle contact array 24, the fourth receptacle contact array 25, and the fifth receptacle contact array 26.

[0014] As shown in Figures 1 and 2, the first plug contact array 8, the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, the fifth plug contact array 12, and the sixth plug contact array 13 correspond to the first receptacle contact array 22, the second receptacle contact array 23, the third receptacle contact array 24, the fourth receptacle contact array 25, the fifth receptacle contact array 26, and the sixth receptacle contact array 27, respectively.

[0015] Here, the pitch direction, width direction, and up-down direction are defined. The pitch direction, width direction, and up-down direction are directions that are perpendicular to each other.

[0016] 3 to 5, the pitch direction is defined as the longitudinal direction of the second plug contact array 9. That is, the pitch direction corresponds to the column direction of the second plug contact array 9. Referring to FIG. 3, the pitch direction includes an inward pitch direction approaching the center of the plug 5 in the pitch direction and an outward pitch direction moving away from the center of the plug 5 in the pitch direction.

[0017] As shown in FIG. 1 , the vertical direction is a direction perpendicular to the connector mounting surface 3A of the upper substrate 3. The vertical direction includes upward and downward. The upward direction is the direction in which the plug 5 moves relative to the receptacle 4 when the plug 5 is removed from the receptacle 4. The downward direction is the direction in which the plug 5 moves relative to the receptacle 4 when the plug 5 is mated with the receptacle 4. Therefore, the vertical direction is also the direction in which the plug 5 is inserted into and removed from the receptacle 4.

[0018] 3, as described above, the width direction is a direction perpendicular to the pitch direction and the up-down direction. The width direction includes an inward direction toward the center of the plug 5 in the width direction and an outward direction away from the center of the plug 5 in the width direction.

[0019] The above-mentioned up-and-down directions are defined merely for the sake of convenience and do not suggest the orientation of the connector assembly 1 when it is actually in use. Furthermore, as described above, each direction is defined using the structure of the plug 5, but each direction is also used when explaining the structure of the receptacle 4. For example, the pitch direction of the receptacle 4 is the direction that coincides with the pitch direction of the plug 5 when the receptacle 4 is mated with the plug 5. Furthermore, the width direction of the receptacle 4 is the direction that coincides with the width direction of the plug 5 when the receptacle 4 is mated with the plug 5.

[0020] 3 to 5, the multiple plug contact arrays 7 all extend in the pitch direction. Therefore, the multiple plug contact arrays 7 extend parallel to one another. The multiple plug contact arrays 7 are arranged side by side in the width direction. Furthermore, the positions of the multiple plug contact arrays 7 in the pitch direction are aligned with one another.

[0021] 6 to 8, the multiple receptacle contact arrays 21 all extend in the pitch direction. Therefore, the multiple receptacle contact arrays 21 extend parallel to one another. The multiple receptacle contact arrays 21 are arranged side by side in the width direction. Furthermore, the positions of the multiple receptacle contact arrays 21 in the pitch direction are aligned with one another.

[0022] Next, the plug 5 will be described in detail with reference to Figures 3 to 5 and Figures 9 to 12. However, when referring to Figures 3, 5, 9, and 10, please note that the upward and downward directions do not correspond to the upward and downward directions on the paper. Also, while Figure 4 shows a plan view of the plug 5, please also note that the plan view of the plug 5 shown in Figure 4 is a view of the plug 5 observed from the receptacle 4 that faces the plug 5 in the vertical direction.

[0023] As shown in FIG. 4, the plug housing 6 includes a plurality of pitch beams 30 and two width beams 31 .

[0024] The multiple pitch beams 30 all extend in the pitch direction and parallel to one another. The multiple pitch beams 30 include a first pitch beam 32, a second pitch beam 33, a third pitch beam 34, a fourth pitch beam 35, and a fifth pitch beam 36.

[0025] The first pitch beam 32 holds the first plug contact array 8. The second pitch beam 33 holds the second plug contact array 9. The third pitch beam 34 holds the third plug contact array 10 and the fourth plug contact array 11. The fourth pitch beam 35 holds the fifth plug contact array 12. The fifth pitch beam 36 holds the sixth plug contact array 13.

[0026] Both of the two width beams 31 extend in the width direction. The two width beams 31 extend parallel to each other. The two width beams 31 are arranged so as to sandwich the multiple pitch beams 30 in the pitch direction. Therefore, the multiple pitch beams 30 extend from one of the two width beams 31 to the other.

[0027] Between two adjacent pitch beams 30, a through hole 40 (extended through hole) is formed which passes through the plug housing 6 in the up-down direction. That is, a plurality of through holes 40 are formed in the plug housing 6. Each of the plurality of through holes 40 extends from one of the two width beams 31 to the other. The plurality of through holes 40 includes a first through hole 41, a second through hole 42, a third through hole 43, and a fourth through hole 44. Each of the through holes 40 has an inner circumferential surface 40A.

[0028] The first through hole 41 is formed between the first pitch beam 32 and the second pitch beam 33. The second through hole 42 is formed between the second pitch beam 33 and the third pitch beam 34. The third through hole 43 is formed between the third pitch beam 34 and the fourth pitch beam 35. The fourth through hole 44 is formed between the fourth pitch beam 35 and the fifth pitch beam 36.

[0029] The outer peripheral surface 6A of the plug housing 6 has a generally square outline in plan view. The outer peripheral surface 6A of the plug housing 6 includes two width side surfaces 50 facing outward in the width direction and two pitch side surfaces 51 facing outward in the pitch direction. The two width side surfaces 50 are the side surfaces of the plug housing 6 located furthest outward in the width direction. The two pitch side surfaces 51 are the side surfaces of the plug housing 6 located furthest outward in the pitch direction.

[0030] The plug housing 6 is made of one part. That is, the plug housing 6 is formed by a single injection molding in one continuous cavity. The plug housing 6 is not made by connecting multiple parts. Therefore, the multiple pitch beams 30 are joined to each other in an unbroken manner. For example, the second pitch beam 33 and the third pitch beam 34 are joined to each other seamlessly via the two width beams 31.

[0031] 5, all of the multiple plug contact arrays 7 have the same shape, so the third plug contact array 10 will be described as a representative example. The third plug contact array 10 is composed of multiple plug contacts 14 arranged at a predetermined pitch in the pitch direction.

[0032] 5, 9, and 10, each plug contact 14 is formed in an L-shape when viewed in the pitch direction, and includes, in this order, a soldering portion 15, a buried portion 16, and a contact portion 17. That is, the soldering portion 15 extending in the width direction and the contact portion 17 extending in the vertical direction are connected to each other via the buried portion 16.

[0033] The soldering portion 15 is a portion soldered to an electrode pad (not shown) located on the connector mounting surface 3A of the upper substrate 3 in FIG. 1 . As shown in FIGS. 9 and 10 , the soldering portion 15 includes an exposed soldering portion 15A that protrudes outward in the width direction from the third pitch beam 34 and is therefore observable in a planar view, and a covered soldering portion 15B that is covered by the second pitch beam 33 and is therefore not observable in a planar view. The exposed soldering portion 15A is located inside the second through hole 42. Therefore, it can be said that the soldering portion 15 protrudes into the second through hole 42. A leading end surface 15C, which is a cut surface of the soldering portion 15 facing outward in the width direction, is not flush with the inner peripheral surface 42A of the second through hole 42. The leading end surface 15C is located outward in the width direction from the inner peripheral surface 42A of the second through hole 42. That is, the soldering portion 15 extends so as to penetrate the inner peripheral surface 42A of the second through-hole 42. As shown in Fig. 10, the soldering portion 15 has an exposed surface 15D that is exposed upward. That is, both the soldering exposed portion 15A and the soldering covered portion 15B are exposed upward. Therefore, both the soldering exposed portion 15A and the soldering covered portion 15B can be soldered to the corresponding electrode pads arranged on the connector mounting surface 3A of the upper substrate 3.

[0034] 9 and 10, buried portion 16 is curved in an arc shape, smoothly connecting soldering portion 15 extending in the width direction with contact portion 17 extending in the up-down direction. Buried portion 16 is buried in plug housing 6. This prevents contact portion 17 from being contaminated with solder or flux when soldering portion 15 is soldered.

[0035] The contact portion 17 is a portion that protrudes downward from the buried portion 16 and is exposed from the plug housing 6. The contact portion 17 has high rigidity against bending, and is configured to be substantially unable to be elastically displaced relative to the plug housing 6.

[0036] In this embodiment, each plug contact 14 is formed in an L-shape, but there is no limitation to the shape of each plug contact 14. For example, each plug contact 14 may have a straight shape without a bent portion.

[0037] 4, the soldering portions 15 of each plug contact 14 constituting the second plug contact array 9 protrude into the first through hole 41. Similarly, the soldering portions 15 of each plug contact 14 constituting the third plug contact array 10 protrude into the second through hole 42. Similarly, the soldering portions 15 of each plug contact 14 constituting the fourth plug contact array 11 protrude into the third through hole 43. Similarly, the soldering portions 15 of each plug contact 14 constituting the fifth plug contact array 12 protrude into the fourth through hole 44.

[0038] In contrast, the soldering portions 15 of each plug contact 14 constituting the first plug contact array 8 protrude outward in the width direction from one width side surface 50. Similarly, the soldering portions 15 of each plug contact 14 constituting the sixth plug contact array 13 protrude outward in the width direction from the other width side surface 50.

[0039] Next, the plug housing 6 will be further described with reference to FIGS.

[0040] As shown in FIG. 11 , the plug housing 6 has a lower surface 6B facing upward. The lower surface 6B is the uppermost surface of the plug housing 6. As shown in FIGS. 11 and 12 , a plurality of pitch extension grooves 60 are formed in the lower surface 6B of the plug housing 6. Each of the plurality of pitch extension grooves 60 extends in the pitch direction. Each of the plurality of pitch extension grooves 60 extends from one of the two pitch side surfaces 51 to the other. The plurality of pitch extension grooves 60 are aligned in the width direction. The plurality of pitch extension grooves 60 include a first pitch extension groove 61, a second pitch extension groove 62, a third pitch extension groove 63, and a fourth pitch extension groove 64.

[0041] In this embodiment, the multiple pitch extension grooves 60 extend so as to intersect with the multiple through holes 40, respectively, in bottom view. That is, the first pitch extension groove 61 extends so as to intersect with the first through hole 41. The second pitch extension groove 62 extends so as to intersect with the second through hole 42. The third pitch extension groove 63 extends so as to intersect with the third through hole 43. The fourth pitch extension groove 64 extends so as to intersect with the fourth through hole 44. Therefore, each pitch extension groove 60 is divided by the corresponding through hole 40 in the pitch direction. Due to this division, each pitch extension groove 60 does not overlap with the corresponding through hole 40, and is composed of two pitch extension dividing grooves 60A that sandwich the corresponding through hole 40 in the pitch direction.

[0042] 11, each pitch extension dividing groove 60A accommodates a metal piece 65 made of the same material as the plug contact 14. However, the metal piece 65 may be omitted.

[0043] Next, a method for manufacturing the plug 5 will be described with reference to Fig. 13 to Fig. 19. Fig. 13 shows a manufacturing flow of the plug 5. As shown in Fig. 13, the method for manufacturing the plug 5 includes an assembly manufacturing step (S100), an accommodation step (S110), an insert molding step (S120), a separation step (S130), and a support portion removal step (S140).

[0044] Assembly manufacturing step (S100): 14, in the assembly manufacturing step, plug contact assemblies 70 (contact assemblies) are manufactured. Each plug contact assembly 70 includes a plug contact array 7, a connecting beam 71 that connects the plurality of plug contacts 14 of the plug contact array 7 to each other, and two support portions 72 that sandwich the connecting beam 71 in the pitch direction.

[0045] The connecting beam 71 includes a connecting beam main body 71A facing the plug contact array 7 in the width direction, and two connection portions 71B protruding outward in the pitch direction from both ends of the connecting beam main body 71A. The connecting beam main body 71A of the connecting beam 71 is connected to the soldering portion 15 of each plug contact 14. That is, each plug contact 14 protrudes from the connecting beam main body 71A of the connecting beam 71 in the order of the soldering portion 15, buried portion 16, and contact portion 17.

[0046] Each support portion 72 is disposed so as to face the plug contact array 7 in the pitch direction. The thickness direction of each support portion 72 is equal to the vertical direction. Each support portion 72 is formed with a circular positioning hole 72A.

[0047] The plug contact assembly 70 configured as described above is typically formed by pressing a metal sheet.

[0048] In this embodiment, the plug 5 requires six plug contact arrays 7, so six plug contact assemblies 70 are manufactured when one plug 5 is manufactured. The six plug contact assemblies 70 are manufactured as separate parts. In this embodiment, the multiple plug contact assemblies 70 have the same shape. However, instead of this, the multiple plug contact assemblies 70 may have different shapes.

[0049] Containment Step (S110): 15 and 16 show an injection molding die 73 for injection-molding the plug housing 6. The injection molding die 73 includes a fixed-side mold plate 74 and a movable-side mold plate 75. The movable-side mold plate 75 is configured to be movable up and down relative to the fixed-side mold plate 74. As shown in FIG. 15 , to accommodate multiple plug contact assemblies 70 in the injection molding die 73, first, with the injection molding die 73 open, the multiple plug contact assemblies 70 are set on the dividing surface 74A of the fixed-side mold plate 74 using multiple positioning pins 74B protruding upward from the dividing surface 74A of the fixed-side mold plate 74. At this time, the positioning pins 74B are inserted into the positioning holes 72A of each plug contact assembly 70, thereby positioning each plug contact assembly 70 relative to the fixed-side mold plate 74 in the pitch direction and width direction. To position one plug contact assembly 70, two positioning pins 74B are inserted into two positioning holes 72A, respectively, so the plug contact assembly 70 cannot rotate horizontally when set on the dividing surface 74A of the fixed-side template 74. Furthermore, because the two positioning holes 72A are formed as far away from each other as possible in the pitch direction, each plug contact assembly 70 can be positioned with respect to the fixed-side template 74 with high precision.

[0050] 15, the multiple plug contact assemblies 70 are manufactured as separate parts. Therefore, as shown in FIG. 15, the multiple plug contact assemblies 70 can be arranged closely together in the width direction, which contributes to downsizing of the plug 5 in the width direction. If the multiple plug contact assemblies 70 were manufactured in a connected state and insert molding were performed while maintaining the connected state, the contact portions 17 of the plug contacts 14 of two plug contact assemblies 70 adjacent in the width direction would have to be made extremely short. This is because, in a developed view of two plug contact assemblies 70 adjacent in the width direction, the contact portion 17 of each plug contact 14 of one of the two plug contact assemblies 70 adjacent in the width direction would overlap with the connecting beam 71 of the other plug contact assembly 70.

[0051] 16, the injection molding die 73 is clamped. At this time, the two support portions 72 of the plug contact assembly 70 are used to support both ends of the plug contact assembly 70 within the injection molding die 73. Specifically, the two support portions 72 are sandwiched between a fixed-side mold plate 74 and a movable-side mold plate 75 in the vertical direction, thereby supporting both ends of the plug contact assembly 70 within the injection molding die 73.

[0052] Insert molding step (S120): Next, molten resin is supplied into the cavity of the injection mold 73. Then, the plug housing 6 is molded integrally with the plurality of plug contact assemblies 70 by insert molding. The plug housing 6 is molded by insert molding in a single operation. The plug housing 6 is molded in a single cavity. The plug housing 6 is molded as a single part.

[0053] 17 and 18 show a molded product 76 removed from the injection molding die 73. As shown in Fig. 17 and 18, in the insert molding step, the plug housing 6 is molded so that the two support portions 72 of each plug contact assembly 70 are exposed outward in the pitch direction beyond the two pitch side surfaces 51 of the plug housing 6.

[0054] Also, as shown in Figure 18, in the insert molding step, the plug housing 6 is molded so that the connecting beam bodies 71A of the connecting beams 71 of the plug contact assemblies 70 corresponding to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, and the fifth plug contact array 12 are between the two width side surfaces 50 of the plug housing 6 and are spaced apart from the two width side surfaces 50.

[0055] Furthermore, in the insert molding step, the plug housing 6 is molded so that the connecting beam bodies 71A of the connecting beams 71 of the plug contact assemblies 70 corresponding to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, and the fifth plug contact array 12 are exposed in the vertical direction within the first through hole 41, the second through hole 42, the third through hole 43, and the fourth through hole 44. In other words, the plug housing 6 is molded so that the plug housing 6 has the first through hole 41, the second through hole 42, the third through hole 43, and the fourth through hole 44 that penetrate the plug housing 6 in the vertical direction so that the connecting beam bodies 71A of the connecting beams 71 of the plug contact assemblies 70 corresponding to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, and the fifth plug contact array 12 are exposed in the vertical direction. On the other hand, the plug housing 6 is formed so that the connecting beams 71 of the plug contact assemblies 70 corresponding to the first plug contact array 8 and the sixth plug contact array 13 are positioned outward in the width direction from the corresponding width side surfaces 50 .

[0056] Separation step (S130) Next, at least a portion of each plug contact assembly 70 is removed by cutting, thereby disjointing the plurality of plug contacts 14 .

[0057] That is, for the plug contact assemblies 70 corresponding to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, and the fifth plug contact array 12, the portions of each plug contact assembly 70 that are exposed in the vertical direction in each through hole 40 are removed by cutting, as shown in FIG. 19. In FIG. 19, the areas to be removed are illustrated by hatching. In the example of FIG. 19, the connection beam bodies 71A of the connection beams 71 of each plug contact assembly 70 are removed by cutting. For the plug contact assemblies 70 corresponding to the first plug contact array 8 and the sixth plug contact array 13, the connection beams 71 are entirely exposed, so the entire connection beams 71 are removed by cutting.

[0058] Support part removal step (S140) Next, the two support portions 72 of each plug contact assembly 70 are removed by cutting.

[0059] That is, for the plug contact assemblies 70 corresponding to the second plug contact array 9, the third plug contact array 10, the fourth plug contact array 11, and the fifth plug contact array 12, as shown in FIG. 19, the two support portions 72 of each plug contact assembly 70 and the portions of the two connection portions 71B that protrude outward in the pitch direction from the two pitch side surfaces 51 of the plug housing 6 are removed by cutting.

[0060] On the other hand, for the plug contact assembly 70 corresponding to the first plug contact array 8 and the sixth plug contact array 13, since the connecting beam 71 is entirely exposed, the two support portions 72 are typically removed together with the connecting beam 71 by cutting.

[0061] However, the separation step and the support portion removal step are typically performed simultaneously. Alternatively, the support portion removal step may be omitted, leaving the two support portions 72 of each plug contact assembly 70 as they are.

[0062] 9, the soldering portion 15 of each plug contact 14 protrudes into the corresponding through hole 40. Also, as shown in FIGS. 11 and 12, a plurality of pitch extension grooves 60 corresponding to the connecting beams 71 of the plurality of plug contact assemblies 70 are formed in the lower surface 6B of the plug housing 6. As shown in FIG. 11, the unremoved portions of the two connecting portions 71B of the connecting beam 71 remain as metal pieces 65 in the two pitch extension dividing grooves 60A of the pitch extension groove 60. However, to reduce the weight of the plug 5, the metal pieces 65 may be configured to fall off from the pitch extension dividing grooves 60A. For example, if the plug housing 6 is molded so that the connecting portions 71B of the connecting beam 71 shown in FIG. 14 are covered with a slide core that is slidable in the pitch direction during insert molding, the plug housing 6 does not directly come into contact with the metal pieces 65. This allows the metal pieces 65 to be easily removed together with the corresponding support portions 72 in the support portion removing step after the separation step, without cutting each plug contact assembly 70.

[0063] Next, the receptacle 4 will be described in detail with reference to Figures 6 to 8 and 20 to 22. However, since the configuration of the receptacle 4 is similar in many respects to that of the plug 5, descriptions that overlap with the description of the plug 5 will be omitted where appropriate.

[0064] As shown in FIG. 7, the receptacle housing 20 includes a plurality of pitch beams 80 and two width beams 81 .

[0065] The multiple pitch beams 80 all extend in the pitch direction. The multiple pitch beams 80 extend parallel to one another. The multiple pitch beams 80 include a first pitch beam 82, a second pitch beam 83, a third pitch beam 84, a fourth pitch beam 85, and a fifth pitch beam 86.

[0066] The first pitch beam 82 holds the first receptacle contact array 22. The second pitch beam 83 holds the second receptacle contact array 23. The third pitch beam 84 holds the third receptacle contact array 24 and the fourth receptacle contact array 25. The fourth pitch beam 85 holds the fifth receptacle contact array 26. The fifth pitch beam 86 holds the sixth receptacle contact array 27.

[0067] Both of the two width beams 81 extend in the width direction. The two width beams 81 extend parallel to each other. The two width beams 81 are arranged so as to sandwich the multiple pitch beams 80 in the pitch direction. Therefore, the multiple pitch beams 80 extend from one of the two width beams 81 to the other.

[0068] Between two adjacent pitch beams 80, a through hole 90 (extended through hole) is formed that passes through the receptacle housing 20 in the up-down direction. That is, a plurality of through holes 90 is formed in the receptacle housing 20. Each of the plurality of through holes 90 extends from one of the two width beams 81 to the other. The plurality of through holes 90 includes a first through hole 91, a second through hole 92, a third through hole 93, and a fourth through hole 94. Each through hole 90 has an inner circumferential surface 90A.

[0069] A first through hole 91 is formed between the first pitch beam 82 and the second pitch beam 83. A second through hole 92 is formed between the second pitch beam 83 and the third pitch beam 84. A third through hole 93 is formed between the third pitch beam 84 and the fourth pitch beam 85. A fourth through hole 94 is formed between the fourth pitch beam 85 and the fifth pitch beam 86.

[0070] As shown in Fig. 4, the outer peripheral surface 20A of the receptacle housing 20 has a generally square outline in plan view. The outer peripheral surface 20A of the receptacle housing 20 includes two width side surfaces 100 facing outward in the width direction and two pitch side surfaces 101 facing outward in the pitch direction. The two width side surfaces 100 are the side surfaces of the receptacle housing 20 located furthest outward in the width direction. The two pitch side surfaces 101 are the side surfaces of the receptacle housing 20 located furthest outward in the pitch direction.

[0071] The receptacle housing 20 is made of one part. That is, the receptacle housing 20 is formed by a single injection molding within a single continuous cavity. The receptacle housing 20 is not made by connecting multiple parts. Therefore, the multiple pitch beams 80 are joined to each other in an unbroken manner. As an example, the second pitch beam 83 and the third pitch beam 84 are joined to each other seamlessly via the two width beams 81.

[0072] 8, all of the multiple receptacle contact arrays 21 have the same shape, so we will explain the third receptacle contact array 24 as a representative example. The third receptacle contact array 24 is composed of multiple receptacle contacts 110 arranged at a predetermined pitch in the pitch direction.

[0073] 8, 20, and 21, the receptacle contact 110 includes, in this order, a soldering portion 111, a buried portion 112, and a contact portion 113. That is, the soldering portion 111 and the contact portion 113 are connected to each other via the buried portion 112.

[0074] The soldering portion 111 is a portion soldered to an electrode pad (not shown) arranged on the connector mounting surface 2A of the lower substrate 2 in FIG. 1. As shown in FIG. 21, the soldering portion 111 includes an exposed soldering portion 111A that protrudes widthwise from the third pitch beam 84 and is therefore observable in a planar view, and a covered soldering portion 111B that is covered by the third pitch beam 84 and is therefore not observable in a planar view. The exposed soldering portion 111A is located inside the second through hole 92. Therefore, it can be said that the soldering portion 111 protrudes into the second through hole 92. A leading end surface 111C, which is a cut surface of the soldering portion 111 facing outward in the width direction, is not flush with the inner peripheral surface 92A of the second through hole 92. The leading end surface 111C is located widthwise outward of the inner peripheral surface 92A of the second through hole 92. That is, the soldering portion 111 extends so as to penetrate the inner circumferential surface 92A of the second through-hole 92. The soldering portion 111 has an exposed surface 111D exposed downward. That is, both the soldering exposed portion 111A and the soldering covered portion 111B are exposed downward. Therefore, both the soldering exposed portion 111A and the soldering covered portion 111B can be soldered to corresponding electrode pads arranged on the connector mounting surface 2A of the lower substrate 2.

[0075] The buried portion 112 extends upward from the soldering portion 111. The buried portion 112 connects the soldering portion 111 and the contact portion 113. The buried portion 112 is buried in the receptacle housing 20. This prevents the contact portion 113 from being contaminated with solder or flux when the soldering portion 111 is soldered.

[0076] The contact portion 113 is configured to be elastically deformable in the width direction in order to make electrical contact with the contact portion 17 of the corresponding plug contact 14 of the plug 5. The contact portion 113 includes, in this order, a curved portion 113A, a descending portion 113B, a horizontal portion 113C, and an S-shaped portion 113D.

[0077] The curved portion 113A is a portion that protrudes inward in the width direction from the upper end of the buried portion 112 and curves upward to be convex.

[0078] The descending portion 113B protrudes downward from the curved portion 113A.

[0079] The horizontal portion 113C protrudes inward in the width direction from the descending portion 113B.

[0080] The S-shaped portion 113D protrudes upward from the horizontal portion 113C in an S-shape when viewed in the pitch direction. The S-shaped portion 113D faces the descending portion 113B in the width direction.

[0081] The contact portion 113 is capable of elastic deformation in the width direction by being supported in a cantilever manner by the buried portion 112. More specifically, the S-shaped portion 113D of the contact portion 113 is capable of elastic deformation in the width direction.

[0082] When the contact portion 17 of the plug contact 14 shown in FIG. 10 is inserted between the descending portion 113B and the S-shaped portion 113D of the contact portion 113 of the corresponding receptacle contact 110 shown in FIG. 21, the S-shaped portion 113D elastically deforms slightly inward in the width direction, and comes into contact with the contact portion 17 of the plug contact 14 with a predetermined contact pressure.

[0083] As described above, in this embodiment, each receptacle contact 110 has a contact portion 113 that is elastically deformable in the width direction. However, instead of this, the contact portion 113 may be elastically deformable in the vertical direction.

[0084] 7, the soldering portions 111 of each receptacle contact 110 constituting the second receptacle contact array 23 protrude into the first through hole 91. Similarly, the soldering portions 111 of each receptacle contact 110 constituting the third receptacle contact array 24 protrude into the second through hole 92. Similarly, the soldering portions 111 of each receptacle contact 110 constituting the fourth receptacle contact array 25 protrude into the third through hole 93. Similarly, the soldering portions 111 of each receptacle contact 110 constituting the fifth receptacle contact array 26 protrude into the fourth through hole 94.

[0085] In contrast, the soldering portions 111 of each receptacle contact 110 constituting the first receptacle contact array 22 protrude outward in the width direction from one of the width side surfaces 100. Similarly, the soldering portions 111 of each receptacle contact 110 constituting the sixth receptacle contact array 27 protrude outward in the width direction from the other width side surface 100.

[0086] The rest of the structure of the receptacle 4 is the same as that of the plug 5 .

[0087] Next, a description will be given of a method for manufacturing the receptacle 4. Similar to the method for manufacturing the plug 5, the method for manufacturing the receptacle 4 includes an assembly manufacturing step (S100), an accommodation step (S110), an insert molding step (S120), a separation step (S130), and a support portion removal step (S140).

[0088] Assembly manufacturing step (S100): 22, in the assembly manufacturing step, receptacle contact assemblies 114 (contact assemblies) are manufactured. Each receptacle contact assembly 114 includes a receptacle contact array 21, a connecting beam 115 that connects the multiple receptacle contacts 110 of the receptacle contact array 21 to each other, and two support portions 116 that sandwich the connecting beam 115 in the pitch direction.

[0089] The connecting beam 115 includes a connecting beam main body 115A that faces the receptacle contact array 21 in the width direction, and two connection portions 115B that protrude outward in the pitch direction from both ends of the connecting beam main body 115A. The connecting beam main body 115A of the connecting beam 115 is connected to the soldering portion 111 of each receptacle contact 110. That is, each receptacle contact 110 protrudes from the connecting beam main body 115A of the connecting beam 115 in the order of the soldering portion 111, buried portion 112, and contact portion 113.

[0090] Each support portion 116 is disposed so as to face the receptacle contact array 21 in the pitch direction. The thickness direction of each support portion 116 is equal in the vertical direction. Each support portion 116 is formed with a circular positioning hole 116A.

[0091] The receptacle contact assembly 114 configured as described above is typically formed by pressing a metal sheet.

[0092] In this embodiment, since the receptacle 4 requires six receptacle contact arrays 21, six receptacle contact assemblies 114 are manufactured when one receptacle 4 is manufactured. The six receptacle contact assemblies 114 are manufactured as separate parts. In this embodiment, the multiple receptacle contact assemblies 114 have the same shape. However, instead, the multiple receptacle contact assemblies 114 may have different shapes.

[0093] The rest of the manufacturing method of the receptacle 4 is the same as that of the plug 5.

[0094] The first embodiment of the present disclosure has been described above, and the first embodiment has the following features.

[0095] As shown in FIG. 4, the plug 5 (connector) is formed by integrally insert-molding a third plug contact array 10 (at least one contact array) including a plurality of plug contacts 14 (contacts) and a plug housing 6 (housing) that holds the third plug contact array 10. An outer peripheral surface 6A of the plug housing 6 includes two width side surfaces 50 that face opposite each other in a width direction perpendicular to the pitch direction of the third plug contact array 10. As shown in FIG. 13, the manufacturing method of the plug 5 includes an assembly manufacturing step (S100), a housing step (S110), an insert molding step (S120), and a separation step (S130). In the assembly manufacturing step, as shown in FIG. 14, a plug contact assembly 70 (at least one contact assembly) is manufactured, which includes a plug contact array 7, a connecting beam 71 that connects the plurality of plug contacts 14 of the plug contact array 7 to each other, and two support portions 72 that sandwich the connecting beam 71 in the pitch direction. In the accommodation step, as shown in FIGS. 15 and 16 , the plug contact assembly 70 is accommodated in an injection molding die 73 so that both ends of the plug contact assembly 70 are supported within the injection molding die 73 using two support portions 72. In the insert molding step, as shown in FIGS. 17 and 18 , a plug housing 6 is molded integrally with the plug contact assembly 70 by insert molding so that the connecting beam 71 of the plug contact assembly 70 is between the two side surfaces 50 and spaced apart from the two side surfaces 50 in the width direction. In the separation step, as shown in FIG. 19 , at least a portion of the plug contact assembly 70 is removed so that the multiple plug contacts 14 are separated. According to the above method, the plug housing 6 can be molded so that the connecting beam 71 connecting the multiple plug contacts 14 to each other is between the two side surfaces 50 and spaced apart from the two side surfaces 50 in the width direction. As an application example, the plug housing 6 can be applied to a multi-row connector in which three or more rows of plug contact arrays 7 are held by insert molding in a single plug housing 6. The same applies to the receptacle 4.

[0096] 15 and 16, in the accommodation step, the two support portions 72 are sandwiched between the fixed-side mold plate 74 and the movable-side mold plate 75 in the direction in which the movable-side mold plate 75 advances and retreats relative to the fixed-side mold plate 74 of the injection molding die 73, thereby supporting both ends of the plug contact assembly 70 within the injection molding die 73. The same applies to the receptacle 4.

[0097] 17, in the insert molding step, the plug housing 6 is molded so that the two support portions 72 of the plug contact assembly 70 are exposed outside the outer peripheral surface 6A of the plug housing 6. The same applies to the receptacle 4.

[0098] 13 and 19, the method for manufacturing the plug 5 further includes, after the insert molding step, a support portion removing step (S140) of removing the two support portions 72 of the plug contact assembly 70. The same applies to the receptacle 4.

[0099] 18 and 19, in the insert molding step, the plug housing 6 is molded so that it has a through hole 40 (at least one through hole) that passes through the plug housing 6 in the vertical direction so that at least a portion of the plug contact assembly 70 is exposed in the vertical direction. According to the above method, it becomes easy to remove at least a portion of the plug contact assembly 70 when separating the multiple plug contacts 14 in the separation step. However, the multiple through holes 40 may be omitted, and at least a portion of the plug contact assembly 70 may be punched out simultaneously with the corresponding portion of the plug housing 6. The same applies to the receptacle 4.

[0100] 15, in the assembly manufacturing step, the multiple plug contact assemblies 70 are manufactured as separate parts. According to the above method, the multiple plug contact assemblies 70 can be packed together in the width direction, which contributes to reducing the size of the plug 5 in the width direction. The same applies to the receptacle 4.

[0101] 14, each plug contact 14 includes a soldering portion 15, a buried portion 16, and a contact portion 17, in this order. Each plug contact 14 protrudes from the connecting beam 71 in the order of soldering portion 15, buried portion 16, and contact portion 17. The same applies to each receptacle contact 110, as shown in FIG. 22. The same applies to the receptacle 4.

[0102] 10, in manufacturing plug 5, plug housing 6 is molded in the insert molding step so that contact portion 17 cannot be elastically displaced relative to plug housing 6. In contrast, in manufacturing receptacle 4, receptacle housing 20 is molded in the insert molding step so that contact portion 113 can be elastically displaced relative to receptacle housing 20, as shown in FIG.

[0103] 4 and 12, the plug 5 is formed by integrally insert-molding a third plug contact array 10 including a plurality of contacts 14 and a plug housing 6 that holds the third plug contact array 10. The outer peripheral surface 6A of the plug housing 6 includes two pitch side surfaces 51 that face opposite each other in the pitch direction of the third plug contact array 10. The plug housing 6 has a second through hole 42 (at least one through hole) that penetrates the plug housing 6 in the vertical direction, and a second pitch extension groove 62 (at least one pitch extension groove) that extends from one of the two pitch side surfaces 51 to the other. The plurality of plug contacts 14 of the third plug contact array 10 protrude into the second through hole 42. The same applies to the receptacle 4.

[0104] 12, the second pitch extension grooves 62 are formed so as to intersect with the second through holes 42. The same applies to the receptacle 4.

[0105] 11, a metal piece 65 made of the same material as the plurality of plug contacts 14 is housed in the pitch extension dividing grooves 60A of the second pitch extension grooves 62. The plug 5 may be surface-mounted on the connector mounting surface 3A of the upper substrate 3 using this metal piece 65. The same applies to the receptacle 4.

[0106] 4, the second through holes 42 (extended through holes) corresponding to the third plug contact array 10 extend in the pitch direction. The plug contacts 14 of the third plug contact array 10 protrude into the second through holes 42. The same applies to the receptacle 4.

[0107] 4, the plug 5 has a second plug contact array 9 (first contact array) and a third plug contact array 10 (second contact array) adjacent to each other in the width direction perpendicular to the pitch direction. The plug housing 6 of the plug 5 includes first through holes 41 (first extended through holes) and second through holes 42 (second extended through holes) extending in the pitch direction. The first through holes 41, the second plug contact array 9, the second through holes 42, and the third plug contact array 10 are arranged in this order in the width direction. The multiple plug contacts 14 of the second plug contact array 9 protrude into the first through holes 41. The multiple plug contacts 14 of the third plug contact array 10 protrude into the second through holes 42. The same applies to the receptacle 4.

[0108] 21, each receptacle contact 110 includes, in this order, a soldering portion 111, a buried portion 112, and a contact portion 113. The contact portion 113 is elastically displaceable relative to the receptacle housing 20.

[0109] 21, the soldering portion 111 of each receptacle contact 110 protrudes into the second through hole 92. Similarly, as shown in FIG. 10, the soldering portion 15 of each plug contact 14 protrudes into the second through hole 42.

[0110] 10, each plug contact 14 includes, in this order, a soldering portion 15, a buried portion 16, and a contact portion 17. The contact portion 17 is not elastically deformable relative to the plug housing 6.

[0111] (First Modification) Next, a first modified example of the present disclosure will be described with reference to Fig. 23. The following description will focus on differences between this modified example and the first embodiment, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0112] 9, in the first embodiment, the soldering portion 15 of each plug contact 14 of the third plug contact array 10 protrudes into the second through hole 42. That is, the soldering portion 15 of each plug contact 14 of the third plug contact array 10 includes an exposed soldering portion 15A that protrudes outward in the width direction from the third pitch beam 34 and is therefore observable in a planar view, and a covered soldering portion 15B that is covered by the third pitch beam 34 and is therefore not observable in a planar view.

[0113] 23 , in this modification, the soldering portion 15 of each plug contact 14 of the third plug contact array 10 does not protrude into the second through hole 42. In other words, the soldering portion 15 of each plug contact 14 of the third plug contact array 10 does not include the above-mentioned exposed soldering portion 15A. As a result, the tip surface 15C of the soldering portion 15 of each plug contact 14 of the third plug contact array 10 is substantially flush with the inner circumferential surface 42A of the second through hole 42.

[0114] With the above configuration, when the soldering portion 15 of each plug contact 14 is soldered to an electrode pad (not shown) arranged on the connector mounting surface 3A of the upper substrate 3, mainly the exposed surface 15D of the solder covering portion 15B is soldered to the electrode pad.

[0115] (Second Modification) Next, a second modified example of the present disclosure will be described with reference to Figures 24 and 25. The following description will focus on differences between this modified example and the first embodiment, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0116] In the first embodiment described above, as shown in Figure 9, the first through hole 41, the second plug contact array 9, the second through hole 42, and the third plug contact array 10 are arranged in this order in the width direction, with the soldering portion 15 of each plug contact 14 of the second plug contact array 9 protruding into the first through hole 41, and the soldering portion 15 of each plug contact 14 of the third plug contact array 10 protruding into the second through hole 42.

[0117] 24 , in this modification, the soldering portions 15 of each plug contact 14 of the second plug contact array 9 and the soldering portions 15 of each plug contact 14 of the third plug contact array 10 both protrude into the second through holes 42 arranged between the second plug contact array 9 and the third plug contact array 10. According to the above configuration, the first through holes 41 are not necessary, which contributes to downsizing of the plug 5 in the width direction.

[0118] 25. That is, the plug contact assembly 70 has a second plug contact array 9, a third plug contact array 10, a connecting beam 71 that connects the plurality of plug contacts 14 of the second plug contact array 9 and the third plug contact array 10 to each other, and two support portions 72.

[0119] (Third Modification) Next, a third modified example of the present disclosure will be described with reference to Figures 26 and 27. The following description will focus on the differences between this modified example and the second modified example, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0120] 24 , in the second modified example, the soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 both protrude into the second through holes 42 arranged between the second plug contact array 9 and the third plug contact array 10. The soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 face each other in the width direction.

[0121] 26, in this modification, the soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 are not opposed to each other in the width direction, but are arranged in a staggered pattern. In other words, the third plug contact array 10 is shifted by half a pitch in the pitch direction relative to the second plug contact array 9. The above configuration also eliminates the need for the first through holes 41, which contributes to downsizing of the plug 5 in the width direction.

[0122] 27. That is, the plug contact assembly 70 has a second plug contact array 9, a third plug contact array 10, a connecting beam 71 that connects the plurality of plug contacts 14 of the second plug contact array 9 and the third plug contact array 10 to each other, and two support portions 72. The connecting beam 71 connects the plurality of plug contacts 14 of the second plug contact array 9 and the third plug contact array 10 to each other so that the plurality of plug contacts 14 of the second plug contact array 9 and the plurality of plug contacts 14 of the third plug contact array 10 are arranged in a staggered manner.

[0123] (Fourth Modification) Next, a fourth modified example of the present disclosure will be described with reference to Figures 28 to 30. The following description will focus on differences between this modified example and the first embodiment, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0124] In the above first embodiment, as shown in Figure 4, a second through hole 42 is formed between the second pitch beam 33 and the third pitch beam 34, and the second through hole 42 extends from one of the two width beams 31 to the other.

[0125] In contrast, in this modification, as shown in FIG. 28 , a plurality of split through holes 120 (through holes) are formed between the second pitch beam 33 and the third pitch beam 34 and are aligned in the pitch direction. The “at least one through hole” corresponds to the plurality of split through holes 120. The plurality of split through holes 120 are formed so as to be adjacent to the plurality of plug contacts 14 of the third plug contact array 10 in the width direction. Therefore, a plurality of reinforcing beams 121 are formed between the second pitch beam 33 and the third pitch beam 34. Each reinforcing beam 121 is formed between two split through holes 120 adjacent to each other in the pitch direction. All of the plurality of reinforcing beams 121 extend in the width direction and connect the second pitch beam 33 and the third pitch beam 34. The plurality of reinforcing beams 121 contribute to the mechanical strength of the plug housing 6.

[0126] The soldering portions 15 of the plurality of plug contacts 14 of the third plug contact array 10 protrude into the respective divided through holes 120 .

[0127] 29, the pitch extension groove 60 extends so as to intersect with the multiple divided through holes 120. Therefore, a pitch extension divided groove 60C is formed on the lower surface 121B of each reinforcing beam 121. Just as a metal piece 65 is housed in the pitch extension divided groove 60A, a metal piece 66 is also housed in the pitch extension divided groove 60C. The metal piece 66 is made of the same material as the plug contact 14. Both the metal piece 65 and the metal piece 66 are parts of the connecting beam body 71A of the connecting beam 71 of the plug contact assembly 70 in FIG. 14 that have not been removed and remain in the plug housing 6. However, like the metal piece 65, the metal piece 66 can be omitted.

[0128] 30, in the stage of the molded product 76 immediately after the insert molding (S120), the connecting beam main body 71A of the connecting beam 71 is exposed in the vertical direction at the multiple divided through-holes 120. In the separation step (S130), the portions of the connecting beam main body 71A of the connecting beam 71 that are exposed in the vertical direction at each divided through-hole 120 are removed by cutting.

[0129] (Fifth Modification) Next, a fifth modified example of the present disclosure will be described with reference to Figures 31 to 33. The following description will focus on the differences between this modified example and the fourth modified example, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0130] 29 , in the above-described fourth modified example, the pitch extension groove 60 is formed so as to intersect with the plurality of divided through holes 120. That is, during insert molding, the plug housing 6 is molded so that the connecting beams 71 of the plug contact assembly 70 intersect with the plurality of divided through holes 120.

[0131] In contrast, in this modified example, as shown in FIG. 32 , the pitch extension groove 60 is formed so as not to intersect with the multiple divided through holes 120. That is, during insert molding, the plug housing 6 is molded so that the connecting beam 71 of the plug contact assembly 70 does not intersect with the multiple divided through holes 120. Therefore, the pitch extension groove 60 extends seamlessly in the pitch direction (extends in an unbroken manner). In this modified example, the connecting beam 71 of the plug contact assembly 70 is not removed in the separation step (S130) but remains in the plug housing 6. Therefore, the connecting beam 71 remaining in the plug housing 6 contributes to the mechanical strength of the plug housing 6.

[0132] 33, in the stage of molded product 76 immediately after insert molding (S120), soldering portion 15 of each plug contact 14 is exposed in the vertical direction in the corresponding divided through-hole 120. In the separation step (S130), soldering portion 15 of each plug contact 14 is removed by cutting in the corresponding divided through-hole 120.

[0133] (Sixth Modification) Next, a sixth modified example of the present disclosure will be described with reference to Figures 34 and 35. The following description will focus on the differences between this modified example and the fourth modified example, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0134] 28, in the fourth modified example, a plurality of divided through holes 120 are formed side by side in the pitch direction between the first pitch beam 32 and the second pitch beam 33. Similarly, a plurality of divided through holes 120 are formed side by side in the pitch direction between the second pitch beam 33 and the third pitch beam 34.

[0135] The soldering portions 15 of the plurality of plug contacts 14 of the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 of the third plug contact array 10 protrude outward in the width direction.

[0136] The soldering portions 15 of the multiple plug contacts 14 of the second plug contact array 9 each protrude into the multiple divided through holes 120 formed between the first pitch beam 32 and the second pitch beam 33, and the soldering portions 15 of the multiple plug contacts 14 of the third plug contact array 10 each protrude into the multiple divided through holes 120 formed between the second pitch beam 33 and the third pitch beam 34.

[0137] 34, in this modification, the soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 protrude in directions approaching each other. That is, the soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 protrude inward in the width direction, while the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 protrude outward in the width direction.

[0138] The soldering portions 15 of the plurality of plug contacts 14 in the second plug contact array 9 and the soldering portions 15 of the plurality of plug contacts 14 in the third plug contact array 10 each protrude into the interior of the plurality of divided through holes 120 formed between the second pitch beam 33 and the third pitch beam 34. According to the above configuration, the plurality of divided through holes 120 formed between the first pitch beam 32 and the second pitch beam 33 in the fourth modified example are not necessary, which contributes to downsizing of the plug 5 in the width direction.

[0139] 35, in the stage of the molded product 76 immediately after the insert molding (S120), the connecting beam main body 71A of the connecting beam 71 is exposed in the vertical direction at the multiple divided through-holes 120. In the separation step (S130), the portions of the connecting beam main body 71A of the connecting beam 71 that are exposed in the vertical direction at each divided through-hole 120 are removed by cutting.

[0140] (Seventh Modification) Next, a seventh modified example of the present disclosure will be described with reference to Fig. 36. The following description will focus on the differences between this modified example and the first embodiment, and redundant explanations will be omitted. This modified example can also be applied to receptacle 4.

[0141] In this modification, as shown in FIG. 36 , two width extensions 60D are formed on the bottom surface 6B of the plug housing 6. The phrase "at least one width extension groove" corresponds to the two width extensions 60D. Either of the two width extensions 60D may be omitted. The two width extensions 60D extend from the pitch extension division groove 60A so as to move away from each other in the width direction. A cross-shaped metal piece 67 is housed in the pitch extension division groove 60A and the two width extensions 60D. The metal piece 67 is made of the same material as the plug contacts 14. The plug 5 may be surface-mounted on the connector mounting surface 3A of the upper board 3 using this metal piece 67. However, the metal piece 67 may be omitted.

[0142] (Eighth Modification) Next, an eighth modified example of the present disclosure will be described with reference to Figures 37 and 38. Below, the differences between this modified example and the first embodiment will be mainly described, and overlapping descriptions will be omitted.

[0143] In the first embodiment, the soldering portion 111 of each receptacle contact 110 protrudes into the corresponding through-hole 90, as shown in FIG.

[0144] 37, in this modification, the contact portions 113 of the multiple receptacle contacts 110 in the second receptacle contact array 23 and the contact portions 113 of the multiple receptacle contacts 110 in the third receptacle contact array 24 protrude into the interior of the second through holes 92 formed between the second pitch beam 83 and the third pitch beam 84. In this case, as shown in FIG. 38, each receptacle contact assembly 114 accommodated in the injection molding die 73 in the insert molding step includes a connecting beam 115 that connects the second receptacle contact array 23 and the third receptacle contact array 24, the multiple receptacle contacts 110 in the second receptacle contact array 23 and the multiple receptacle contacts 110 in the third receptacle contact array 24, and two support portions 116 that sandwich the connecting beam 115 in the pitch direction. The contact portion 113 of each receptacle contact 110 is connected to the connecting beam 115. In other words, each receptacle contact 110 protrudes from the connecting beam 115 in the order of the contact portion 113, buried portion 112, and soldered portion 111.

[0145] The first embodiment and the first to eighth modifications have been described above. The modifications may be implemented in combination with one another. For example, the first modification can be applied not only to the first embodiment but also to the second to eighth modifications. [Explanation of symbols]

[0146] 1 Connector Assembly 2 Lower board 2A connector mounting surface 3 Upper board 3A connector mounting surface 4 Receptacle (connector) 5 Plug (connector) 6 Plug housing (housing) 6A Outer surface 6B Bottom 7 Plug contact array (contact array) 8. First plug contact array 9 Second plug contact array (contact array, first contact array) 10 Third plug contact array (contact array, second contact array) 11 Fourth plug contact array (contact array) 12 5th plug contact array (contact array) 13 No. 6 plug contact array 14 Plug contact (contact) 15 Soldering section 15A exposed soldering area 15B Soldered coating 15C Tip surface (cut surface) 15D exposed surface 16 Burial part 17 Contact area 20 Receptacle housing (housing) 20A outer surface 21 Receptacle Contact Array (Contact Array) 22 First receptacle contact array 23 Second receptacle contact array (contact array) 24 Third receptacle contact array (contact array) 25 4th receptacle contact array (contact array) 26 5th receptacle contact array (contact array) 27 No. 6 Receptacle Contact Array 30 Pitch Beam 31 wide beam 32 First Pitch Beam 33 Second Pitch Beam 34 Third Pitch Beam 35 4th Pitch Beam 36 5th Pitch Beam 40 Through hole (extension through hole) 40A inner surface 41 1st through hole (through hole, extension through hole, 1st extension through hole) 42 2nd through hole (through hole, extension through hole, 2nd extension through hole) 42A Inner surface 43 Third through hole (through hole, extension through hole) 44 4th through hole (through hole, extension through hole) 50 width side 51 Pitch Side 60 pitch extension groove 60A Pitch Extension Dividing Groove 60C pitch extension dividing groove 60D width extension 61 First pitch extension groove (pitch extension groove) 62 Second pitch extension groove (pitch extension groove) 63 Third pitch extension groove (pitch extension groove) 64 4th pitch extension groove (pitch extension groove) 65 Metal piece 66 Metal piece 67 Metal piece 70 Plug contact assembly (contact assembly) 71 Connecting beam 71A Connecting beam body 71B Connection 72 Support part 72A Positioning hole 73 Injection mold 74 Fixed side template 74A Split plane 74B Locating Pin 75 Movable side template 76 Molded products 80 pitch beam 81 wide beam 82 First Pitch Beam 83 Second Pitch Beam 84 Third Pitch Beam 85 4th Pitch Beam 86 5th Pitch Beam 90 Through hole (extension through hole) 90A Inner surface 91 1st through hole (through hole, extension through hole) 92 2nd through hole (through hole, extension through hole) 92A Inner surface 93 Third through hole (through hole, extension through hole) 94 4th through hole (through hole, extension through hole) 100 width side 101 Pitch Side 110 Receptacle Contact (Contact) 111 Soldering section 111A Exposed soldering area 111B Soldered coating 111C Tip surface 112 Buried part 113 Contact part 113A curved section 113B Descending section 113C Horizontal section 113D S-shaped part 114 Receptacle contact assembly (contact assembly) 115 Connecting beam 115A Connecting beam body 115B connection 116 Support part 116A Positioning hole 120 Split through hole (through hole) 121 Reinforced beam 121B Bottom side

Claims

1. at least one contact array including a plurality of contacts; a housing holding the at least one contact array; are integrally formed by insert molding, the outer peripheral surface of the housing includes two pitch sides facing opposite to each other in a pitch direction of the at least one contact array; A connector, The housing includes: At least one through hole that passes through the housing in the vertical direction; at least one pitch extension groove extending from one of the two pitch sides to the other; and the plurality of contacts of the at least one contact array protrude into the at least one through-hole or have a cut surface flush with an inner circumferential surface of the at least one through-hole; connector.

2. 2. The connector of claim 1, the at least one pitch extension groove is formed to intersect with the at least one through hole; connector.

3. 3. The connector according to claim 1 or 2, the at least one pitch extension groove contains a metal piece made of the same material as the plurality of contacts; connector.

4. The connector according to any one of claims 1 to 3, the at least one through hole corresponding to the at least one contact array includes an elongated through hole extending in the pitch direction; the plurality of contacts of the at least one contact array protrude into the extended through hole or have a cut surface flush with an inner circumferential surface of the extended through hole; connector.

5. 5. The connector according to claim 4, the at least one contact array includes two contact arrays adjacent to each other in a width direction perpendicular to the pitch direction, the extended through-hole is formed between the two contact arrays, the plurality of contacts in one of the two contact arrays; the plurality of contacts of the other of the two contact arrays; The cut surface protrudes into the extended through hole or is flush with the inner circumferential surface of the extended through hole. connector.

6. 6. The connector of claim 5, the plurality of contacts in one of the two contact arrays; the plurality of contacts of the other of the two contact arrays are arranged in a staggered pattern; connector.

7. The connector according to any one of claims 1 to 3, the at least one contact array includes a first contact array and a second contact array adjacent to each other in a width direction perpendicular to the pitch direction; the at least one through hole includes a first extended through hole and a second extended through hole extending in the pitch direction; the first extended through hole, the first contact array, the second extended through hole, and the second contact array are arranged in this order in the width direction; the plurality of contacts of the first contact array protrude into the first extended through hole or have cut surfaces flush with an inner circumferential surface of the first extended through hole; the plurality of contacts of the second contact array protrude into the second extended through-hole or have cut surfaces flush with the inner circumferential surface of the second extended through-hole; connector.

8. The connector according to any one of claims 1 to 3, the at least one through hole corresponding to the at least one contact array includes a plurality of through holes aligned in the pitch direction; the plurality of contacts of the at least one contact array protrude into any of the plurality of through holes or have a cut surface that is flush with an inner circumferential surface of any of the plurality of through holes; connector.

9. 9. The connector of claim 8, the at least one contact array includes two contact arrays adjacent to each other in a width direction perpendicular to the pitch direction, the plurality of through holes are formed between the two contact arrays, the plurality of contacts in one of the two contact arrays; the plurality of contacts of the other of the two contact arrays; a cut surface that protrudes into any one of the plurality of through holes or is flush with an inner circumferential surface of any one of the plurality of through holes; connector.

10. 10. The connector according to claim 1, Each contact includes, in that order, a solder portion, a buried portion, and a contact portion; The contact portion is elastically displaceable with respect to the housing. connector.

11. 11. The connector of claim 10, The soldering portion of each contact protrudes into the at least one through-hole or has a cut surface that is flush with an inner peripheral surface of the at least one through-hole. connector.

12. 11. The connector of claim 10, the contact portion of each contact protrudes into the at least one through hole or has a cut surface that is flush with an inner circumferential surface of the at least one through hole; connector.

13. 10. The connector according to claim 1, Each contact includes, in that order, a solder portion, a buried portion, and a contact portion; The contact portion is not elastically displaceable relative to the housing. connector.

14. 14. The connector according to any one of claims 1 to 13, The housing has at least one width extension groove formed therein, the width extension groove extending from the at least one pitch extension groove in a width direction perpendicular to the pitch direction, a metal piece of the same material as the plurality of contacts is accommodated in the at least one width-extending groove; connector.

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