Terminal Modules and Connectors

Abstract

To reduce the size of a connector while suppressing disconnection of a flexible conductor.SOLUTION: A terminal module electrically connected to a mating connector by being fitted to the mating connector which relatively approaches along a first direction directed from one side to the other side comprises: a case containing a ceiling wall and a pair of side walls extending to one side from the ceiling wall; an elastic member which can be extended and contracted along the first direction while being housed in the case; a first terminal which is supported by the pair of side walls in a state of being urged to one side with the elastic member, and which can be moved to the other side by being pressed by the mating connector; a second terminal that is positioned so as to be separated on the other side of the first terminal and extends to the first direction; and a flexible conductor which electrically connects the first terminal and the second terminal to each other. The flexible conductor includes a contraction created part in which contraction is created in the first direction when the first terminal is moved to the other side.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a terminal module and a connector. [Background technology]

[0002] For example, in an automobile or the like, when connecting devices such as a motor and a PCU (Power Control Unit), a technology is known in which connectors provided on the cases of the devices are fitted together to eliminate the need for a wire harness and save space. For example, Patent Document 1 discloses a technology in which a mating connector, which is the plug-in side, is fitted to a connector, which is the receiving side.

[0003] In Patent Document 1, the connector includes a coil spring and an electrical contact member provided at the tip of the coil spring. When the connectors are mated, a mating contact included in the mating connector compresses the coil spring via the electrical contact member. As a result, the electrical contact member is pressed against the mating contact by the coil spring, and the electrical contact member and the mating contact are electrically connected.

[0004] The electrical contact member is electrically connected to the external connection member by a braided wire. The braided wire is arranged to bend with the movement of the electrical contact member. The bending of the braided wire allows the electrical contact member to move while maintaining electrical connection with the external connection member when the mating contact is connected to the electrical contact member. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2018-101556 A Summary of the Invention [Problem to be solved by the invention]

[0006] As described above, in connectors in which parts move when mated, flexible conductors such as braided wires are used to electrically connect the moving parts (electrical contact parts) and the fixed parts (external connection parts). Since the flexible conductor is made of relatively flexible electric wires, etc., there is a risk of it breaking when it rubs against other parts (e.g., the housing) included in the connector. Since it is difficult to completely predict how the flexible conductor will bend when the connector is mated, in order to prevent it from breaking, it has been necessary to provide a space in the housing that adds an additional margin to the movable range of the flexible conductor. As a result, there has been a problem that the connector becomes large and it is difficult to save space.

[0007] In view of the above problems, the present disclosure has an object to provide a terminal module that can reduce the size of a connector while suppressing breakage of a flexible conductor. Also, the present disclosure has an object to provide a connector that can be reduced in size while suppressing breakage of a flexible conductor. [Means for solving the problem]

[0008] The terminal module of the present disclosure is a terminal module that engages with a mating connector that approaches relatively along a first direction from one side to the other side, and electrically connects to the mating connector, and includes a case including a ceiling wall and a pair of side walls extending from the ceiling wall to the one side, an elastic member housed in the case and capable of expanding and contracting along the first direction, a first terminal that is supported by the pair of side walls while being biased toward the one side by the elastic member and can move to the other side when pressed by the mating connector, a second terminal that is located away from the other side of the first terminal and extends in the first direction, and a flexible conductor that electrically connects the first terminal and the second terminal, wherein the flexible conductor has a shaped portion that is shaped to contract in the first direction when the first terminal moves to the other side. Effect of the Invention

[0009] According to the present disclosure, it is possible to reduce the size of the connector while suppressing breakage of the flexible conductor. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a cross-sectional view that shows a schematic diagram of a connector and a mating connector according to the present embodiment in an unmated state. [Diagram 2] FIG. 2 is a cross-sectional view showing a schematic diagram of a connector and a mating connector in the middle of being fitted together according to the present embodiment. [Diagram 3] FIG. 3 is a cross-sectional view showing a schematic diagram of the connector and the mating connector according to the present embodiment in a mated state. [Figure 4] FIG. 4 is a perspective view of the terminal module according to this embodiment, as viewed obliquely from above and to the left. [Diagram 5] FIG. 5 is a front view of the terminal module of FIG. 3 as viewed from the front side. [Figure 6] FIG. 6 is a side view of the terminal module of FIG. 3 as viewed from the left side. [Figure 7] FIG. 7 is a plan view of the terminal module of FIG. 3 as viewed from above. [Figure 8] 8 is a cross-sectional view of the terminal module taken along the line indicated by the arrow VIII in FIG. [Figure 9] FIG. 9 is an explanatory diagram showing an example of a method for forming a curled portion in a flexible conductor. [Figure 10] FIG. 10 is a diagram for explaining a comparative example of this embodiment. [Figure 11] FIG. 11 is a diagram illustrating how the flexible conductor according to the embodiment buckles in a fitted state. [Figure 12] FIG. 12 is a diagram showing a flexible conductor according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] [Description of the embodiments of the present disclosure] The gist of the present disclosure includes the following configurations.

[0012] (1) A terminal module disclosed herein is a terminal module that engages with a mating connector that approaches relatively along a first direction from one side to the other side, and electrically connects to the mating connector, the terminal module comprising: a case including a ceiling wall and a pair of side walls extending from the ceiling wall to the one side; an elastic member housed in the case and expandable and contractable along the first direction; a first terminal that is supported by the pair of side walls while being biased toward the one side by the elastic member and that can move to the other side when pressed by the mating connector; a second terminal that is located away from the other side of the first terminal and extends in the first direction; and a flexible conductor that electrically connects the first terminal and the second terminal, the flexible conductor having a shaped portion that is shaped to contract in the first direction when the first terminal moves to the other side.

[0013] By forming the flexible conductor to contract in the first direction, the range of motion of the flexible conductor when the mating connector is mated is reduced, which makes it possible to reduce the space required inside the connector, thereby making it possible to miniaturize the connector while preventing breakage of the flexible conductor.

[0014] (2) Preferably, the bending portion is bent in a second direction perpendicular to the first direction when the first terminal moves to the other side. With this configuration, the range of movement of the flexible conductor in the second direction when the connector is mated is reduced, making it possible to reduce the size of the connector while preventing breakage of the flexible conductor.

[0015] (3) Preferably, the forming portion is formed into a wave shape or a spiral shape. By configuring in this way, the forming portion can be formed relatively easily.

[0016] (4) Preferably, the flexible conductor is a braided wire, a coated wire in which a conductive strand is coated with an insulator, a laminate in which a plurality of conductive flat plates are laminated, or a conductive single wire.

[0017] (5) Preferably, in an unmated state before being mated with the mating connector, the length of the flexible conductor in the first direction is longer than a natural length of the flexible conductor in the first direction.

[0018] With this configuration, a restoring force is generated in the flexible conductor in an unmated state, which causes the flexible conductor to return to its natural length. This restoring force can absorb the load in the first direction applied to the flexible conductor when mating, thereby preventing the flexible conductor from buckling due to an overload. This reduces the range of motion of the flexible conductor, thereby enabling the connector to be made more compact.

[0019] (6) Preferably, in the unmated state, the length of the elastic member in the first direction is shorter than the natural length of the elastic member in the first direction, and in the unmated state, the restoring force generated in the flexible conductor toward the other side is smaller than the restoring force generated in the elastic member toward the one side.

[0020] In the unmated state, a restoring force is generated in the flexible conductor to return it to its natural length, and a force is applied to the first terminal toward the other side. With this configuration, the elastic member presses the first terminal toward one side with a larger restoring force, so that the first terminal can be held in a predetermined position in the unmated state.

[0021] (7) A connector according to the present disclosure includes a terminal module according to any one of (1) to (6) above, and a housing in which the terminal module is housed.

[0022] [Details of the embodiment of the present disclosure] Hereinafter, the details of the embodiments of the present disclosure will be described with reference to the drawings.

[0023] <Overall Connector Configuration> FIG. 1 is a cross-sectional view that shows a connector 80 and a mating connector 90 according to the present embodiment before mating. The state of the connector 80 before mating with the mating connector 90 is referred to as an "unmated state." FIG. 2 is a cross-sectional view that shows a connector 80 and a mating connector 90 in the middle of mating. FIG. 3 is a cross-sectional view that shows a connector 80 and a mating connector 90 after mating. The state of the connector 80 after mating with the mating connector 90 is referred to as a "mated state."

[0024] In the following description, the direction in which the mating connector 90 is attached to and detached from the connector 80 is referred to as the "upper-lower direction (first direction in this disclosure)" and is shown as the z-direction in the drawings. The side in which the mating connector 90 is attached to the connector 80 is the "upper side (positive side in the z-direction, the other side in this disclosure)". In addition, in the connector 80, the direction perpendicular to the upper-lower direction and in which the elastic member 30 is located relative to the flexible conductor 60 described below is referred to as the "front-rear direction (second direction in this disclosure)" and is shown as the x-direction in the drawings. The side in which the elastic member 30 is located relative to the flexible conductor 60 is the "front side (positive side in the x-direction)". In addition, the direction perpendicular to the upper-lower direction and the front-rear direction is referred to as the "left-right direction" and is shown as the y-direction in the drawings. The side that is the left side when facing the front side is the "left side (positive side in the y-direction)". Note that the above directions are relative directions for explaining the configuration of the connector 80, and do not mean the directions when the connector 80 is actually attached to the device.

[0025] The connector 80 and the mating connector 90 are provided in devices mounted on an automobile. For example, the connector 80 is provided in a PCU (one example of a device) including an inverter circuit, and the mating connector 90 is provided in a motor (one example of a mating device). When the mating connector 90 is inserted into the connector 80 as shown in Fig. 3 after passing through the states shown in Figs. 1 and 2, the connector 80 and the mating connector 90 are fitted together, and the PCU and the motor are electrically connected. The fitting of the connector 80 and the mating connector 90 will be described later.

[0026] The connector 80 includes a terminal module 10 and a housing 70. The terminal module 10 will be described below with reference to Figures 4 to 8 as appropriate, and the housing 70 will be described with reference to Figure 1.

[0027] Terminal module configuration Fig. 4 is a perspective view of the terminal module 10 according to this embodiment, as viewed from diagonally above and to the left. Fig. 5 is a front view of the terminal module 10, as viewed from the front side. Fig. 6 is a side view of the terminal module 10, as viewed from the left side. Fig. 7 is a plan view of the terminal module 10, as viewed from above. Fig. 8 is a cross-sectional view of the terminal module 10 taken along the cutting line indicated by the arrow VIII in Fig. 5. Here, Figs. 1, 2 and 3 show the connector 80 and the mating connector 90 in the same cross section as Fig. 8.

[0028] The terminal module 10 is a module for electrically connecting a mating terminal 91 (FIG. 1) included in a mating connector 90 to an electric circuit (not shown) included in a device. The terminal module 10 includes a case 20, an elastic member 30, a first terminal 40, a second terminal 50, and a flexible conductor 60. The configuration of each part of the terminal module 10 described below is the configuration in a connector 80 in an unmated state (i.e., the state in FIG. 1).

[0029] The case 20 has a ceiling wall 21, a pair of left and right side walls 22, 22, and a pair of front and rear side walls 23, 23. The case 20 is made of metal (e.g., stainless steel), and the ceiling wall 21, the side walls 22, 22, and the side walls 23, 23 are integrally formed by pressing a plate material. The ceiling wall 21 is a flat plate-like region provided along the front-rear and left-right directions. The front-rear and left-right widths of the ceiling wall 21 are greater than the front-rear and left-right widths of the elastic member 30, and the elastic member 30 is entirely covered by the ceiling wall 21 in a plan view as shown in FIG. 7.

[0030] The pair of side walls 22, 22 are a pair of parallel walls extending downward from the left and right edges of the ceiling wall 21. Since the pair of side walls 22, 22 have mirror-symmetric shapes, the left side wall 22 will be representatively described below. As shown in Fig. 6, the side wall 22 has a base 22A, a first leg 22B, and a second leg 22C.

[0031] The base 22A is an area continuous with the ceiling wall 21. The base 22A has the same width as the ceiling wall 21 in the front-to-rear direction. The base 22A has a protrusion 27 that protrudes to the right (i.e., toward the inside in the left-right direction). The inner surface in the left-right direction of the protrusion 27 faces the left-right side of the elastic member 30 with a small gap therebetween, as shown in FIG. 5. The protrusion 27 has the function of receiving the elastic member 30 that bends in the left-right direction when the elastic member 30 is compressed or expanded.

[0032] The first leg 22B is a region that extends downward from the base 22A in the center of the base 22A in the front-rear direction while sloping forward. The first leg 22B has a greater width in the up-down direction than the sloping width in the front-rear direction. The first leg 22B has a smaller width in the front-rear direction than the base 22A (specifically, about one-quarter the width of the base 22A).

[0033] The rear surface of the first leg 22B functions as a guide surface 22B1 that guides the guided portion 44, described below, when the mating connector 90 is mated. Since the guide surface 22B1 extends downward while being inclined in the front-rear direction, the guided portion 44 is guided in the up-down direction along the guide surface 22B1 and is also guided in the front-rear direction. The first leg 22B has a first receiving portion 24 that extends forward at its lower end. The upper surface of the first receiving portion 24 extends in the front-rear direction and is capable of receiving a first engagement portion 43, described below, included in the first terminal 40.

[0034] The second leg 22C is an area extending downward from the base 22A below and behind the base 22A. The second leg 22C is located behind the first leg 22B, and the first leg 22B and the second leg 22C are separated in the front-rear direction. A guided portion 44 included in the first terminal 40, which will be described later, is inserted between the first leg 22B and the second leg 22C. The second leg 22C has a width smaller than that of the base 22A in the front-rear direction (specifically, about one-fourth the width of the base 22A). The second leg 22C has a lower end 25 and a second receiving portion 26 that protrudes rearward above the lower end 25. The upper surface of the second receiving portion 26 is a surface that extends along the front-rear direction and is capable of receiving a second engagement portion 45 included in the first terminal 40, which will be described later.

[0035] The pair of side walls 23, 23 are a pair of parallel walls extending downward from the front-rear edges of the ceiling wall 21. The pair of side walls 23, 23 have a width smaller than the ceiling wall 21 in the left-right direction (specifically, about one-third the width of the ceiling wall 21). The pair of side walls 23, 23 also have a width smaller than the side wall 22 in the up-down direction (specifically, about one-half the width of the side wall 22). The inner surfaces of the pair of side walls 23, 23 in the front-rear direction face the sides of the elastic member 30 in the front-rear direction with a small gap therebetween, as shown in FIG. 8. The pair of side walls 23, 23 have a function of receiving the elastic member 30 that bends in the front-rear direction when the elastic member 30 is compressed or expanded.

[0036] The elastic member 30 is a coil spring made of a metal (e.g., stainless steel) wire wound into a coil shape. Note that the elastic member 30 may be a member other than a coil spring as long as it can expand and contract in the vertical direction and tilt in the front-rear direction. For example, the elastic member 30 may be another spring member (e.g., a leaf spring) or a rubber member.

[0037] The elastic member 30 is accommodated in the case 20. That is, the elastic member 30 is accommodated in a space surrounded by a ceiling wall 21, a pair of side walls 22, 22, and a pair of side walls 23, 23, with the lower side open. The elastic member 30 is sandwiched between the ceiling wall 21 and a first portion 41 (described later) included in the first terminal 40 in a state in which the elastic member 30 is compressed in the vertical direction. In this state, the elastic member 30 can be further compressed in the vertical direction. That is, the elastic member 30 is compressed by the ceiling wall 21 and the first portion 41 in a range that is less than the natural length of the spring and longer than the contact length.

[0038] 8, the elastic member 30 has a main body portion 31, an upper end portion 32, and a lower end portion 33. The upper end portion 32 is a region that corresponds to approximately one revolution from the upper end of the elastic member 30, and is in contact with the ceiling wall 21. The lower end portion 33 is a region that corresponds to approximately one revolution from the lower end of the elastic member 30, and is in contact with the first portion 41. The main body portion 31 is a region that is located between the upper end portion 32 and the lower end portion 33.

[0039] The first terminal 40 is a terminal capable of physically contacting the mating terminal 91, and is attached to a pair of side walls 22, 22. The first terminal 40 has a first portion 41 and a second portion 42. The first terminal 40 is made of metal (e.g., copper alloy), and the first portion 41 and the second portion 42 are integrally formed by pressing a plate material. The first portion 41 is provided parallel to the ceiling wall 21 (i.e., along the front-rear and left-right directions) while being spaced apart from the lower side of the ceiling wall 21. The second portion 42 is an area extending upward from the rear edge of the first portion 41. Therefore, the first terminal 40 has an L-shape when viewed from the side as shown in FIG. 6 (or viewed in cross section as shown in FIG. 8).

[0040] An upper surface 41A of the first portion 41 functions as a receiving surface that receives a lower end portion 33 of the elastic member 30. A lower surface 41B of the first portion 41 functions as a contact surface that can come into contact with a mating contact 93 included in a mating terminal 91.

[0041] 4 and 7, the first portion 41 has a pair of left and right first engaging portions 43, 43 and a pair of left and right guided portions 44, 44. The first engaging portions 43 are areas that protrude outward in the left-right direction at the front edge of the first portion 41, and abut against the first receiving portion 24 of the first leg 22B in the up-down direction. The guided portions 44 are areas that protrude outward in the left-right direction at the center portion of the first portion 41 in the front-rear direction, and are inserted into the gap between the first leg 22B and the second leg 22C.

[0042] 6 and 8, the front surface 42A of the second portion 42 faces the elastic member 30 and faces the rear side wall 23 with a small gap in the front-rear direction. The rear surface 42B of the second portion 42 faces the opposite side of the elastic member 30. As shown in FIGS. 4 and 5, the second portion 42 has a pair of left and right second engagement portions 45, 45. The second engagement portions 45 are areas that protrude outward in the left-right direction slightly below the vertical center of the second portion 42 and come into contact with the second receiving portion 26 of the second leg portion 22C in the vertical direction.

[0043] The first terminal 40 is biased downward by the elastic member 30. The first engaging portion 43 abuts against the first receiving portion 24, and the second engaging portion 45 abuts against the second receiving portion 26, thereby restricting the downward movement of the first terminal 40. That is, in the unfitted state, the first terminal 40 is sandwiched between the elastic member 30 and the pair of side walls 22, 22 (specifically, the pair of first receiving portions 24, 24 and the pair of second receiving portions 26, 26).

[0044] The second terminal 50 is a flat terminal electrically connected to an electric circuit (not shown) included in the PCU, and is attached to a housing 70 described below. As shown in Fig. 6, the second terminal 50 is a member located above the first terminal 40 and extending in the vertical direction. The second terminal 50 has an upper portion 51, a lower portion 52, and a narrowed portion 53. The second terminal 50 is made of metal (e.g., copper alloy), and the upper portion 51, the lower portion 52, and the narrowed portion 53 are integrally formed by pressing a plate material.

[0045] As shown in FIG. 1, the upper portion 51 is an area provided outside the housing 70 and connected to an electric circuit (not shown). The lower portion 52 is an area extending downward from the upper portion 51 and is provided inside the housing 70. As shown in FIG. 6, the lower portion 52 is located above the ceiling wall 21. A flexible conductor 60 is connected to a rear surface 52B of the lower portion 52. A front surface 52A of the lower portion 52 faces the housing 70 (FIG. 1) with a small gap therebetween in the front-rear direction. The narrowed portion 53 is an area recessed inward in the left-right direction in the boundary region between the upper portion 51 and the lower portion 52, and is provided at an opening Ap2 (described later) formed in the housing 70.

[0046] The flexible conductor 60 is a flexible conductor, and electrically connects the first terminal 40 and the second terminal 50. In this embodiment, the flexible conductor 60 is a band-shaped braided wire in which a plurality of conductive metal wires (e.g., copper wires) are braided.

[0047] The flexible conductor 60 is not particularly limited as long as it is a flexible conductor. For example, the flexible conductor 60 may be a tubular braided wire or a coated electric wire in which a conductive twisted wire is coated with an insulator. The flexible conductor 60 may also be a laminate (also called a laminated bus bar or flexible bus bar) in which a plurality of conductive flat plates (for example, copper thin plates) are laminated.

[0048] The flexible conductor 60 has a first joint 61 connected to the first terminal 40, a second joint 62 connected to the second terminal 50, and a bending portion 63 located between the first joint 61 and the second joint 62.

[0049] 6, the first joint 61 is connected to the rear surface 42B of the first terminal 40 with the end 60a of the flexible conductor 60 facing downward and the forming portion 63 facing upward. The second joint 62 is connected to the rear surface 52B of the second terminal 50 with the end 60b (the end opposite to the end 60a) of the flexible conductor 60 facing upward and the forming portion 63 facing downward. The first joint 61 and the second joint 62 are resistance-welded or pressure-bonded to the rear surface 42B and the rear surface 52B, respectively, and have higher rigidity than the forming portion 63.

[0050] The second portion 42 of the first terminal 40 and the lower portion 52 of the second terminal 50 overlap in the front-rear direction while being separated in the up-down direction. The first joint portion 61 and the second joint portion 62 also overlap in the front-rear direction while being separated in the up-down direction.

[0051] The forming portion 63 is a portion that is formed so as to contract in the vertical direction when the connector 80 and the mating connector 90 are mated and the first terminal 40 moves upward as shown in Figs. 1 to 3. In this embodiment, the forming portion 63 is formed into a wave shape (zigzag shape) as shown in Fig. 6. The forming portion 63 includes a plurality of first vertices 63a that are convex on the front side and a plurality of second vertices 63b that are convex on the rear side. The first vertices 63a and the second vertices 63b are positioned alternately.

[0052] FIG. 9 is an explanatory diagram showing an example of a method for forming a shaping portion 63 in the flexible conductor 60. This method is a part of a method for manufacturing the terminal module 10. First, as shown in (a) of FIG. 9, the flexible conductor 60 is resistance-welded or crimped to the first terminal 40 and the second terminal 50. As a result, a first joint 61 and a second joint 62 are formed. The resistance-welded or crimped region is shown as "region R1". Next, as shown in (b) of FIG. 9, the region between the first joint 61 and the second joint 62 of the flexible conductor 60 is pressed by a press machine P1, and pressure and heat are applied to shaping the region into a predetermined waveform. As a result, the shaping portion 63 is formed in the flexible conductor 60 as shown in (c) of FIG. 9.

[0053] Please refer to Figure 1. Here, when no load is applied to the flexible conductor 60, the length of the flexible conductor 60 in the vertical direction is a natural length L1. In the unfitted state shown in FIG. 1, the length of the flexible conductor 60 in the vertical direction is a length L2 that is longer than the natural length L1. That is, in the unfitted state, the flexible conductor 60 is stretched in the vertical direction by a predetermined length L3 (=L2-L1) from the natural length L1. At this time, a restoring force F1 for contracting the flexible conductor 60 to the natural length L1 is generated in the flexible conductor 60, and the first terminal 40 is pulled upward by the restoring force F1 of the flexible conductor 60. The restoring force F1 can be expressed by the following formula (1) using the spring constant K1 of the shaping portion 63 of the flexible conductor 60.

[0054] F1 = K1 L3 (1)

[0055] Here, in the unfitted state, the elastic member 30 is compressed by a predetermined length L4 from its natural length, and the first terminal 40 is pressed downward by a restoring force F2 of the elastic member 30. The restoring force F2 can be expressed by the following formula (2) using the spring constant K2 of the elastic member 30.

[0056] F2 = K2 L4 (2)

[0057] Then, by making the downward restoring force F2 of the elastic member 30 equal to or greater than the upward restoring force F1 of the flexible conductor 60 (F2≧F1), even if the restoring force F1 acts on the first terminal 40 in the unfitted state, the first terminal 40 can be held in the position shown in Fig. 1 (the position where the lower surface 41B abuts against a lower split body 72 described below). In this embodiment, since the spring constant K2 of the elastic member 30 is sufficiently greater than the spring constant K1 of the shaping portion 63 (K2>>K1), the restoring force F2 is greater than the restoring force F1.

[0058] <Housing configuration> Referring to FIG. 1, the housing 70 is a resin member that houses the terminal module 10. The housing 70 has an upper split body 71, a lower split body 72, and a cover 73. The upper split body 71 and the lower split body 72 are members divided into upper and lower parts. The housing 70 is configured by combining the upper split body 71 and the lower split body 72, and further combining the cover 73. The upper split body 71 is a housing that is open downward, and has an upper wall 71A, a front wall 71B, and a rear wall 71C. The respective parts 71A to 71C of the upper split body 71 are integrally formed by, for example, injection molding.

[0059] The upper wall 71A is a wall that abuts against the ceiling wall 21 in the up-down direction and is provided along the front-rear and left-right directions. The front wall 71B is a wall that abuts against the pair of side walls 22, 22 in the front-rear direction and extends downward from the front edge of the upper wall 71A. The lower end of the front wall 71B is located lower than the lower surface 41B of the first terminal 40. The rear wall 71C is a wall that extends upward from the rear edge of the upper wall 71A. The rear wall 71C faces the lower portion 52 of the second terminal 50 in the front-rear direction. The upper end of the rear wall 71C is located at the same position as the narrowed portion 53 of the second terminal 50 in the up-down direction.

[0060] The lower split body 72 is a cylindrical body having an opening Ap1 formed in the vertical direction. The lower split body 72 has a cylindrical portion 72A, a front wall 72B, a partition wall 72C, and a rear wall 72D. The portions 72A to 72D of the lower split body 72 are integrally formed by, for example, injection molding.

[0061] The tubular portion 72A is a rectangular tubular region provided on the lower side of the lower split body 72. The tubular portion 72A forms an opening Ap1 that allows the mating connector 90 to enter from below. The inner dimensions of the tubular portion 72A are larger than the outer dimensions of a mating terminal 91 and a fitting portion 94 (described later) included in the mating connector 90, allowing the mating terminal 91 and the fitting portion 94 to enter the tubular portion 72A.

[0062] The upper end of the cylindrical portion 72A abuts against the lower surface 41B of the first terminal 40. Therefore, the terminal module 10 is held in the housing 70 in a state where it is sandwiched vertically between the upper wall 71A and the upper end of the cylindrical portion 72A. The lower surface 41B of the first terminal 40 is exposed to the lower side of the connector 80 through the opening Ap1. The width of the cylindrical portion 72A in the front-rear direction is larger than the width of the first terminal 40 in the front-rear direction, and the rear end of the cylindrical portion 72A is located rearward of the second portion 42.

[0063] The front wall 72B is a wall that protrudes forward from the middle of the vertical direction of the cylindrical portion 72A and then extends upward. The front wall 71B of the upper split body 71 abuts against the rear side of the front wall 72B, and the lower end of the front wall 71B is inserted into the gap formed by the front wall 72B and the cylindrical portion 72A.

[0064] The partition wall 72C is a wall extending forward from the upper end of the rear side of the tubular portion 72A. The partition wall 72C has a function of partitioning a space into which the mating connector 90 enters (a space in which the opening Ap1 is located) and a space S1 in which the flexible conductor 60 is located when the mating connector 90 is mated.

[0065] The rear wall 72D is a wall that protrudes rearward from the middle of the vertical direction of the cylindrical portion 72A and then extends upward. A cover 73 abuts against the front side of the rear wall 72D, and a lower end of the cover 73 is inserted into a gap formed between the rear wall 72D and the cylindrical portion 72A.

[0066] The cover 73 is a member located on the rear side of the first terminal 40, the second terminal 50, and the flexible conductor 60. A space S1 surrounded by the rear wall 71C, the partition wall 72C, and the cover 73 is formed inside the housing 70. The flexible conductor 60 is accommodated in the space S1.

[0067] Between the cover 73 and the rear wall 71C, an opening Ap2 that is open in the vertical direction is formed. The second terminal 50 is inserted into the housing 70 through the opening Ap2. A narrowed portion 53 is located in the opening Ap2, and the second terminal 50 is fixed to the housing 70 by sandwiching the cover 73, which is located in the left-right direction of the opening Ap2, between the upper portion 51 and the lower portion 52.

[0068] <Mating connector configuration> The mating connector 90 has a mating terminal 91 and a mating housing 92. The mating terminal 91 is provided in the mating housing 92 by insert molding. The mating terminal 91 is a conductive member (e.g., a copper alloy) and has an L-shape including a region extending in the up-down direction and a region extending forward from the region. The mating terminal 91 has a mating contact 93 that abuts against the lower surface 41B of the first terminal 40. The mating contact 93 is provided in a bead shape on the upper surface of the mating terminal 91 by plastically deforming a portion of the mating terminal 91.

[0069] The mating housing 92 is a member made of resin. The mating housing 92 has a mating portion 94 that can enter the opening Ap1, and a flange portion 95 that extends in the front-rear and left-right directions. The mating portion 94 has an upwardly convex shape, and holds the mating terminal 91 on its upper surface. The flange portion 95 is larger in the front-rear and left-right directions than the opening Ap1, and in the mated state shown in FIG. 3, it abuts against the lower end of the tube portion 72A included in the housing 70, thereby preventing the mating connector 90 from entering the connector 80 beyond a predetermined position.

[0070] <Mating a connector with a mating connector> 1 to 3, a manner in which the mating connector 90 is fitted to the connector 80 will be described. As shown in Figs. 1 and 2, when the mating connector 90 moves upward and approaches the connector 80, the mating terminal 91 and fitting portion 94 of the mating connector 90 enter the inside of the housing 70 through the opening Ap1. Then, the mating contact 93 of the mating terminal 91 comes into contact with the lower surface 41B of the first terminal 40. When the mating connector 90 is fitted to the connector 80, it is sufficient that the connector 80 and the mating connector 90 are relatively close to each other in the vertical direction, and the connector 80 may move downward to approach the mating connector 90.

[0071] When the mating connector 90 moves further upward after the mating contact 93 comes into contact with the lower surface 41B, the first terminal 40 is pressed by the mating contact 93 and moves upward while compressing the elastic member 30. At this time, the guided portion 44 (FIG. 6) of the first terminal 40 slides against the guide surface 22B1 of the first leg 22B, so that the first terminal 40 moves upward as indicated by the arrow AR1 (FIG. 2) and also moves rearward by an amount that the guide surface 22B1 inclines in the front-rear direction. Since the guide surface 22B1 has a greater width in the up-down direction than the width of the inclination in the front-rear direction, the amount of upward movement of the first terminal 40 during mating is greater than the amount of rearward movement.

[0072] The lower surface 41B of the first terminal 40 moving rearward comes into sliding contact in the front-rear direction with the mating contact 93 moving upward. This removes foreign matter (e.g., a film of sulfide, oxide, etc. formed on the lower surface 41B) adhering between the lower surface 41B and the mating contact 93.

[0073] 3, when the mating connector 90 moves further upward, the mating connector 90 fits into the connector 80. In this state, the first portion 41 of the first terminal 40 is subjected to a downward biasing force from the elastic member 30 and an upward pressing force from the mating contact 93, and is sandwiched in the vertical direction between the elastic member 30 and the mating contact 93. In this way, the first portion 41 is pressed against the mating contact 93 by the elastic member 30, so that the first terminal 40 can be electrically connected to the mating contact 93 more reliably.

[0074] Effects of this embodiment First, the effect of providing the curling portion 63 will be described. When the mating connector 90 is mated with the connector 80, the first terminal 40 moves upward so as to approach the second terminal 50 located away from it in the vertical direction. Accordingly, the creased portion 63 of the flexible conductor 60 contracts so as to be folded in the vertical direction. More specifically, as shown in Figs. 2 and 3, the first vertices 63a move forward while approaching each other in the vertical direction. The second vertices 63b move backward while approaching each other in the vertical direction.

[0075] Fig. 10 is a diagram illustrating a comparative example of this embodiment. In Fig. 10, the first terminal 40 and the second terminal 50 are electrically connected by a flexible conductor W9 (braided wire) that does not have a bending portion 63, instead of the flexible conductor 60 of this embodiment. Fig. 10(a) shows the flexible conductor W9 in an unfitted state, and Fig. 10(b) shows the flexible conductor W9 in a fitted state.

[0076] Since the flexible conductor W9 does not have the bending portion 63, it bends only rearward (away from the elastic member 30) when the mating connector 90 is mated. Therefore, in order to prevent the housing and the flexible conductor W9 from rubbing against each other, a cover C9 positioned further away from the flexible conductor W9 in the unmated state is provided instead of the cover 73. A space S9 surrounded by the rear wall 71C of the upper split body 71, the partition wall 72C of the lower split body 72, and the cover C9 is wider in the front-rear direction.

[0077] In contrast, the flexible conductor 60 of this embodiment, as shown in Figures 2 and 3, bends both forward and backward and contracts in the up-down direction when the mating connector 90 is mated. This reduces the range of movement of the flexible conductor 60 in the front-to-rear direction when the mating connector 90 is mated, and the space S1 provided for the range of movement of the flexible conductor 60 can be made smaller. The space S1 is particularly smaller in the front-to-rear direction than the space S9. This allows the connector 80 to be made smaller while preventing breakage of the flexible conductor 60.

[0078] In addition, the bending of the bending portion 63 is restricted as compared with the flexible conductor W9 due to the bending. Specifically, the bending portion 63 is easily bent at the first vertex 63a and the second vertex 63b, and therefore the bending starts from the first vertex 63a and the second vertex 63b. That is, the bending of the bending portion 63 is more predictable than that of the flexible conductor W9. Therefore, the margin provided in the space S1 to prevent the flexible conductor 60 and the housing 70 from contacting each other can be reduced, and the connector 80 can be made smaller.

[0079] Next, the effect of extending the flexible conductor 60 beyond the natural length L1 in the unfitted state will be described.

[0080] FIG. 11 is a diagram illustrating how the flexible conductor 60 according to the embodiment buckles in a fitted state. When the flexible conductor 60 is contracted in the up-down direction by mating with the mating connector 90, the flexible conductor 60 may buckle in the front-rear direction in order to release the load acting on the flexible conductor 60 during contraction in the front-rear direction. For example, as shown in Fig. 11, at least a part of the first vertices 63a may be deformed so as to bend rearward beyond the front surface 42A of the second portion 42 and the front surface 52A of the lower portion 52. When the flexible conductor 60 buckles in this way, the range of motion of the flexible conductor 60 in the front-rear direction becomes larger than when no buckling occurs (Fig. 3), and therefore it becomes necessary to make the space S1 provided for the range of motion of the flexible conductor 60 larger.

[0081] In contrast, in this embodiment, the length L2 in the vertical direction of the flexible conductor 60 in the unmated state is longer than the natural length L1 in the vertical direction of the flexible conductor 60 by a predetermined length L3. The flexible conductor 60, which was stretched longer than the natural length L1 in the unmated state, contracts and approaches the natural length L1 when the mating connector 90 is mated. Therefore, when the flexible conductor 60 contracts, the restoring force F1 of the flexible conductor 60 becomes smaller, and the load in the vertical direction applied to the flexible conductor 60 is consumed. This makes it possible to suppress buckling in the front-rear direction when the flexible conductor 60 contracts.

[0082] More specifically, in the fitting state shown in FIG. 3, the vertical length of the flexible conductor 60 is set to a length L5 that is equal to or greater than the natural length L1 and less than the length L2. That is, in the fitting state, the flexible conductor 60 is in a state of being stretched by a predetermined length L6 (= L5 - L1) in the vertical direction compared to the natural length L1. The predetermined length L6 is 0 or more and less than the predetermined length L3. At this time, a restoring force F3 for contracting to the natural length L1 is generated in the flexible conductor 60, and the first terminal 40 is pulled upward by the restoring force F3 of the flexible conductor 60. When the length L5 is equal to the natural length L1, the restoring force F3 becomes 0, and the first terminal 40 is not pulled upward or downward. The restoring force F3 can be expressed by the following formula (3).

[0083] F3 = K1·L6 ···(3)

[0084] Since the predetermined length L6 is less than the predetermined length L3, the restoring force F3 of the flexible conductor 60 in the fitting state is smaller than the restoring force F1 of the flexible conductor 60 in the non-fitting state (F3 < F1). Just by this difference in the restoring force (F1 - F3), the vertical load applied to the flexible conductor 60 when the flexible conductor 60 contracts can be absorbed, so that buckling of the flexible conductor 60 due to an overload can be suppressed.

[0085] Note that the length L5 of the flexible conductor 60 in the fitting state may be less than the natural length L1. In this case, the flexible conductor 60 in the fitting state is in a state of being contracted by a predetermined length L7 (= L1 - L5) in the vertical direction compared to the natural length L1, and a restoring force F4 (= K1·L7) for extending to the natural length L1 is generated in the flexible conductor 60. The direction of the restoring force F4 is opposite to that of the restoring forces F1 and F3. Also in this case, just by the amount of the restoring force F1, the vertical load applied to the flexible conductor 60 when the flexible conductor 60 contracts can be absorbed, so that buckling of the flexible conductor 60 due to an overload can be suppressed.

[0086] <<Modification Example>> Hereinafter, a modification example of the embodiment will be described. In the modification example, the same reference numerals are given to the parts that are not changed from the embodiment, and the description thereof is omitted.

[0087] <<Modification of the shaping portion>> Fig. 12 is a diagram showing a flexible conductor 600 according to a modified example. Fig. 12(a) shows the flexible conductor 600 in an unfitted state, and Fig. 12(b) shows the flexible conductor 600 in a fitted state. In the above embodiment, the shaping portion 63 has a wavy shape. However, the shaping portion may have a shape other than a wavy shape.

[0088] The flexible conductor 600 is a flexible conductor, and electrically connects the first terminal 40 and the second terminal 50. In this modification, the flexible conductor 600 may be a braided wire or a covered electric wire. The flexible conductor 600 may also be a conductive solid wire (made of, for example, a copper alloy).

[0089] The flexible conductor 600 has a first joint 610 that is resistance-welded or crimped to the rear surface 42B of the first terminal 40, a second joint 620 that is resistance-welded or crimped to the rear surface 52B of the second terminal 50, and a forming portion 630 located between the first joint 610 and the second joint 620. The forming portion 630 is formed into a spiral shape as shown in Fig. 12. The forming portion 630 is formed, for example, by heating the flexible conductor 600 while it is wound around a rod material.

[0090] Since the shaping portion 630 has a helical shape, when the first terminal 40 moves upward, the shaping portion 630 contracts in the up-down direction. As a result, similar to the above embodiment, the range of motion of the flexible conductor 600 during fitting can be reduced, and the connector 80 can be made smaller while preventing breakage of the flexible conductor 600.

[0091] As in the above embodiment and modified example, by forming the curled portion in a wave shape or a spiral shape, the curled portion can be formed relatively easily.

[0092] "others" In the above embodiment, the flexible conductor 60 is connected to the rear surface 42B of the first terminal 40 and the rear surface 52B of the second terminal 50. However, the flexible conductor 60 may be connected to the front surface 42A of the first terminal 40 and the front surface 52A of the second terminal 50.

[0093] In the above embodiment, an example has been described in which the first terminal 40 moves diagonally upward and rearward when the mating connector 90 is mated. However, it is not essential that the first terminal 40 moves rearward when mated, and the first terminal 40 may move only upward. In this case, the guide surface 22B1 of the first leg 22B has a shape that extends straight downward, and the guided portion 44 is guided only in the up-down direction.

[0094] 《Addendum》 In addition, at least a part of the above-mentioned embodiment and various modified examples may be arbitrarily combined with each other. In addition, the embodiment disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present disclosure is defined by the claims, and it is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0095] 10 Terminal Module 20 cases 21 Ceiling Wall 22 Side wall 22A Base 22B 1st leg 22B1 Guide surface 22C 2nd leg 23 Side wall 24 First receiving part 25 Lower end 26 Second receiving part 27 Convex 30 Elastic member 31 Main body 32 Upper end 33 Lower end 40 1st terminal 41 Part 1 41A Top 41B Bottom surface 42 Part 2 42A Front 42B Rear 43 First engagement portion 44 Guided part 45 Second engagement portion 50 2nd terminal 51 Upper part 52 Lower part 52A Front 52B Rear 53 Waist part 60 Flexible conductor 600 Flexible conductor 60a End 60b end 61 1st joint 610 1st joint 62 Second joint 620 2nd joint 63 Crease section 630 Crease section 63a First apex 63b Second apex 70 Housing 71 Upper split body 71A Upper wall 71B Front wall 71C back wall 72 Lower part body 72A Cylinder part 72B Front wall 72C Partition wall 72D back wall 73 Cover 80 Connectors 90 Mating connector 91 Mating terminal 92 Mating Housing 93 Counter Contact 94 Fitting part 95 Flange Ap1 aperture Ap2 aperture S1 space S9 space W9 Flexible conductor C9 Cover P1 Press Machine L1 natural length L2 Length L3 predetermined length L4 predetermined length L5 Length L6 predetermined length L7 Predetermined length F1 Resiliency F2 Restoration Force F3 Resiliency F4 Restoration K1 spring constant K2 spring constant AR1 Arrow

Claims

1. A terminal module that is fitted with a mating connector that approaches relatively along a first direction from one side to the other side and is electrically connected to the mating connector, A case including a ceiling wall and a pair of side walls extending from the ceiling wall to the one side; an elastic member that is accommodated in the case and is stretchable along the first direction; a first terminal supported by the pair of side walls in a state in which the first terminal is biased to the one side by the elastic member and is movable to the other side by being pressed by the mating connector; a second terminal located on the other side of the first terminal and extending in the first direction; a flexible conductor electrically connecting the first terminal and the second terminal; Equipped with the flexible conductor has a creased portion creased to contract in the first direction when the first terminal moves to the other side, the bending portion is formed to bend in both sides in a second direction perpendicular to the first direction when the first terminal moves to the other side, so that a manner of bending is restricted in advance before the bending, and includes a first vertex portion that is convex on one side in the second direction and a second vertex portion that is convex on the other side in the second direction in a state where no load is applied, The first vertex portion and the second vertex portion are more easily bent than other portions of the forming portion.

2. A terminal module that mates with a mating connector that approaches relatively along a first direction from one side to the other side, and electrically connects to the mating connector, A case including a ceiling wall and a pair of side walls extending from the ceiling wall to the one side; an elastic member that is accommodated in the case and is stretchable along the first direction; a first terminal supported by the pair of side walls in a state in which the first terminal is biased to the one side by the elastic member and is movable to the other side by being pressed by the mating connector; a second terminal located on the other side of the first terminal and extending in the first direction; a flexible conductor electrically connecting the first terminal and the second terminal; Equipped with the flexible conductor has a creased portion creased to contract in the first direction when the first terminal moves to the other side, The terminal module, wherein the bending portion is formed into a spiral shape when no load is applied, so that the manner of bending is regulated in advance before the bending occurs.

3. The forming portion is formed into a wave shape. The terminal module according to claim 1 .

4. The flexible conductor is a braided wire, a coated wire in which a conductive stranded wire is coated with an insulator, a laminate in which a plurality of conductive flat plates are laminated, or a conductive single wire. The terminal module according to any one of claims 1 to 3.

5. In an unmated state before being mated with the mating connector, a length of the flexible conductor in the first direction is longer than a natural length of the flexible conductor in the first direction. The terminal module according to any one of claims 1 to 4.

6. A terminal module that mates with a mating connector that approaches relatively along a first direction from one side to the other side, and electrically connects to the mating connector, A case including a ceiling wall and a pair of side walls extending from the ceiling wall to the one side; an elastic member that is accommodated in the case and is stretchable along the first direction; a first terminal supported by the pair of side walls in a state in which the first terminal is biased to the one side by the elastic member and is movable to the other side by being pressed by the mating connector; a second terminal located on the other side of the first terminal and extending in the first direction; a flexible conductor electrically connecting the first terminal and the second terminal; Equipped with the flexible conductor has a creased portion creased to contract in the first direction when the first terminal moves to the other side, The bending direction of the bending portion is regulated before the bending portion is bent, In an unmated state before being mated with the mating connector, the length of the flexible conductor in the first direction is longer than a natural length of the flexible conductor in the first direction.

7. In the unfitted state, a length of the elastic member in the first direction is shorter than a natural length of the elastic member in the first direction, In the unfitted state, a restoring force toward the other side generated in the flexible conductor is smaller than a restoring force toward the one side generated in the elastic member. The terminal module according to claim 5 or 6.

8. A terminal module according to any one of claims 1 to 7; a housing in which the terminal module is accommodated; A connector comprising:

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