Connector manufacturing method

Abstract

To provide a novel manufacturing method of a connector obtained by integrally forming a contact array and a housing that holds the contact array by insert molding, and provide a novel structure.SOLUTION: In a housing step, a plug contact assembly 70 is housed into an injection mold 73 so that both ends of the plug contact assembly 70 are supported in the injection mold 73 by using two supporting parts 72. In an insert molding step, a plug housing 6 is molded integrally with the plug contact assembly 70 by insert molding so that a connection beam 71 of the plug contact assembly 70 is separated from two width side surfaces 50 in a width direction between the two width side surfaces 50. In a 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

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

Background Art

[0002] In Patent Document 1, as shown in FIG. 39 of the present application, when molding a housing 1001 that holds a plurality of contacts 1000 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

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present disclosure is to provide a novel manufacturing method and a novel structure of a connector formed integrally by insert molding of a contact array and a housing that holds the contact array.

Means for Solving the Problems

[0005] A method for manufacturing a connector comprising: an assembly manufacturing step of manufacturing at least one contact assembly comprising: at least one contact array including a plurality of contacts; a housing holding the at least one contact array, integrally formed by insert molding, wherein the outer circumferential surface of the housing includes two width sides facing opposite directions in the width direction perpendicular to the pitch direction of the at least one contact array; and the assembly manufacturing step of manufacturing at least one contact assembly comprising: the at least one contact array; a connecting beam 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; and the 2 A manufacturing method is provided, comprising: a housing step of housing the at least one contact assembly in an injection mold so that the at least one contact assembly is supported at both ends in the injection mold using two support parts; an insert molding step of integrally molding the housing with the at least one contact assembly by insert molding such that the connecting beam of the at least one contact assembly is between the two width sides and away from the two width sides in the width direction; and a separation step of removing at least a portion of the at least one contact assembly so that the plurality of contacts are separated. In the housing step, the two support portions may be sandwiched between the fixed mold plate and the movable mold plate in the direction of advancement and retraction of the movable mold plate relative to the fixed mold plate of the injection molding die, thereby supporting both ends of the at least one contact assembly within the injection molding die. In the insert molding step, the housing may be molded such that the two support portions of the at least one contact assembly are exposed outside the outer circumferential surface of the housing. The process may further include a support removal step after the insert molding step, in which the two support parts of the at least one contact assembly are removed. In the insert molding step, the housing may be molded such that it 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 includes a plurality of contact assemblies, and in the assembly manufacturing step, the plurality of contact assemblies may be manufactured as separate parts from each other. Each contact includes a soldered portion, an embedded portion, and a contact portion in that order, and each contact may protrude from the connecting beam in the order of the soldered portion, the embedded portion, and the contact portion. Each contact includes a soldered portion, an embedded portion, and a contact portion in that order, and each contact may protrude from the connecting beam in the order of the contact portion, the embedded portion, and the soldered portion. In the insert molding step, the housing may be molded such that the contact portion is elastically displaceable relative to the housing. In the insert molding step, the housing may be molded such that the contact portion cannot be elastically displaced relative to the housing. A connector is provided, comprising at least one contact array including a plurality of contacts and a housing holding the at least one contact array, integrally formed by insert molding, wherein the outer circumferential surface of the housing includes two pitch sides facing opposite directions in the pitch direction of the at least one contact array, the housing having at least one through hole penetrating the housing vertically and 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 cross-section that is flush with the inner circumferential surface of the at least one through hole. The at least one pitch extension groove may be formed to intersect the at least one through hole. The at least one pitch extension groove may contain a metal piece made of the same material as the plurality of contacts. The at least one through-hole corresponding to the at least one contact array includes an extended through-hole extending in the pitch direction, and the plurality of contacts of the at least one contact array may protrude into the extended through-hole or have a cross-section flush with the inner circumferential surface of the extended through-hole. The at least one contact array includes two adjacent contact arrays in the width direction perpendicular to the pitch direction, the extension through-hole is 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 the extension through-hole or have a cross-section that is flush with the inner circumferential surface of the extension 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 pattern. The at least one contact array has a first contact array and a second contact array adjacent to each other in the width direction perpendicular to the pitch direction, and the at least one through hole includes a first extension through hole and a second extension through hole extending in the pitch direction, and the first contact array, the first extension through hole, the second contact array, and the second extension through hole are arranged in this order in the width direction, and the plurality of contacts of the first contact array may protrude into the first extension through hole or have a cross-section flush with the inner circumferential surface of the first extension through hole, and the plurality of contacts of the second contact array may protrude into the second extension through hole or have a cross-section flush with the inner circumferential surface of the second extension through hole. 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, and the plurality of contacts of the at least one contact array may protrude into any of the plurality of through-holes or have a cross-section that is flush with the inner circumferential surface of any of the plurality of through-holes. The at least one contact array includes two adjacent contact arrays in the width direction perpendicular to the pitch direction, 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 any of the plurality of through holes or have a cross-section that is flush with the inner surface of any of the plurality of through holes. Each contact includes a soldered portion, an embedded portion, and a contact portion, in that order, and the contact portion may be elastically displaceable relative to the housing. The soldered portion of each contact may protrude into the interior of the at least one through hole, or it may have a cross-section 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 interior of the at least one through hole, or it may have a cross-section that is flush with the inner circumferential surface of the at least one through hole. Each contact includes a soldered portion, an embedded portion, and a contact portion, in that order, and the contact portion may be unable to be elastically displaced relative to the housing. The housing has at least one width extension groove that extends 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 house a metal piece made of the same material as the plurality of contacts. [Effects of the Invention]

[0006] According to the present disclosure, a novel manufacturing method and a novel structure of a connector are provided, which integrally form a contact array and a housing holding the contact array by insert molding.

Brief Description of the Drawings

[0007] [Figure 1] Perspective view of a connector assembly. (First Embodiment) [Figure 2] Perspective view of the connector assembly seen from another angle. (First Embodiment) [Figure 3] Perspective view of a plug connector. (First Embodiment) [Figure 4] Plan view of a plug connector. (First Embodiment) [Figure 5] Perspective view of a plurality of plug contact arrays arranged in the width direction. (First Embodiment) [Figure 6] Perspective view of a receptacle connector. (First Embodiment) [Figure 7] Plan view of a receptacle connector. (First Embodiment) [Figure 8] Perspective view of a plurality of receptacle contact arrays arranged in the width direction. (First Embodiment) [Figure 9] Cross-sectional perspective view of a plug connector. (First Embodiment) [Figure 10] Cross-sectional view of a plug connector. (First Embodiment) [Figure 11] Perspective view of a plug connector. (First Embodiment) [Figure 12] Bottom view of a plug connector. (First Embodiment) [Figure 13] Manufacturing flow of a plug connector. (First Embodiment) [Figure 14] Perspective view of a plug contact assembly. (First Embodiment) [Figure 15] Perspective view showing an injection molding die in which a plurality of plug contact assemblies are set. (First Embodiment) [Figure 16]Front view of an injection mold accommodating a plurality of plug contact assemblies. (First Embodiment) [Figure 17] Perspective view of a molded product taken out from an injection mold. (First Embodiment) [Figure 18] Plan view of a molded product. (First Embodiment) [Figure 19] Plan view of a molded product showing the area to be removed by hatching. (First Embodiment) [Figure 20] Cross-sectional perspective view of a receptacle connector. (First Embodiment) [Figure 21] Cross-sectional view of a receptacle connector. (First Embodiment) [Figure 22] Perspective view of a receptacle contact assembly. (First Embodiment) [Figure 23] Cross-sectional perspective view of a plug connector. (First Modified Example) [Figure 24] Partial plan view of a plug connector. (Second Modified Example) [Figure 25] Plan view of a plug contact assembly. (Second Modified Example) [Figure 26] Partial plan view of a plug connector. (Third Modified Example) [Figure 27] Plan view of a plug contact assembly. (Third Modified Example) [Figure 28] Partial plan view of a plug connector. (Fourth Modified Example) [Figure 29] Exploded perspective view of a plug connector. (Fourth Modified Example) [Figure 30] Partial plan view of a molded product. (Fourth Modified Example) [Figure 31] Partial plan view of a plug connector. (Fifth Modified Example) [Figure 32] [[ID=4)]](Exploded perspective view of a plug connector. (Fifth Modified Example) [Figure 33] Partial plan view of a molded product. (Fifth Modified Example) [Figure 34] Partial plan view of a plug connector. (Sixth Modified Example) [Figure 35] This is a partial plan view of the molded product. (Sixth modified example) [Figure 36] Disassembled perspective view of a plug connector. (Seventh modified example) [Figure 37] This is a perspective view of a partially cutaway receptacle connector. (Variation 8) [Figure 38] This is a perspective view of a cutout in a molded product. (Variation 8) [Figure 39] This is a simplified diagram of Figure 4 in Patent Document 1. [Modes for carrying out the invention]

[0008] (First Embodiment) The first embodiment of this disclosure will be described below with reference to Figures 1 to 22.

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

[0010] The lower substrate 2 and 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 Figures 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 include 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 to at least one. Typically, the plug 5 includes at least three plug contact arrays 7.

[0012] As shown in Figures 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 include 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 to at least one. Typically, the receptacle 4 includes at least three receptacle contact arrays 21. The multiple receptacle contact arrays 21 are all said to 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, we define the pitch direction, width direction, and vertical direction. The pitch direction, width direction, and vertical direction are mutually orthogonal directions.

[0016] As shown in Figures 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 Figure 3, the pitch direction includes the inward direction, which is toward the center of the plug 5 in the pitch direction, and the outward direction, which is toward the center of the plug 5 in the pitch direction.

[0017] As shown in Figure 1, the vertical direction is perpendicular to the connector mounting surface 3A of the upper substrate 3. The vertical direction includes upward and downward. Upward is the direction in which the plug 5 moves relative to the receptacle 4 when the plug 5 is removed from the receptacle 4. Downward is the direction in which the plug 5 moves relative to the receptacle 4 when the plug 5 is mated into 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] Returning to Figure 3, the width direction is, as mentioned above, a direction perpendicular to the pitch direction and the vertical direction. The width direction includes the inward direction, which is closer to the center of the plug 5 in the width direction, and the outward direction, which is further away from the center of the plug 5 in the width direction.

[0019] The above-mentioned vertical directions are merely defined for explanatory purposes and do not indicate the actual orientation of the connector assembly 1 in its usage state. Furthermore, as mentioned above, each direction was defined using the structure of the plug 5, but each direction is also used when describing the structure of the receptacle 4. For example, the pitch direction in the receptacle 4 is the direction that coincides with the pitch direction of the plug 5 when the receptacle 4 is mated to the plug 5. Also, the width direction in the receptacle 4 is the direction that coincides with the width direction of the plug 5 when the receptacle 4 is mated to the plug 5.

[0020] As shown in Figures 3 to 5, each of the plug contact arrays 7 extends in the pitch direction. Therefore, the plug contact arrays 7 extend parallel to each other. Furthermore, the plug contact arrays 7 are arranged in the width direction. Moreover, the positions of the plug contact arrays 7 in the pitch direction are aligned with each other.

[0021] Similarly, as shown in Figures 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 each other. Furthermore, the multiple receptacle contact arrays 21 are arranged in the width direction. Moreover, the positions of the multiple receptacle contact arrays 21 in the pitch direction are aligned with each other.

[0022] Next, the plug 5 will be described in detail with reference to Figures 3 to 5 and Figures 9 to 12. However, please note that when referring to Figures 3, 5, 9, and 10, the upward and downward orientations do not coincide with the top and bottom of the paper. Also, please note that Figure 4 shows a plan view of the plug 5, and that the plan view of the plug 5 shown in Figure 4 is a view of the plug 5 from the receptacle 4 facing it in the vertical direction.

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

[0024] Each of the multiple pitch beams 30 extends in the pitch direction. The multiple pitch beams 30 extend parallel to each other. 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 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 that penetrates the plug housing 6 vertically. In other words, the plug housing 6 has multiple through-holes 40. Each of the multiple through-holes 40 extends from one of the two width beams 31 to the other. The multiple through-holes 40 include a first through-hole 41, a second through-hole 42, a third through-hole 43, and a fourth through-hole 44. Each through-hole 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 circumferential surface 6A of the plug housing 6 has a roughly square contour in plan view. The outer circumferential surface 6A of the plug housing 6 includes two width sides 50 facing outward in the width direction and two pitch sides 51 facing outward in the pitch direction. The two width sides 50 are the sides of the plug housing 6 that are located furthest outward in the width direction. The two pitch sides 51 are the sides of the plug housing 6 that are located furthest outward in the pitch direction.

[0030] Furthermore, the plug housing 6 is made from a single component. That is, the plug housing 6 is formed in a single injection molding process within a single 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 in an unbroken manner via two width beams 31.

[0031] As shown in Figure 5, since all of the plug contact arrays 7 have the same shape, 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] As shown in Figures 5, 9, and 10, each plug contact 14 is formed in an L-shape when viewed in the pitch direction, and includes a soldering portion 15, a recessed portion 16, and a contact portion 17 in that order. 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 recessed portion 16.

[0033] The soldering portion 15 is the portion that is soldered to an electrode pad (not shown) located on the connector mounting surface 3A of the upper substrate 3 in Figure 1. As shown in Figures 9 and 10, the soldering portion 15 includes a soldering exposed portion 15A that is observable in a plan view by protruding outward in the width direction from the third pitch beam 34, and a soldering covered portion 15B that is not observable in a plan view by being covered by the second pitch beam 33. The soldering exposed portion 15A is located inside the second through hole 42. Therefore, it can be said that the soldering portion 15 protrudes into the inside of the second through hole 42. The tip surface 15C, which is the cross-section of the soldering portion 15 facing outward in the width direction, is not flush with the inner circumferential surface 42A of the second through hole 42. The tip surface 15C is located outward in the width direction from the inner circumferential surface 42A of the second through hole 42. That is, the soldering portion 15 extends through the inner circumferential surface 42A of the second through hole 42. As shown in Figure 10, the soldering portion 15 has an exposed surface 15D that is exposed upward. That is, both the exposed soldering portion 15A and the covered soldering portion 15B are exposed upward. Therefore, both the exposed soldering portion 15A and the covered soldering portion 15B can be soldered to the corresponding electrode pads located on the connector mounting surface 3A of the upper substrate 3.

[0034] As shown in Figures 9 and 10, the embedded portion 16 is curved in an arc shape, smoothly connecting the soldering portion 15, which extends in the width direction, and the contact portion 17, which extends in the vertical direction. The embedded portion 16 is embedded in the plug housing 6. This prevents the contact portion 17 from being contaminated by solder or flux when the soldering portion 15 is soldered.

[0035] The contact portion 17 is a part that protrudes downward from the embedded portion 16 and is exposed from the plug housing 6. The contact portion 17 has high rigidity against bending, so that it is substantially unable to undergo elastic displacement relative to the plug housing 6.

[0036] In this embodiment, each plug contact 14 is formed in an L-shape, but the shape of each plug contact 14 is not limited. For example, each plug contact 14 may have a straight shape without a bent portion.

[0037] As shown in Figure 4, the soldered portion 15 of each plug contact 14 constituting the second plug contact array 9 protrudes into the first through hole 41. Similarly, the soldered portion 15 of each plug contact 14 constituting the third plug contact array 10 protrudes into the second through hole 42. Similarly, the soldered portion 15 of each plug contact 14 constituting the fourth plug contact array 11 protrudes into the third through hole 43. Similarly, the soldered portion 15 of each plug contact 14 constituting the fifth plug contact array 12 protrudes into the fourth through hole 44.

[0038] In contrast, the soldered portion 15 of each plug contact 14 constituting the first plug contact array 8 protrudes outward in the width direction from one width side surface 50. Similarly, the soldered portion 15 of each plug contact 14 constituting the sixth plug contact array 13 protrudes 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 Figures 11 and 12.

[0040] As shown in Figure 11, the plug housing 6 has an upward-facing lower surface 6B. The lower surface 6B is the uppermost surface of the plug housing 6. As shown in Figures 11 and 12, a plurality of pitch extension grooves 60 are formed on 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 sides 51 to the other. The plurality of pitch extension grooves 60 are arranged 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 when viewed from the bottom. Specifically, 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 in the pitch direction by the corresponding through hole 40. Due to this division, each pitch extension groove 60 eliminates the portion that overlaps 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] As shown in Figure 11, each pitch extension division groove 60A houses a metal piece 65 made of the same material as the plug contact 14. However, the metal piece 65 can be omitted.

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

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

[0045] The connecting beam 71 includes a connecting beam body 71A facing the plug contact array 7 in the width direction, and two connecting portions 71B projecting outward in the pitch direction from both ends of the connecting beam body 71A. The connecting beam 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 body 71A of the connecting beam 71 in the order of soldering portion 15, embedded portion 16, and contact portion 17.

[0046] Each support portion 72 is positioned 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 has a circular positioning hole 72A formed in it.

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

[0048] In this embodiment, since the plug 5 requires six plug contact arrays 7, six plug contact assemblies 70 are manufactured when manufacturing one plug 5. 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, the multiple plug contact assemblies 70 may have different shapes.

[0049] Storage step (S110): Figures 15 and 16 show an injection molding die 73 for injection molding the plug housing 6. The injection molding die 73 includes a fixed mold plate 74 and a movable mold plate 75. The movable mold plate 75 is configured to move up and down relative to the fixed mold plate 74. As shown in Figure 15, in order to house multiple plug contact assemblies 70 in the injection molding die 73, first, with the injection molding die 73 open, multiple positioning pins 74B that protrude upward from the dividing surface 74A of the fixed mold plate 74 are used to set the multiple plug contact assemblies 70 on the dividing surface 74A of the fixed mold plate 74. At this time, each positioning pin 74B is inserted into each positioning hole 72A of each plug contact assembly 70, thereby positioning each plug contact assembly 70 relative to the fixed mold plate 74 in the pitch direction and width direction. Since two positioning pins 74B are inserted into two positioning holes 72A to position one plug contact assembly 70, the plug contact assembly 70 cannot rotate horizontally when it is set on the dividing surface 74A of the fixed mold plate 74. Furthermore, since the two positioning holes 72A are formed as far apart as possible from each other in the pitch direction, high-precision positioning of each plug contact assembly 70 relative to the fixed mold plate 74 is achieved.

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

[0051] Next, as shown in Figure 16, the injection molding die 73 is clamped. At this time, the plug contact assembly 70 is supported at both ends within the injection molding die 73 using the two support parts 72 of the plug contact assembly 70. Specifically, the plug contact assembly 70 is supported at both ends within the injection molding die 73 by sandwiching the two support parts 72 vertically between the fixed mold plate 74 and the movable mold plate 75.

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

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

[0054] Furthermore, as shown in Figure 18, in the insert molding step, the plug housing 6 is molded such that the connecting beam body 71A of the connecting beam 71 of the plug contact assembly 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 is between the two width sides 50 of the plug housing 6 and away from the two width sides 50.

[0055] Furthermore, in the insert molding step, the plug housing 6 is molded such that the connecting beam body 71A of the connecting beam 71 of the plug contact assembly 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 is exposed vertically within the first through hole 41, the second through hole 42, the third through hole 43, and the fourth through hole 44, respectively. In other words, the plug housing 6 is molded such 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 vertically, so that the connecting beam body 71A of the connecting beam 71 of the plug contact assembly 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 is exposed vertically. On the other hand, the plug housing 6 is formed such that the connecting beams 71 of each plug contact assembly 70 corresponding to the first plug contact array 8 and the sixth plug contact array 13 are located outward in the width direction from the corresponding width side surface 50.

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

[0057] Specifically, 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 Figure 19, the portion of each plug contact assembly 70 that is exposed vertically in each through hole 40 is removed by cutting. In Figure 19, the area to be removed is illustrated with hatching. In the example in Figure 19, the connecting beam body 71A of the connecting beam 71 of each plug contact assembly 70 is 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 entire connecting beam 71 is exposed, so the entire connecting beam 71 is 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] Specifically, 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 Figure 19, the two support portions 72 of each plug contact assembly 70 and the portions of the two connecting portions 71B that protrude outward in the pitch direction from the two pitch sides 51 of the plug housing 6 are removed by cutting.

[0060] On the other hand, for the plug contact assemblies 70 corresponding to the first plug contact array 8 and the sixth plug contact array 13, the connecting beam 71 is exposed overall, so typically the two support parts 72 are removed by cutting along with the connecting beam 71.

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

[0062] Thus, as shown in Figure 9, the soldered portion 15 of each plug contact 14 protrudes into the corresponding through hole 40. Also, as shown in Figures 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 on the lower surface 6B of the plug housing 6. Then, as shown in Figure 11, the remaining portions of the two connecting portions 71B of the connecting beam 71 remain as metal pieces 65 in the two pitch extension division grooves 60A of the pitch extension groove 60. However, in order to lighten the plug 5, the metal pieces 65 may be made to fall out of the pitch extension division grooves 60A. For example, if the plug housing 6 is molded so that it does not directly touch the metal pieces 65 by covering the connecting portions 71B of the connecting beam 71 shown in Figure 14 with a slide core that can slide in the pitch direction during insert molding, the metal pieces 65 can be easily removed together with the corresponding support portion 72 without cutting each plug contact assembly 70 in the support portion removal step after the separation step.

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

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

[0065] Each of the multiple pitch beams 80 extends in the pitch direction. The multiple pitch beams 80 extend parallel to each other. 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 width beams 81 extend in the width direction. The two width beams 81 extend parallel to each other. The two width beams 81 are positioned 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 penetrates the receptacle housing 20 vertically. In other words, the receptacle housing 20 has multiple through-holes 90. Each of the multiple through-holes 90 extends from one of the two width beams 81 to the other. The multiple through-holes 90 include 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] The first through-hole 91 is formed between the first pitch beam 82 and the second pitch beam 83. The second through-hole 92 is formed between the second pitch beam 83 and the third pitch beam 84. The third through-hole 93 is formed between the third pitch beam 84 and the fourth pitch beam 85. The fourth through-hole 94 is formed between the fourth pitch beam 85 and the fifth pitch beam 86.

[0070] As shown in Figure 4, the outer circumferential surface 20A of the receptacle housing 20 has a roughly square contour in plan view. The outer circumferential surface 20A of the receptacle housing 20 includes two width sides 100 facing outward in the width direction and two pitch sides 101 facing outward in the pitch direction. The two width sides 100 are the sides of the receptacle housing 20 that are located furthest outward in the width direction. The two pitch sides 101 are the sides of the receptacle housing 20 that are located furthest outward in the pitch direction.

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

[0072] As shown in Figure 8, since all of the multiple receptacle contact arrays 21 have the same shape, the third receptacle contact array 24 will be described 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] As shown in Figures 8, 20, and 21, the receptacle contact 110 includes a soldered portion 111, an embedded portion 112, and a contact portion 113 in that order. That is, the soldered portion 111 and the contact portion 113 are connected to each other via the embedded portion 112.

[0074] The soldering portion 111 is the portion that is soldered to an electrode pad (not shown) located on the connector mounting surface 2A of the lower substrate 2 in Figure 1. As shown in Figure 21, the soldering portion 111 includes a soldering exposed portion 111A that is observable in a plan view by protruding in the width direction from the third pitch beam 84, and a soldering covered portion 111B that is not observable in a plan view by being covered by the third pitch beam 34. The soldering exposed 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. The tip surface 111C, which is the cross-section of the soldering portion 111 facing outward in the width direction, is not flush with the inner circumferential surface 92A of the second through hole 92. The tip surface 111C is located outward in the width direction from the inner circumferential surface 92A of the second through hole 92. In other words, the soldering portion 111 extends through the inner circumferential surface 92A of the second through hole 92. The soldering portion 111 has an exposed surface 111D that is exposed downwards. That is, both the soldering exposed portion 111A and the soldering covered portion 111B are exposed downwards. Therefore, both the soldering exposed portion 111A and the soldering covered portion 111B can be soldered to the corresponding electrode pads located on the connector mounting surface 2A of the lower substrate 2.

[0075] The embedded portion 112 extends upward from the soldering portion 111. The embedded portion 112 connects the soldering portion 111 and the contact portion 113. The embedded portion 112 is embedded in the receptacle housing 20. This prevents the contact portion 113 from being contaminated by 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 electrically contact the contact portion 17 of the corresponding plug contact 14 of the plug 5. The contact portion 113 includes a curved portion 113A, a downward portion 113B, a horizontal portion 113C, and an S-shaped portion 113D in that order.

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

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

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

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

[0081] The contact portion 113 is supported in a cantilever-like manner by the embedded portion 112, allowing it to be elastically deformable in the width direction. More specifically, the S-shaped portion 113D of the contact portion 113 is elastically deformable in the width direction.

[0082] Then, when the contact portion 17 of the plug contact 14 shown in Figure 10 is inserted between the descending portion 113B and the S-shaped portion 113D of the corresponding receptacle contact 110 shown in Figure 21, the S-shaped portion 113D undergoes slight elastic deformation in the width direction, and the S-shaped portion 113D comes into contact with the contact portion 17 of the plug contact 14 with a predetermined contact pressure.

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

[0084] As shown in Figure 7, the soldered portion 111 of each receptacle contact 110 constituting the second receptacle contact array 23 protrudes into the first through-hole 91. Similarly, the soldered portion 111 of each receptacle contact 110 constituting the third receptacle contact array 24 protrudes into the second through-hole 92. Similarly, the soldered portion 111 of each receptacle contact 110 constituting the fourth receptacle contact array 25 protrudes into the third through-hole 93. Similarly, the soldered portion 111 of each receptacle contact 110 constituting the fifth receptacle contact array 26 protrudes into the fourth through-hole 94.

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

[0086] The rest of the structure of receptacle 4 is identical to that of plug 5.

[0087] Next, the manufacturing method for the receptacle 4 will be described. The manufacturing method for the receptacle 4, like that for the plug 5, includes an assembly manufacturing step (S100), a housing step (S110), an insert molding step (S120), a separation step (S130), and a support part removal step (S140).

[0088] Assembly manufacturing step (S100): As shown in Figure 22, the assembly manufacturing step manufactures a receptacle contact assembly 114 (contact assembly). Each receptacle contact assembly 114 includes a receptacle contact array 21, a connecting beam 115 that connects a plurality of receptacle contacts 110 of the receptacle contact array 21 to each other, and two support parts 116 that sandwich the connecting beam 115 in the pitch direction.

[0089] The connecting beam 115 includes a connecting beam body 115A facing the receptacle contact array 21 in the width direction, and two connecting portions 115B that project outward in the pitch direction from both ends of the connecting beam body 115A. The connecting beam 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 projects from the connecting beam body 115A of the connecting beam 115 in the order of soldering portion 111, embedded portion 112, and contact portion 113.

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

[0091] The receptacle contact assembly 114, configured as described above, is typically formed by press-forming a thin 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 produced. 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 other manufacturing method for receptacle 4 is the same as that for plug 5.

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

[0095] As shown in Figure 4, the plug 5 (connector) is formed integrally by 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. The outer peripheral surface 6A of the plug housing 6 includes two width sides 50 that are opposite to each other in the width direction perpendicular to the pitch direction of the third plug contact array 10. As shown in Figure 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 Figure 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 a plurality of plug contacts 14 of the plug contact array 7 to each other, and two support parts 72 that sandwich the connecting beam 71 in the pitch direction. In the housing step, as shown in Figures 15 and 16, the plug contact assembly 70 is housed in the injection molding die 73 so that the plug contact assembly 70 is supported at both ends within the injection molding die 73 using two support parts 72. In the insert molding step, as shown in Figures 17 and 18, the plug housing 6 is integrally molded with the plug contact assembly 70 by insert molding so that the connecting beam 71 of the plug contact assembly 70 is between two width sides 50 and away from the two width sides 50 in the width direction. In the separation step, as shown in Figure 19, at least a portion of the plug contact assembly 70 is removed so that the multiple plug contacts 14 are separated. By this 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 two width sides 50 and away from the two width sides 50 in the width direction. As an example of application, it can be applied to a multi-row connector in which the plug housing 6 as a single part holds three or more rows of plug contact arrays 7 by insert molding. The same applies to the receptacle 4.

[0096] Furthermore, as shown in Figures 15 and 16, during the housing step, the plug contact assembly 70 is supported at both ends within the injection molding die 73 by the two support portions 72 sandwiched between the fixed mold plate 74 and the movable mold plate 75 in the direction of the movable mold plate 75 moving back and forth relative to the fixed mold plate 74 of the injection molding die 73. The same applies to the receptacle 4.

[0097] Furthermore, as shown in Figure 17, in the insert molding step, the plug housing 6 is molded such 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] Furthermore, as shown in Figures 13 and 19, the manufacturing method of the plug 5 further includes a support removal step (S140) after the insert molding step, in which the two support portions 72 of the plug contact assembly 70 are removed. The same applies to the receptacle 4.

[0099] Furthermore, as shown in Figures 18 and 19, in the insert molding step, the plug housing 6 is molded such that it has through holes 40 (at least one through hole) that penetrate the plug housing 6 vertically so that at least a portion of the plug contact assembly 70 is exposed in the vertical direction. According to the above method, when separating the multiple plug contacts 14 in the separation step, it becomes easier to remove at least a portion of the plug contact assembly 70. 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] Furthermore, as shown in Figure 15, in the assembly manufacturing step, multiple plug contact assemblies 70 are manufactured as separate parts from each other. This method allows multiple plug contact assemblies 70 to be compressed in the width direction, thus contributing to miniaturization of the plug 5 in the width direction. The same applies to the receptacle 4.

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

[0102] Furthermore, as shown in Figure 10, in the manufacturing of the plug 5, the plug housing 6 is molded in the insert molding step such that the contact portion 17 cannot be elastically displaced relative to the plug housing 6. In contrast, as shown in Figure 21, in the manufacturing of the receptacle 4, the receptacle housing 20 is molded in the insert molding step such that the contact portion 113 can be elastically displaced relative to the receptacle housing 20.

[0103] Furthermore, as shown in Figures 4 and 12, the plug 5 is formed integrally by 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 circumferential surface 6A of the plug housing 6 includes two pitch side surfaces 51 that are opposite to 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] Furthermore, as shown in Figure 12, the second pitch extension groove 62 is formed to intersect with the second through hole 42. The same applies to the receptacle 4.

[0105] Furthermore, as shown in Figure 11, the pitch extension division groove 60A of the second pitch extension groove 62 houses multiple metal pieces 65 made of the same material as the plug contacts 14. The plug 5 may be surface-mounted onto the connector mounting surface 3A of the upper substrate 3 using these metal pieces 65. The same applies to the receptacle 4.

[0106] Furthermore, as shown in Figure 4, the second through-hole 42 (extended through-hole) corresponding to the third plug contact array 10 extends in the pitch direction. Multiple plug contacts 14 of the third plug contact array 10 protrude into the interior of the second through-hole 42. The same applies to the receptacle 4.

[0107] Furthermore, as shown in Figure 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 a first through hole 41 (first extended through hole) and a second through hole 42 (second extended through hole) extending in the pitch direction. 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. Multiple plug contacts 14 of the second plug contact array 9 protrude into the first through hole 41. Multiple plug contacts 14 of the third plug contact array 10 protrude into the second through hole 42. The same applies to the receptacle 4.

[0108] Furthermore, as shown in Figure 21, each receptacle contact 110 includes a soldered portion 111, an embedded portion 112, and a contact portion 113, in that order. The contact portion 113 is elastically displaceable relative to the receptacle housing 20.

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

[0110] Furthermore, as shown in Figure 10, each plug contact 14 includes a soldered portion 15, an embedded portion 16, and a contact portion 17, in that order. The contact portion 17 is not elastically displaceable relative to the plug housing 6.

[0111] (First variation) Next, a first modified example of this disclosure will be described with reference to Figure 23. The following description will focus on the differences between this modified example and the first embodiment described above, omitting any redundant explanations. This modified example is also applicable to receptacle 4.

[0112] In the first embodiment described above, as shown in Figure 9, the soldered portion 15 of each plug contact 14 of the third plug contact array 10 protrudes into the second through hole 42. That is, the soldered portion 15 of each plug contact 14 of the third plug contact array 10 includes a soldered exposed portion 15A that is observable in a plan view as it protrudes outward in the width direction from the third pitch beam 34, and a soldered covered portion 15B that is not observable in a plan view as it is covered by the third pitch beam 34.

[0113] In contrast, in this modified example, as shown in Figure 23, the soldered portion 15 of each plug contact 14 of the third plug contact array 10 does not protrude into the second through hole 42. That is, the soldered portion 15 of each plug contact 14 of the third plug contact array 10 does not include the exposed soldered portion 15A. As a result, the tip surface 15C of the soldered 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 soldering the soldering portion 15 of each plug contact 14 to an electrode pad (not shown) located on the connector mounting surface 3A of the upper substrate 3, the exposed surface 15D of the soldering coating portion 15B will be primarily soldered to the electrode pad.

[0115] (Second variation) 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 the differences between this modified example and the first embodiment described above, omitting any redundant explanations. This modified example is also applicable 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 soldered portion 15 of each plug contact 14 of the second plug contact array 9 protruding into the first through hole 41, and the soldered portion 15 of each plug contact 14 of the third plug contact array 10 protruding into the second through hole 42.

[0117] In contrast, in this modified example, as shown in Figure 24, the soldering portions 15 of each plug contact 14 in the second plug contact array 9 and the soldering portions 15 of each plug contact 14 in the third plug contact array 10 both protrude into the second through-hole 42 located between the second plug contact array 9 and the third plug contact array 10. With this configuration, the first through-hole 41 becomes unnecessary, which contributes to downsizing the plug 5 in the width direction.

[0118] In manufacturing the modified plug 5, the plug contact assembly 70 is configured as shown in Figure 25. Specifically, the plug contact assembly 70 includes a second plug contact array 9 and a third plug contact array 10, a connecting beam 71 that connects the multiple plug contacts 14 of the second plug contact array 9 and the third plug contact array 10 to each other, and two support parts 72.

[0119] (Third variation) Next, a third modified example of this 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 described above, omitting any redundant explanations. This modified example is also applicable to receptacle 4.

[0120] In the second modified example described above, as shown in Figure 24, the soldered portions 15 of the multiple plug contacts 14 of the second plug contact array 9 and the multiple plug contacts 14 of the third plug contact array 10 both protrude into the second through-hole 42 located between the second plug contact array 9 and the third plug contact array 10. Furthermore, the soldered portions 15 of the multiple plug contacts 14 of the second plug contact array 9 and the multiple plug contacts 14 of the third plug contact array 10 face each other in the width direction.

[0121] In contrast, in this modified example, as shown in Figure 26, the soldering portions 15 of the multiple plug contacts 14 of the second plug contact array 9 and the soldering portions 15 of the multiple plug contacts 14 of the third plug contact array 10 are not facing each other in the width direction, but are arranged in a staggered pattern. That is, the third plug contact array 10 is offset by half a pitch in the pitch direction relative to the second plug contact array 9. In this configuration as well, the first through hole 41 is unnecessary, which contributes to downsizing the plug 5 in the width direction.

[0122] In manufacturing the modified plug 5, the plug contact assembly 70 is configured as shown in Figure 27. Specifically, the plug contact assembly 70 includes a second plug contact array 9 and a third plug contact array 10, a connecting beam 71 that connects the multiple plug contacts 14 of the second plug contact array 9 and the third plug contact array 10 to each other, and two support parts 72. The connecting beam 71 connects the multiple plug contacts 14 of the second plug contact array 9 and the multiple plug contacts 14 of the third plug contact array 10 to each other so that they are arranged in a staggered pattern.

[0123] (Fourth variation) Next, a fourth modified example of this disclosure will be described with reference to Figures 28 to 30. The following description will focus on the differences between this modified example and the first embodiment described above, omitting any redundant explanations. This modified example is also applicable to receptacle 4.

[0124] In the first embodiment described above, 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 modified example, as shown in Figure 28, a plurality of divided through-holes 120 (through-holes) are formed between the second pitch beam 33 and the third pitch beam 34, aligned in the pitch direction. "At least one through-hole" corresponds to the plurality of divided through-holes 120. The plurality of divided through-holes 120 are formed so as to be adjacent in the width direction to the plurality of plug contacts 14 of the third plug contact array 10. 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 adjacent divided through-holes 120 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] Furthermore, the soldering portions 15 of the multiple plug contacts 14 of the third plug contact array 10 each protrude into the interior of the multiple divided through holes 120.

[0127] Furthermore, as shown in Figure 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 remnants of the connecting beam body 71A of the connecting beam 71 in the plug contact assembly 70 of Figure 14 that were not removed and remained in the plug housing 6. However, like the metal piece 65, the metal piece 66 can be omitted.

[0128] In this modified example, as shown in Figure 30, at the stage of the molded product 76 immediately after insert molding (S120), the connecting beam body 71A of the connecting beam 71 is exposed vertically in multiple divided through holes 120. In the separation step (S130), the portion of the connecting beam body 71A of the connecting beam 71 that is exposed vertically in each divided through hole 120 is removed by cutting.

[0129] (Fifth variation) Next, a fifth modification of this disclosure will be described with reference to Figures 31 to 33. The following description will focus on the differences between this modification and the fourth modification described above, omitting any redundant explanations. This modification is also applicable to receptacle 4.

[0130] In the fourth modified example described above, as shown in Figure 29, the pitch extension groove 60 is formed 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 intersects with the multiple divided through holes 120.

[0131] In contrast, in this modified example, as shown in Figure 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 intersects with the multiple divided through holes 120. Therefore, the pitch extension groove 60 extends in an unbroken manner in the pitch direction. In this modified example, the connecting beam 71 of the plug contact assembly 70 is not removed in the separation step (S130) and 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] In this modified example, as shown in Figure 33, at the stage of the molded product 76 immediately after insert molding (S120), the soldered portion 15 of each plug contact 14 is exposed vertically in the corresponding divided through-hole 120. In the separation step (S130), the soldered portion 15 of each plug contact 14 is removed by cutting in the corresponding divided through-hole 120.

[0133] (Sixth variation) Next, a sixth modified example of this 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 described above, omitting any redundant explanations. This modified example is also applicable to receptacle 4.

[0134] In the fourth modified example described above, as shown in Figure 28, a plurality of divided through-holes 120 are formed between the first pitch beam 32 and the second pitch beam 33, aligned in the pitch direction. Similarly, a plurality of divided through-holes 120 are formed between the second pitch beam 33 and the third pitch beam 34, aligned in the pitch direction.

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

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

[0137] In contrast, in this modified example, as shown in Figure 34, the soldered portions 15 of the multiple plug contacts 14 of the second plug contact array 9 and the soldered portions 15 of the multiple plug contacts 14 of the third plug contact array 10 protrude toward each other. That is, the soldered portions 15 of the multiple plug contacts 14 of the second plug contact array 9 protrude inward in the width direction, while the soldered portions 15 of the multiple plug contacts 14 of the third plug contact array 10 protrude outward in the width direction.

[0138] Furthermore, the soldered portions 15 of the multiple plug contacts 14 of the second plug contact array 9 and the multiple plug contacts 14 of the third plug contact array 10 protrude into the interior of the multiple divided through-holes 120 formed between the second pitch beam 33 and the third pitch beam 34. With this configuration, the multiple divided through-holes 120 formed between the first pitch beam 32 and the second pitch beam 33 in the fourth modified example become unnecessary, thus contributing to the downsizing of the plug 5 in the width direction.

[0139] In this modified example, as shown in Figure 35, at the stage of the molded product 76 immediately after insert molding (S120), the connecting beam body 71A of the connecting beam 71 is exposed vertically in multiple divided through holes 120. In the separation step (S130), the portion of the connecting beam body 71A of the connecting beam 71 that is exposed vertically in each divided through hole 120 is removed by cutting.

[0140] (Seventh variation) Next, a seventh modified example of this disclosure will be described with reference to Figure 36. The following description will focus on the differences between this modified example and the first embodiment described above, omitting any redundant explanations. This modified example is also applicable to receptacle 4.

[0141] In this modified example, as shown in Figure 36, two width extensions 60D are formed on the lower surface 6B of the plug housing 6. "At least one width extension groove" corresponds to the two width extensions 60D. Either one of the two width extensions 60D may be omitted. The two width extensions 60D extend away from each other in the width direction from the pitch extension division groove 60A. 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 contact 14. The plug 5 may be surface-mounted to the connector mounting surface 3A of the upper substrate 3 using this metal piece 67. However, the metal piece 67 can be omitted.

[0142] (Variation 8) Next, an eighth modified example of this disclosure will be described with reference to Figures 37 and 38. The following description will focus on the differences between this modified example and the first embodiment described above, omitting any redundant explanations.

[0143] In the first embodiment described above, as shown in Figure 21, the soldered portion 111 of each receptacle contact 110 protrudes into the corresponding through hole 90.

[0144] In contrast, in this modified example, as shown in Figure 37, the contact portions 113 of the multiple receptacle contacts 110 of the second receptacle contact array 23 and the contact portions 113 of the multiple receptacle contacts 110 of the third receptacle contact array 24 protrude into the second through-hole 92 formed between the second pitch beam 83 and the third pitch beam 84. In this case, as shown in Figure 38, each receptacle contact assembly 114 housed in the injection mold 73 during the insert molding step comprises the second receptacle contact array 23 and the third receptacle contact array 24, a connecting beam 115 that connects the multiple receptacle contacts 110 of the second receptacle contact array 23 and the multiple receptacle contacts 110 of the third receptacle contact array 24 to each other, and two support portions 116 that sandwich the connecting beam 115 in the pitch direction. Then, 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 contact portion 113, embedded portion 112, and soldered portion 111.

[0145] The first embodiment and the first to eighth modifications have been described above. Each modification may be implemented in combination with others. 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 circuit board 2A connector mounting side 3 Upper circuit board 3A connector mounting side 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. Fifth plug contact array (contact array) 13. Sixth Plug Contact Array 14. Plug Contacts (Contacts) 15 Soldering section 15A soldering exposed part 15B Soldering Insulation 15C Tip surface (cut surface) 15D exposed surface 16 Buried 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. Fourth receptacle contact array (contact array) 26. Fifth receptacle contact array (contact array) 27. Sixth Receptacle Contact Array 30 pitch beam 31 width beam 32. First pitch beam 33. Second pitch beam 34. Third pitch beam 35. Fourth pitch beam 36. Fifth 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 divided groove 60C Pitch Extension Divided 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. Fourth 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 section 72 Support part 72A Positioning hole 73 Injection molding dies 74 Fixed side template 74A Split plane 74B Positioning pin 75 Movable side template 76 Molded products 80 pitch beam 81 width beam 82. First pitch beam 83. Second pitch beam 84. Third pitch beam 85. Fourth pitch beam 86. Fifth 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 Lenses (Contact Lenses) 111 Soldering section 111A Exposed solder joint 111B Soldering Insulation 111C Tip surface 112 Buried part 113 Contact area 113A Curved section 113B Descending section 113C Horizontal part 113D S-shaped part 114 Receptacle Contact Assembly (Contact Assembly) 115 Connecting beam 115A Connecting beam body 115B Connection section 116 Support part 116A Positioning hole 120 Split through hole (through hole) 121 Reinforcement beam 121B Bottom side

Claims

1. A contact array containing multiple contacts, A housing that holds the at least one contact array, It is formed integrally by insert molding. The outer circumferential surface of the housing includes two width sides facing opposite directions in the width direction perpendicular to the pitch direction of the at least one contact array, A method for manufacturing a connector, An assembly manufacturing step for manufacturing at least one contact assembly having at least one contact array, a connecting beam 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, A housing step of housing the at least one contact assembly in the injection molding die so that the at least one contact assembly is supported at both ends within the injection molding die using the two support parts, Insert molding step of integrally molding the housing with the at least one contact assembly by insert molding such that the connecting beam of the at least one contact assembly is between the two width sides and away from the two width sides in the width direction, A separation step of removing at least a portion of the at least one contact assembly so that the plurality of contacts are separated, including, Manufacturing method.

2. A manufacturing method according to claim 1, In the aforementioned housing step, the two support portions are sandwiched between the fixed mold plate and the movable mold plate in the direction of advancement and retraction of the movable mold plate relative to the fixed mold plate of the injection molding die, thereby supporting both ends of the at least one contact assembly within the injection molding die. Manufacturing method.

3. A manufacturing method according to claim 1 or 2, In the insert molding step, the housing is molded such that the two support portions of the at least one contact assembly are exposed outside the outer circumferential surface of the housing. Manufacturing method.

4. A manufacturing method according to claim 3, The insert molding step further includes a support removal step of removing the two support parts of the at least one contact assembly, Manufacturing method.

5. A manufacturing method according to any one of claims 1 to 4, In the insert molding step, the housing is molded such that it 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. Manufacturing method.

6. A manufacturing method according to any one of claims 1 to 5, The aforementioned at least one contact assembly includes a plurality of contact assemblies, In the assembly manufacturing step, the plurality of contact assemblies are manufactured as separate parts from each other. Manufacturing method.

7. A manufacturing method according to any one of claims 1 to 6, Each contact includes, in this order, a soldering portion, an embedded portion embedded in the housing, and a contact portion that contacts the contact of the mating connector. Each contact protrudes from the connecting beam in the following order: the soldering portion, the embedded portion, and the contact portion. Manufacturing method.

8. A manufacturing method according to any one of claims 1 to 6, Each contact includes, in this order, a soldering portion, an embedded portion embedded in the housing, and a contact portion that contacts the contact of the mating connector. Each contact protrudes from the connecting beam in the following order: the contact portion, the embedded portion, and the soldered portion. Manufacturing method.

9. A manufacturing method according to claim 7 or 8, In the insert molding step, the housing is molded such that the contact portion is elastically displaceable relative to the housing. Manufacturing method.

10. A manufacturing method according to claim 7 or 8, In the insert molding step, the housing is molded such that the contact portion cannot be elastically displaced relative to the housing. Manufacturing method.

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