connector

Abstract

To provide a connector capable of being miniaturized while connecting a conductor part of an electric wire to a flexible conductor of a sheet-like conductive member with high reliability.SOLUTION: A connector contains: a first insulator 14 that includes a first holding surface and a convex part 14B that is projected and formed onto the first holding surface; and a second insulator 15 that includes a second holding surface that is opposite to the first holding surface and a concave part 15C formed to the second holding surface. The first insulator 14 and the second insulator 15 are alternately coupled so that a sheet-like conductive member 11 and a covered electric wire 12 are nipped between the first holding surface and the second holding surface, and at least a part of the convex part 14B is housed into the concave part 15C, and a conductive part 12A of the covered electric wire 12 is electrically connected to a flexible conductor 11A of the sheet-like conductive member 11.SELECTED DRAWING: Figure 9

Description

Technical Field

[0005] , , ,

[0001] The present invention relates to a connector, and more particularly to a connector for connecting a conductor portion of an electric wire to a flexible conductor of a sheet-shaped conductive member.

Background Art

[0002] In recent years, so-called smart clothing that can acquire user's biological information such as heart rate and body temperature just by wearing it has attracted attention. This smart clothing includes electrodes made of flexible conductors arranged at measurement locations, and by electrically connecting a wearable device as a measurement device to the electrodes, biological information can be transmitted to the wearable device. The connection between the electrode and the wearable device can be made, for example, by using a connector connected to a flexible conductor.

[0003] However, when the wearable device is separated from the measurement location, it is necessary to form an electric circuit from the electrode arranged at the measurement location to the mounting position of the connector. If such an electric circuit is formed by a flexible conductor, the electrical resistance becomes high and the cost also increases. Therefore, in order to connect between an electrode made of a flexible conductor and a wearable device with an electric wire having low electrical resistance and low cost, the development of a small connector for connecting an electric wire to a flexible conductor arranged on clothing is desired.

[0004] As a connector for connecting an electric wire to a flexible conductor, for example, Patent Document 1 discloses a connector as shown in FIG. 50. This connector has a first connector 2 connected to an end portion of a sheet-shaped conductive member 1 and a second connector 4 attached to the tip of an electric wire 3. By fitting the second connector 4 to the first connector 2, the electric wire 3 can be connected to the flexible conductor of the sheet-shaped conductive member 1.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2007-214087 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] However, in order to connect the electric wire 3 to the flexible conductor of the sheet-like conductive member 1, a first connector 2 and a second connector 4 that mate with each other are required. This results in a larger device, and because there is a detachable connection point between the first connector 2 and the second connector 4, there is a problem of reduced reliability of the electrical connection.

[0007] This invention was made to solve the problems of the conventional methods, and aims to provide a connector that can reliably connect the conductor portion of an electric wire to a flexible conductor of a sheet-like conductive member while also being miniaturized. [Means for solving the problem]

[0008] The connector according to this invention is A connector for connecting the conductive portion of an electric wire to a flexible conductor exposed on at least one surface of a sheet-like conductive member, A first insulator having a first retaining surface and a protrusion formed protruding from the first retaining surface, A second insulator having a second retaining surface facing the first retaining surface and a recess formed on the second retaining surface that corresponds to a convex portion. Equipped with, The first insulator and the second insulator are connected to each other such that a sheet-like conductive member and an electric wire are sandwiched between the first retaining surface and the second retaining surface. At least a portion of the protrusion is housed in the recess, thereby electrically connecting the conductor portion of the electric wire to the flexible conductor of the sheet-like conductive member within the recess. 、 The convex portion has a prismatic shape and the concave portion has a cylindrical inner surface, or the convex portion has a cylindrical shape and the concave portion has a cylindrical inner surface. It is.

[0009] Convex The part preferably has a groove-shaped intermediate holding part that holds the intermediate part of the conductor section of the electric wire.

[0010] The device may be configured to include a conductive relay member positioned within a recess, such that the conductor portion of the electric wire is electrically connected to a flexible conductor via the relay member. Specifically, the relay member preferably has a cylindrical tubular portion, the flexible conductor is sandwiched between the outer surface of the convex portion and the inner surface of the tubular portion, and the conductor portion of the electric wire is sandwiched between the outer surface of the tubular portion and the inner surface of the concave portion. Alternatively, the relay member preferably has a cylindrical tubular portion, with the conductor portion of the electric wire sandwiched between the outer surface of the convex portion and the inner surface of the tubular portion, and the flexible conductor sandwiched between the outer surface of the tubular portion and the inner surface of the concave portion.

[0011] The conductor portion of the electric wire can also be configured to make direct contact with a flexible conductor for electrical connection. In this case, the recess can be equipped with a contact force securing member that is positioned outside the conductor portion and the flexible conductor that are in contact with each other within the recess and that secures the contact force between the conductor portion and the flexible conductor. The contact force securing member is preferably made of a metal material and has a cylindrical shape.

[0012] The sheet-like conductive member can be configured to extend in a predetermined direction from the first and second insulators along the first and second retaining surfaces, and the electric wire can be configured to extend in a direction opposite to the predetermined direction from the first and second insulators along the first and second retaining surfaces.

[0013] Preferably, one of the first insulator and the second insulator has a tip-holding portion that holds the tip of the conductor portion of the electric wire. The tip holding portion may have a slit into which the tip of the conductor portion is inserted. Further, the electric wire has an insulating coating portion that covers the outer peripheral portion of the conductor portion, and it is preferable that the first insulator and the second insulator have an insulating coating holding portion that holds the insulating coating portion of the electric wire.

[0014] One of the first insulator and the second insulator has a boss, and the other of the first insulator and the second insulator has a through-hole through which the boss passes, and it is preferable that the head of the boss passing through the through-hole is thermally deformed. The boss can also have a slit into which the conductor portion of the electric wire is inserted.

Advantages of the Invention

[0015] According to this invention, the first insulator and the second insulator are connected to each other such that the sheet-like conductive member and the electric wire are sandwiched between the first holding surface and the second holding surface, and at least a part of the convex portion of the first insulator is accommodated in the concave portion of the second insulator, whereby the conductor portion of the electric wire is electrically connected to the flexible conductor of the sheet-like conductive member in the concave portion. Therefore, it is possible to miniaturize while reliably connecting the conductor portion of the electric wire to the flexible conductor of the sheet-like conductive member.

Brief Description of the Drawings

[0017] Embodiments of this invention will be described below with reference to the attached drawings. Embodiment 1 Figures 1 to 4 show a connector according to Embodiment 1. This connector connects a coated wire 12 to a sheet-like conductive member 11 and includes a housing 13 made of an insulating resin material.

[0018] The sheet-like conductive member 11 has a front and back surface facing opposite directions, and at least the flexible conductor 11A is exposed on the front surface. As the sheet-like conductive member 11, for example, a conductive fabric woven with conductive threads such as silver can be used. When such a conductive fabric is used, the flexible conductor 11A will be exposed not only on the front surface but also on the back surface of the sheet-like conductive member 11. Alternatively, a sheet-like conductive member 11 can be made by applying conductive ink to the surface of a non-conductive fabric by printing or other means to form the flexible conductor 11A on the surface. Furthermore, a member in which a flexible conductor 11A consisting of a conductive pattern is formed on the surface of an insulating sheet body such as a resin film may also be used as the sheet-like conductive member 11. The sheet-like conductive member 11 has a strip shape that extends in a predetermined direction.

[0019] The insulated wire 12 has a structure in which the outer circumference of the conductor portion, which will be described later, is covered with an insulating coating. The connector according to Embodiment 1 electrically connects the conductor portion of the insulated wire 12 to the flexible conductor 11A of the sheet-like conductive member 11. The insulated wire 12 extends in the same direction as the strip-shaped sheet-like conductive member 11.

[0020] For convenience, we will refer to the predetermined direction in which the sheet-like conductive member 11 extends toward the housing 13 as the +Y direction, the width direction of the strip-shaped sheet-like conductive member 11 as the X direction, and the direction perpendicular to the XY plane as the Z direction.

[0021] Figure 5 shows an exploded perspective view of the connector. The connector has a first insulator 14 and a second insulator 15, and these first and second insulators 14 and 15 constitute the housing 13.

[0022] A sheet-like conductive member 11 is positioned on the +Z side of the first insulator 14, and a conductor portion 12A exposed from the insulating coating portion 12B of the insulated wire 12 is positioned on the +Z side of the sheet-like conductive member 11. The conductor portion 12A of the insulated wire 12 may be either a so-called single wire, which is composed of a single conductor, or a so-called stranded wire, which is composed of multiple conductors twisted together. Furthermore, the connector has a contact force securing member 16, which is positioned on the +Z direction side of the conductor portion 12A of the insulated wire 12, and a second insulator 15 is positioned on the +Z direction side of the contact force securing member 16.

[0023] As shown in Figure 6, the first insulator 14 has a substantially rectangular flat plate portion 14A extending along the XY plane, and a substantially prismatic convex portion 14B is formed on the surface of the flat plate portion 14A on the +Z direction side (first holding surface) and protrudes toward the +Z direction. Furthermore, an insertion groove 14C extending in the +Y direction from the convex portion 14B is formed on the surface of the flat plate portion 14A on the +Z direction side, and an insertion groove 14D having a larger groove width than the insertion groove 14C is formed at the +Y direction end of the insertion groove 14C.

[0024] Furthermore, a concave projection-receiving portion 14E, which is recessed in the -Z direction, is formed in the flat plate portion 14A located on the -Y direction side of the convex portion 14B. The flat plate portion 14A has three through holes 14F that are formed on both sides of the insertion groove 14C in the X direction and on the -Y direction side of the projection housing portion 14E, and that penetrate the flat plate portion 14A in the Z direction. Furthermore, stepped portions 14G extending in the Y direction are formed on both sides of the flat plate portion 14A in the X direction.

[0025] As shown in Figure 7, the second insulator 15 has a substantially rectangular flat plate portion 15A extending along the XY plane and a dome-shaped portion 15B projecting from the flat plate portion 15A in the +Z direction. A recess 15C is formed from the -Z direction surface (second retaining surface) of the flat plate portion 15A into the dome-shaped portion 15B and opening in the -Z direction. An insertion groove 15D is formed on the -Z direction surface of the flat plate portion 15A, extending in the +Y direction from a recess 15C, and an insertion groove 15E is formed at the +Y direction end of the insertion groove 15D, having a larger groove width than the insertion groove 15D.

[0026] Furthermore, a projection 15F is formed on the flat plate portion 15A located on the -Y direction side of the recess 15C, projecting in the -Z direction, and a slit 15G is formed in the projection 15F, extending in the Y direction so as to divide the projection 15F in the X direction. The slit 15G serves as a tip-holding portion that holds the tip of the conductor portion 12A of the insulated wire 12, and has a slit width that is slightly narrower than the diameter of the conductor portion 12A. The flat plate portion 15A has three bosses 15H that are formed on both sides of the insertion groove 15D in the X direction and on the -Y direction side of the projection 15F, and that protrude in the -Z direction. Furthermore, side plates 15J are formed on both sides of the flat plate portion 15A in the X direction, each protruding in the -Z direction and extending in the Y direction.

[0027] When the first insulator 14 and the second insulator 15 are connected to each other, the insertion groove 14C of the first insulator 14 and the insertion groove 15D of the second insulator 15 cooperate to hold the conductor portion 12A of the insulated wire 12, and the insertion groove 14D of the first insulator 14 and the insertion groove 15E of the second insulator 15 cooperate to become an insulating coating holding portion that holds the insulating coating portion 12B of the insulated wire 12. As shown in Figure 5, the sheet-like conductive member 11 has through holes 11B and 11C that correspond to the projection 15F and the boss 15H on the -Y direction side of the second insulator 15.

[0028] As shown in Figure 8, the contact force securing member 16 is made of a metal material and has a cylindrical shape. As shown in Figure 9, the contact force securing member 16 is positioned outside the conductor portion 12A of the insulated wire 12 and the flexible conductor 11A of the sheet-like conductive member 11, which are in contact with each other within the recess 15C of the second insulator 15, and is intended to secure the contact force between the conductor portion 12A and the flexible conductor 11A.

[0029] When assembling such a connector, first, the contact force securing member 16 is inserted into the recess 15C of the second insulator 15 from the -Z direction, and the tip of the conductor portion 12A, which is exposed by removing the insulating coating portion 12B at the -Y end of the insulated wire 12, is pressed into the slit 15G formed as a tip holding portion on the projection 15F of the second insulator 15, thereby temporarily holding it in the slit 15G.

[0030] In this state, with the sheet-like conductive member 11 in between, the first insulator 14 is pressed relatively toward the second insulator 15 in the +Z direction. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 14 in the +Z direction (first holding surface) and the surface of the second insulator 15 in the -Z direction (second holding surface). At this time, the protrusion 14B of the first insulator 14, which has a substantially rectangular prism shape, pushes the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 into the contact force securing member 16 located in the recess 15C of the second insulator 15, and inserts them into the interior of the contact force securing member 16 located in the recess 15C of the second insulator 15.

[0031] Furthermore, by pressing the first insulator 14 against the second insulator 15, the three bosses 15H of the second insulator 15 penetrate the three through holes 14F of the first insulator 14. At this time, of the three bosses 15H, the boss 15H located on the -Y direction side penetrates the corresponding through hole 14F of the first insulator 14 through the through hole 11C of the sheet-like conductive member 11 shown in Figure 5. Then, as shown in Figure 4, the first insulator 14 and the second insulator 15 are fixed to each other by thermally deforming the tips of the three bosses 15H that protrude on the -Z side of the first insulator 14, and the assembly of the connector is completed.

[0032] As the protrusion 14B of the first insulator 14 is inserted into the contact force securing member 16 while pressing in the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12, the sheet-like conductive member 11 deforms to conform to the surface of the protrusion 14B, and the conductor portion 12A of the insulated wire 12 is sandwiched between the surface of the sheet-like conductive member 11 and the inner surface of the contact force securing member 16, bending along the deformed surface of the sheet-like conductive member 11.

[0033] As shown in Figure 11, since the protrusion 14B has a substantially prismatic shape, the sheet-like conductive member 11, which is deformed to conform to the surface of the protrusion 14B, and the conductor portion 12A of the insulated wire 12 are sandwiched between the +Y and -Y side surfaces of the protrusion 14B and the inner surface of the cylindrical contact force securing member 16. The conductor portion 12A of the insulated wire 12 then contacts the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11 with a predetermined contact force, thereby making an electrical connection.

[0034] Furthermore, as the conductor portion 12A of the insulated wire 12 bends along the surface of the deformed sheet-like conductive member 11, the tip of the conductor portion 12A, which was temporarily held in the slit 15G of the projection 15F of the second insulator 15, is pulled out of the slit 15G, as shown in Figure 9.

[0035] When the first insulator 14 and the second insulator 15 are connected to each other, as shown in Figure 9, the projection 15F of the second insulator 15 passes through the through hole 11B of the sheet-like conductive member 11 and is housed in the projection housing portion 14E of the first insulator 14, the conductor portion 12A of the insulated wire 12 is held by the insertion groove 14C of the first insulator 14 and the insertion groove 15D of the second insulator 15, and the insulating coating portion 12B of the insulated wire 12 is held by the insertion groove 14D of the first insulator 14 and the insertion groove 15E of the second insulator 15. Furthermore, as shown in Figure 10, the pair of side plates 15J of the second insulator 15 are fitted into the pair of stepped portions 14G of the first insulator 14.

[0036] In the connector of Embodiment 1, the protrusion 14B of the first insulator 14 presses the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12, and is inserted into the contact force securing member 16 which is inserted into the recess 15C of the second insulator 15. As a result, the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are electrically connected. This makes it possible to improve the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A while also making the connector smaller.

[0037] By applying the connector of Embodiment 1 to smart clothing and connecting electrodes (not shown) to the flexible conductor 11A of the sheet-like conductive member 11, it is possible to connect electrodes placed at measurement points to a wearable device using insulated wires 12 that have low electrical resistance and are inexpensive. Furthermore, by sealing the space between the first insulator 14 and the second insulator 15 using a water-resistant adhesive, a waterproof connector can be constructed that prevents water from entering the electrical connection area between the flexible conductor 11A of the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12.

[0038] In the above embodiment 1, the slit 15G formed in the projection 15F of the second insulator 15 constitutes a tip-holding portion that holds the tip of the conductor portion 12A of the insulated wire 12, but the tip-holding portion can also be formed on the first insulator 14. Furthermore, in the above embodiment 1, the three bosses 15H of the second insulator 15 penetrate the three through holes 14F of the first insulator 14. Conversely, it is also possible to configure the system so that multiple bosses 15H formed on the first insulator 14 penetrate multiple through holes formed on the second insulator 15.

[0039] Embodiment 2 Figures 12 to 14 show a connector according to Embodiment 2. Similar to the connector of Embodiment 1, this connector connects a coated wire 12 to a sheet-like conductive member 11 and includes a housing 23 made of an insulating resin material. The sheet-like conductive member 11 and the insulated wire 12 are the same as those used in Embodiment 1.

[0040] Figure 15 shows an exploded perspective view of the connector according to Embodiment 2. The connector has a first insulator 24 and a second insulator 25, and the housing 23 is formed by these first insulator 24 and second insulator 25.

[0041] A sheet-like conductive member 11 is positioned on the +Z side of the first insulator 24, a relay member 26 is positioned on the +Z side of the sheet-like conductive member 11, and a conductor portion 12A exposed from the insulating coating portion 12B of the insulated wire 12 is positioned on the +Z side of the relay member 26. Furthermore, a second insulator 25 is positioned on the +Z direction side of the conductor portion 12A of the insulated wire 12.

[0042] As shown in Figure 16, the first insulator 24 has a substantially rectangular flat plate portion 24A extending along the XY plane, and a substantially prismatic convex portion 24B is formed on the surface of the flat plate portion 24A on the +Z direction side (first holding surface) and protrudes toward the +Z direction. Furthermore, a pair of through holes 24C are formed on the +Y direction side of the protrusion 24B in the flat plate portion 24A, spaced apart from each other in the X direction, and a similar pair of through holes 24D are formed on the -Y direction side of the protrusion 24B, spaced apart from each other in the X direction.

[0043] An insertion groove 24E is formed on the surface of the flat plate portion 24A located on the +Y direction side of the protrusion 24B, passing between a pair of through holes 24C and extending in the +Y direction, and an insertion groove 24F having a larger groove width than the insertion groove 24E is formed at the +Y direction end of the insertion groove 24E. Furthermore, protruding portions 24G are formed at both ends of the flat plate portion 24A in the X direction, each protruding in the +Z direction and extending in the Y direction.

[0044] As shown in Figure 17, the second insulator 25 has a substantially rectangular flat plate portion 25A extending along the XY plane, and a recess 25B is formed in the center of the flat plate portion 25A in the Y direction, recessed in the +Z direction from the -Z direction surface (second retaining surface) of the flat plate portion 25A. Furthermore, a concave sheet-like conductive member accommodating portion 25C is formed on the -Z-direction surface of the flat plate portion 25A to accommodate the +Y-direction end of the sheet-like conductive member 11. The sheet-like conductive member accommodating portion 25C extends from the +Y-direction side of the recess 25B to the -Y-direction end of the flat plate portion 25A.

[0045] An insertion groove 25D is formed on the surface of the flat plate portion 25A, extending from the recess 25B in the +Y direction and the -Y direction. At the +Y direction end of the insertion groove 25D extending from the recess 25B in the +Y direction, an insertion groove 25E is formed, having a larger groove width than the insertion groove 25D. The flat plate portion 25A has two bosses 25F formed on the +Y and -Y sides of the recess 25B, respectively, and protruding in the -Z direction. A slit 25G extending in the Y direction is formed in each boss 25F so as to divide each boss 25F in the X direction. The slits 25G are connected to the insertion groove 25D. Furthermore, stepped portions 25H extending in the Y direction are formed at both ends of the flat plate portion 25A in the X direction.

[0046] As shown in Figure 18, the relay member 26 is formed from a conductive metal material and has a cylindrical tubular portion 26A. The relay member 26 is placed within the recess 25B of the second insulator 25 between the conductor portion 12A of the insulated wire 12 and the flexible conductor 11A of the sheet-like conductive member 11, and is intended to electrically connect the conductor portion 12A and the flexible conductor 11A.

[0047] When assembling the connector of Embodiment 2, first, the conductor portion 12A of the insulated wire 12 is inserted from the -Z direction into the slits 25G of the two bosses 25F of the second insulator 25. In this state, the first insulator 24 is pressed relative to the second insulator 25 in the +Z direction, with the relay member 26 and the sheet-like conductive member 11 sandwiched between them. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 24 on the +Z direction side (first retaining surface) and the surface of the second insulator 25 on the -Z direction side (second retaining surface). At this time, the protrusion 24B of the first insulator 24, which has a substantially prism shape, pushes the sheet-like conductive member 11, the relay member 26, and the conductor portion 12A into the recess 25B of the second insulator 25.

[0048] Furthermore, by pressing the first insulator 24 against the second insulator 25, the two bosses 25F of the second insulator 25 penetrate the through holes 24C and 24D of the first insulator 24. At this time, of the two bosses 25F, the portion of the boss 25F located on the +Y side that is divided by the slit 25G penetrates the through hole 24C, and the portion of the boss 25F located on the -Y side that is divided by the slit 25G penetrates the through hole 24D. Then, as shown in Figure 14, the first insulator 24 and the second insulator 25 are fixed to each other by thermally deforming the tips of the two bosses 25F that protrude in the -Z direction of the first insulator 24, and the assembly of the connector is completed.

[0049] The protrusion 24B of the first insulator 24 pushes the sheet-like conductive member 11, the relay member 26, and the conductor portion 12A into the recess 25B of the second insulator 25. As shown in Figures 19 and 20, the sheet-like conductive member 11 deforms to conform to the surface of the protrusion 24B and is sandwiched between the outer surface of the protrusion 24B and the inner surface of the cylindrical portion 26A of the relay member 26. The conductor portion 12A of the insulated wire 12 is also sandwiched between the outer surface of the cylindrical portion 26A of the relay member 26 and the inner surface of the recess 25B of the second insulator 25. As a result, the conductor portion 12A of the insulated wire 12 is electrically connected to the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11 via the relay member 26.

[0050] The sheet-like conductive member 11 is housed in the sheet-like conductive member housing portion 25C of the second insulator 25, the conductor portion 12A of the insulated wire 12 is held by the insertion groove 24E of the first insulator 24 and the insertion groove 25D of the second insulator 25, and the insulating coating portion 12B of the insulated wire 12 is held by the insertion groove 24F of the first insulator 24 and the insertion groove 25E of the second insulator 25. Furthermore, as shown in Figure 20, a pair of protruding portions 24G of the first insulator 24 are fitted into a pair of stepped portions 25H of the second insulator 25.

[0051] In the connector of Embodiment 2, as in Embodiment 1, it is possible to improve the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A while also miniaturizing the connector.

[0052] Embodiment 3 In the above embodiment 2, the conductor portion 12A of the insulated wire 12 is electrically connected to the flexible conductor 11A of the sheet-like conductive member 11 via the relay member 26. However, as in embodiment 1, the conductor portion 12A of the insulated wire 12 can also be electrically connected by directly contacting the flexible conductor 11A of the sheet-like conductive member 11 without using the relay member 26.

[0053] Figures 21 to 23 show a connector according to Embodiment 3. Similar to the connectors of Embodiments 1 and 2, this connector connects a coated wire 12 to a sheet-like conductive member 11 and includes a housing 33 made of an insulating resin material. The sheet-like conductive member 11 and the insulated wire 12 are the same as those used in Embodiments 1 and 2.

[0054] Figure 24 shows an exploded perspective view of the connector according to Embodiment 3. The connector has a first insulator 24 and a second insulator 35, which were used in Embodiment 2, and the housing 33 is formed by these first insulator 24 and second insulator 35. A sheet-like conductive member 11 is positioned on the +Z side of the first insulator 24, the conductor portion 12A of the insulated wire 12 is positioned on the +Z side of the sheet-like conductive member 11, and the second insulator 35 is positioned on the +Z side of the conductor portion 12A.

[0055] As shown in Figure 25, the second insulator 35 has a flat plate portion 35A with a recess 35B formed therein, similar to the second insulator 25 in Embodiment 2. The flat plate portion 35A, similar to the second insulator 25 in Embodiment 2, has a concave sheet-like conductive member housing portion 25C, insertion grooves 25D and 25E, two bosses 25F each having a slit 25G, and a pair of stepped portions 25H.

[0056] When assembling the connector of Embodiment 3, first, the conductor portion 12A of the insulated wire 12 is inserted from the -Z direction into the slits 25G of the two bosses 25F of the second insulator 35. In this state, the sheet-like conductive member 11 is sandwiched between the first insulator 24 and the second insulator 35, and the first insulator 24 is pressed relative to the second insulator 35 in the +Z direction. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 24 on the +Z direction side (first retaining surface) and the surface of the second insulator 35 on the -Z direction side (second retaining surface). At this time, the protrusion 24B of the first insulator 24, which has a substantially prism shape, pushes the sheet-like conductive member 11 and the conductive portion 12A into the recess 35B of the second insulator 35.

[0057] Furthermore, by pressing the first insulator 24 against the second insulator 35, the two bosses 25F of the second insulator 35 penetrate the through holes 24C and 24D of the first insulator 24, and as shown in Figure 23, the tips of the two bosses 25F protruding from the -Z side of the first insulator 24 are thermally deformed, thereby fixing the first insulator 24 and the second insulator 25 to each other, and completing the assembly of the connector.

[0058] The protrusion 24B of the first insulator 24 pushes the sheet-like conductive member 11 and the conductor portion 12A into the recess 35B of the second insulator 35, so that, as shown in Figures 26 and 27, the sheet-like conductive member 11 and the conductor portion 12A deform to conform to the surface of the protrusion 24B and are sandwiched between the outer surface of the protrusion 24B and the inner surface of the recess 35B of the second insulator 35. As a result, the conductor portion 12A of the insulated wire 12 comes into direct contact with the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11, and is electrically connected.

[0059] In the connector of Embodiment 3, as in Embodiments 1 and 2, it is possible to improve the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A while also miniaturizing the connector.

[0060] Embodiment 4 In the above embodiment 2, the sheet-like conductive member 11 is inserted inside the cylindrical portion 26A of the relay member 26, and the conductor portion 12A of the insulated wire 12 is positioned outside the relay member 26. However, even if the conductor portion 12A of the insulated wire 12 is inserted inside the cylindrical portion 26A of the relay member 26 and the sheet-like conductive member 11 is positioned outside the relay member 26, the conductor portion 12A of the insulated wire 12 can still be electrically connected to the flexible conductor 11A of the sheet-like conductive member 11 via the relay member 26.

[0061] Figures 28 to 30 show a connector according to Embodiment 4. Similar to the connectors of Embodiments 1 to 3, this connector connects a coated wire 12 to a sheet-like conductive member 11 and includes a housing 43 made of an insulating resin material. The sheet-like conductive member 11 and the insulated wire 12 are the same as those used in Embodiments 1 to 3.

[0062] Figure 31 shows an exploded perspective view of the connector according to Embodiment 4. The connector has a first insulator 44 and a second insulator 45, and the housing 43 is formed by these first insulator 44 and second insulator 45.

[0063] A conductor portion 12A exposed from the insulating coating portion 12B of the insulated wire 12 is positioned on the -Z side of the first insulator 44, a relay member 26 used in Embodiment 2 is positioned on the -Z side of the conductor portion 12A, and a sheet-like conductive member 11 is positioned on the -Z side of the relay member 26. Furthermore, a second insulator 45 is positioned on the -Z direction side of the sheet-like conductive member 11.

[0064] As shown in Figure 32, the first insulator 44, like the first insulator 24 in Embodiment 2, has a substantially rectangular flat plate portion 44A, and a substantially cylindrical protrusion 44B is formed on the flat plate portion 44A that protrudes in the -Z direction. At the -Z end of the protrusion 44B, a groove-shaped intermediate holding portion 44C is formed that crosses the protrusion 44B in the Y direction. The intermediate holding portion 44C is for holding the intermediate portion of the conductor portion 12A of the insulated wire 12.

[0065] Furthermore, the flat plate portion 44A, similar to the first insulator 24 in Embodiment 2, has a pair of through holes 24D formed on the +Y direction side of the protrusion 44B and spaced apart from each other in the X direction, an insertion groove 24E passing between the pair of through holes 24D and extending in the Y direction, an insertion groove 24F formed at the +Y direction end of the insertion groove 24E and having a groove width larger than that of the insertion groove 24E, and protruding portions 24G formed on both X-direction ends of the flat plate portion 44A and projecting in the -Z direction. Furthermore, the flat plate portion 44A has a through hole 44H that penetrates the flat plate portion 44A in the Z direction on the -Y direction side of the convex portion 44B.

[0066] As shown in Figure 33, the second insulator 45 has a flat plate portion 45A with a recess 45B formed therein, similar to the second insulator 25 in Embodiment 2. The flat plate portion 45A, similar to the second insulator 25 in Embodiment 2, has a concave sheet-like conductive member housing portion 25C, insertion grooves 25D and 25E, a boss 25F formed on the +Y direction side of the recess 45B and having a slit 25G, and a pair of stepped portions 25H. Furthermore, the flat plate portion 45A has a cylindrical boss 45J that protrudes in the +Z direction on the -Y direction side of the recess 45B.

[0067] When assembling the connector of Embodiment 4, first, the middle portion of the conductor portion 12A of the insulated wire 12 is inserted from the -Z direction into the intermediate holding portion 44C of the protrusion 44B of the first insulator 44. In this state, with the relay member 26 and the sheet-like conductive member 11 sandwiched between them, the first insulator 44 is pressed relatively toward the second insulator 45 in the +Z direction. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 44 on the -Z direction side (first holding surface) and the surface of the second insulator 45 on the +Z direction side (second holding surface). At this time, the substantially cylindrical protrusion 44B of the first insulator 44 pushes the conductor portion 12A, the relay member 26, and the sheet-like conductive member 11 into the recess 45B of the second insulator 45.

[0068] Furthermore, by pressing the first insulator 44 against the second insulator 45, the bosses 25F and 45J of the second insulator 45 penetrate the through holes 24D and 44H of the first insulator 44. As shown in Figure 29, the tips of the bosses 25F and 45J protruding from the +Z side of the first insulator 44 are thermally deformed, thereby fixing the first insulator 44 and the second insulator 45 together, and completing the assembly of the connector.

[0069] The protrusion 44B of the first insulator 44 pushes the conductor portion 12A, the relay member 26, and the sheet-like conductive member 11 into the recess 45B of the second insulator 45. As shown in Figures 34 and 35, the conductor portion 12A of the insulated wire 12 deforms to conform to the surface of the protrusion 44B and is sandwiched between the outer surface of the protrusion 44B and the inner surface of the cylindrical portion 26A of the relay member 26. The sheet-like conductive member 11 is also sandwiched between the outer surface of the cylindrical portion 26A of the relay member 26 and the inner surface of the recess 45B of the second insulator 45. As a result, the conductor portion 12A of the insulated wire 12 is electrically connected to the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11 via the relay member 26.

[0070] In the connector of Embodiment 4, as in Embodiments 1 to 3, it is possible to improve the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A while also miniaturizing the connector.

[0071] Embodiment 5 Figures 36 and 37 show a connector according to Embodiment 5. Similar to the connectors of Embodiments 1 to 4, this connector connects a coated wire 12 to a sheet-like conductive member 11 and includes a housing 53 made of an insulating resin material. The sheet-like conductive member 11 and the insulated wire 12 are the same as those used in Embodiments 1 to 4. In the connector according to Embodiment 5, similar to the connector of Embodiment 3, the electrical connection is made by the direct contact between the conductor portion 12A of the insulated wire 12 and the flexible conductor 11A of the sheet-like conductive member 11.

[0072] Figure 38 shows an exploded perspective view of the connector according to Embodiment 5. The connector has a first insulator 54 and a second insulator 55, and the housing 53 is formed by these first insulator 54 and second insulator 55. The conductor portion 12A of the insulated wire 12 is positioned on the +Z side of the first insulator 54, the sheet-like conductive member 11 is positioned on the +Z side of the conductor portion 12A of the insulated wire 12, and the second insulator 35 is positioned on the +Z side of the sheet-like conductive member 11.

[0073] As shown in Figure 39, the first insulator 54 has a flat plate portion 54A extending along the XY plane, and a substantially cylindrical protrusion 54B projecting toward the +Z direction is formed on the surface of the flat plate portion 54A on the +Z direction side (first holding surface). An intermediate holding portion 54C in the shape of a groove is formed on the upper surface of the protrusion 54B, crossing the protrusion 54B in the Y direction. The intermediate holding portion 54C is for holding the intermediate portion of the conductor portion 12A of the insulated wire 12, and extends not only on the upper surface of the protrusion 54B but also on the side surface of the protrusion 54B.

[0074] Furthermore, on the surface of the flat plate portion 54A on the +Z direction side, an insertion groove 54D is formed on the +Y direction side of the convex portion 54B, extending in the Y direction and having a groove width larger than that of the intermediate holding portion 54C. Furthermore, a peripheral wall 54E is formed on the periphery of the flat plate portion 54A, projecting in the +Z direction. At the -Y end of the flat plate portion 54A, a sheet-like conductive member lead-out portion 54F is formed by cutting out the peripheral wall 54E, and at the +Y end of the flat plate portion 54A, a covered wire lead-out portion 54G connected to the insertion groove 54D is formed by cutting out the peripheral wall 54E.

[0075] As shown in Figure 40, the second insulator 55 has a flat plate portion 55A that extends along the XY plane, and a recess 55B that is recessed in the +Z direction is formed in the center of the -Z direction surface (second retaining surface) of the flat plate portion 55A.

[0076] Furthermore, an insertion groove 55C is formed on the -Z-direction surface of the flat plate portion 55A, extending in the Y direction from the +Y-direction side of the recess 55B to the +Y-direction end of the flat plate portion 55A, and a projection 55D connected to the insertion groove 55C is formed at the +Y-direction end of the flat plate portion 55A. The insertion groove 55C has the same groove width as the insertion groove 54D of the first insulator 54, and the projection 55D has a width corresponding to the insulated wire outlet portion 54G of the first insulator 54. Furthermore, a stepped portion 55E is formed on the peripheral edge of the flat portion 55A.

[0077] When assembling the connector of Embodiment 5, first, the middle portion of the conductor portion 12A of the insulated wire 12 is inserted from the +Z direction into the intermediate holding portion 54C of the protrusion 54B of the first insulator 54. In this state, with the sheet-like conductive member 11 in between, the first insulator 54 is pressed relatively toward the second insulator 55 in the +Z direction. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 54 on the +Z direction side (first holding surface) and the surface of the second insulator 55 on the -Z direction side (second holding surface). At this time, the substantially cylindrical protrusion 54B of the first insulator 54 pushes the conductor portion 12A and the sheet-like conductive member 11 into the recess 55B of the second insulator 55.

[0078] Furthermore, the sheet-like conductive member 11 is pulled out through the sheet-like conductive member pull-out portion 54F of the first insulator 54, and the insulated wire 12 is pulled out through the insulated wire pull-out portion 54G of the first insulator 54. By pressing the second insulator 55 against the first insulator 54, the peripheral wall 54E of the first insulator 54 is fitted into the stepped portion 55E of the second insulator 55. For example, the connector assembly is completed by bonding the peripheral wall 54E of the first insulator 54 and the stepped portion 55E of the second insulator 55 to each other using an adhesive.

[0079] The protrusion 54B of the first insulator 54 pushes the sheet-like conductive member 11 and the conductor portion 12A into the recess 55B of the second insulator 55, so that, as shown in Figures 41 and 42, the sheet-like conductive member 11 and the conductor portion 12A deform to conform to the surface of the protrusion 54B and are sandwiched between the outer surface of the protrusion 54B and the inner surface of the recess 55B of the second insulator 55. As a result, the conductor portion 12A of the insulated wire 12 comes into direct contact with the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11, and is electrically connected.

[0080] In the connector of Embodiment 5, as in Embodiments 1 to 4, it is possible to miniaturize the connector while improving the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A.

[0081] Embodiment 6 Figures 43 and 44 show a connector according to Embodiment 6. This connector, like the connector of Embodiment 5, uses a contact force securing member to ensure contact force between the conductor portion 12A of the insulated wire 12 and the flexible conductor 11A of the sheet-like conductive member 11, similar to Embodiment 1.

[0082] The connector includes a housing 63 formed from an insulating resin material. Figure 45 shows an exploded perspective view of the connector according to Embodiment 6. The connector has a first insulator 54 and a second insulator 65, which were used in Embodiment 5, and the housing 63 is formed by these first insulator 54 and second insulator 65. The conductor portion 12A of the insulated wire 12 is positioned on the +Z side of the first insulator 54, the sheet-like conductive member 11 is positioned on the +Z side of the conductor portion 12A of the insulated wire 12, and the contact force securing member 66 is positioned on the +Z side of the sheet-like conductive member 11. Furthermore, a second insulator 65 is positioned on the +Z direction side of the contact force securing member 66.

[0083] As shown in Figure 46, the contact force securing member 66 is made of a metal material and has a cylindrical tubular portion 66A. Furthermore, as shown in Figure 47, the second insulator 65, like the second insulator 55 in Embodiment 5 shown in Figure 40, has a flat plate portion 65A extending along the XY plane, and a recess 65B that is recessed in the +Z direction is formed in the center of the -Z direction surface (second retaining surface) of the flat plate portion 65A.

[0084] The recess 65B has a larger diameter than the recess 55B of the second insulator 55 in Embodiment 5, and is sized to accommodate the cylindrical portion 66A of the contact force securing member 66. The flat plate portion 65A has an insertion groove 55C, a projection 55D, and a stepped portion 55E, similar to the second insulator 55 in Embodiment 5.

[0085] When assembling the connector of Embodiment 6, first, the middle portion of the conductor portion 12A of the insulated wire 12 is inserted from the +Z direction into the intermediate holding portion 54C of the protrusion 54B of the first insulator 54, and the contact force securing member 66 is inserted from the -Z direction into the recess 65B of the second insulator 65. In this state, with the sheet-like conductive member 11 in between, the first insulator 54 is pressed relatively toward the second insulator 65 in the +Z direction. As a result, the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 are sandwiched between the surface of the first insulator 54 on the +Z direction side (first holding surface) and the surface of the second insulator 65 on the -Z direction side (second holding surface).

[0086] At this time, the convex portion 54B of the first insulator 54, which has a substantially cylindrical shape, pushes the conductor portion 12A of the insulated wire 12 and the sheet-like conductive member 11 into the contact force securing member 66 located in the recess 65B of the second insulator 65, thereby inserting them into the interior of the contact force securing member 66.

[0087] By pressing the first insulator 54 against the second insulator 65, the peripheral wall 54E of the first insulator 54 is fitted into the stepped portion 55E of the second insulator 65. For example, the connector assembly is completed by bonding the peripheral wall 54E of the first insulator 54 and the stepped portion 55E of the second insulator 65 to each other using an adhesive.

[0088] As the protrusion 54B of the first insulator 54 is inserted into the contact force securing member 66 while pressing in the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12, the sheet-like conductive member 11 and the conductor portion 12A deform to conform to the surface of the protrusion 54B and are sandwiched between the outer surface of the protrusion 54B and the inner surface of the contact force securing member 66, as shown in Figures 48 and 49. In this way, by positioning the contact force securing member 66 on the outside of the sheet-like conductive member 11 and the conductor portion 12A of the insulated wire 12 within the recess 65B, the conductor portion 12A of the insulated wire 12 contacts the flexible conductor 11A exposed on the surface of the sheet-like conductive member 11 with a predetermined contact force, thereby electrically connecting them.

[0089] In the connector of Embodiment 6, as in Embodiments 1 to 5, it is possible to miniaturize the connector while improving the reliability of the electrical connection between the flexible conductor 11A and the conductor portion 12A.

[0090] In the embodiments 1 to 6 described above, a coated wire 12 is used as the wire connected to the sheet-like conductive member 11. However, it is also possible to connect a wire consisting only of a conductor portion 12A that is not covered by an insulating coating portion 12B, which is made of an insulator, to the sheet-like conductive member 11. Furthermore, in embodiments 1 to 6 described above, the conductor portion 12A of one insulated wire 12 is connected to the flexible conductor 11A of one sheet-like conductive member 11 by accommodating one protrusion 14B, 24B, 44B, 54B formed on the first insulators 14, 24, 44, 54 in one recess 15C, 25B, 35B, 45B, 55B, 65B formed on the second insulators 15, 25, 35, 45, 55, 65, respectively. However, it is also possible to configure the system to connect the conductor portions of multiple wires to the flexible conductors of multiple sheet-like conductive members using a first insulator having multiple protrusions and a second insulator having multiple recesses. [Explanation of Symbols]

[0091] 1 Sheet-shaped conductive member, 2 First connector, 3 Electric wire, 4 Second connector, 11 Sheet-shaped conductive member, 11A Flexible conductor, 11B, 11C, 14F, 24C, 24D, 44H Through hole, 12 Insulated electric wire, 12A Conductor part, 12B Insulating coating part, 13, 23, 33, 43, 53, 63 Housing, 14, 24, 44, 54 First insulator, 14A, 15A, 24A, 25A, 35A, 44A, 45A, 54A, 55A, 65A Flat plate part, 14B, 24B, 44B, 54B Protruding part, 14C, 14D, 15D, 15E, 24E, 24F, 25D, 25E, 54D, 55C Insertion groove, 14E Projection housing section, 14G, 25H, 55E Stepped section, 15, 25, 35, 45, 55, 65 Second insulator, 15B Dome-shaped section, 15C, 25B, 35B, 45B, 55B, 65B Recess, 15F, 55D Projection, 15G, 25G Slit, 15H, 25F, 45J Boss, 15J Side plate, 16, 66 Contact force securing member, 24G Protruding section, 25C Sheet-like conductive member housing section, 26 Intermediate member, 26A, 66A Cylindrical section, 44C, 54C Intermediate holding section, 54E Peripheral wall, 54F Sheet-like conductive member outlet section, 54G Insulated wire outlet section.

Claims

1. A connector for connecting the conductive portion of an electric wire to a flexible conductor exposed on at least one surface of a sheet-like conductive member, A first insulator having a first retaining surface and a protrusion formed protruding from the first retaining surface, A second insulator having a second retaining surface facing the first retaining surface and a recess formed on the second retaining surface that corresponds to the protrusion. Equipped with, The first insulator and the second insulator are connected to each other such that the sheet-like conductive member and the electric wire are sandwiched between the first retaining surface and the second retaining surface. At least a portion of the protrusion is housed in the recess, thereby electrically connecting the conductor portion of the electric wire to the flexible conductor of the sheet-like conductive member within the recess. A connector in which the convex portion has a prismatic shape and the concave portion has a cylindrical inner surface, or a connector in which the convex portion has a cylindrical shape and the concave portion has a cylindrical inner surface.

2. The connector according to claim 1, wherein the protrusion has a groove-shaped intermediate holding portion for holding the intermediate portion of the conductor portion of the electric wire.

3. The recess is provided with a conductive relay member, The connector according to claim 1 or 2, wherein the conductor portion of the electric wire is electrically connected to the flexible conductor via the relay member.

4. The relay member has a cylindrical tubular portion, The flexible conductor is sandwiched between the outer surface of the protrusion and the inner surface of the cylindrical portion. The connector according to claim 3, wherein the conductor portion of the electric wire is sandwiched between the outer surface of the cylindrical portion and the inner surface of the recess.

5. The relay member has a cylindrical tubular portion, The conductor portion of the electric wire is sandwiched between the outer surface of the protrusion and the inner surface of the cylindrical portion. The connector according to claim 3, wherein the flexible conductor is sandwiched between the outer surface of the cylindrical portion and the inner surface of the recess.

6. The connector according to claim 1 or 2, wherein the conductor portion of the electric wire is electrically connected in direct contact with the flexible conductor.

7. The connector according to claim 6, further comprising the conductor portion and the flexible conductor, which are in contact with each other within the recess and a contact force securing member disposed on the outside of the flexible conductor and which secures the contact force between the conductor portion and the flexible conductor.

8. The connector according to claim 7, wherein the contact force securing member is made of a metal material and has a cylindrical shape.

9. The sheet-like conductive member extends in a predetermined direction from the first insulator and the second insulator along the first retaining surface and the second retaining surface, The connector according to claim 1 or 2, wherein the electric wire extends from the first insulator and the second insulator in a direction opposite to the predetermined direction along the first retaining surface and the second retaining surface.

10. The connector according to claim 1 or 2, wherein one of the first insulator and the second insulator has a tip-holding portion for holding the tip of the conductor portion of the electric wire.

11. The connector according to claim 10, wherein the tip holding portion has a slit into which the tip of the conductor portion is inserted.

12. The electric wire has an insulating coating that covers the outer periphery of the conductor portion, The connector according to claim 10, wherein the first insulator and the second insulator each have an insulating coating holding portion for holding the insulating coating portion of the electric wire.

13. One of the first insulator and the second insulator has a boss, The other of the first insulator and the second insulator has a through hole through which the boss passes, The connector according to claim 1 or 2, wherein the head of the boss that has passed through the through hole is thermally deformed.

14. The connector according to claim 13, wherein the boss has a slit into which the conductor portion of the electric wire is inserted.

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