Connector assembly including a connector manufactured by insert molding

Abstract

(Problem) The objective is to provide a connector assembly having a connector that allows the contact portion to be mounted more securely in a housing. (Solution) A connector assembly comprising a first connector and a second connector capable of connecting to the first connector. The second connector comprises a housing and a plurality of terminals. The plurality of terminals are arranged adjacent to each other along an arrangement direction and have a contact portion extending along a connection direction between a first fixing portion and a second fixing portion, and said contact portion is mounted to the housing by insert molding. The housing has a plurality of recesses formed between the terminals of the plurality of terminals and a bridge portion. The recesses are recessed into the interior of the housing from the first surface side toward the second surface side opposite the first surface. The bridge portion is formed along the connection direction together with the plurality of recesses and connects the sides between the terminals of the plurality of terminals to each other in the arrangement direction.

Description

Technology Field

[0001] The present invention relates to a connector assembly having a connector manufactured by insert molding. Background Technology

[0002] The manufacture of a connector by insert molding generally involves preparing a plurality of strip-shaped metal materials formed as terminals in a state connected to a carrier, installing a mold on these plurality of strip-shaped metal materials, injecting resin into the mold, and separating the strip-shaped metal materials from the carrier. When injecting resin into the mold, it is necessary to apply considerable pressure to the resin to ensure that the resin reaches every corner of the mold; however, as a result, the strip-shaped metal materials may shake due to the flow of resin with considerable force, and a misalignment in the pitch between terminals may occur in the resulting connector.

[0003] To solve this problem, for example, in the technology of Patent Document 1, resin is injected while supporting one end (connecting part) and the other end (solder tail part) of the terminal, one side of the extension part between the one end and the other end (contact part), and additionally a part of the other side by means of a mold, and in particular, each terminal is positioned by pushing the taper formed at the one end (connecting part) by the receiving taper of the mold. Prior art literature

[0004] Japanese Published Patent Application No. Hei 8-31486 Japanese Published Patent Application No. Hei 10-106684 The problem to be solved

[0005] According to the technology of Patent Document 1, positional misalignment of the pitch between terminals can be prevented to some extent, but since the mold supports only one end and the other end of the terminals and does not support the terminals at all, it is not sufficient to prevent positional misalignment of the pitch between terminals. In particular, in terminals with long extensions, positional misalignment of the pitch between terminals easily occurs.

[0006] In addition, as disclosed in Patent Document 2, for example, when the entire surface of one side of an extension is used as a contact part, there is a risk that the mounting of the extension to the housing may become uncertain, and in particular, in the case of a long terminal, the problem of misalignment is likely to increase.

[0007] The objective of the present invention is to overcome the drawbacks of the prior art and to provide a connector assembly having a connector in which the pitch between terminals in the arrangement direction of a plurality of terminals is accurately defined, and the contact portion, which is an extension, can be more securely mounted to a housing. means of solving the problem

[0008] To solve the above problem, a connector assembly according to one aspect of the present invention comprises a first connector and a second connector capable of connecting to the first connector, wherein the second connector comprises a second housing and a plurality of second terminals arranged adjacently along an arrangement direction, each having a first fixing part fixed to the second housing toward the first connector side in the connection direction between the first connector and the second connector, a second fixing part fixed to the second housing toward the side opposite to the first connector side, and a contact part extending along the connection direction between the first fixing part and the second fixing part, wherein the contact part has the plurality of second terminals which are exposed to the outside of the second housing on the entire surface of a first surface formed by the arrangement direction and the extension direction, and which are mounted to the second housing by insert molding on at least a part other than the first surface, and the second housing is formed by a plurality of recesses formed between the terminals of the plurality of second terminals, such that they face the first surface from the first surface side. A connector assembly is characterized by having a plurality of recesses that are recessed into the interior of the second housing along the direction of the recess toward the second side, and a bridge portion formed along the connection direction together with the plurality of recesses, which connects the sides between the terminals of the plurality of second terminals in the arrangement direction, and the contact portions are separated from each other by a predetermined distance defined by the plurality of recesses in the arrangement direction.

[0009] According to this solar connector assembly, in a connector constituting part of a connector device, the contact portions can be separated from each other in the arrangement direction by a predetermined distance defined by the indentation, and the contact portions can also be more securely mounted to the housing by means of a cross-linking portion. Effects of the invention

[0010] According to the present invention, a connector assembly having a connector is provided that can more accurately define the distance between terminals in the arrangement direction of a plurality of terminals and can also more reliably mount a contact portion to a housing. Brief explanation of the drawing

[0011] FIG. 1 is a perspective view of the connector assembly. FIG. 2 is a perspective view of the connector assembly. Figure 3 is a perspective view of a receptacle connector. Figure 4 is an exploded perspective view of a receptacle connector. Figure 5 is a front view of a receptacle connector. Figure 6 is a cross-sectional view taken along line VI-IV of Figure 5. FIG. 7 is a perspective view of the section along line VI-IV of FIG. 5. Figure 8 is a cross-sectional view taken along line VII-VII of Figure 5. FIG. 9 is a perspective view of the section along line VII-VII of FIG. 5. FIG. 10 is a cross-sectional view along line X-X of FIG. 5. FIG. 11 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line VI-IV of FIG. 5. FIG. 12 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line VI-IV of FIG. 5. FIG. 13 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line VI-IV of FIG. 5. FIG. 14 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line X-X of FIG. 5. FIG. 15 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line X-X of FIG. 5. FIG. 16 is a drawing illustrating a method of manufacturing a receptacle connector (1) by insert molding, and is a cross-sectional view showing the manufacturing process at the same location as the cross-section along line X-X of FIG. 5. Fig. 17 is a front view of a plug connector. Fig. 18 is an exploded perspective view of a plug connector. FIG. 19 is a cross-sectional view along line XIX-XIX of FIG. 17. FIG. 20 is a perspective view of the section along line XIX-XIX of FIG. 19. FIG. 21 is a cross-sectional view along line XX-XX of FIG. 19. Specific details for implementing the invention

[0012] (Form for carrying out the invention)

[0013] Hereinafter, a connector assembly according to one exemplary embodiment for carrying out the present invention will be described in detail with reference to the drawings. However, the dimensions, materials, shapes, and relative positions of components described in the following embodiments are optional unless they are essential to the present invention, and may be changed depending on the configuration of the device to which the present invention is applied or various conditions. Furthermore, the scope of the present invention is not limited to the embodiments specifically described below.

[0014] In FIGS. 1 and FIGS. 2, perspective views of the connector assembly (10) are shown at different angles. The connector assembly (10) consists of a set of a receptacle connector (first connector) (1) and a plug connector (second connector) (5) that can be connected to the receptacle connector (1). FIGS. 1 and FIGS. 2 show the state before they are connected.

[0015] In actual use, the receptacle connector (1) and the plug connector (5) are each mounted on separate substrates (not shown). To connect the plug connector (5), the receptacle connector (1) has a fitting hole (31) formed in a concave shape along the connection direction "Z" between the receptacle connector (1) and the plug connector (5). The fitting hole (31) extends to the middle of the receptacle connector (1). Correspondingly, the plug connector (5) has a fitting protrusion (movable part (71)) formed in a convex shape along the connection direction "Z". By fitting the fitting protrusion (movable part (71)) of the plug connector (5) into the fitting hole (31) of the receptacle connector (1), the receptacle connector (1) and the plug connector (5) can be connected, and through this connection, the plurality of terminals (2) formed on the receptacle connector (1) and the plurality of terminals (6) formed on the plug connector (5) are each brought into contact, thereby electrically connecting the substrate on which the receptacle connector (1) is mounted and the substrate on which the plug connector (5) is mounted.

[0016] FIG. 3 shows a perspective view of a receptacle connector, FIG. 4 shows an exploded perspective view thereof, FIG. 5 shows a front view of the receptacle connector, FIG. 6 shows a cross-sectional view along line VI-IV of FIG. 5, FIG. 7 shows a perspective view along line VI-IV of FIG. 5, FIG. 8 shows a cross-section along line VII-VII of FIG. 5, FIG. 9 shows a perspective view along line VII-VII of FIG. 5, and FIG. 10 shows a cross-section along line X-X of FIG. 5.

[0017] The receptacle connector (1) has an overall roughly rectangular shape and has a symmetrical shape in the width direction “X” and the depth direction “Y”, respectively. In the following description and drawings, if it is considered convenient to distinguish between the left and right members in the width direction “X”, and between the front and inner members in the depth direction “Y”, the letters “A” and “B” are added in addition to the reference numbers.

[0018] The receptacle connector (1) comprises a resin housing (3), a plurality of terminals (2) mounted on the housing (3) by insert molding, and two fixing brackets (4). The terminals (2) and the fixing brackets (4) are each mounted on the housing (3) by insert molding, at least in part thereof. Therefore, it is impossible in reality to detach the terminals (2) and the fixing brackets (4) from the housing (3), and please understand that FIG. 4 is a drawing for convenience, assuming that they could be detached from the housing (3).

[0019] A plurality of terminals (2) all have the same shape and structure and are arranged adjacent to each other along the arrangement direction “X”. As described below, these plurality of terminals (2) are formed by punching and bending a single metal plate. A plurality of terminals arranged adjacent to each other along the arrangement direction “X” constitute a terminal group. In the illustrated example, two such terminal groups are formed separated from each other in the depth direction “Y”. The gap formed between these two separated terminal groups can form a part of the fitting hole (31) that fits the fitting protrusion (movable part (71)) of the plug connector (5). Additionally, the terminal group does not need to be two, and one or three or more may be formed.

[0020] Each terminal (2) is extended in the overall connection direction "Z". At one end of the plug connector (5) side "Z2" in the connection direction "Z" of each terminal (2), a contact portion (21) capable of contacting the terminal (6) of the plug connector (5) is formed, while at the other end of the plug connector (5) side "Z1" opposite to the plug connector (5) side, a mounting portion (22) fixed to the housing (3) is formed.

[0021] The contact portion (21) is not mounted on the housing (3) and is formed as a free end in a state where it can be elastically deformed in the depth direction “Y”. Near the middle of the contact portion (21) is bent to protrude slightly in the direction toward the inside of the fitting hole (31) in the depth direction “Y” (“Y1” or “Y2”), and a contact point (21a) is formed at the tip of the protrusion.

[0022] The mounting portion (22) is a part mounted on the substrate and extends parallel to the substrate along the depth direction “Y” toward the outside of the housing (3) (“Y1” or “Y2”), and has a lower surface on the substrate “Z1” side, two sides on the arrangement direction “X” side, and an outer cross-section.

[0023] Between the contact portion (21) and the mounting portion (22), a leg portion (extension portion) (23), a horizontal portion (24), and a vertical portion (25) are formed in this order.

[0024] The leg portion (23) is a relatively long portion located between the mounting portion (22) and the horizontal portion (24), and is extended in a straight line shape along the extension direction “Z”. In addition, in this embodiment, the extension direction “Z” is assumed to coincide with the connection direction “Z”, but it is not necessary for it to coincide with the connection direction.

[0025] The horizontal section (24) is a part located between the leg section (23) and the vertical section (25), and extends horizontally along the depth direction “Y” from the leg section (23) toward the interior of the fitting hole (31) (“Y1 or Y2”) in a state where the end of the leg section (23) opposite to the mounting section (22) in the extension direction “Z” is bent at approximately a right angle.

[0026] The vertical section (25) is a part located between the horizontal section (24) and the contact section (21), and extends perpendicularly in the connection direction “Z” with the end of the horizontal section (24) opposite to the leg section (23) in the depth direction “Y” bent at approximately a right angle.

[0027] These leg portions (23), horizontal portions (24), and vertical portions (25) are mounted in the housing (3) in at least part together with the mounting portion (22).

[0028] The fixed bracket (4) is formed by punching and bending a metal plate, just like the terminal (2), and includes a base (40), a leg (41), and a mounting part (42).

[0029] The donation (40) is a part that extends horizontally along the depth direction “Y” and is formed inside the housing (3), so it cannot actually be seen from the outside.

[0030] The leg portion (41) is a part that extends vertically along the connection direction “Z” formed by bending each end of the base (40) at approximately a right angle, and since it is formed inside the housing (3) just like the base (40), it cannot actually be seen from the outside.

[0031] The mounting portion (42) is a plate-shaped portion formed by bending each end of the leg portion (41), and unlike the base (40) and the leg portion (41), it is formed in a state exposed to the outside of the housing (3) and extends parallel to the substrate along the depth direction “Y” toward the outside of the housing (3) (“Y1” or “Y2”).

[0032] The housing (3) includes a fitting surface (30a) forming the entrance of the fitting hole (31), a cross-section, i.e., a bottom surface (30b), located opposite the fitting surface (30a) in the connection direction “Z”, a side surface (30c) extending in the width direction “X”, and a side surface (30d) extending in the depth direction “Y”. In addition, in this embodiment, the width direction “X” to which the side surface (30c) extends is assumed to coincide with the arrangement direction “X” of the terminal (2), but they do not necessarily have to coincide.

[0033] An opening of the fitting hole (31) is formed in the fitting surface (30a). On the wall surface of the fitting hole (31), a plurality of walls (32) are formed protruding along the depth direction “Y” toward the interior of the fitting hole (31) (“Y1” or “Y2”), and a plurality of grooves (32a) are formed between these walls (32) along the connection direction “Z”. Each terminal (2) is installed in these grooves (31a).

[0034] On the bottom surface (30b), the mounting portion (22) of the terminal (2) and the mounting portion (44) of the fixing bracket (4) are formed in a state exposed to the outside. The receptacle connector (1) is mounted on the substrate through these mounting portions (22, 44).

[0035] On the side (30c), one large indentation (37) extending along the arrangement direction “X” and a plurality of small indentations (38) arranged along the arrangement direction “X” of the terminal (2) are formed.

[0036] The indentations (38) are spaced apart by a predetermined distance “H” from each other in the arrangement direction “X” of the terminals (2) and extend along the connection direction “Z”. These indentations (38) are intended solely to reduce the amount of resin used in the housing (3) and are not directly related to the function of the receptacle connector (1).

[0037] A leg portion (23-1), which is part of the leg portion (23), is formed inside the recess (37) and is exposed to the outside of the housing (3). The leg portion (23-1) is extended over a predetermined range “m” (first predetermined range) (see FIG. 5, FIG. 8, etc.) along the extension direction “Z” and is exposed to the outside on the first surface (23a) (“XZ surface”) of the leg portion (23) formed by the arrangement direction “X” and the extension direction “Z”. The first surface (23a) is formed within the same surface as other first surfaces (23a) of adjacent leg portions (23-1) in the arrangement direction “X”; furthermore, all first surfaces (23a) of the leg portions (23-1) exposed to the outside are formed within the same surface “XZ surface” formed by the arrangement direction “X” and the extension direction “Z”. Additionally, the first surface (23a) is formed to protrude slightly toward the side ("Y2" or "Y1") closer to the first surface (23a) in the direction ("Y1" or "Y2") from the second surface (23b) of the leg portion (23) facing the first surface (23a), rather than the surface (36a) of the exposed portion (36) of the housing (3) adjacent to each other in the arrangement direction "X".

[0038] In the arrangement direction “X,” a plurality of through holes (35) are formed between adjacent leg portions (23-1) (between terminals). These through holes (35) have a length that spans a predetermined range “n” (a second predetermined range) (see FIG. 5, FIG. 8, etc.) included in the range “m” along the extension direction “Z”. Each through hole (35) extends into the interior of the housing (3) along the penetration direction “Y” from the exposed first surface (23a) side toward the second surface (23b) side (“Y1” or “Y2”). In addition, in this embodiment, the range “n” is set smaller than the range “m”, but it is not strictly necessary to do so, and it may be the same size. However, by setting it smaller, the demolding operation of the mold can be facilitated when forming the through holes (35). In addition, in this embodiment, the penetration direction “Y” is set to follow the depth direction “Y”, but it is not strictly necessary to do so.

[0039] The leg portions (23-1) are spaced apart from each other by a predetermined distance "G" defined by the plurality of through holes (35) in the arrangement direction "X". Additionally, through the leg portions (23-1), the entire terminal (2) having the leg portions (23-1) is also spaced apart from each other by a predetermined distance "G" defined by the plurality of through holes (35) in the arrangement direction "X". In other words, the receptacle connector (1) does not have a pitch misalignment between the terminals.

[0040] It is preferable that the cross-sectional “XZ plane” of the through hole (35) intersecting the depth direction “Y” be set to gradually and / or stepwise decrease in size as it moves toward the interior of the housing (3) from the exposed first surface (23a) side toward the second surface (23b) side (“Y1” or “Y2”) in at least part. By configuring it this way, the demolding operation of the mold can be facilitated. In this embodiment, in particular, on the interior side of the housing (3), or in other words, on the second surface (23b) side, the dimensions of the through hole (35) in the arrangement direction “X” are set to gradually decrease as it moves toward the interior of the housing (3). As a result, the shape of the cross-sectional part (39-1) of the through hole (35) in the cross-sectional (XY plane) intersecting the extension direction “Z” is approximately trapezoidal, as can be clearly seen in the partial enlarged view of FIG. 10. Meanwhile, on the exposed side of the housing (3), in other words, the first side (23a) side, or furthermore, the thickness portion of the terminal, such a structure is not adopted, and the shape of the cross-sectional portion (39-2) of the through hole (35) in the same cross-sectional “XY plane” is approximately rectangular. Additionally, although not specifically illustrated, the dimensions of the through hole (35) in the extension direction “Z” rather than the arrangement direction “X” may be set to gradually and / or stepwise decrease as it moves toward the interior of the housing (3).

[0041] The portion spanning the range “n” in the leg portion (23-1) is mounted on the housing (3) in the second surface (23b), and also in at least the portion (23c-1) on the second surface (23b) side of the side (23c) between the leg portions (23-1) (between terminals). Meanwhile, the portion (23c-2) on the first surface (23a) side in the depth direction “Y” of the side (23c) may have a thinner resin than the portion (23c-1) in relation to the cross-section “XZ surface” of the aforementioned through hole (35), and may also be exposed to the outside. Although the resin of the housing (3) may be thinner than that of the part (23c-1), the leg part (23) is entirely covered by the housing (3) on the side of the first surface (23a), or in other words, is supported by the resin of the housing (3), so no problems arise.

[0042] Additionally, the portion other than the portion spanning the range “n” in the leg portion (23-1), that is, the portion spanning the range “s”, is mounted on the housing (3) on the second surface (23b) and on the side (23c) between the leg portions (23-1) (between terminals).

[0043] Additionally, the part other than the leg portion (23-1) in the leg portion (23), that is, the leg portion (23-2), is mounted on the housing (3) on the first surface (23a), the second surface (23b), and the side (23c) between the leg portions (23-2) (between terminals).

[0044] In the housing (3), two spaces (33A, 33B) are formed on the side opposite to the fitting hole (31) in the connection direction “Z”. These spaces (33A, 33B) extend from the bottom surface (30b) of the housing (3) on the receptacle connector side “Z1” in the connection direction “Z” toward the plug connector (5) side “Z2” to the middle of the receptacle connector (1). These spaces (33A, 33B) are partitioned by a partition wall (34) extending along the width direction “X” and positioned in the center of the depth direction “Y”. Inside the housing (3), these spaces (33A, 33B) are each in communication with the through hole (35A, 35B).

[0045] It is preferable that the cross-sectional “XY plane” of the space (33A, 33B) intersecting the connection direction “Z” be set to gradually and / or stepwise decrease in size as it moves from the bottom surface (30b) of the housing (3) toward the plug connector (5) side “Z2” in at least part. In this embodiment, the surface (33b) of the partition wall (34) constituting the cross-sectional “YZ plane” intersecting the width direction “X” is inclined so as to approach the side of the surface (33a) of the housing (3) mounted on the second surface (23b) of the leg portion (23) toward the plug connector (5) side “Z2” from the bottom surface (30b) of the housing (3). By configuring it this way, the demolding operation of the mold can be facilitated.

[0046] Referring to FIGS. 11 to 16, a method for manufacturing a receptacle connector (1) by insert molding is described. FIGS. 11 to 13 are cross-sectional views showing the manufacturing process at the same position as the cross-section along line VI-IV of FIG. 5, while FIGS. 14 to 16 are cross-sectional views showing the manufacturing process at the same position as the cross-section along line X-X of FIG. 5.

[0047] First, a plurality of strip-shaped metal materials (200) connected to a carrier (not shown) are prepared by punching and bending a metal plate. By being connected to the carrier, these strip-shaped metal materials (200) are arranged adjacent to each other along the arrangement direction “X”. Each of these strip-shaped metal materials (200) eventually becomes a terminal (2) of a receptacle connector (1). More specifically, as is evident from FIG. 11, 14, etc., one end (221) of the plug connector (5) side “Z2” in the connection direction “Z” forms the contact portion (21) of the terminal (2), the other end (222) of the plug connector (5) opposite side in the connection direction “Z” forms the mounting portion (22) of the terminal (2), and the extension portion (223) extending along the extension direction “Z” between the one end (221) and the other end (222) forms the leg portion (23) of the terminal (2). The extension portion (223) has a first surface “XZ surface” (223a) formed by the arrangement direction “X” and the extension direction “Z”, similar to the leg portion (23) of the terminal (2), a second surface “XZ surface” (223b) formed by the arrangement direction “X” and the extension direction “Z”, and additionally, a side surface (223c) made of a band-shaped metal material between the extension portions (223).

[0048] Next, as shown in FIGS. 11, 12 and FIGS. 14, 15, a plurality of molds (301 to 303) are installed on a strip-shaped metal material (200).

[0049] First, a mold (301) is installed. In the mold (301), two protrusions (333A, 333B) are formed that protrude "Z2" from the receptacle connector (1) side toward the plug connector (5) side. When molding the resin, these protrusions (333A, 333B) form a space (33A, 33B) of the housing (3), and the space (334) between the protrusions (333A, 333B) forms a partition (34) of the housing (3). The two opposing sides (333a, 333b) of the protrusions (333A, 333B) formed along the width direction "X" are inclined to approach each other "Z2" from the receptacle connector (1) side toward the plug connector (5) side. The mold (301) is installed such that, for a plurality of strip-shaped metal materials (200), the protrusions (333A, 333) are positioned on the second surface (223b) side of each strip-shaped metal material (200) in the insertion direction “Z”. In addition, in this embodiment, the insertion direction “Y” is assumed to coincide with the depth direction “Y”, but it is not necessary for it to coincide with the depth direction. Near the source of each protrusion (333A, 333B), a groove (322) is formed that extends along the depth direction “Y” in the “Y2” or “Y1” direction, respectively. By forming these grooves (322), the other end (222) of the strip-shaped metal material forming the mounting portion (22) of the terminal (2) is exposed to the outside.

[0050] Next, a mold (302) is installed. Each of the molds (302A, 302B) includes two convex portions (335, 338). All of these convex portions (335, 338) protrude along the depth direction “Y” in the “Y1” or “Y2” direction in each of the molds (302A, 302B). The convex portion (335) additionally includes mainly three parts (339-1, 339-2, 337) along the depth direction “Y”. When molding the resin, part (339-1) forms a roughly trapezoidal cross-sectional portion (39-1) of the through hole (35) (see FIG. 10), part (339-2) forms a roughly rectangular cross-sectional portion (39-2) of the through hole (35) (see FIG. 10), and part (337) forms a recess (37) of the housing (3). The convex portion (338) forms a recess (38) of the housing (3). Although not clearly visible in the drawing, part (339-1) is formed in a multi-segmented state along the width direction “X” corresponding to the through hole (35), and also has a shape that gradually expands as it faces the outside of the housing (3), in other words, it has a shape that forms a trapezoid in the cross-sectional “XY plane” intersecting the extension direction “Z” corresponding to the approximately trapezoidal cross-sectional part (39-1) (see FIG. 10) of the through hole (35). Likewise, part (339-2) is formed in a multi-segmented state along the width direction “X” corresponding to the through hole (35), and also has a shape that forms a trapezoid in the cross-sectional “XY plane” intersecting the extension direction “Z” corresponding to the approximately rectangular cross-sectional part (39-2) (see FIG. 10) of the through hole (35). Meanwhile, the portion (337) is formed as a single rectangular shape extending in the width direction “X”, just like the convex portion (338).

[0051] When installing the mold (302), the convex portion (335) is inserted along the insertion direction “Y” from the first surface “XZ surface” (223a) of the extension portion (223) toward the second surface “XZ surface” (223b) (“Y1” or “Y2”) between the extension portions (223) from the front end (335a) side. At this time, the side surface (the surface on the ground in FIG. 11) of the portion (339-2) of the convex portion (335) is positioned facing the side surface (223c) of the strip-shaped metal material (200) on the “YZ surface,” and the front end (335a) of the convex portion (335) is abutted against the side surface (333a) of the protrusion (333) of the mold (301).

[0052] Finally, a mold (303) is installed. The mold (303) is installed to cover one end (221) of a plurality of strip-shaped metal materials (200) in “Z1” from the plug connector (5) side toward the receptacle connector (1) side. The mold (303) has a central protrusion (331) and side protrusions (332) formed symmetrically so as to interpose the central protrusion (331) in the depth direction “Y”. The fitting hole (31) of the housing (3) is formed on the inner side of the side protrusion (332) in the depth direction “Y”. A space (321) for accommodating one end (221) is formed between the central protrusion (331) and the side protrusion (332). The mold (303) is installed to cover one end (221) of the strip-shaped metal material (200) in a state where it is received in this space (321).

[0053] After installing the molds (301 to 303), resin is injected into the molds as shown in FIGS. 13 and 16. As a result, the strip-shaped metal material (200) is mounted in the housing in a predetermined portion. As described above, the mold (302) is installed so that the tip (335a) of the convex portion (335) is in contact with the side (333a) of the protrusion (333) of the mold (301), so that resin does not flow into the contacted portion, and as a result, the space (33A, 33B) and the plurality of through holes (35) are in communication within the housing (3). In addition, the mold (302) is installed such that the side (the surface on the ground in FIG. 11) of the convex portion (335) faces the side (223c) of the strip-shaped metal material (200) in the “YZ surface,” so that even if a strong force is applied by the flow of the resin when injecting the resin, the strip-shaped metal material (200) does not shake, and as a result, the distance between the extension portions (223) in the arrangement direction “X” is maintained, and there is no misalignment in the pitch between the terminals in the resulting connector. However, since a small gap is formed between the side (339-2) of the convex portion (335) (the surface on the ground in FIG. 11) and the side (223c) of the strip-shaped metal material (200), resin is introduced into these gaps, and as a result, as shown in FIG. 10, the second side (23b) side portion (23c-1) of the side (23c) of the resulting terminal (2) is covered with resin. Meanwhile, since no resin is attached to the first side (223a) side portion of the side (223c), as shown in FIG. 10, the first side (23a) side portion (23c-2) of the side (23c) of the resulting terminal (2) is exposed to the outside.

[0054] After the resin injected into the mold cools and hardens and the housing (3) is formed, the mold (301 to 303) is demolded from the housing (3) and the strip-shaped metal material (200). In particular, the side (333a, 333b) of the protrusion (333A, 333B) is inclined to approach the side of the surface (33a) of the housing (3) mounted on the second surface (23b) of the leg (23) from the receptacle connector (1) side toward the plug connector (5) side “Z2” as described above, and the part (339-1) of the convex portion (339) has a shape that gradually expands toward the outside of the housing (3) in the cross-sectional “XY plane” intersecting the extension direction “Z”, so that the demolding operation of the mold (301, 302) is easy.

[0055] Finally, the receptacle connector (1) is completed by detaching the strip-shaped metal material (200) from the carrier.

[0056] FIG. 17 shows a front view of a plug connector, FIG. 18 shows an exploded perspective view thereof, FIG. 19 shows a cross-sectional view along line XIX-XIX of FIG. 17, FIG. 20 shows a perspective view along line XIX-XIX of FIG. 19, and FIG. 21 shows a cross-sectional view along line XXX-XX of FIG. 19.

[0057] The plug connector (5), like the receptacle connector (1), has a symmetrical shape in the width direction “X” and the depth direction “Y”, respectively. In the following description and drawings, if it is considered convenient to distinguish between the front side member and the inner side member in the depth direction “Y”, the letters “A” and “B” are added in addition to the reference number.

[0058] The plug connector (5) comprises a resin housing (7), a plurality of terminals (6) mounted on the housing (7) by insert molding, and two fixing brackets (8). The terminals (6) and the fixing brackets (8) are each mounted on the housing (7) by insert molding in at least a portion thereof. Therefore, please understand that it is impossible in reality to detach the terminals (6) and the fixing brackets (8) from the housing (7), and that FIG. 18 is a drawing for convenience assuming, for example, that they could be detached from the housing (3).

[0059] The fixed member (8) is formed by punching and bending a metal plate, just like the terminal (6), and includes a base (80), a leg portion (81), and a mounting portion (82). Since the fixed member (8) is the same as the fixed member (4) of the receptacle connector (1), it is not described in detail here.

[0060] The housing (7) includes a main body (70) and a movable part (71). The main body (70) is formed in a frame shape using a part of the metal fitting (8), namely the base (80), in the “XY” plane perpendicular to the “Z” connection direction of the receptacle connector (1) and the plug connector (5), and has a hole (78) in the center. The movable part (71) is formed in a roughly rectangular shape overall and is positioned in the approximately center of the hole (78) of the main body (70) in the “XY” plane.

[0061] A plurality of terminals (6) all have the same shape and structure and are arranged adjacent to each other along the arrangement direction “X”. These plurality of terminals (6) are formed by punching and bending a single metal plate, just like the terminal (2) of the receptacle connector (1).

[0062] Each terminal (6) is extended in the overall connection direction "Z". At one end of the receptacle connector (1) side "Z1" in the connection direction "Z" of each terminal (6), a contact part (61) mounted on the main body (70) is formed, and at the other end of the plug connector (5) side "Z2", a mounting part (62) fixed to the main body (70) is formed.

[0063] The contact portion (61) extends along the connection direction "Z" between the first fixing portion (60) and the second fixing portion (68). The first surface "XZ surface" (61a) of the contact portion (61), formed by the arrangement direction "X" and the extension direction "Z", is exposed to the outside of the housing (7) on its entire surface to make contact with the terminal (2) of the receptacle connector (1). This first surface (61a) is formed within the same surface as other first surfaces (61a) of adjacent contact portions (61) in the arrangement direction "X"; furthermore, all first surfaces (61a) of the contact portion (61) exposed to the outside are formed within the same surface "XZ surface" formed by the arrangement direction "X" and the extension direction "Z".

[0064] The first fixed part (60) is located at "Z1" on the receptacle connector (1) side in the connection direction "Z". The end (60a) of the fixed part (60) is fixed to the movable part (71) using the housing part (73), etc., which is embedded in the housing (7) in a state where it is bent approximately at a right angle toward "Z2" on the plug connector (5) side in the connection direction "Z".

[0065] The second fixed part (68) is located on the side "Z2" opposite to the receptacle connector (1) side in the connection direction "Z", and is formed as an inclined part by bending the end of the contact part (61). The first surface (68a) and the second surface (68b) opposite to the first surface (68a) in the inclined part are fixed to the movable part (71) using the housing part (74), which is mounted on both of them.

[0066] The mounting portion (62) is a portion mounted on the substrate and extends parallel to the substrate along the depth direction “Y” toward the outside of the housing (7) (“Y1” or “Y2”).

[0067] Between the mounting section (62) and the fixed section (68), a vertical section (63), a horizontal section (64), a vertical section (65), a horizontal section (66), and a vertical section (67) are formed in this order.

[0068] A portion of the vertical section (63) and the horizontal section (64) is fixed to the main body (70) together with the mounting section (62). Meanwhile, the vertical section (65), the horizontal section (66), and the vertical section (67) elastically connect the horizontal section (64) fixed to the main body (70) and the fixed section (68) fixed to the movable section (71) without being connected to either the main body (70) or the movable section (71). As a result, the movable section (71) functions as a floating section. The movable section (71) is floatable mainly in the width direction “X” and the depth direction “Y”, and through the operation of this movable section (71), even if a misalignment occurs between the receptacle connector (1) and the plug connector (5) when they are connected, such misalignment can be allowed.

[0069] The movable part (71) includes a front surface (71a) located at the receptacle connector (1) side "Z1" in the connection direction "Z", a side surface (71c) extending in the width direction "X", and a side surface (71d) extending in the depth direction "Y". Meanwhile, the main body (70) includes a bottom surface (70b) located opposite the front surface (71a), or in other words, at the plug connector (5) side "Z2" in the connection direction "Z". In addition, in this embodiment, the width direction "X" to which the side surface (71c) extends is assumed to coincide with the arrangement direction "X" of the terminal (6), but they do not necessarily have to coincide.

[0070] In the front view (71a), the top (60b) of the fixed part (60) is exposed to the outside of the housing (7). The top (60b) exposed to the outside forms the same plane as the front view (71b) in the “XY” plane perpendicular to the connection direction “Z”, and together with the housing (7), forms the top of the plug connector (5).

[0071] On the side (71c), a plurality of walls (72) are formed protruding outward ("Y1" or "Y2") along the depth direction "Y," and a plurality of grooves (72a) are formed between these walls (72) along the connection direction "Z." Each terminal (2) is installed in these grooves (72a).

[0072] In the arrangement direction “X,” a plurality of indentations (75, 76) are formed along the connection direction “Z” between the contact portions (61) of adjacent terminals (2). The indentations (75, 76) are formed at a distance “H” apart from each other in the arrangement direction “X” of the terminals (2), and are also formed at a distance apart from each other in the connection direction “Z”, and each has a length that spans a predetermined range (first predetermined range) “q” and “r” along the connection direction “Z”. Each indentation (75, 76) is indented into the interior of the housing (7) along the indentation direction “Y” from the exposed first surface (61a) side toward the second surface (61b) side opposite the first surface (61a) (“Y1” or “Y2”). In addition, in this embodiment, the indentation direction “Y” is made to coincide with the depth direction “Y,” but it is not necessary for it to coincide with the depth direction. These indentations (75, 76) are formed through the same manufacturing process as the through hole (35) of the receptacle connector (1). Accordingly, the contact portion (61) is separated from each other by a predetermined distance “H” defined by these plurality of indentations (75, 76) in the arrangement direction “X”. In other words, the plug connector (5) does not have a pitch misalignment between terminals, just like the receptacle connector (1).

[0073] It is preferable that the cross-section “XZ surface” of the through hole (35) formed in the receptacle connector (1), and the cross-section “XZ surface” of the indentation (75, 76) intersecting the indentation direction “Y,” be set to gradually and / or stepwise decrease in size as it moves toward the interior of the housing (7) from the exposed first surface (61a) side toward the second surface (61b) side (“Y1” or “Y2”) in at least part. By configuring it this way, the demolding operation of the mold can be facilitated. In this embodiment, in particular, on the interior side of the housing (7), or in other words, on the second surface (61b) side, the dimensions of the indentation (75, 76) in the arrangement direction “X” are set to gradually decrease as it moves toward the interior of the housing (7). In addition, regarding the portion (76a) of the receptacle connector (1) side in the connection direction "Z" of the indentation (76), the dimensions of the indentation (76) in the extension direction "Z" are also set to gradually decrease as they move toward the interior of the housing (7). Furthermore, similar to the through hole (35) formed in the housing (3) of the receptacle connector (1) (see FIG. 10), the shape of the indentation (75, 76) in the cross-section "XY plane" intersecting the extension direction "Z" may be approximately trapezoidal, and the first plane (61a) side of the cross-section may be approximately rectangular.

[0074] The portion spanning the ranges “q” and “r” in the contact portion (61) is mounted on the housing (7) in the second surface (61b), and also on the side (61c) between the contact portions (61) (between terminals), particularly on the second surface (61b) side in the recess direction “Y”. Meanwhile, the first surface (61a) side of the side (61c) may have a thinner resin than the second surface (61b) side of the side (61c) in relation to the cross-section “XZ surface” of the aforementioned recess (75, 76), and may also be exposed to the outside. Since the contact portion (61) is exposed to the outside of the housing (7) on the entire surface of the first surface “XZ surface” (61a), in other words, it is not supported by the resin of the housing (7), so the mounting to the housing (7) is weak in the portions “q” and “r” in the contact portion (61) that form the indentation (75, 76), and as a result, there is a risk of peeling off from the housing (7) in those portions.

[0075] To solve this problem, a cross-linking portion (77) is formed along the connection direction "Z" along with the indentations (75, 76). The cross-linking portion (77) includes all structures capable of reinforcing the vulnerability of the contact portion (61) to the housing (7) caused by the formation of the indentations (75, 76). In the example described herein, the resin of the housing (7) is used as the cross-linking portion (77). The resin constituting the cross-linking portion (77) is filled on the first surface (61a) side rather than the indentations (75, 76) along the connection direction "Z" in the indentation direction "Y", and connects the side surface (61c) between the terminals of the plurality of terminals (7) to each other in the arrangement direction "X". Thus, the contact portion (61) is more securely mounted to the housing (7). The cross-linking portion (77) has a length that extends over a predetermined range (second predetermined range) “p” along the connection direction “Z”, and in the portion that extends over the range “p”, in addition to the second surface (61b), the side surface (61c) between the contact portions (61) (between terminals) is also connected to each other in the arrangement direction “X”. The resin constituting the cross-linking portion (77) may be filled until it reaches the same surface as the first surface (61a) of the contact portions (61) adjacent to each other in the arrangement direction “X”, and, for example, the surface (77a) of the cross-linking portion (77) may be formed within the same surface as the first surface (61a) of the contact portions (61) adjacent to each other in the arrangement direction “X”. When the surface (77a) of the cross-linking portion (77) and the first surface (61a) of the contact portion (61) are formed within the same surface, the force applied to the contact portion (61) can be distributed to the cross-linking portion (77) when the receptacle connector (1) and the plug connector (5) are connected, and accordingly, damage to the contact portion (61) can be reduced. It is preferable that the cross-linking portion (77) be positioned adjacent to the indentations (75, 76) in the connection direction "Z" and also positioned between the indentations (75, 76). By forming the cross-linking portion (77) near the indentations (75, 76), the above problem can be solved more effectively.

[0076] Furthermore, the present invention is not limited to the aforementioned embodiments, and various other modifications are possible. For example, instead of forming a through hole in the plug connector (5), a recess may be formed, such as in a receptacle connector.

[0077] It should be understood that the foregoing description relates to preferred embodiments and merely represents the article and the method of manufacturing it. It may be acknowledged that variations and modifications of different embodiments will be readily apparent to a person skilled in the art in light of the foregoing teachings. Accordingly, exemplary embodiments and alternative embodiments may be made without departing from the spirit of the article and method described in the appended claims. Explanation of the symbols

[0078] 1 : First connector (receptacle connector) 2A, 2B : Terminal 3 : 1st Housing 4 : Gold 5 : Second connector (plug connector) 6A, 6B: Terminal 7 : 2nd Housing 8 : Gold 10: Connector assembly 21 : Contact part 22 : Department Head 23 : Leg section (extension section) 23a : 1st side 23b : 2nd side 23c : Side 30b : Bottom (cross-section) 31 : Joint 33A, 33B : Space 35A, 35B: Through hole 36 : Exposed part 37A, 37B: Indentation 38A, 38B: Indentation 39-1: Approximately trapezoidal cross-section 39-2: Approximately rectangular cross-section 42 : Department Head 60 : Fixed part (1st fixed part) 60a : End 61 : Contact part (extension part) 61a : 1st side 61b : 2nd side 61c : Side 68 : Fixed part (2nd fixed part) 70 : Main body 71 : Movable part (floating part) 75A, 75B: Indentation 76A, 76B: Indentation 77A, 77B: Bridge section 200: Strip-shaped metal material 301 : Mold (3rd Mold) 302A, B: Mold (1st mold) 303 : Mold (2nd mold) 335 : Convex part

Claims

Claim 1 A connector assembly comprising a first connector and a second connector capable of connecting to the first connector, wherein the second connector comprises a second housing and a plurality of second terminals arranged adjacently along an arrangement direction, each having a first fixing part fixed to the second housing toward the first connector side in the connection direction between the first connector and the second connector, a second fixing part fixed to the second housing toward the side opposite to the first connector side, and a contact part extending along the connection direction between the first fixing part and the second fixing part, wherein the contact part has the plurality of second terminals, which are exposed to the outside of the second housing on the entire surface of a first surface formed by the arrangement direction and the extension direction, and are mounted to the second housing by insert molding on at least a part other than the first surface, and the second housing comprises a plurality of recesses formed between the terminals of the plurality of second terminals, wherein the second housing has a recess along the direction of the recess from the first surface side toward the second surface side opposite the first surface. A connector assembly having a plurality of grooves that are indented inward, and a bridge portion formed along the connection direction together with the plurality of grooves, the bridge portion connecting the sides of the terminals of the plurality of second terminals in the arrangement direction, wherein the contact portions are spaced apart from each other by a predetermined distance defined by the plurality of grooves in the arrangement direction. Claim 2 A connector assembly according to claim 1, wherein the surface of the cross-linking portion exposed to the outside of the second housing is formed within the same surface as the first surface of the contact portion adjacent to each other in the arrangement direction. Claim 3 A connector assembly according to claim 1, wherein the above-mentioned bridge portion is arranged adjacent to the above-mentioned groove in the above-mentioned connection direction. Claim 4 A connector assembly according to claim 1, wherein the cross-linking portion is disposed between the grooves in the connection direction. Claim 5 A connector assembly according to claim 1, wherein the first fixed portion forms a part of the top portion of the second connector in the connection direction. Claim 6 A connector assembly according to claim 1, wherein the end of the first fixed part is embedded in the second housing in a state where it is bent back toward the second connector side in the connection direction. Claim 7 A connector assembly according to claim 1, wherein the second fixed portion is an inclined portion formed by bending the end of the contact portion, and is mounted on the second housing on both the first surface and the second surface of the inclined portion. Claim 8 A connector assembly according to claim 1, wherein the indentation has a length extending over a first predetermined range along the connection direction, and the portion extending over the first predetermined range in the contact portion is mounted on the second housing in the second surface. Claim 9 A connector assembly according to claim 1, wherein the recess has a length extending over a first predetermined range along the connection direction, and the portion extending over the first predetermined range in the contact portion is mounted on the second housing on at least the second side of the side between the terminals of the plurality of second terminals, and on the first side of the side, the resin of the housing is thinner than the second side or is exposed to the outside. Claim 10 A connector assembly according to claim 1, wherein the cross-linking portion has a length extending over a second predetermined range along the connection direction, and the portion extending over the second predetermined range in the contact portion is mounted on the second housing on the side between the second surface and the terminals of the plurality of second terminals. Claim 11 A connector assembly according to claim 1, wherein the cross-section of the indentation intersecting the indentation direction is set to gradually and / or stepwise decrease as it faces the interior of the second housing. Claim 12 A connector assembly according to claim 11, wherein the dimensions of the indentation in the arrangement direction and / or connection direction are set to decrease gradually and / or stepwise as it faces the interior of the second housing. Claim 13 A connector assembly according to claim 1, wherein the second housing comprises a main body and a floating part connected by the second terminal, and the contact part is fixed to the floating part.

Images