CABLE CONNECTION COMPONENT AND CABLE STRUCTURE

The cable connection component includes a locator extending in the alignment direction, a plurality of first restriction portions disposed in the locator and separately restricting movements, at least in the alignment direction, of tip ends in an extension direction of the plurality of cables, and a plurality of second restriction portions disposed in the locator and separately restricting movements, at least in the alignment direction, of the plurality of cables at positions on a proximal side of the plurality of cables away from the tip ends of the plurality of cables along the extension direction by a predetermined distance, and the plurality of conductor portions exposed from the plurality of cables between the plurality of first restriction portions and the plurality of second restriction portions are soldered to the plurality of connection portions of the substrate.

BACKGROUND OF THE INVENTION

The present invention relates to a cable connection component, particularly to a cable connection component that is used for connecting a plurality of cables to a substrate.

The present invention also relates to a cable structure in which a plurality of cables are connected to a substrate.

As a cable structure in which a plurality of cables are electrically connected to a substrate, for instance, JP 6513439 B discloses a cable structure as shown inFIG.39. A plurality of cables1are aligned along a surface of a substrate2. Each cable1has a structure in which an outer periphery of a conductor portion3is covered with an insulating coating portion4, and the insulating coating portion4is partly peeled off on the rear side of a front end portion5of the cable1, whereby an exposure portion6in which the conductor portion3is exposed is formed. When each conductor portion3exposed at the exposure portion6is soldered to a corresponding connection pad8of the substrate2with solder7, the cables1are electrically connected to the substrate2.

The cable structure as above can be produced by, for example, bonding the cables1to one another with an adhesive while being aligned, and, in each cable1, forming the exposure portion6at which the conductor portion3is partly exposed with use of a cutting tool or laser, followed by a process of soldering the conductor portion3at the exposure portion6to the corresponding connection pad8of the substrate2.

In the cable structure of JP 6513439 B, however, while the cables1are aligned and bonded to each other with an adhesive, in the exposure portions6at which the conductor portions3of the cables1are exposed, the conductor portion3of each cable1can freely move, and there is no means for restricting positions of each cable1on the tip end side and the root portion side of the exposure portion6. Therefore, the conductor portion3is easily misaligned with respect to the corresponding connection pad8during the process of soldering the conductor portion3of the cable1to the connection pad8of the substrate2, disadvantageously. When the conductor portion3is misaligned with respect to the connection pad8, reliability in electrical connection between the conductor portions3of the cables1and the connection pads8of the substrate2may be impaired.

SUMMARY OF THE INVENTION

The present invention has been made to overcome the conventional problems as above and aims at providing a cable connection component that enables connection of a plurality of cables to a plurality of connection portions, while preventing misalignment of the cables with respect to the connection portions of the substrate.

The present invention also aims at providing a cable structure in which a plurality of cables are connected to a plurality of connection portions of a substrate without occurrence of misalignment therebetween.

SOLUTION TO PROBLEMS

The cable connection component according to the present invention is a cable connection component for soldering a plurality of cables to a plurality of connection portions of a substrate, the plurality of cables being aligned in a predetermined alignment direction and having conductor portions whose outer peripheries are separately covered with insulating coating portions; the cable connection component comprising:a locator extending in the alignment direction;a plurality of first restriction portions disposed in the locator and separately restricting movements, at least in the alignment direction, of tip ends in an extension direction of the plurality of cables; anda plurality of second restriction portions disposed in the locator and separately restricting movements, at least in the alignment direction, of the plurality of cables at positions on a proximal side of the plurality of cables away from the tip ends of the plurality of cables along the extension direction by a predetermined distance,wherein the plurality of conductor portions exposed from the plurality of cables between the plurality of first restriction portions and the plurality of second restriction portions are soldered to the plurality of connection portions of the substrate.

The cable structure according to the present invention comprises:a plurality of cables aligned in a predetermined alignment direction and having conductor portions whose outer peripheries are separately covered with insulating coating portions;a substrate including a plurality of connection portions aligned in the alignment direction; andthe above-described cable connection component,wherein the plurality of conductor portions exposed from the plurality of cables between the plurality of first restriction portions and the plurality of second restriction portions are soldered to the plurality of connection portions of the substrate.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention are described below based on the accompanying drawings.

FIG.1shows a cable structure according to Embodiment 1. The cable structure is configured such that a plurality of cables21are connected to a sheet type substrate31using a cable connection component11.

The cables21are aligned in a predetermined alignment direction and each extend in a direction perpendicular to the alignment direction in parallel to a surface of the substrate31. Each cable21has a structure in which an outer periphery of a conductor portion21A is covered with an insulating coating portion21B. By use of the cable connection component11, the conductor portions21A of the cables21are electrically connected to a plurality of connection portions to be described later of the substrate31. The conductor portion21A of the cable21may be either a so-called solid wire constituted of one conductor or a so-called stranded wire constituted of plural conductors being stranded.

The cable connection component11extends along the alignment direction of the cables21.

For convenience, the substrate31is defined as extending along an XY plane, the alignment direction of the cables21is referred to as “X direction,” the direction in which each cable21extends toward the cable connection component11is referred to as “+Y direction,” and the direction perpendicular to an XY plane is referred to as “Z direction.”

As shown inFIG.2, the cable connection component11includes a locator12extending in the X direction and made of an insulating resin, and a plurality of metal terminals13attached to the locator12.

The locator12includes a pair of support members12A disposed at opposite ends in the X direction of the locator12, and a second beam12B extending in the X direction and joining the pair of support members12A to each other.

The pair of support members12A each include a substrate-mounting surface12C extending along an XY plane and facing in the +Z direction, and a boss12D is formed in a center part of the substrate-mounting surface12C to project in the +Z direction.

The second beam12B is provided with a plurality of second insertion grooves12E aligned in the X direction and each opened toward the +Z direction. The second insertion grooves12E correspond to the cables21, each have a groove width and a groove depth that allow insertion of the insulating coating portion21B of the cable21, and is configured to be capable of restricting movement, at least in the X direction, of the cable21inserted in the second insertion groove12E.

The metal terminals13correspond to the cables21and the second insertion grooves12E, and as shown inFIG.3, a fixing portion13A of flat plate shape is formed at the −Y directional end of each metal terminal13. To the +Y directional end of the fixing portion13A, a curved portion13B that is curved so as to protrude toward the +Z direction is joined, and a heated portion13C of flat plate shape is formed to be joined to the curved portion13B at the +Y directional end of the metal terminal13.

The fixing portion13A is retained at the bottom part of the corresponding second insertion groove12E of the second beam12B of the locator12through press fitting or insertion molding, whereby the metal terminal13is fixed to the second beam12B.

In the +Z directional surface of a top part of the curved portion13B, a conductor portion insertion groove13D is formed along the Y direction. The conductor portion insertion groove13D has a groove width that allows insertion of the conductor portion21A of the cable21; when the conductor portion21A drawn and exposed from the corresponding cable21is inserted in the conductor portion insertion groove13D, movement of the conductor portion21A in the X direction is restricted.

As shown inFIG.4, the metal terminal13has a so-called cantilever shape extending in the +Y direction from the corresponding second insertion groove12E of the second beam12B, and there is a predetermined height difference in the Z direction between the curved portion13B and the fixing portion13A. Specifically, between the +Z directional surface of the fixing portion13A fixed to the bottom part of the second insertion groove12E of the second beam12B and a bottom surface of the conductor portion insertion groove13D formed at the top part of the curved portion13B, provided is a height difference H1corresponding to the thickness of the insulating coating portion21B of the cable21.

In addition, the heated portion13C disposed on the +Y direction side of the curved portion13B of the metal terminal13is deviated to the +Z direction side from the fixing portion13A and is brought into contact with and heated by a heating portion of a heater (not shown) in the assembling operation of the cable structure, whereby the conductor portion21A of the cable21inserted in the conductor portion insertion groove13D is soldered to the connection portion of the substrate31.

As shown inFIG.5, at the +Y directional end of the cable21, formed is a conductor-exposed portion P1in which the insulating coating portion21B in a predetermined length is removed to thereby expose the conductor portion21A.

In the cable connection component11shown inFIG.4, the conductor portion insertion grooves13D of the metal terminals13constitute a plurality of first restriction portions that separately restrict movements, at least in the X direction, of the conductor portions21A exposed at the +Y directional tip ends of the cables21, and the second insertion grooves12E of the second beam12B of the locator12constitute a plurality of second restriction portions that separately restrict movements, at least in the X direction, of the insulating coating portions21B of the cables21at positions away from the tip ends of the cables21in the −Y direction, i.e., on the proximal side of the cables21, by a predetermined distance.

As shown inFIG.6, the substrate31is formed of, for example, a so-called flexible printed circuit (FPC), includes a sheet body31A made of an insulating material, and has a plurality of connection portions31B exposed on the −Z directional surface of the sheet body31A, the connection portions31B being aligned in the X direction along the −Y directional edge of the substrate31and each formed of a flexible conductor. The connection portions31B correspond to the cables21and the metal terminals13.

The substrate31is not limited to a FPC but may be a so-called printed circuit board or another rigid substrate having no flexibility.

In the opposite end portions in the X direction of the substrate31, formed are a pair of through holes31C corresponding to a pair of the bosses12D of the locator12.

In the assembling operation of the cable structure, first, the cables21are disposed on the locator12of the cable connection component11as shown inFIG.7. In this process, the insulating coating portion21B of each cable21is inserted in the corresponding second insertion groove12E of the locator12, the conductor portion21A of the conductor-exposed portion P1at the +Y directional end of the cable21is situated on the +Z direction side of the curved portion13B of the corresponding metal terminal13, and part of the conductor portion21A is inserted in the conductor portion insertion groove13D of the curved portion13B.

That is, the conductor portions21A exposed at the +Y directional tip ends of the cables21are separately inserted in the conductor portion insertion grooves13D (first restriction portions) of the corresponding metal terminals13, and the insulating coating portions21B are separately inserted in the corresponding second insertion grooves12E (second restriction portions) of the second beam12B at positions away from the +Y directional tip ends of the cables21in the −Y direction by the predetermined distance.

Next, as shown inFIG.8, the substrate31is disposed on the +Z direction side of the cable connection component11on which the cables21are disposed. With this constitution, the substrate-mounting surfaces12C of the pair of support members12A of the locator12are opposed to the −Z directional surface of the substrate31on which the connection portions31B are exposed.

Meanwhile, cream solder31D is preliminarily printed on the connection portions31B exposed on the −Z directional surface of the substrate31.

Further, the substrate31and the cable connection component11are relatively moved in the Z direction, whereby the substrate31is mounted on the substrate-mounting surfaces12C of the pair of support members12A of the locator12as shown inFIG.9. At this time, the pair of bosses12D of the locator12shown inFIG.2are separately fitted with the pair of through holes31C of the substrate31, whereby the substrate31is positionally aligned with the cable connection component11. With this constitution, the conductor portions21A of the cables21disposed on the +Z direction side of the curved portions13B of the metal terminals13of the cable connection component11are situated on the −Z direction side of the connection portions31B of the substrate31.

Here, the locator12is preferably fixed to the substrate31by a jig (not shown) such that the metal terminals13do not move in the −Z direction relatively to the connection portions31B of the substrate31. It is also possible to configure the locator12to be fixed to the substrate31in the Z direction with the pair of bosses12D of the locator12fitted with the pair of through holes31C of the substrate31.

In this state, a heater41is disposed on the metal terminals13from the −Z direction as shown inFIG.10. As the heater41, a so-called pulse heat-type heater can be used, for example, and a heating portion (not shown) formed at the +Z directional end of the heater41and extending in the X direction is disposed so as to make contact with the metal terminals13. Meanwhile, the heating portion of the heater41makes contact with the heated portion13C of each metal terminal13shown inFIG.4.

By applying electric current to the heater41from a power source (not shown) connected to the heater41, the metal terminals13in contact with the heating portion are heated, the cream solder31D printed on the connection portions31B of the substrate31is melted, and the metal terminals13are separately soldered to the connection portions31B of the substrate31as shown inFIG.11.

In this process, as shown inFIG.12, the conductor portion21A of the cable21that is situated between the curved portion13B of each metal terminal13and the corresponding connection portion31B of the substrate31, together with the metal terminal13, is soldered to the connection portion31B with the solder31E to be thereby electrically connected to the connection portion31B.

Thus, the assembling operation of the cable structure is completed.

A cross-sectional view of the thus assembled cable structure is shown inFIG.13. While the conductor portion21A exposed at the conductor-exposed portion P1at the +Y directional tip end of the cable21is inserted in the conductor portion insertion groove13D of the metal terminal13, and the insulating coating portion21B is inserted in the second insertion groove12E of the second beam12B at a position away from the +Y directional tip end of the cable21in the Y direction by the predetermined direction, the conductor portion21A inserted in the conductor portion insertion groove13D is electrically connected to the connection portion31B of the substrate31with the solder31E.

Since the conductor portion21A of the conductor-exposed portion P1of the cable21is inserted in the conductor portion insertion groove13D of the curved portion13B of the metal terminal13, movement in the X direction of the conductor portion21A is restricted, and the distance between the top part of the curved portion13B and the connection portion31B of the substrate31in the Z direction is narrowed, whereby the soldering between the metal terminal13and the connection portion31B is facilitated, compared to the case where the conductor portion insertion groove13D is not provided. Accordingly, it is possible to electrically connect the conductor portion21A of the cable21to the connection portion31B of the substrate31with high reliability.

As described above, owing to the conductor portion insertion groove13D of the metal terminal13constituting the first restriction portion and the second insertion groove12E of the second beam12B constituting the second restriction portion, the conductor portion21A of the cable21is electrically connected to the connection portion31B of the substrate31while movement of the cable21at least in the X direction is restricted at two positions separated from each other in the Y direction, whereby the plurality of cables21are prevented from misalignment with respect to the plurality of connection portions31B of the substrate31and can be connected to the connection portions31B.

In addition, since the conductor portion21A of each cable21is connected to the corresponding connection portion31B of the substrate31with use of the metal terminal13, the plurality of cables21can be connected to the substrate31with excellent retention strength.

In place of the metal terminal13, a metal terminal43shown inFIG.14may be used. The metal terminal43is configured such that, in the metal terminal13shown inFIG.3, in place of the heated portion13C of flat plate shape, a heated portion43C that is curved to protrude toward the −Z direction is joined to the +Y directional end of the curved portion13B, an inclination portion43E obliquely extends from the heated portion43C toward the +Y direction and +Z direction, and a conductor portion insertion hole43F is formed in the inclination portion43E to penetrate the metal terminal43.

The conductor portion insertion hole43F serves as the first restriction portion that restricts movement in the X direction of the +Y directional tip end of the cable21when the conductor portion21A of the cable21is passed through the conductor portion insertion hole43F.

As shown inFIG.15, as with the metal terminal13shown inFIG.3, the metal terminal43is fixed to the bottom part of the second insertion groove12E of the second beam12B of the locator12. The insulating coating portion21B of the cable21is inserted in the second insertion groove12E of the locator12, the conductor portion21A of the conductor-exposed portion P1of the cable21is inserted in the conductor portion insertion groove13D of the curved portion13B of the metal terminal43, and the tip end of the conductor portion21A penetrates the conductor portion insertion hole43F in the inclination portion43E of the metal terminal43; in this state, the metal terminal43and the conductor portion21A are soldered to the connection portion31B of the substrate31.

In the soldering process, the heating portion of the heater41shown inFIG.10makes contact with the heated portion43C of the metal terminal43, whereby the metal terminal43is heated.

While the conductor portion insertion groove13D of the curved portion13B of the metal terminal13constitutes the first restriction portion that restricts movement, at least in the X direction, of the conductor portion21A exposed at the +Y directional tip end of the cable21in the cable structure using the metal terminal13, the conductor portion insertion hole43F of the inclination portion43E constitutes the first restriction portion in the metal terminal43. In the meantime, due to the conductor portion insertion groove13D of the curved portion13B, the conductor portion21A makes contact with the connection portion31B of the substrate31at a proper position, and in addition, the distance in the Z direction between the top part of the curved portion13B and the connection portion31B of the substrate31is narrowed so that the metal terminal43is easily soldered to the connection portion31B; hence, the reliability in electrical connection between the conductor portion21A of the cable21and the connection portion31B of the substrate31is improved.

With use of the metal terminal43as above, similarly, the cables21can be connected to the connection portions31B of the substrate31while being prevented from misalignment with respect to the connection portions31B, and the cables21can be connected to the substrate31with excellent retention force.

In addition, a metal terminal44shown inFIG.16may also be used. In the metal terminal44, as with the metal terminal43, a heated portion44C that is curved to protrude toward the −Z direction is joined to the +Y directional end of the curved portion13B, an inclination portion44E obliquely extends from the heated portion44C toward the +Y direction and +Z direction, and a conductor portion insertion slit44F is formed in the inclination portion44E.

The conductor portion insertion slit44F serves as the first restriction portion that restricts movement in the X direction of the +Y directional end of the cable21when the conductor portion21A of the cable21is inserted in the conductor portion insertion slit44F.

With use of the metal terminal44as above, similarly, the cables21can be connected to the connection portions31B of the substrate31while being prevented from misalignment with respect to the connection portions31B, and the cables21can be connected to the substrate31with excellent retention force.

FIG.17shows a cable structure according to Embodiment2. The cable structure is configured such that, in the cable structure of Embodiment 1, the cables21are connected to the sheet type substrate31using a cable connection component51in place of the cable connection component11. Each cable21has a structure in which an outer periphery of the conductor portion21A is covered with the insulating coating portion21B, and the substrate31is the same as the one used in Embodiment 1.

As shown inFIG.18, the cable connection component51includes a locator52extending in the X direction and made of an insulating resin, and a plurality of metal terminals53attached to the locator52.

The locator52includes a pair of support members52A disposed at opposite ends in the X direction of the locator52, the second beam12B extending in the X direction and joining the pair of support members52A to each other, and a first beam52B disposed at a distance in the +Y direction from the second beam12B, extending in the X direction, and joining the pair of support members52A to each other.

While the pair of support members52A of the locator52have a longer length in the Y direction than that of the support members12A of the locator12in Embodiment 1, as with the support members12A, the pair of support members52A each include the substrate-mounting surface12C extending along an XY plane and facing in the +Z direction, and the boss12D is formed in a center part of the substrate-mounting surface12C to project in the +Z direction.

The second beam12B of the locator52is the same as the second beam12B of the locator12in Embodiment 1 and includes the plurality of second insertion grooves12E aligned in the X direction.

Further, while the first beam52B of the locator52extends parallel to the second beam12B in the X direction and has a shorter length in the Y direction than that of the second beam12B, as with the second beam12B, the first beam52B includes the plurality of first insertion grooves52E aligned in the X direction. The first insertion grooves52E correspond to the cables21and the second insertion grooves12E and each has a bottom surface of cylindrical shape conforming to the outer peripheral surface of the insulating coating portion21B of the cable21. In addition, as with the second insertion groove12E, the first insertion groove52E has a groove width and a groove depth that allow insertion of the insulating coating portion21B of the cable21, and is configured to be capable of restricting movement, at least in the X direction, of the cable21inserted in the first insertion groove52E.

The metal terminals53correspond to the cables21, the second insertion grooves12E, and the first insertion grooves52E. As shown inFIG.19, each metal terminal53includes the fixing portion13A of flat plate shape, a curved portion53B joined to the fixing portion13A on its +Y direction side, and the heated portion13C of flat plate shape joined to the curved portion53B on its +Y direction side. In other words, the metal terminal53is configured such that, in the metal terminal13used in Embodiment 1, the curved portion53B in place of the curved portion13B is disposed between the fixing portion13A and the heated portion13C, and the conductor portion insertion groove13D is formed on the +Z directional surface of the top part of the curved portion53B, as with the metal terminal13in Embodiment 1.

As shown inFIG.20, the metal terminal53has a so-called cantilever shape extending in the +Y direction from the corresponding second insertion groove12E of the second beam12B, and there is a height difference H1between the curved portion53B and the fixing portion13A, the height difference H1corresponding to the thickness of the insulating coating portion21B of the cable21. The heated portion13C joined to the curved portion53B on its +Y direction side is disposed at the same position in the Z direction as the fixing portion13A.

Moreover, the first insertion groove52E formed in the first beam52B of the locator52is situated on the +Y direction side of the metal terminal53and is deviated in the −Z direction from the second insertion groove12E formed in the second beam12B so that there is a predetermined level difference H2therebetween.

As shown inFIG.21, the cable21used in Embodiment 2 is configured such that, at a position away from the +Y directional end thereof in the −Y direction by a predetermined distance, the insulating coating portion21B is removed to form the conductor-exposed portion P1where the conductor portion21A is exposed in a predetermined length in the Y direction. That is, the conductor portion21A at the conductor-exposed portion P1positioned on the front side from the +Y directional end of the cable21is exposed, and the insulating coating portion21B is left unremoved on the +Y direction side and the −Y direction side of the conductor-exposed portion P1.

In the cable connection component51shown inFIG.20, the first insertion grooves52E formed in the first beam52B of the locator52constitute the first restriction portions that separately restrict movements, at least in the X direction, of the insulating coating portions21B at the +Y directional tip ends of the cables21, and the second insertion grooves12E of the second beam12B of the locator52constitute the second restriction portions that separately restrict movements, at least in the X direction, of the insulating coating portions21B at positions away from the tip ends of the cables21in the −Y direction, i.e., on the proximal side of the cables21, by a predetermined distance.

In the assembling operation of the cable structure, first, the cables21are disposed on the locator52of the cable connection component51as shown inFIG.22. In this process, the insulating coating portion21B is inserted in the corresponding first insertion groove52E (first restriction portion) of the locator52at the +Y directional tip end of each cable21, the conductor portion21A exposed at the conductor-exposed portion P1of the cable21is situated on the +Z direction side of the curved portion53B of the corresponding metal terminal53and inserted in the conductor portion insertion groove13D of the curved portion53B, and the insulating coating portion21B on the −Y direction side of the conductor-exposed portion P1is inserted in the corresponding second insertion groove12E (second restriction portion) of the locator52.

Next, as shown inFIG.23, the substrate31is disposed on the +Z direction side of the cable connection component51on which the cables21are disposed. With this constitution, the substrate-mounting surfaces12C of the pair of support members52A of the locator52are opposed to the −Z directional surface of the substrate31on which the connection portions31B are exposed.

Meanwhile, the cream solder31D is preliminarily printed on the connection portions31B exposed on the −Z directional surface of the substrate31.

Further, the substrate31and the cable connection component51are relatively moved in the Z direction, whereby the substrate31is mounted on the substrate-mounting surfaces12C of the pair of support members52A of the locator52, and in this state, the heater41is disposed on the metal terminals53from the −Z direction as shown inFIG.24. The heating portion of the heater41makes contact with the heated portion13C of each metal terminal53shown inFIG.20.

Here, when the substrate31is mounted on the substrate-mounting surfaces12C of the pair of support members52A of the locator52, the locator52is preferably fixed to the substrate31by a jig (not shown) such that the metal terminals53do not move in the −Z direction relatively to the connection portions31B of the substrate31.

By applying electric current to the heater41from a power source (not shown) connected to the heater41, the metal terminals53in contact with the heating portion are heated, the cream solder31D printed on the connection portions31B of the substrate31is melted, and the metal terminals53are separately soldered to the connection portions31B of the substrate31as shown inFIG.25.

In this process, as shown inFIG.26, the conductor portion21A of the cable21that is situated between the curved portion53B of each metal terminal53and the corresponding connection portion31B of the substrate31, together with the metal terminal53, is soldered to the connection portion31B with the solder31E to be thereby electrically connected to the connection portion31B.

Thus, the assembling operation of the cable structure is completed.

A cross-sectional view of the thus assembled cable structure is shown inFIG.27. While the insulating coating portion21B at the +Y directional tip end of the cable21is inserted in the first insertion groove52E of the first beam52B of the locator52, and the insulating coating portion21B on the −Y direction side of the conductor-exposed portion P1is inserted in the second insertion groove12E of the second beam12B, the conductor portion21A of the conductor-exposed portion P1inserted in the conductor portion insertion groove13D of the metal terminal53is electrically connected to the connection portion31B of the substrate31with the solder31E.

Since the conductor portion21A of the cable21is inserted in the conductor portion insertion groove13D of the curved portion53B of the metal terminal53, movement in the X direction of the conductor portion21A at the conductor-exposed portion P1is restricted, and the distance in the Z direction between the top part of the curved portion53B and the connection portion31B of the substrate31is narrowed, whereby the soldering between the metal terminal53and the connection portion31B is facilitated, compared to the case where the conductor portion insertion groove13D is not provided. Accordingly, it is possible to electrically connect the conductor portion21A of the cable21to the connection portion31B of the substrate31with high reliability.

As described above, owing to the first insertion groove52E of the first beam52B constituting the first restriction portion and the second insertion groove12E of the second beam12B constituting the second restriction portion, the conductor portion21A of the cable21is electrically connected to the connection portion31B of the substrate31while movement of the cable21at least in the X direction is restricted at two positions separated from each other in the Y direction, whereby the plurality of cables21are prevented from misalignment with respect to the plurality of connection portions31B of the substrate31and can be connected to the connection portions31B also in Embodiment 2. In addition, since the conductor portion21A of each cable21is connected to the corresponding connection portion31B of the substrate31with use of the metal terminal53, the plurality of cables21can be connected to the substrate31with excellent retention strength.

FIG.28shows a cable structure according to Embodiment3. The cable structure is configured such that, in the cable structure of Embodiment 2, the cables21are connected to the sheet type substrate31using a cable connection component61in place of the cable connection component51. Each cable21has a structure in which an outer periphery of the conductor portion21A is covered with the insulating coating portion21B, and the substrate31is the same as the one used in Embodiments 1 and 2.

As shown inFIG.29, the cable connection component61includes a locator62extending in the X direction and made of an insulating resin.

The locator62includes the pair of support members52A disposed at opposite ends in the X direction of the locator62, a second beam62B extending in the X direction and joining the pair of support members52A to each other, and the first beam52B disposed at a distance in the +Y direction from the second beam62B, extending in the X direction, and joining the pair of support members52A to each other.

The pair of support members52A of the locator62are the same as the pair of support members52A of the locator52in Embodiment 2 and each include the substrate-mounting surface12C extending along an XY plane and facing in the +Z direction, and the boss12D is formed in a center part of the substrate-mounting surface12C to project in the +Z direction.

The first beam52B of the locator62is the same as the first beam52B of the locator52in Embodiment 2 and includes the plurality of first insertion grooves52E aligned in the X direction.

The second beam62B of the locator62includes a plurality of second insertion grooves62E aligned in the X direction as with the second beam12B of the locator52in Embodiment 2, and each second insertion groove62E has a bottom surface of cylindrical shape conforming to the outer peripheral surface of the insulating coating portion21B of the cable21.

As shown inFIG.30, the first insertion groove52E of the first beam52B is deviated in the −Z direction from the second insertion groove62E formed in the second beam62B so that there is a predetermined level difference H2therebetween.

Meanwhile, the cable connection component61in Embodiment 3 does not include such metal terminal as those used in Embodiments 1 and 2.

In the cable connection component61shown inFIG.30, the first insertion grooves52E formed in the first beam52B of the locator62constitute the first restriction portions that separately restrict movements, at least in the X direction, of the insulating coating portions21B at the +Y directional tip ends of the cables21, and the second insertion grooves62E of the second beam62B of the locator62constitute the second restriction portions that separately restrict movements, at least in the X direction, of the insulating coating portions21B of the cables21at positions away from the tip ends of the cables21in the −Y direction, i.e., on the proximal side of the cables21, by a predetermined distance.

In the assembling operation of the cable structure, first, the cables21are disposed on the locator62of the cable connection component61as shown inFIG.31. At this time, the cables21do not each include a conductor-exposed portion in which the insulating coating portion21B is removed to expose the conductor portion21A.

The insulating coating portion21B at the +Y directional tip end of each cable21is inserted in the corresponding first insertion groove52E (first restriction portion) of the locator62, and at a position away from the +Y directional tip end of the cable21in the −Y direction by a predetermined distance, the insulating coating portion21B is inserted in the corresponding second insertion groove62E (second restriction portion) of the locator62.

In this state, a laser beam is emitted to the outer peripheral surfaces of the cables21between the first beam52B and the second beam62B of the locator62, whereby the insulating coating portions21B of the cables21are removed. Thus, the conductor-exposed portion P1where the conductor portion21A is exposed is formed between, of each cable21, a portion inserted in the first insertion groove52E of the first beam52B and a portion inserted in the second insertion groove62E of the second beam62B, as shown inFIG.32.

Next, as shown inFIG.33, the substrate31is disposed on the +Z direction side of the cable connection component61on which the cables21are disposed. With this constitution, the substrate-mounting surfaces12C of the pair of support members52A of the locator62are opposed to the −Z directional surface of the substrate31on which the connection portions31B are exposed.

Meanwhile, the cream solder31D is preliminarily printed on the connection portions31B exposed on the −Z directional surface of the substrate31.

Further, the substrate31and the cable connection component61are relatively moved in the Z direction, whereby the substrate31is mounted on the substrate-mounting surfaces12C of the pair of support members52A of the locator62as shown inFIG.34. With this constitution, the conductor portions21A exposed at the conductor-exposed portions P1of the cables21retained by the cable connection component61are situated on the −Z direction side of the connection portions31B of the substrate31.

Here, the locator62is preferably fixed to the substrate31by a jig (not shown) such that the conductor portions21A exposed at the conductor-exposed portions P1of the cables21do not move in the −Z direction relatively to the connection portions31B of the substrate31.

In this state, as shown inFIG.35, the heater41is disposed from the −Z direction to the cable connection component61. Although not shown inFIG.35, the heater41is disposed on the conductor-exposed portions P1of the cables21, and the heating portion of the heater41makes contact with the conductor portions21A exposed at the conductor-exposed portions P1of the cables21.

By applying electric current to the heater41from a power source (not shown) connected to the heater41with the heater41being pressed in the +Z direction, the conductor portions21A of the cables21in contact with the heating portion are heated, the cream solder31D printed on the connection portions31B of the substrate31is melted, and the conductor portions21A of the cables21are separately soldered to the connection portions31B of the substrate31as shown inFIG.36.

In this process, as shown inFIG.37, the conductor portion21A exposed at the conductor-exposed portion P1of each cable21is soldered to the connection portion31B with the solder31E to be thereby electrically connected to the connection portion31B.

Thus, the assembling operation of the cable structure is completed.

A cross-sectional view of the thus assembled cable structure is shown inFIG.38. At the +Y directional tip end of the cable21, the insulating coating portion21B is inserted in the first insertion groove52E of the first beam52B of the locator62, and at a position away from the +Y directional tip end of the cable21in the −Y direction by a predetermined distance, the insulating coating portion21B is inserted in the second insertion groove62E of the second beam62B; in this state, the conductor portion21A at the conductor-exposed portion P1of the cable21, which is soldered as being pressed in the +Z direction by the heater41, is electrically connected to the connection portion31B of the substrate31with the solder31E.

As described above, owing to the first insertion groove52E of the first beam52B constituting the first restriction portion and the second insertion groove62E of the second beam62B constituting the second restriction portion, the conductor portion21A of the cable21is electrically connected to the connection portion31B of the substrate31while movement of the cable21at least in the X direction is restricted at two positions separated from each other in the Y direction, whereby the plurality of cables21are prevented from misalignment with respect to the plurality of connection portions31B of the substrate31and can be connected to the connection portions31B also in Embodiment 3.

In addition, since metal terminals are not used in Embodiment 3, the number of components can be reduced, and a cable structure having a simple structure can be realized.

In Embodiment 3 described above, the conductor-exposed portions P1of the cables21are formed by emitting a laser beam to the outer peripheral surfaces of the cables21between the first beam52B and the second beam62B of the locator62, but this is not the sole case. For instance, by providing a cut to the insulating coating portion21B of each cable21using a cutting tool or another tool and sliding the insulating coating portion21B toward a tip end of the cable21, the conductor-exposed portion P1where the conductor portion21A is exposed can be formed.