Connector

A connector includes: half body parts each including a connector body, and a plurality of terminals attached to the body; end parts formed on both ends of the body formed by allowing the bodies to abut each other; and reinforcing brackets attached to the respective end parts. Each of the bodies is a member integrated with the terminals by primary insert molding, and includes a protrusion extending in the longitudinal direction and holding the terminals, and an embedded part connected to both ends in the longitudinal direction of the protrusion. The end part includes a covering part covering at least the embedded part of each of the bodies, and the covering part is a member integrated with the embedded part and the bracket by secondary insert molding. The connector allows for the spacing between protrusions to be narrowed, simplifying manufacturing, reducing size, and improving reliability.

TECHNICAL FIELD

The present disclosure relates to a connector.

BACKGROUND ART

Conventionally, connectors such as board to board connectors, etc., have been used to electrically connect pairs of parallel circuit boards together. These types of connectors are attached to mutually facing surfaces on pairs of circuit boards and provide conduction when mated together (for example see patent document 1).

FIG. 11is a perspective view illustrating a known connector.

In the drawing,811is a connector housing mounted on a circuit board (not illustrated), which has a pair of elongated long protrusions812extending in the longitudinal direction. A plurality of terminals861is attached in the respective protrusions812along the longitudinal direction of the connector.

Furthermore, when the connector is mated with the counterpart connector not illustrated, the protrusions812are inserted into a pair of recessed grooves formed in a counterpart housing of a counterpart connector. Thus, the terminals861contact and become conductive with respective terminals (not illustrated) attached in the recessed grooves.

SUMMARY

However, with the known connector, since the terminals861are formed integrally with the housing811, when attempting to reduce size, the spacing between the protrusions812becomes smaller to reduce the pitch of the terminals861, making manufacturing difficult. Since the terminals861are normally integrated with the pair of protrusions812of the housing811using a molding method called overmolding or insert molding, when the spacing between the protrusions812becomes smaller to reduce the pitch of the terminal861, it is difficult to accurately dispose the lot of terminals861at positions corresponding to the pair of protrusions812in the mold of the housing811.

Here, an objective is to resolve the problems of the convention connector, enabling narrowing the interval between protrusions for mounting a plurality of terminals and therefore enabling size reduction, and providing a connector with high reliability.

Thus, a connector includes: half body parts each including a connector body, and a plurality of terminals attached to the connector body; body end parts formed on both ends of the connector body formed by allowing the connector bodies to abut each other; and reinforcing brackets attached to the respective body end parts. Each of the connector bodies is a member integrated with the terminals by primary insert molding, and includes a protrusion extending in the longitudinal direction and holding the terminals, and an embedded part connected to both ends in the longitudinal direction of the protrusion. The body end part includes a covering part covering the embedded part of each of the connector bodies, and the covering part is a member integrated with the embedded part and the reinforcing bracket by secondary insert molding.

In another connector, an extended end part is connected to both ends in the longitudinal direction of the protrusion, and the embedded part extends from the extended end part.

In yet another connector, the reinforcing bracket includes an upper plate extending in the width direction of the connector body, a pair of left and right legs connected to both left and right edges of the upper plate and extending downward, and an end wall outer surface covering part and an end wall inner surface covering part connected to both front and rear edges of the upper plate and extending downward, the embedded part is disposed so as at least partially overlap with the upper plate, the legs, the end wall outer surface covering part, and the end wall inner surface covering part when viewed from vertical, front-back, and left-right directions.

In yet another connector, the embedded part of each of the connector bodies includes a parallel inner surface extending in the longitudinal direction of the connector body and facing the embedded part of another connector body, and a distance L2between the opposed parallel inner surfaces is smaller than a width L1of the end wall inner surface covering part of the reinforcing bracket disposed so as to face the gap between the opposed parallel inner surfaces.

In yet another connector, the end wall inner surface covering part is opposed to an inclined inner surface of the embedded part, the inclined inner surface being connected to each of the opposed parallel inner surfaces and inclined with respect to the longitudinal direction of the connector body, and has a gap from the inclined inner surface.

In yet another connector, the embedded part of each of the connector bodies extends in the longitudinal direction of the connector body and includes an outer surface opposed to the leg of the reinforcing bracket, and a length L4of the outer surface is smaller than a length L3of the leg.

In yet another connector, an extended end part of each of the connector bodies is inclined inward in the width direction of the connector and extends from both ends in the longitudinal direction of the protrusion, and a width of the body end part is smaller than a width of the connector.

A connector pair includes the connector of the present disclosure and a counterpart connector that mates with the connector.

In a connector according to the present disclosure, the interval between protrusions where the plurality of terminals is mounted can be narrowed, simplifying manufacturing, reducing size, and improving reliability.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An embodiment will be described in detail below with reference to the drawings.

FIG. 1is a perspective view illustrating a first connector according to the present embodiment,FIG. 2is an exploded view illustrating the first connector according to the present embodiment, andFIG. 3is a perspective view illustrating a left half body part of the first connector according to the present embodiment.

In the figures,1is a first connector serving as one of a pair of board to board connectors according to the present embodiment. The first connector1is a surface mount type connector mounted on the surface of a first substrate (not illustrated) serving as a mounting member and is mated with a second connector101serving as a counterpart connector. Furthermore, the second connector101is the other of the pair of board to board connectors and is a surface mount type connector mounted on the surface of a second substrate (not illustrated) serving as a mounting member.

Note that while the first connector1and the second connector101are ideally used for electrically connecting the first substrate and the second substrate serving as substrates, the connectors can also be used to electrically connect other members. Examples of the first substrate and the second substrate include printed circuit boards, flexible flat cables (FFC), flexible printed circuit boards (FPC), etc. used in electronic equipment, etc., but may be any type of substrate.

Furthermore, expressions indicating directions such as up, down, left, right, front, and back used to describe the operations and configurations of the parts of the first connector1and the second connector101in the present embodiment are not absolute, but rather relative directions, and though appropriate when the parts of the first connector1and the second connector101are in the positions illustrated in the figures, these directions should be interpreted differently when these positions change in order to correspond to said change.

The first connector1is configured by connecting a pair of left and right half body parts, that is, a left half body part10A and a right half body part10B to each other using a first reinforcing bracket51as a reinforcing bracket and a covering part16integrally molded by a molding method referred to as overmolding, outsert molding, or insert molding (hereinafter referred to as “insert molding”). Note that the left half body part10A and the right half body part10B are identical members disposed so as to face each other and thus, when collectively described, they are described as half body parts10. The left half body part10A and the right half body part10B are substantially gate-shaped in plan view (shape projected onto the X-Y surface), and a space between the connected left half body part10A and right half body part10B is an elongated recessed groove13extending in the longitudinal direction (X axis direction) of the first connector1. The recessed groove13is a though-hole opened on the upper surface and lower surface of the first connector1.

Note that, in the present embodiment, for convenience of explanation, in the first connector1, a pair of, that is, two half body parts10are arranged in parallel, however, three or more half body parts10may be arranged in parallel. The half body parts10need not be substantially gate-shaped, and may have any shape provided that both ends of the longitudinal direction can be connected to each other with the first reinforcing bracket51and the covering part16.

The half body parts10are integrally formed from an insulating material such as a synthetic resin or the like, and have a first housing11that is a substantially gate-shaped connector body in the plan view. Each of the first housing11includes an elongated band-like bottom plate part17that extends in the longitudinal direction (X-axis direction) of this first housing11, and an elongated first protrusion12as an elongated protrusion that is integrally formed on the upper surface of the bottom plate part17and extends in the longitudinal direction of the first housing11. The first protrusion12is a member having an inverted U-shaped cross section, and has a curved mating surface12alocated on the upper side (Z-axis positive direction side), and an outer surface12band inner surface12c, which are connected to both left and right sides of the mating surface12a. The outer surface12band the inner surface12care a pair of flat surfaces that face each other in parallel, and extend in the longitudinal direction of the first housing11. Note that the dimensions of the first protrusion12in the width direction (Y axis direction) are smaller than the dimensions of the bottom plate part17in the width direction, and thus, the bottom plate part17protrudes outward in the width direction from the outer surface12band the inner surface12cat the lower end (end in the Z-axis negative direction side) of the first protrusion12. Furthermore, the lower surface of the bottom plate part17is a mounting surface17aof the first housing11, which faces the surface of the first substrate.

A first terminal61as a terminal is disposed in each first protrusion12. The plurality of (32in the example illustrated in the figures) first terminals61is arranged at a prescribed pitch. The first terminal61is a member integrally formed by applying a process such as punching, bending, or the like to a conductive metal plate, and includes a body part63that extends in the width direction of the first protrusion12, a tail part62connected to one end of the body part63, a contact part65that is bent by approximately 90 degrees, connected to the other end of the body part63, and vertically extends, and an upper end part64that is bent by approximately 90 degrees and connected to the upper end of the contact part65.

The body part63is the part embedded and retained in the bottom plate part17. In addition, the tail part62extends outward from the bottom plate part17in the width direction, and is connected to the connection pad coupled to the conductive trace on the first substrate by soldering or the like. Note that the conductive trace is typically a signal line. The contact part65is a part that comes into contact with a second terminal161described below of the second connector101when the first connector1is mated with the second connector101, and preferably includes a contact recess65adented from the surface.

The first terminals61are integrated with the first housing11by insert molding. That is, first housing11is molded by filling the cavity of a mold, in which first terminal61has been set beforehand, with an insulating material. Thus, the first terminal61is integrally attached to the first housing11in the state where with the lower surfaces of the body part63and tail part62are exposed to the mounting surface17aof the bottom plate part17, and the surfaces of the contact part65and upper end part64are exposed on the outer surface12bor the inner surface12cand mating surface12aof the first protrusion12.

In addition, the first terminals61attached to each first protrusion12are oriented such that the adjacent first terminals face opposite to each other in the width direction of the first protrusion12. In the illustrated example, the first terminal61located at the front end (end in the X-axis positive direction) among the first terminals61attached to the first protrusion12of the left half body part10A is oriented such that the tail part62protrudes outward (in the Y-axis positive direction), while the first terminal61located the second from the front end is oriented such that the tail part62protrudes inward (in the Y-axis negative direction). In this manner, since the first terminals61are attached to the first protrusion12so as to be alternately oriented in opposite directions, the pitch of the tail parts62that protrude from each of both sides of the first protrusion12is twice the pitch of the first terminals61. Therefore, connection work by soldering and the like to the connection pad of the first substrate can easily be performed. In addition, the pitch of the contact part65exposed on the outer surface12of the first protrusion12b, and the pitch of the contact part65exposed on the inner surface12care also twice the pitch of the first terminals61.

Furthermore, the first terminals61are members integrated with the first housing11by insert molding, and thus are not separated from the first housing11. However, note that the first terminals are drawn separately from the first housing11inFIG. 2for convenience of explanation.

A first protruding end part18that is a body end part functioning as a mating guide part is disposed on both ends in the longitudinal direction of the first protrusion12. The first protruding end part18is a member connected to both ends in the longitudinal direction of each first protrusion12, and is formed to connect the left half body part10A to the right half body part10B. In the state where the first connector1is mated with the second connector101, the first protruding end part18functions as an insertion protrusion inserted into the mating recess122of a second protruding end part121described below of the second connector101.

The first protruding end part18is constituted of an extended end part14and an embedded part15of the left and right half body parts10, and of covering part16and the first reinforcing bracket51.

The extended end part14extending in the longitudinal direction is integrally connected to both ends in the longitudinal direction of the first protrusion12of each of the half body parts10, and the embedded part15further extending in the longitudinal direction of the first protrusion12is integrally connected to each extended end part14. Note that the extended end part14diagonally extends inward, and the embedded part15extends in the longitudinal direction from an inwardly-eccentric position at the tip of the extended end part14, and is located inward of the outer surface12bof the first protrusion12. That is, the extended end part14of the left half body part10A diagonally extends in the right direction (the Y-axis negative direction), and the embedded part15extends in the longitudinal direction from a rightward-eccentric position at the tip of the extended end part14. In addition, the extended end part14of the right half body part10B diagonally extends in the left direction (the Y-axis positive direction), and the embedded part15extends in the longitudinal direction from a leftward-eccentric position at the tip of the extended end part14.

At least a part of the extended end parts14and the whole of the embedded parts15of the left and right half body parts10are covered with the covering part16formed from an insulating material such as a synthetic resin or the like. Specifically, the covering part16is formed by bringing the embedded parts15of the left and right half body parts10into proximity with each other, being covered with first reinforcing bracket51, and insert-molded. As a result, the extended end parts14and the embedded parts15of the left and right half body parts10, the covering part16and the first reinforcing bracket51are integrated to form the first protruding end part18, thereby connecting the left and right half body parts10to each other. However, the covering part16does not necessarily cover the whole of the embedded parts15, and may cover the embedded parts15to a degree sufficient to connect the left and right half body parts10to each other, however, in order to maximize the coupling force, it is desirable to cover the entire embedded part15. Note that the covering part16is a member integrated with other members by insert molding and is not independently present while separated from the other members, and however, for convenience of explanation, is depicted as independently present inFIG. 2.

As illustrated inFIG. 3, the extended end part14has an upper surface14alocated on the upper side, an outer surface14band an inner surface14cthat are connected to left and right sides of the upper surface14a, and a lower surface14dlocated on the lower side. The lower surface14dis located above the mounting surface17a, and at least a part of the lower surface14dis covered with the covering part16. The upper surface14ais substantially flush with the mating surface12aof the first protrusion12. Additionally, the inner surface14cis a surface diagonally inclined inward with respect to the inner surface12cof the first protrusion12. The outer surface14bincludes an inclined outer surface14b1diagonally inclined inward with respect to the outer surface12bof the first protrusion12, and a parallel outer surface14b2that is substantially parallel to the outer surface12bof the first protrusion12. The parallel outer surface14b2is substantially flush with the outer surface of the covering part16and becomes a part of the outer surface of the first protruding end part18.

The embedded part15is a member substantially shaped like a rectangular parallelepiped, and has an upper surface15alocated on the upper side, an outer surface15band an inner surface15con both left and right sides, a lower surface15dlocated on the lower side, and end surfaces15eat both ends in the longitudinal direction of the first connector1. The upper surface15aand the lower surface15dare planes that are parallel to each other, and the distance between the upper surface15aand the lower surface15d, that is, the thickness of the embedded part15is smaller than the thickness of the extended end part14and the first protrusion12. Note that the upper surface15ais located below the mating surface12a, and the lower surface15dis located above the mounting surface17a. Further, the outer surface15bis a plane that is substantially parallel to the outer surface12bof the first protrusion12, but is located inward of the outer surface12b, that is, close to the center in the width direction of the first housing11. The inner surface15cincludes a parallel inner surface15c1that is substantially parallel to the inner surface12cof the first protrusion12, and an inclined inner surface15c2that is substantially parallel to the inner surface14cof the extended end part14. The end surface15eis a plane that is orthogonal to the longitudinal direction of the first connector1. The embedded part15is entirely covered with the covering part16, that is, embedded in the covering part16.

In this way, since the extended end part14diagonally extends inward and the embedded part15is located inner from the outer surface12bof the first protrusion12, the width (dimension in the Y-axis direction) of the first protruding end part18can be made smaller than the width of the first connector1(distance between the outer surfaces12bof the left and right first protrusions12). Note that in the case where the width of the first protruding end part18need not be smaller than the width of the first connector1, the extended end part14is not necessarily inclined inward, but can also be extended straightly. Furthermore, the extended end part14may be omitted by extending the embedded part15directly from both ends in the longitudinal direction of the first protrusion12. In this case, the dimension of the first connector1in the longitudinal direction can be reduced. Furthermore, when three or more half body parts10are arranged in parallel, the extended end part14can be extended into a Y-shape from both ends in the longitudinal direction of the first protrusion12.

The first reinforcing bracket51is a member integrally formed by applying a process such as punching, bending, or the like to a metal plate, and includes a substantially rectangular upper plate54that extends in the width direction of the first housing11, substantially rectangular legs55that are connected to both left and right edges of the upper plate54and extend downward, and an end wall outer surface covering part52and an end wall inner surface covering part53that are connected to both front and back edges of the upper plate54, respectively, and extend downward. A tail part52ais connected to the lower end of the end wall outer surface covering part52. The width of the end wall outer surface covering part52is greater than the width of the end wall inner surface covering part53.

As described above, the first reinforcing bracket51is integrated with the covering part16to constitute the first protruding end part18. Then, the upper plate54is embedded in the upper surface of the first protruding end part18, and the upper surface of the upper plate54is flush with the upper surface of the covering part16to constitute most of the upper surface of the first protruding end part18. Also, the left and right legs55are embedded in the left and right outer surfaces of the first protruding end part18, respectively, and the outer surfaces of the legs55are flush with the outer surface of the covering part16to constitute most of the outer surface of the first protruding end part18. In addition, the end wall outer surface covering part52and the end wall inner surface covering part53are embedded in the end wall outer surface and the end wall inner surface, respectively, of the first protruding end part18, and the outer surfaces of the end wall outer surface covering part52and the end wall inner surface covering part53are flush with the end wall outer surface and the end wall inner surface of the covering part16to constitute most of the end wall outer surface and the end wall inner surface of the first protruding end part18.

The tail part52ais bent by approximately 90 degrees and connected to the lower end of the end wall outer surface covering part52, extends outward in the longitudinal direction of the first housing11, and is connected to the connection pad coupled with the conductive trace on the first substrate by soldering or the like. The conductive trace is typically a power line. Note that, as necessary, the lower ends of the legs55may approach or contact the surface of the first substrate. In this case, connecting, the connection strength of the first reinforcing bracket51to the first substrate is improved by connecting the lower ends of the legs55to the connection pad on the first substrate by soldering, or the like.

The operation of manufacturing the first connector1having the abovementioned configuration will be described below.

FIG. 4is a perspective view illustrating a first step of manufacturing the left half body part of the first connector according to the present embodiment,FIGS. 5A and 5Bare two-sided views illustrating a first step of manufacturing the first protruding end part of the first connector according to the present embodiment,FIGS. 6A and 6Bare two-sided views illustrating a second step of manufacturing the first protruding end part of the first connector according to the present embodiment,FIGS. 7A and 7Bare enlarged views illustrating main parts of the first and second steps of manufacturing the first protruding end part of the first connector according to the present embodiment, andFIGS. 8A to 8Dare cross-sectional views illustrating the first and second steps of manufacturing the first protruding end part of the first connector according to the present embodiment. Note thatFIGS. 5A and 6Aare top views,FIGS. 5B and 6Bare bottom views,FIG. 7Ais an enlarged view illustrating a part E inFIG. 5B,FIG. 7Bis an enlarged view illustrating the F part inFIG. 6B,FIG. 8Ais a cross-sectional view taken along a line A-A inFIG. 5A,FIG. 8Bis a cross sectional view taken along line B-B inFIG. 5A,FIG. 8Cis a cross sectional view taken along a line C-C inFIG. 6A, andFIG. 8Dis a cross-sectional view taken along a line D-D inFIG. 6A.

The first terminal61is a member made from a metal plate bent in the plate thickness direction, and is fabricated by applying a process such as punching, bending, or the like to the metal plate, and as illustrated inFIG. 4, the plurality of first terminals61connected to a flat plate-shaped terminal carrier68is supplied. Note that the first terminals61each are a member as illustrated inFIG. 2connecting the tip of the tail part62to the terminal carrier68via an elongated connection arm68aand cutting the tail part62away from the connection arm68aat a cutting part68b.

Then, in the step of being integrated with the first housing11by insert molding, the plurality of first terminals61connected to the carrier68are supplied as illustrated inFIG. 4.FIG. 4illustrates the example of manufacturing the left half body part10A. In this case, the first terminals61oriented such that the tail parts62protrude outward (side in the Y-axis positive direction) are connected to the right terminal carrier68inFIG. 4, and the first terminals61oriented such that the tail parts62protrude outward (side in the Y-axis negative direction) are connected to the left terminal carrier68inFIG. 4, and these terminals in that state are set in a primary mold not illustrated. The plurality of first terminals61is simultaneously positioned and set in the mold by holding and operating the terminal carrier68to which the plurality of first terminals61is connected.

Subsequently, a molten insulating material such as a synthetic resin is filled in the cavity of the mold. In other words, the primary insert molding is performed. Note that the insulating material may be any type of material, but is here an LCP (liquid crystal polymer). In the primary insert molding, it is desirable to select the material in terms of flowability. Then, when the filled insulating material is cooled and solidified to form the first housing11, the mold is opened, and the left half body part10A with the terminal carrier68connected to the first terminals61as illustrated inFIG. 4is removed. Similarly, the right half body part10B with the terminal carrier68connected to the first terminals61is also manufactured.

Subsequently, only the terminal carrier68(the left terminal carrier68inFIG. 4) connected to the tail parts62protruding inward is removed from the left half body part10A with the terminal carrier68connected to the first terminals61as illustrated inFIG. 4, and the terminal carrier68(the right terminal carrier68inFIG. 4) connected to the tail parts62protruding outward is left as it is. Similarly, only the terminal carrier68connected to the tail parts62protruding inward from the right half body part10B with the terminal carrier68connected to the first terminals61is removed, and the terminal carrier68connected to the tail parts62protruding outward is left as it is.

Subsequently, as illustrated inFIGS. 5A and 5B, the left half body part10A and the right half body part10B with the terminal carriers68connected only to the tail parts62protruding outward are set in a secondary mold (not illustrated) so as to be opposed to each other. Specifically, the inner sides of the left and right half body parts10face each other, and the first housings11of the left and right half body parts10are parallel to each other, the mounting surfaces17aof the first housing11of the left and right half body parts10are flush with each other, the end surfaces15eof both ends in the longitudinal direction are flush with each other, and the embedded parts15of the left and right half body parts10are adjacent to each other but are not in contact. As illustrated inFIG. 7A, the opposed left and right half body parts10are located such that the spacing between the parallel inner surfaces15c1of the opposed embedded part15is a predetermined distance L2, and are set in a secondary mold.

Furthermore, the first reinforcing bracket51is set in the secondary mold so as to cover at least a part of the extended end parts14and the entire embedded parts15of the left and right half body parts10. In this case, the first reinforcing bracket51is set in the state where a tip of a tail part52ais connected to a bracket carrier58as a carrier. Note that the tail part52ais removed from the bracket carrier58at a cutting part58bto obtain the first reinforcing bracket51as illustrated inFIG. 2. Specifically, as illustrated inFIGS. 7A, 8A, and 8B, the first reinforcing bracket51is set such that the upper plate54and the upper surface15aof the embedded part15have a gap therebetween, the leg55and the outer surface15bof the embedded part15have a gap therebetween, the end wall outer surface covering part52and the end surfaces15eof the embedded part15have a gap therebetween, the end wall inner surface covering part53and the inclined inner surface15c2of the embedded part15have a gap therebetween, and the lower end of the leg55is located lower than the lower surface15dof the embedded part15and at the approximately same height as the mounting surface17a.

Subsequently, a molten insulating material such as a synthetic resin is filled in the cavity of the mold. In other words, the secondary insert molding is performed. Note that the insulating material may be any type of material, but here, the material is LCP in consideration of fluidity as in the primary insert molding. In the secondary insert molding, the insulating material may be selected by focusing on strength and melt bonding with the insulating material of the primary insert molding. Then, when the filled insulating material is cooled and solidified to form the covering part16, the mold is opened, and the left and right half body parts10having both ends in the longitudinal direction connected to each other with the first protruding end part18as illustrated inFIGS. 6A and 6Bare taken out.

In this case, the left and right half body parts10are integrated with the covering part16in the state where at least a part of the extended end part14and the entire embedded part15are covered with the covering part16, and the first reinforcing bracket51is integrated with the covering part16so as to cover at least a part of the outer surface of the covering part16. Specifically, as illustrated inFIGS. 7B, 8C, and 8D, in the first reinforcing bracket51, the gap between the upper plate54, the leg55, the end wall outer surface covering part52, and the end wall inner surface covering part53, and the top surface15a, the outer surface15b, the end surface15e, and the inclined inner surface15c2of the embedded part15is filled with the insulating material of the covering part16. The gap between the parallel inner surfaces15c1of the embedded parts15facing each other is also filled by the insulating material of the covering part16. Furthermore, the lower side of the lower surface15dof the embedded part15is also filled by the insulating material of the covering part16, and the lower surface of the covering part16is substantially flush with the mounting surface17a. Furthermore, the parallel outer surface14b2of the extended end part14is substantially flush with the outer surface of the covering part16and becomes a part of the outer surface of the first protruding end part18.

As illustrated inFIG. 7A, since there is a gap between the end wall inner surface covering part53of the first reinforcing bracket51and the inclined inner surface15c2of the embedded part15, and the inclined inner surface15c2is inclined, the molten insulating material filled into the cavity of the mold in the secondary insert molding smoothly flows between the end wall inner surface covering part53and the left and right inclined inner surfaces15c2and between the parallel inner surfaces15c1of the opposed embedded part15, filling the cavity without any gap. Furthermore, the space between the end wall inner surface covering part53and the left and right inclined inner surfaces15c2increase, increasing the filling amount of the insulating material.

Additionally, as illustrated inFIG. 7A, it is desirable that the dimension in the width direction of the first connector1in the end wall inner surface covering part53of the first reinforcing bracket51opposed to the gap between the parallel inner surfaces15c1of the embedded part15, that is, a width L1is set to be larger than a distance L2that is the spacing between the parallel inner surfaces15c1. In other words, it is preferable that L1is larger than L2. Note that the width of the end wall outer surface covering part52is greater than the width of the end wall inner surface covering part53. As a result, the boundary between the parallel inner surface15c1of the embedded part15formed by the primary insert molding and the covering part16formed by the secondary insert molding is covered with the end wall outer surface covering part52and the end wall inner surface covering part53as viewed from the front-rear direction (X-axis direction) and thus, is hard to be separated, increasing the strength of the first protruding end part18.

Furthermore, as illustrated inFIG. 7A, it is preferable that the dimension in the longitudinal direction of the first connector1in the leg55of the first reinforcing bracket51, that is, a length L3is set to be larger than a length L4of the outer surface15bof the embedded part15. In other words, it is preferable that L3is larger than L4. The end of the outer surface15bnear the center in the longitudinal direction of the first connector1is preferably located closer to both ends in the longitudinal direction of the first connector1than the end of the legs55in the longitudinal direction of the first connector1. As a result, the boundary between the outer surface15bof the embedded part15formed by the primary insert molding and the covering part16formed by the secondary insert molding is seen from the width direction (Y-axis direction) and is covered by the legs55, and thus the strength of the first protruding end part18is improved.

Furthermore, the embedded part15is disposed so as to at least partially overlap with, that is, stack on any of the upper plate54, the end wall outer surface covering part52, the end wall inner surface covering part53, and the leg55of the first reinforcing bracket51when viewed both in the vertical direction (width direction) and in the front-back direction (longitudinal direction). Thus, the strength of the first protruding end part18is increased.

Finally, the remaining terminal carrier68and the bracket carrier58are cut away from the left and right half body parts10with the both ends in the longitudinal direction connected to each other with the first protruding end part18as illustrated inFIGS. 6A and 6B. Thus, the first connector1as illustrated inFIG. 1can be obtained.

Next, the configuration of the second connector101that forms a connector pair with the first connector1and the operation of mating the first connector1with the second connector101will be described.

FIG. 9is a perspective view illustrating the state immediately before mating of the first connector with the second connector according to the present embodiment when viewed from the first connector side.

The second connector101as a counterpart connector according to the present embodiment has the second housing111as a counterpart connector body integrally formed of an insulating material such as synthetic resin. As illustrated in the figure, this second housing111is a substantially rectangular body with the shape of a substantially rectangular thick plate. A substantially rectangular enclosed recess112to be mated with the first housing11is formed on the side where the first connector1of the second housing111is fitted into, that is, the side of the mating surface111a(side in the Z-axis positive direction). A second protrusion113that is an island part mating with the recessed groove13is integrally formed with the second housing111in the recess112, and side wall parts114extending in parallel with the second protrusion113are integrally formed with the second housing111on both sides of the second protrusion113.

The second protrusion113and the side wall part114protrude upward (in the Z-axis positive direction) from the bottom surface of the recess112, and extend in the longitudinal direction of the second connector101. Therefore, a recessed groove112athat is an elongated recess extending in the longitudinal direction (X-axis direction) of the second connector101is formed as a part of the recess112on each side of the second protrusion113.

Second terminal housing groove cavities115ain the shape of recessed grooves for housing the respective second terminals161are formed on the surfaces of both sides of the second protrusion113and the inner surface of the side wall part114. In addition, second terminal housing hole cavities115bin the shape of holes for housing the respective second terminals161are formed on the second protrusion113and the side wall part114. Since the second terminal housing groove cavities115aand the second terminal housing hole cavities115bare integrated with each other on the bottom surface of the recessed groove112a, when the second terminal housing groove cavities115aand the second terminal housing hole cavities115bare collectively described, they will be described as the second terminal housing cavities115. The second terminal housing cavities115corresponding to the number of the first terminals61are disposed at a pitch corresponding to the first terminals.

The second terminal161is a member integrally formed by applying a process such as punching or the like to a conductive metal plate, and includes a body part (not illustrated), a tail part162connected to the lower end of the body part, a connection part that extend in the width direction (Y-axis direction) of the second connector101from the vicinity of the lower end of the body part, and a contact part165that extends upward (Z-axis positive direction) from that connection part. It is preferable that a contact protrusion165athat protrudes toward the body part is formed near the tip of the contact part165.

The body part is a part that is press-fit and retained in the second terminal housing hole cavity115b. In addition, the tail part162is bent and connected to the lower end of the body part, extends in the width direction of the second housing111, and is connected to the connection pad coupled to the conductive trace on the second substrate by soldering or the like. Note that the conductive trace is typically a signal line. Furthermore, the contact part165is a part that contacts the first terminal61equipped on the first connector1when the first connector1is mated with the second connector101, and the contact protrusion165apreferably engages with the contact recess65aformed on the contact part65of the first terminal61.

The second terminal161is inserted into the second terminal housing cavity115from below the second housing111and attached to the second housing111. Thus, the body part of the second terminal161is press-fit and retained in the second terminal housing hole cavity115b, the contact part165is housed in the second terminal housing groove cavity115aand exposed on the recessed groove112a, and the lower surface of the tail part162is exposed on the mounting surface111bthat is the lower surface of the second housing111.

In addition, similar to the first terminals61, the second terminals161attached to each recessed groove112aare oriented such that the adjacent second terminals are opposed to each other in the width direction of the recessed groove112a. In the examples illustrated inFIG. 9, the second terminal161located on the front end (end in the X-axis positive direction) among the second terminals161attached to the recessed groove112aon the side in the Y-axis positive direction is oriented such that the tail part162projects in the Y-axis negative direction, while the second terminal161located the second from the front end is oriented such that the tail part162projects in the Y-axis positive direction. In this manner, since the second terminals161are attached to the recessed groove112aso as to be alternately oriented in opposite directions, the pitch of the tail parts162exposed on the mounting surface111bon both sides of the recessed groove112ais set to twice the pitch of the second terminals161. Therefore, connection work by soldering or the like to the connection pad of the second substrate can easily be performed. The pitch of the contact parts165exposed on the recessed groove112ais also set to twice the pitch of the second terminals161.

Second protruding end parts121as mating guide parts are disposed on both ends in the longitudinal direction of the second housing111. A mating recess122that is a part of the recess112is formed on each of the second protruding end parts121. The mating recess122is a substantially rectangular recess connected to both ends in the longitudinal direction of each recessed groove112a. In the state where the first connector1is mated with the second connector101, the first protruding end part18of the first connector1is inserted into the mating recess122. A second reinforcement bracket151that is a counterpart bracket is attached to the second protruding end part121. The second reinforcement bracket151is integrated with the second housing111by insert molding.

The second reinforcement bracket151is a part integrally formed by applying a process such as punching, bending, or the like to a metal plate, and includes a second body part152that extends in the width direction of the second housing111, a side covering part153connected to both left and right ends of the second body part152, contact side parts154disposed on left and right inner walls of the mating recess122, and a tail part156connected to the lower end of the second body part152. The tail part156extends outward in the longitudinal direction of the second connector101, and is connected and fixed to the connection pad not illustrated exposed on the surface of the second substrate by soldering or the like. Furthermore, for example, the connection pad is preferably coupled with the conductive trace, which is a power line.

The operation for mating the first connector1and the second connector101having the abovementioned configuration will be described next.

Here, the first connector1is mounted on the surface of the first substrate by connecting the tail parts62of first terminals61to the connection pad coupled to the conductive trace on the first substrate not illustrated by soldering or the like, and connecting the tail part52aof the first reinforcing bracket51to the connection pad coupled to the conductive trace on the first substrate not illustrated by soldering or the like. It is assumed that the conductive trace coupled to the connection pad to which the tail parts62of the first terminals61are connected is a signal line, while the conductive trace coupled to the connection pad to which the tail part52aof the first reinforcing bracket51is connected is a power line.

Likewise, the second connector101is mounted on the surface of the second substrate by connecting the tail parts162of second terminal161to the connection pad coupled to the conductive trace on the second substrate not illustrated by soldering or the like, and connecting the tail part156of the second reinforcement bracket151to the connection pad coupled to the conductive trace on the second substrate not illustrated by soldering or the like. It is assumed that the conductive trace coupled to the connection pad to which the tail parts162of the second terminals161are connected is a signal line, while the conductive trace coupled to the connection pad to which the tail part156of the second reinforcement bracket151is connected is a power line.

First, an operator places the mating surface12aof the first protrusion12, which is the mating surface of the first housing11of the first connector1, and the mating surface111aof the second housing111of the second connector101as opposed to each other, and when the position of the first protrusion12of the first connector1coincides with the position of the corresponding recessed groove112aof the second connector1, and the position of the first protruding end part18of the first connector1coincides with the position of the corresponding mating recess122of the first connector101, the alignment between the first connector1and the second connector101is completed.

In this state, when the first connector1and/or the second connector101is moved to come closer to the counterpart side, that is, the mating direction, the first protrusion12and the first protruding end part18of the first connector1are inserted into the recessed groove112aand the mating recess122of the second connector101. This completes mating of the first connector1with the second connector101. Then, the first terminal61becomes conductive with the second terminal161.

Next, a modification of the first connector1will be described.

FIG. 10is an exploded view illustrating a left half body part in the modification of the first connector according to the present embodiment.

In the illustrated modification, the first terminal61includes no body part63, and has a contact part65that vertically extends, a tail part62that is bent by approximately 90 degrees and connected to the lower end of the contact part65, and an upper end part64that is bent by approximately 90 degrees and connected to the upper end of the contact part65. Note that an embedded part64athat is bent by approximately 90 degrees and extends downward is connected to the tip of the upper end part64. The embedded part64ais a part embedded in the first protrusion12downward from the mating surface12a.

In the first terminal61illustrated inFIG. 2and the like, the tail part62extends in a opposite direction to the facing direction of the contact part65, however, in the first terminal61in the modified example illustrated inFIG. 10, the tail part62extends in the same direction as the facing direction of the contact part65. Accordingly, it is easy to hold the terminal carrier68connected to the tips of the tail parts62via the elongated connection arms68a, and set the plurality of first terminals61in the primary mold from both left and right sides such that the first terminals are alternately oriented in opposite directions.

Note, the other configurations, operations, and effects of the first terminal61in the modification inFIG. 10are the same as those of the first terminal61illustrated inFIG. 2and the like and thus, description thereof is omitted.

As described above, in the present embodiment, the first connector1includes the half body parts10that each include the first housing11and the plurality of first terminals61attached to the first housing11, and the first protruding end parts18formed at the both ends in the first housing11of the half body parts10by allowing the first housings11to abut each other, and the first reinforcing brackets51attached to the first protruding end parts18. Each of the first housings11is a member integrated with the first terminal61by the primary insert molding, and includes the first protrusion12that extends in the longitudinal direction and holds the first terminals61, the extended end parts14connected to the both ends in the longitudinal direction of the first protrusion12, and the embedded part15that extends from the extended end parts14. The first protruding end part18includes the covering part16that covers at least a part of the extended end part14and the entirety of the embedded part15of each first housing11, and the covering part16is a member integrated with the extended end part14, the embedded part15, and the first reinforcing bracket51by the secondary insert molding.

This may reduce the spacing between the first protrusions12of the first housing11, to which the plurality of first terminals61is mounted, enabling reduction of the first connector1in size. In addition, manufacturing the first connector1is simplified and reliability of the first connector1is improved.

The first reinforcing bracket51includes an upper plate54that extends in the width direction of the first housing11, the pair of left and right legs55that are connected to both left and right edges of the upper plate54and extend downward, and the end wall outer surface covering part52and an end wall inner surface covering part53that are connected to both the front and rear edges of the upper plate54and extend downward. The embedded part15is disposed so as at least partially overlap with the upper plate54, the leg55, the end wall outer surface covering part52, and the end wall inner surface covering part53when viewed from the vertical, front-back, and left-right directions. As a result, the embedded part15of the left half body part10A is firmly connected to the embedded part15of the right half body part10B with the covering part16integrated with the first reinforcing bracket51to reliably constitute the first protruding end part18to connect the left half body part10A to the right half body part10B.

Furthermore, the embedded part15of each first housing11includes the parallel inner surface15c1that extends in the longitudinal direction of the first housing11and faces the embedded part15of the other first housing11. The distance L2between the opposed parallel inner surfaces15c1is smaller than the width L1of the end wall inner surface covering part53of the first reinforcing bracket51disposed so as to face the gap between the opposed parallel inner surfaces15c1. As a result, the boundary between the parallel inner surface15c1of the embedded part15formed by the primary insert molding and the covering part16formed by the secondary insert molding overlap with the end wall inner surface covering part53when viewed from the front-back direction, and thus, is hard to be separated, increasing the strength of the first protruding end part18.

Furthermore, the end wall inner surface covering part53is disposed so as to be opposed to the inclined inner surface15c2, which is connected to each of the opposed parallel inner surfaces15c1and is opposed to the inclined inner surface15c2of the embedded part15inclined with respect to the longitudinal direction of the first housing11, and has a gap from the inclined inner surface15c2.

Furthermore, the embedded part15of each first housing11includes the outer surface15bthat extends in the longitudinal direction of the first housing11and faces the leg55of the first reinforcing bracket51, and the length L4of the outer surface15bis smaller than the length L3of the leg55. As a result, the boundary between the outer surface15bof the embedded part15formed by the primary insert molding and the covering part16formed by the secondary insert molding is covered with the leg55when viewed from the left and right direction, and thus, is hard to be separated, increasing the strength of the first protruding end part18.

Furthermore, the extended end part14of each first housing11is inclined inward in the width direction of the first connector1, and extends from both ends in the longitudinal direction of the first protrusion12, and the width of the first protruding end part18is smaller than the width of the first connector1. In this way, the width of the first protruding end part18can be smaller than the width of the first connector1, in mating the first connector1with the second connector101, even when the contact side parts154are disposed on the left and right inner walls of the mating recess122of the second housing111, into which the first protruding end part18is inserted, and the width of the mating recess122becomes substantially small, it is allowable.

Note that the disclosure of the present specification describes characteristics related to a preferred and exemplary embodiment. Various other embodiments, modifications, and variations within the scope and spirit of the claims appended hereto could naturally be conceived of by persons skilled in the art by summarizing the disclosures of the present specification. For example, the staggered arrangement of the terminals does not have to be systematic. In addition, the arrangement of the terminals on the left and right half body parts does not need to be the same. Furthermore, the left and right half body parts do not need to be axially symmetric.

The present disclosure can be applied to connectors.