Connector

A board-to-board connector capable of preventing a short-circuit from occurring between contacts when connectors are fitted to each other. Pin-shaped male-side contact portions protrude from one surface of a male-side insulating film, and male-side terminal portions are provided on the other surface of said male-side insulating film. This makes it possible to prevent a short-circuit from occurring between adjacent female-side contacts by the male-side contacts.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a board-to-board connector for electrically connecting two circuit boards.

2. Description of the Related Art

Conventionally, as shown inFIGS. 28 to 38, there has been proposed a board-to-board connector comprising a male connector901and a female connector1101that can be fitted to the male connector901(see Japanese Laid-Open Patent Publication (Kokai) No. 2012-226977).

The male connector901is mounted on a first circuit board991(seeFIGS. 36 and 37). As shown inFIG. 28, the male connector901includes a base film915having insulating properties, conductor traces951provided on one surface of the base film915, and a reinforcing layer916provided on the other surface of the base film915. The base film915is formed of resin, such as polyimide, and the reinforcing layer916is formed of metal, such as stainless steel.

The conductor traces951are formed by patterning a copper foil affixed to the one surface of the base film915by performing etching thereon. The conductor traces951are arranged at a predetermined pitch.

As shown inFIGS. 28 to 31, each conductor trace951includes a protruding terminal953. The conductor trace951has a rectangular plate-like shape. The protruding terminal953has a cylindrical shape, and is circular in cross-sectional shape (seeFIGS. 30 and 31). The protruding terminal953protrudes from a surface of the conductor trace951. The protruding terminal953is integrally formed with the conductor trace951by etching using a photolithography technique or the like method.

A pair of sides of the base film951, extending along a longitudinal direction D, are each formed into a comb-like shape such that recesses915A and protrusions915B are alternately arranged (seeFIG. 28). The recesses915A and the conductor traces951positionally correspond to each other. Therefore, part of each conductor trace951is exposed on a mounting surface901A of the male connector901(seeFIG. 29). Each exposed portion (tale portion958) of each conductor trace951is soldered to a connection pad (not shown) of the first circuit board991shown inFIGS. 36 and 37.

The female connector1101is plate-shaped (seeFIGS. 33 and 34), and is mounted on a second circuit board1191(seeFIGS. 36 and 37). The female connector1101includes frame bodies1111. Each frame body1111is a plate-shaped member having a layer structure in which a cover film1117and a frame reinforcing layer1116formed by a pair of reinforcing layers are laminated in the mentioned order on conductor traces1150, described hereinafter (seeFIG. 32). The cover film1117is an insulating thin plate member and is formed of resin, such as polyimide. The frame reinforcing layer1116is formed of metal, such as stainless steel. The pair of reinforcing layers of the frame reinforcing layer1116are referred to as the first reinforcing layer1116A and the second reinforcing layer1116B.

Part surrounded by the frame bodies1111forms a connection recess1114(seeFIG. 33) for accommodating part of a main body911of the male connector901except main body end portions911C (seeFIGS. 29 and 30). As shown inFIGS. 32 to 34, a bottom portion1114A of the connection recess1114is a plate-shaped member having a layer structure in which a reinforcing layer1118, a base film1115, and the conductor traces1150are laminated in the mentioned order starting from the side of a mounting surface1101A. The conductor traces1150are arranged on one surface of the base film1115, and the reinforcing layer1118is arranged on the other surface of the same. The material and manufacturing method used for forming the conductor traces1150and the reinforcing layer1118are the same as those for the conductor traces951and the reinforcing layer916of the male connector901.

The conductor traces1150include female conductors1151and auxiliary conductors1152. The female conductors1151are arranged at equally-spaced intervals. Four of the plurality of arranged female conductors1151are replaced by the auxiliary conductors1152, respectively.

Each female conductor1151includes a reception terminal1153(seeFIG. 33). The reception terminal1153is accommodated in a terminal accommodating opening1154. As shown inFIG. 35, the reception terminal1153includes a main arm portion1153A, an auxiliary arm portion1153B, and a protruding portion1153C.

Each auxiliary conductor1152includes a holding portion1157(seeFIGS. 33 and 35). The holding portion1157is accommodated in a holding portion-accommodating opening1159. The holding portion1157includes base portions1157A, first arm portions1157B, second arm portions1157D, and protruding portions1157C.

To fit the male connector901and the female connector1101, as shown inFIGS. 36 and 37, first, in a state in which a fitting surface901B (seeFIG. 31) of the male connector901and a fitting surface1101B (seeFIG. 33) of the female connector1101are opposed to each other, the male connector901is moved down to the female connector1101as indicated by an arrow B inFIG. 36, and part of the main body911of the male connector901except the main body end portions911C is accommodated in the connection recess1114. At this time, the protruding terminals953are each inserted into a main inner opening1154A1inside the main arm portion1153A, which is inside the reception terminal1153, and a first inner opening1159A1inside the holding portion1157, which is located between the first arm portions1157B (seeFIG. 35).

Next, the male connector901is slid in a locking direction C (seeFIG. 37) relative to the female connector1101. When the male connector901has been slid, the protruding terminals953are each enter a positioning opening1154C inside the reception terminal1153, and a second inner opening1159A2inside the holding portion1157(seeFIGS. 35 and 38). As a result, spacing between a contact portion1153A3of the reception terminal1153, a contact portion1153B3of the auxiliary arm portion1153B, and the protruding portion1153C is widened by side portions of the protruding terminal953. Then, by action of returning forces of the main arm portion1153A and the auxiliary arm portion1153B, the contact portion1153A3of the main arm portion1153A, the contact portion1153B3of the auxiliary arm portion1153B, and the protruding portion1153C are in a state pressed against the side portions of the protruding terminal953. That is, the contact portion1153A3of the main arm portion1153A, the contact portion1153B3of the auxiliary arm portion1153B, and the protruding portion1153C hold the side portions of the protruding terminal953by the returning forces thereof. Thus, the protruding terminal953and the reception terminal1153are positively brought into contact with each other to attain electrical conduction.

However, since the plate-shaped conductor traces951of the male connector901are provided on the one surface of the base film915, and the cylindrical protruding terminals953protrude from the surfaces of the conductor traces951, after the part of the main body911of the male connector901except the main body end portions911C is accommodated in the connection recess1114, if the male connector901is erroneously slid in the longitudinal direction D of the connector (seeFIG. 28) relative to the female connector1101, each conductor trace951of the male connector901may short-circuit adjacent ones of the female conductors1151. To avoid this short-circuit, it is only necessary to increase spacing between each adjacent pair of conductor traces951of the male connector901or increase spacing between the conductor traces951and the female conductors1151in the fitting direction, but this increases the size of the board-to-board connector.

SUMMARY OF THE INVENTION

The present invention has been made in view of these circumstances, and an object thereof is to make it difficult for a short circuit to occur between female-side contacts when connectors are fitted to each other, without increasing the size of a board-to-board connector.

To attain the above object, in a first aspect of the present invention, there is provided a board-to-board connector that includes a male connector which is mounted on a first substrate, and a female connector which is mounted on a second substrate and can be fitted to the male connector, and electrically connects between the first substrate and the second substrate, the male connector comprising a male-side insulating film, a plurality of male-side contacts which are provided on the male-side insulating film, and a male-side reinforcing member provided on the male-side insulating film, wherein each male-side contact includes a male-side terminal portion which is connected to the first substrate, and a male-side contact portion which is pin-shaped and formed continuously with the male-side terminal portion such that the male-side contact portion protrudes from one surface of the male-side insulating film and can be brought into contact with an associated one of female-side contacts of the female connector, wherein a plurality of the male-side contact portions are arranged on the one surface of the male-side insulating film, wherein a plurality of the male-side terminal portions are arranged on the other surface of the male-side insulating film, and wherein the male-side reinforcing member includes a male-side reinforcing member main body portion which is arranged along the plurality of the male-side terminal portions on the other surface.

Preferably, the female connector comprises a female-side insulating film, and a plurality of the female-side contacts provided on the female-side insulating film, wherein each female-side contact includes a female-side contact portion which is provided on one surface of the female-side insulating film and can be brought into contact with an associated one of the male-side contact portions, and a female-side terminal portion which is formed continuously with the female-side contact portion such that the female-side terminal portion protrudes from the other surface of the female-side insulating film, and is connected to the second substrate, wherein a plurality of the female-side contact portions are arranged on the one surface of the female-side insulating film, and wherein a plurality of the female-side terminal portions are arranged on the other surface of the female-side insulating film.

More preferably, the male-side reinforcing member includes fixing portions that are formed continuously with the male-side reinforcing member main body portion, and are provided on opposite end portions of the other surface of the male-side insulating film in a direction of arranging the plurality of the male-side contact portions, and protruding portions that are formed continuously with the fixing portions, respectively, and are provided on opposite end portions of the one surface of the male-side insulating film in the direction of arranging the plurality of the male-side contact portions, and wherein the female connector includes protruding portion-supporting members that are provided on opposite end portions of the one surface of the female-side insulating film in a direction of arranging the plurality of the female-side contact portions, and have protruding portion-receiving holes for guiding the protruding portions toward the second substrate, respectively.

Further preferably, when the protruding portions are inserted in the protruding portion-receiving holes of the female connector, each female-side contact portion is elastically deformed to thereby sandwich each associated male-side contact portion in a predetermined direction orthogonal to the thickness direction of the female-side insulating film, whereby a predetermined contact force is generated between the female-side contact portion and the male-side contact portion.

Further preferably, the male connector can be relatively slid with respect to the female connector in a second predetermined direction orthogonal to the thickness direction of the female-side insulating film from a protruding portion insertion completion position in which the protruding portions have been inserted in the protruding portion-receiving holes of the female connector to a sliding completion position in which each female-side contact portion is elastically deformed to thereby cause each associated male-side contact portion to be sandwiched in a first predetermined direction orthogonal to the thickness direction of the female-side insulating film, whereby a predetermined contact force is generated between the female-side contact portion and the male-side contact portion, wherein the first predetermined direction is a direction orthogonal to the direction of arranging the female-side contact portions, and wherein the second predetermined direction is a direction parallel to the direction of arranging the female-side contact portions.

Further preferably, the male connector can be relatively slid with respect to the female connector in a second predetermined direction orthogonal to the thickness direction of the female-side insulating film from a protruding portion insertion completion position in which the protruding portions have been inserted in the protruding portion-receiving holes of the female connector to a sliding completion position in which each female-side contact portion is elastically deformed to thereby cause each associated male-side contact portion to be sandwiched in a first predetermined direction orthogonal to the thickness direction of the female-side insulating film, whereby a predetermined contact force is generated between the female-side contact portion and the male-side contact portion, wherein the first predetermined direction is a direction parallel to the direction of arranging the female-side contact portions, and wherein the second predetermined direction is a direction orthogonal to the direction of arranging the female-side contact portions.

Even more preferably, the protruding portions are hook-shaped, and when the male connector is slid from the protruding portion insertion completion position to the sliding completion position, the male connector is locked by the protruding portions in the thickness direction of the female-side insulating film.

Even further preferably, each male-side contact portion is formed such that a front end portion thereof is expanded, and when the male connector is slid from the protruding portion insertion completion position to the sliding completion position, the female-side contact portion is sandwiched by the front end portion of the male-side contact portion and the male-side insulating film in a thickness direction of the male-side insulating film.

To attain the above object, in a second aspect of the present invention, there is provided a method of manufacturing a male connector of the board-to-board connector according, comprising a thin film-processing step of providing a metal thin film on the other surface of the male-side insulating film, a patterning step of forming the plurality of the male-side terminal portions and the male-side reinforcing member main body portion by etching the metal thin film, after execution of the thin film-processing step, a through hole-forming step of forming through holes reaching the male-side terminal portions through the male-side insulating film by etching processing, after execution of the patterning step, and a contact portion-forming step of forming the male-side contact portions which are pin-shaped at respective locations corresponding to the through holes, after execution of the through hole-forming step.

To attain the above object, in a third aspect of the present invention, there is provided a method of manufacturing a male connector of the board-to-board connector, comprising a thin film-processing step of providing a metal thin film on the other surface of the male-side insulating film, a patterning step of forming the plurality of the male-side terminal portions, the male-side reinforcing member main body portion, and the fixing portions, by etching the metal thin film, after execution of the thin film-processing step, a through hole-forming step of forming through holes reaching the male-side terminal portions, and protruding portion insertion through holes reaching the fixing portions, through the male-side insulating film, by etching processing, after execution of the patterning step, and a contact portion-forming step of forming the male-side contact portions which are pin-shaped at respective locations corresponding to the through holes, and forming the protruding portions at respective locations corresponding to the protruding portion insertion through holes, after execution of the through hole-forming step.

To attain the above object, in a fourth aspect of the present invention, there is provided a method of manufacturing a male connector of the board-to-board connector according to claim1, comprising a contact portion-side thin film-processing step of providing a contact portion-side metal thin film on the one surface of the male-side insulating film, a through hole-forming step of forming through holes reaching the contact portion-side metal thin film through the male-side insulating film by etching processing, after execution of the contact portion-side thin film-processing step, a terminal portion-side thin film-processing step of providing a terminal portion-side metal thin film on the other surface of the male-side insulating film after execution of the through hole-forming step, and a patterning step of forming the male-side contact portions which are pin-shaped at respective locations corresponding to the through holes by etching the contact portion-side metal thin film, and forming the male-side terminal portions and the male-side reinforcing member main body portion by etching the terminal portion-side metal thin film, after execution of the terminal portion-side thin film-processing step.

To attain the above object, in a fifth aspect of the present invention, there is provided a method of manufacturing a male connector of the board-to-board connector, comprising a contact portion-side thin film-processing step of providing a contact portion-side metal thin film on the one surface of the male-side insulating film, a through hole-forming step of forming through holes reaching the contact portion-side metal thin film and protruding portion insertion through holes through the male-side insulating film by etching processing, after execution of the contact portion-side thin film-processing step, a terminal portion-side thin film-processing step of providing a terminal portion-side metal thin film on the other surface of the male-side insulating film, after execution of the through hole-forming step, and a patterning step of forming the male-side contact portions which are pin-shaped at respective locations corresponding to the through holes, and the protruding portions at respective locations corresponding to the protruding portion insertion through holes, by etching the contact portion-side metal thin film, and forming the male-side terminal portions, the male-side reinforcing member main body portion, and the fixing portions, by etching the terminal portion-side metal thin film, after execution of the terminal portion-side thin film-processing step.

To attain the above object, in a sixth aspect of the present invention, there is provided a method of manufacturing a female connector of the board-to-board connector, comprising a thin film-processing step of providing a metal thin film on the one surface of the female-side insulating film, a patterning step of forming the plurality of the female-side contact portions by etching the metal thin film on the one surface of the female-side insulating film, after execution of the thin film-processing step, a cutout and through hole-forming step of forming cutouts and through holes reaching the female-side contact portions through the female-side insulating film by etching processing, after execution of the patterning step, and a terminal portion-forming step of forming the plurality of the female-side terminal portions at respective locations corresponding to the cutouts on the other surface of the female-side insulating film, after execution of the cutout and through hole-forming step.

To attain the above object, in a seventh aspect of the present invention, there is provided a method of manufacturing a female connector of the board-to-board connector, comprising a thin film-processing step of providing a metal thin film on the one surface of the female-side insulating film, a patterning step of forming the plurality of the female-side contact portions and the protruding portion-supporting members by etching the metal thin film on the one surface of the female-side insulating film, after execution of the thin film-processing step, a cutout and through hole-forming step of forming cutouts and through holes reaching the female-side contact portions through the female-side insulating film by etching processing, after execution of the patterning step, and a terminal portion-forming step of forming the plurality of the female-side terminal portions at respective locations corresponding to the cutouts on the other surface of the female-side insulating film, after execution of the cutout and through hole-forming step.

According to the present invention, it is possible to make it difficult for a short circuit to occur between female-side contacts when the connectors are fitted to each other, without increasing the size of the board-to-board connector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention will now be described in detail with reference to the drawings showing preferred embodiments thereof.

As shown inFIGS. 1 and 2, a board-to-board connector101according to a first embodiment of the present invention comprises a male connector301that is mounted on a first circuit board (first substrate), not shown, and a female connector501that is mounted on a second circuit board (second substrate), not shown, and can be fitted to the male connector301. The board-to-board connector101electrically connects the first circuit board and the second circuit board, which are arranged opposed to each other.

The male connector301can be fitted to and removed from the female connector501along a thickness direction T2 of a female-side insulating film510of the female connector501.

As shown inFIGS. 1,2, and3, the male connector301includes a male-side insulating film310, a plurality of male-side contacts330provided on the male-side insulating film310, and a male-side reinforcing member350provided on the male-side insulating film310.

The planar shape of the male-side insulating film310is a belt-like shape. The material of the male-side insulating film310is e.g. resin, such as polyimide.

Each male-side contact330includes a male-side terminal portion331that is soldered to a pad (not shown) of the first circuit board, and a prism-shaped (pin-shaped) male-side contact portion332that is formed continuously with the male-side terminal portion331, and protrudes from one surface310A of the male-side insulating film310. The male-side contact portions332are brought into contact with female-side contact portions531of female-side contacts530of the female connector501. The material of the male-side terminal portion331and the male-side contact portion332is e.g. copper or copper alloy.

The male-side contact portion332is formed such that a front end portion thereof is expanded (seeFIG. 3). The plurality of male-side contact portions332are arranged in two rows on the one surface310A of the male-side insulating film310. A direction of arranging the plurality of male-side contact portions332is parallel to a longitudinal direction L1 of the male-side insulating film310. The plurality of male-side terminal portions331are arranged in two rows on the other surface310B of the male-side insulating film310. A direction of arranging the plurality of male-side terminal portions331is parallel to the longitudinal direction L1 of the male-side insulating film310.

The male-side reinforcing member350includes a male-side reinforcing member main body351having an H-shaped planar shape and protruding portions352. The male-side reinforcing member main body351includes a male-side reinforcing member main body portion351A and fixing portions351B which are continuous with opposite ends of the male-side reinforcing member main body portion351A, respectively, and the protruding portions352are formed continuously with the fixing portions351B. The male-side reinforcing member main body portion351A is arranged along the plurality of male-side terminal portions331(seeFIG. 2). The fixing portions351B are arranged on opposite ends of the other surface310B of the male-side insulating film310. The protruding portions352are arranged on opposite ends of the one surface310A of the male-side insulating film310in the longitudinal direction L1 of the male-side insulating film310(direction of arranging the plurality of male-side contact portions332). The male-side reinforcing member main body portion351A is belt-shaped, and is arranged between the two rows of the male-side terminal portions331. The male-side reinforcing member main body351is formed of the same material as that of the male-side terminal portions331, and is formed simultaneously with formation of the male-side terminal portions331, as described hereinafter. Each protruding portion352includes a rectangular parallelepiped protruding portion main body352A, and a holding portion352B which is continuous with a front end of the protruding portion main body352A. A vertical cross-section of each protruding portion352is hook-shaped. The material of the protruding portions352is the same as that of the male-side contact portions332, and the protruding portions352are formed simultaneously with formation of the male-side contact portions332.

As shown inFIGS. 1,2, and4, the female connector501includes the female-side insulating film510which is belt-shaped, the plurality of female-side contacts530provided on the female-side insulating film510, a first female-side reinforcing member550provided on one surface510A of the female-side insulating film510, protruding portion-supporting members570each having a protruding portion-receiving hole571which guides an associated one of the protruding portions352of the male connector301toward the second circuit board, a second female-side reinforcing member580fitted on the other surface510B of the female-side insulating film510, and holddowns590formed on the other surface510B of the female-side insulating film510.

The female-side insulating film510has a plurality of cutouts511, a plurality of through holes512which are holes formed through the female-side insulating film510, and a pair of through holes513. The plurality of cutouts511are arranged in two rows along with a longitudinal direction L3 of the female-side insulating film510(seeFIG. 4). The plurality of through holes512are formed in two rows along with the longitudinal direction L3 of the female-side insulating film510. The two rows of the through holes512are sandwiched by the two rows of the cutouts511in a width direction L4 of the female-side insulating film510. The pair of through holes513are formed through the opposite end portions of the female-side insulating film510in the longitudinal direction L3 of the female-side insulating film510. The through holes513and through holes582A, referred to hereinafter, are opposed to each other.

The female-side contacts530are provided on the one surface510A of the female-side insulating film510, and each include the female-side contact portion531that can be brought into contact with an associated one of the male-side contact portions332, and a female-side terminal portion532that is formed continuously with the female-side contact portion531and protrudes from the other surface510B of the female-side insulating film510. The female-side terminal portion532is soldered to a pad (not shown) of the second circuit board. The female-side contact portion531receives the male-side contact portion332via the through hole512. The female-side terminal portion532is formed continuously with the female-side contact portion531by extending through the cutout511. The female-side insulating film510is formed of the same material as that of the male-side insulating film310. The female-side contact portion531and the female-side terminal portion532are formed of e.g. copper or copper alloy.

The plurality of female-side contact portions531are arranged in two rows on the one surface510A of the female-side insulating film510. A direction of arranging the plurality of female-side contact portions531is parallel to the longitudinal direction L3 of the female-side insulating film510. The plurality of female-side terminal portions532are arranged in two rows on the other surface510B of the female-side insulating film510. A direction of arranging the plurality of female-side terminal portions532is parallel to the longitudinal direction L3 of the female-side insulating film510.

The first female-side reinforcing member550has a long and narrow shape, and is located between the two rows of the female-side contact portions531. The first female-side reinforcing member550connects the two protruding portion-supporting members570in a manner continuous therewith.

The protruding portion-supporting members570are arranged on the opposite end portions of the one surface510A of the female-side insulating film510in the longitudinal direction L3 of the female-side insulating film510(direction of arranging the plurality of female-side contact portions531).

The second female-side reinforcing member580is a metallic plate (e.g. stainless steel plate), and has an H-shaped planar shape. The second female-side reinforcing member580includes one second female-side reinforcing member main body581and two fixing portions582. The second female-side reinforcing member main body581connects the two fixing portions582in a manner continuous therewith. The fixing portions582are arranged on the opposite end portions of the other surface510B of the female-side insulating film510in the longitudinal direction L3 of the female-side insulating film510. Each fixing portion582has one through hole582A and two through holes582B. The through hole582A receives an associated one of the holding portions352B when the male connector301is fitted to the female connector501. Each through hole582B is formed with the holddown590. A front end surface of the holddown590and the surface of the fixing portion582are positioned substantially on the same plane.

The length of the protruding portion-receiving hole571(seeFIG. 4) and the through hole582A (seeFIG. 20) in the width direction L4 of the female-side insulating film510is slightly larger than the length of the protruding portion352(seeFIG. 3) in a width direction L2 of the male-side insulating film310. The length of the protruding portion-receiving hole571in the longitudinal direction L3 of the female-side insulating film510is slightly larger than the length of the holding portion352B (seeFIG. 3) in the longitudinal direction L1 of the male-side insulating film310. Further, the through hole513(seeFIG. 4) is equal to the through hole582A in length in the longitudinal direction L3 of the female-side insulating film510. A difference in length between the through hole582A and the protruding portion-receiving hole571in the longitudinal direction L3 of the female-side insulating film510is approximately equal to a difference in length between the holding portion352B and the protruding portion main body352A in the longitudinal direction L1 of the male-side insulating film310(seeFIG. 3). The above-mentioned dimensional relationship makes it possible to fit and remove the male connector301to and from the female connector501in the thickness direction T2 of the female-side insulating film510, and relatively slide the male connector301in the longitudinal direction L3 of the female-side insulating film510, with respect to the female connector501, from the protruding portion insertion completion position (seeFIG. 15) in which the protruding portions352have been inserted in the protruding portion-receiving holes571, to the sliding completion position (seeFIG. 18) in which a predetermined contact force is generated between the male-side contact portions332and the female-side contact portions531. Further, when the male connector301has been slid from the protruding portion insertion completion position to the sliding completion position, the holding portions352B of the protruding portions352are hooked to the protruding portion-supporting members570, respectively, whereby the male connector301is locked in the thickness direction T2 of the female-side insulating film510.

The female-side contact portion531of each female-side contact530includes, as shown inFIG. 4, a pair of contact point portions531A, a pair of spring portions531B, a linking portion531C, and a fixing portion531D. The pair of contact point portions531A are brought into contact with an associated one of the male-side contact portions332of the male connector301in the sliding completion position. The pair of spring portions531B are continuous with the contact point portions531A, respectively, and urge the contact point portions531A against the associated male-side contact portion332in the thickness direction L4 of the female-side insulating film510. As a consequence, the pair of contact point portions531A sandwich the associated male-side contact portion332in the thickness direction L4 of the female-side insulating film510(first predetermined direction in claim5). The linking portion531C connects the pair of spring portions531B in a manner continuous therewith. The fixing portion531D is continuous with the linking portion531C, and is fixed to the one surface510A of the female-side insulating film510. The female-side terminal portion532is formed continuously with the fixing portion531D by extending through the cutout511. A portion toward the female-side insulating film510, in a vertical direction as viewed inFIG. 20, of a free end of each contact point portion531A is formed with an inclined surface531E. The inclined surface531E forms a receiving space for the front end of the male-side contact portion332when the male connector301is in the sliding completion position shown inFIG. 20, and hence it is possible to reduce the dimension of the board-to-board connector101in a fitting direction (direction parallel to a thickness direction T1 of the male-side insulating film310), compared with a contact point portion (not shown) which is not formed with the inclined surface531E. Note that the inclined surface531E does not interfere with the front end of the male-side contact portion332of the male connector301which is in the sliding completion position.

Next, a description will be given of an example of a method of manufacturing the male connector301of the board-to-board connector101with reference toFIGS. 5 to 12.

First, as shown inFIGS. 5 and 6, a metal thin film33is formed on the other surface310B of the male-side insulating film310(thin film-processing step). Methods of forming a thin film include spattering, evaporation coating, and plating. The methods further include one in which the metal thin film33formed in advance is affixed to the other surface310B of the male-side insulating film310.

After execution of the thin film-processing step, the metal thin film33is etched to thereby form the plurality of male-side terminal portions331, the male-side reinforcing member main body portion351A, and the fixing portions351B, as shown inFIGS. 7 and 8(patterning step).

After execution of the pattering step, as shown inFIGS. 9 and 10, rectangular through holes311which reach the male-side terminal portions331are formed through the male-side insulating film310by etching processing (through hole-forming step). At this time, rectangular through holes312(protruding portion insertion through holes) which reach the fixing portions351B are simultaneously formed.

After execution of the through hole-forming step, as shown inFIGS. 11 and 12, the prism-shaped male-side contact portions332are formed at respective locations corresponding to the through holes311on the one surface310A of the male-side insulating film310, and the protruding portions352are formed at respective locations corresponding to the through holes312(contact portion-forming step). Methods of forming the male-side contact portion332and the protruding portion352include a plating method for forming a predetermined shaped object by laminating a plurality of plated layers.

By thus executing the above-described steps, the male side connector301is manufactured.

Next, a description will be given of an example of a method of manufacturing the female connector501of the board-to-board connector101with reference toFIGS. 1,2,3, and4, and the method of manufacturing the male connector301.

First, a metal thin film is formed on the one surface510A of the female-side insulating film510(thin film-processing step).

After execution of the thin film-processing step, the metal thin film on the one surface510A of the female-side insulating film510is etched to thereby form the plurality of female-side contact portions531, the protruding portion-supporting members570, and the first female-side reinforcing member550(patterning step).

After execution of the pattering step, the cutouts511, the through holes512, the through holes513, and holddown-forming through holes (not shown) are formed through the female-side insulating film510by etching processing (cutout and through hole-forming step). The cutouts511and the through holes512reach the female-side contact portions531, respectively.

After execution of the cutout and through hole-forming step, the female-side terminal portions532are formed at respective locations corresponding to the cutouts511on the other surface510B of the female-side insulating film510, and the holddowns590are formed at respective locations corresponding to the holddown-forming through holes (terminal portion-forming step).

After execution of the terminal portion-forming step, the second female-side reinforcing member580having the through holes582A and the through holes582B is affixed to the other surface510B of the female-side insulating film510(affixing step). In doing this, the second female-side reinforcing member580is affixed such that the holddowns590are accommodated in the through holes582B, respectively.

After execution of the affixing step, the inclined surface531E is formed by crushing the portion toward the female-side insulating film510, in the vertical direction as viewed inFIG. 20, of the free end of each contact point portion531A by press processing (inclined surface-forming step).

The female connector501is thus manufactured by execution of the above-described steps.

Next, a description will be given of an operation for fitting the female connector501and the male connector301with reference toFIGS. 1, and13to20.

First, as shown inFIGS. 1 and 13, the female connector501and the male connector301are arranged opposed to each other, and then, the male connector301is relatively moved up in the thickness direction T2 to the female-side insulating film510to thereby fit the male connector301to the female connector501as shown inFIGS. 14,15, and16. At this time, the protruding portions352are inserted in the protruding portion-receiving holes571and the through holes582A of the female connector501, respectively. Further, each of the male-side contact portions332of the male connector301is inserted between the pair of contact point portions531A of an associated one of the female-side contact portions531(seeFIG. 14). At this time, the spring portions531B are hardly elastically deformed. Note that the position of the male connector301when the protruding portions352have been inserted in the protruding portion-receiving holes571is the protruding portion insertion completion position (seeFIG. 16).

Next, the male connector301is relatively slid in the longitudinal direction L3 of the female-side insulating film510from the protruding portion insertion completion position shown inFIG. 16to the sliding completion position (seeFIGS. 17,18, and19) in which each female-side contact portion531is elastically deformed to sandwich the male-side contact portion332between the pair of contact point portions531A thereof in the width direction L4 of the female-side insulating film510, whereby a predetermined contact force is generated between the female-side contact portion531and the male-side contact portion332.

As a result, the male-side contact portion332is sandwiched by the pair of contact point portions531A in the width direction L4 of the female-side insulating film510.

At this time, as shown inFIG. 20, the contact point portions531A of each female-side contact portion531are in a position sandwiched by the front end portion of the male-side contact portion332and the male-side insulating film310in the thickness direction T1 of the male-side insulating film310, and hence the male connector301and the female connector501are prevented from being detached from each other.

According to the present embodiment, since the prism-shaped male-side contact portions332protrude from the one surface310A of the male-side insulating film310, and the male-side terminal portions331are arranged on the other surface310B of the male-side insulating film310, it is possible to prevent each male-side contact330from short-circuiting adjacent ones of the female-side contacts530.

Further, since it is possible to prevent a short-circuit from occurring between the adjacent female-side contacts530, it is possible to reduce the arrangement pitch of the male-side contact portions332and the female-side contact portions531, and thereby reduce the size of the board-to-board connector101.

To reduce possibility of occurrence of a short-circuit in the above-described conventional board-to-board connector, it is only necessary to form a gap between the conductor traces951and the auxiliary conductors1152in the fitting direction. However, this causes a problem that the board-to-board connector is increased in height. To solve this problem, according to the present embodiment, since the male-side terminal portions331are arranged on the other surface310B of the male-side insulating film310, the female-side contact portions531are prevented from being brought into contact with the male-side terminal portions331. Therefore, the female-side contact portions531may be brought into contact with the one surface310A of the male-side insulating film310, which makes it possible to reduce the board-to-board connector101in height.

Further, in the present embodiment, both of the male-side contact portions332and the male-side terminal portions331are not arranged on the one surface310A of the male-side insulating film310, but only the male-side contact portions332are arranged on the one surface310A of the male-side insulating film310, and hence it is possible to make the fitting stroke of the male-side contact portion332to the female-side contact portion531larger than that in the above-described conventional board-to-board connector, which improves contact stability.

Further, in the above-described conventional board-to-board connector, the sliding direction (locking direction C) of the male connector901relative to the female connector1101and the direction in which the contact portion1153A3of the main arm portion1153A and the contact portion1153B3of the auxiliary arm portion1153B of the reception terminal1153of each female conductor1151sandwich the protruding terminal953are parallel to each other, and hence when the protruding terminal953is in a state sandwiched by the contact portion1153A3of the main arm portion1153A and the contact portion1153B3of the auxiliary arm portion1153B of the reception terminal1153of each female conductor1151, if some force acts on the board-to-board connector to cause the male connector901to be displaced in the sliding direction relative to the female connector1101, the protruding terminal953is brought into strong contact with the auxiliary arm portion1153B as a component part of the reception terminal1153, causing deformation of the auxiliary arm portion1153B, and this may cause a problem that the contact stability between the protruding terminal953of the male connector901and the reception terminal1153of the female connector1101cannot be maintained. On the other hand, in the present embodiment, the direction of sliding the male connector301relative to the female connector501and the direction in which the pair of contact point portions531A sandwich the male-side contact portion332is orthogonal to each other, and hence when the male-side contact portion332is in a state sandwiched by the pair of contact point portions531A, even if some force acts on the board-to-board connector to cause the male connector301to be displaced along the sliding direction relative to the female connector501, no significant change in load is caused in a spring-bending direction, which prevents the spring portions531B from being bent, and hence the force of the pair of contact point portions531A for sandwiching the male-side contact portion332hardly changes, so that the contact stability between the male-side contact330and the female-side contact530is maintained.

Further, since the male-side terminal portions331are arranged on the other surface310B of the male-side insulating film310, when the male connector301is mounted on the first substrate, the male-side terminal portions331are directly arranged on the pad of the first substrate, without such a large gap between each tale portion958and the associated pad of the first substrate forming as in the above-described conventional board-to-board connector. Therefore, it is possible to positively and easily solder the male-side terminal portions331to the pads of the first substrate.

Further, since it is possible to simultaneously form the male-side reinforcing member main body portion351A and the fixing portions351B when forming the male-side terminal portions331, the board-to-board connector according to the present embodiment can be manufactured more easily than the above-described conventional board-to-board connector.

Further, the male connector301does not use stainless as its material, and the number of materials of the board-to-board connector according to the invention is one smaller than that of materials of the above-described conventional board-to-board connector, and hence it is easy to reduce the costs.

Next, a description will be given of a male connector302of a board-to-board connector according to a second embodiment of the present invention with reference toFIG. 21.

Component parts identical to those of the connector according to the first embodiment are denoted by identical reference numerals, and detailed description thereof is omitted, while only main component parts different in construction from those of the first embodiment will be described hereafter.

The male connector302of the board-to-board connector according to the second embodiment is a connector of a type which is not slid after being fitted. The male connector302differs from the male connector301of the board-to-board connector101of the first embodiment in the shape of protruding portions362of the male-side reinforcing member. Note that the male-side contact portion332of the second embodiment may be made longer (larger) in width in the longitudinal direction L1 of the male-side insulating film310than the male-side contact portion332of the first embodiment.

Each protruding portion362of the male connector302has no component corresponding to the holding portion352B of the board-to-board connector101of the first embodiment. The length of the protruding portion362in the longitudinal direction L1 of the male side insulting film310is equal to the length of the holding portion352B of the protruding portion352of the male connector301of the first embodiment (length of the holding portion352B in the longitudinal direction L1 of the male side insulting film310). However, the location of the protruding portion362is shifted leftward, as viewed inFIG. 21, by an amount corresponding to a difference in length between the protruding portion main body352A and the holding portion352B in the longitudinal direction L1 of the male side insulting film310of the male connector301.

Since the male connector302is not slid after being fitted to the female connector501, the male connector302is not locked in the thickness direction T2 of the female-side insulating film510, but the female-side contact portion531is sandwiched by the front end portion of the male-side contact portion332and the male-side insulating film310in the thickness direction T1 of the male-side insulating film310, and hence the male connector302is difficult to be removed from the female connector501. When the protruding portions362are inserted in the through holes582A of the female connector501, respectively, the female-side contact portion531is elastically deformed to sandwich the male-side contact portion332between the pair of contact point portions531A thereof in the width direction L4 of the female-side insulating film510(predetermined direction orthogonal to the thickness direction T2 of the of the female-side insulating film510), whereby a predetermined contact force is generated between the female-side contact portion531and the male-side contact portion332.

As a mating female connector of the male connector302, the female connector501of the board-to-board connector101of the first embodiment can be used as it is.

According to the present embodiment, it is possible to position the male connector302with respect to the female connector501. Further, it is possible to fit and remove the male connector302to and from the female connector501by one operation.

Next, a description will be given of an example of a method of manufacturing a male connector601of a board-to-board connector according to a third embodiment of the present invention with reference toFIGS. 22 to 27. The male connector601is a connector of a type which is not slid after being fitted to the female connector.

First, as shown inFIG. 22, a contact portion-side metal thin film34is provided on the one surface310A of the male-side insulating film310(contact portion-side thin film-processing step).

After execution of the contact portion-side thin film-processing step, as shown inFIG. 23, the through holes311circular in shape and the through holes rectangular in shape (protruding portion insertion through holes)312, which reach the contact portion-side metal thin film34, are formed through the male-side insulating film310by etching processing (through hole-forming step).

After execution of the through hole-forming step, as shown inFIGS. 24 and 25, a terminal portion-side metal thin film35is provided on the other surface310B of the male-side insulating film310e.g. by plating (terminal portion-side thin film-processing step).

After execution of the terminal portion-side thin film-processing step, the contact portion-side metal thin film3is etched to thereby form cylindrical (pin-shaped) male-side contact portions333at respective locations corresponding to the through holes311and the protruding portions362at respective locations corresponding to the through holes312, and the terminal portion-side metal thin film35is etched to thereby form the male-side terminal portions331, the male-side reinforcing member main body portion351A, and the fixing portions351B, as shown inFIGS. 26 and 27(patterning step).

By thus executing the above-described steps, the male connector601is manufactured (seeFIG. 26). Component parts identical to those of the connector according to the second embodiment are denoted by identical reference numerals, and detailed description thereof is omitted. Although in the above-described embodiments, the prism-shaped male-side contact portion332is employed as the pin-shaped male-side contact portion, the cylindrical male-side contact portion333is employed in the third embodiment (seeFIG. 26). Note that the male connectors301and302of the above-described embodiments may be manufactured by using this manufacturing method.

Although in the above-described embodiments, the prism-shaped male-side contact portion332and the cylindrical male-side contact portion333are employed as the pin-shaped male-side contact portion, the pin shape of the male-side contact portion is not limited to these, but a pin shape other than the cylindrical shape and the prism shape may be employed.

Further, although in the above-described embodiments, the male connectors301,302, and601include the protruding portions352or362, and the female connector501includes the protruding portion-receiving holes571, the protruding portions352and362and the protruding portion-receiving holes571may be omitted.

Although in the above-described embodiments, the construction is employed in which the male-side contact portion531is elastically deformed to thereby sandwich the male-side contact portion332in the predetermined direction orthogonal to the thickness direction T2 of the female-side insulating film510, it is not necessary to employ the construction for sandwiching the male-side contact portion332. Further, although when the male-side contact portion332is inserted in the female-side contact portion531, the spring portions531B are hardly elastically deformed, the male-side contact portion332and the female-side contact portion531may be constructed such that the male-side contact portion332is brought into contact with the female-side contact portion531, whereby the spring portions531B are elastically deformed.

Further, although in the above-described embodiments, by forming the male-side contact portion332such that the front end portion thereof is expanded, the female-side contact portion531is sandwiched by the front end portion of the male-side contact portion332and the male side insulting film310in the thickness direction T1 of the male side insulting film310, it is not necessary to employ this construction.

Although in the first embodiment, the male-side contact portion332is sandwiched by the pair of contact point portions531A of the female-side contact portion531in the width direction L4 of the female-side insulating film510(first predetermined direction in claim5), and the male connector301can be relatively slid in the longitudinal direction L3 of the female-side insulating film510(second predetermined direction in claim5) with respect to the female connector501, the direction of sliding the male connector301is not limited to this, but for example, the male connector301may be relatively slid in the width direction L4 of the female-side insulating film510(second predetermined direction in claim6) with respect to the female connector501, or may not be slid with respect to the female connector501as in the second embodiment. Further, when the construction is such that the male-side contact portion332is sandwiched between the pair of contact point portions531A of the female-side contact portion531in the longitudinal direction L3 of the female-side insulating film510(first predetermined direction in claim6) and the male connector301can be relatively slid in the width direction L4 of the female-side insulating film510(second predetermined direction in claim6) with respect to the female connector501, the female connector1101of the above-described conventional board-to-board connector can be used as the female connector.

Further, although in the first embodiment, the vertical cross-section of the protruding portion352is formed to be hook-shaped to form the holding portion352B, whereby the male connector301is locked to the female connector501in the thickness direction T2 of the female-side insulating film510by the holding portion352B, it is not necessary to employ this construction, and the protruding portion352may not be formed with the holding portion352B.

It is further understood by those skilled in the art that the foregoing are the preferred embodiments of the present invention, and that various changes and modification may be made thereto without departing from the spirit and scope thereof.