Patent Abstract:
A bridge connector for interconnecting two connectors mounted on circuit boards together includes a planar substrate that supports a length of flexible printed circuit, the substrate has engagement arms that are chamfered to act as male connector portions and be received within receptacle portions for the board connectors to effect a reliable connection between the two connectors.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a relay connector. 
         [0003]    2. Description of the Related Art 
         [0004]    Hitherto, a board-to-board connector has been used in order to connect a pair of parallel circuit boards to each other (refer to, for example, Japanese Patent Application Laid-Open (Kokai) publication No. 2003-272734). This type of board-to-board connector connects a pair of circuit boards arranged in parallel on an identical surface to one another. 
         [0005]      FIG. 15  is a side view of a conventional board-to-board connector. 
         [0006]    In the same drawing, reference numeral  901  designates a first connector to be mounted on a first circuit board  991 A, reference numeral  902  designates a second connector to be fitted to a counterpart connector mounted on a second circuit board  991 B, and reference numeral  801  designates a linking connector for providing electrical connection between the first connector  901  and the second connector  902 . The first connector  901  is provided with a housing  911  and solder tails  961  projecting from the housing  911 , and the solder tails  961  are connected to corresponding conductive traces of the first circuit board  911 A. Therefore, the first connector  901  is mounted on the first circuit board  991 A. 
         [0007]    Further, the second connector  902  is provided with a housing  912 , and contact portions  962  attached to the housing  912 , and connected by fitting to the counterpart connector mounted on the second circuit board  991 B. Accordingly, the contact portions  962  come into contact and become electrically continuous with counterpart terminals of the counterpart connector. 
         [0008]    The linking connector  801  is provided with a housing  811 , and pivotally connected to the first connector  901 . In this case, pivotal shaft pins  915  formed on both sides of the housing  911  of the first connector  901  are pivotally fitted into receiving grooves  813  formed in the housing  811  of the linking connector  801 . The housing  912  of the second connector  902  is fixed to the housing  811  of the linking connector  801 . 
         [0009]    Further, the linking connector  801  includes a plurality of jumper leads  861  arranged in parallel with each other. The jumper leads  861  are formed of flexible conductive metal leads, and both ends of each are connected to each of the solder tails  961  and each of the contact portions  962 . In other words, the solder tails  961  of the first connector  901  and the contact portions  962  of the second connector  902  are connected to each other by the jumper leads  861 . 
         [0010]    A conventional board-to-board connector has the structure described above, and in states of storage, transportation and so forth, the first connector  901  is mounted on the first circuit board  991 A, and the second connector  902  and the counterpart connector are unlocked from each other. Therefore, even if the relative locations of the first circuit board  991 A and the second circuit board  991 B are shifted due to an externally applied shock or the like, no stress is applied thereto from the shock or the like. Moreover, when connecting the first circuit board  991 A and the second circuit board  991 B to one another, the linking connector  801  is pivoted with respect to the first connector  901  mounted on the first circuit board  991 A, while allowing the second connector  902  to be fitted to the counterpart connector mounted on the second circuit board  991 B. Hence, the contact portions  962  come into contact with the counterpart terminals of the counterpart connector, and thereby the first circuit board  991 A and the second circuit board  991 B are connected to each other, in other words, to the electric circuits provided on each of the circuit boards. 
         [0011]    Further, even if the locations are shifted between the first circuit board  991 A and the second circuit board  991 B in a state of being connected to each other by the board-to-board connector, the location shift can be adequately absorbed because the fitting state between the pivotal shaft pins  915  and the receiving grooves  813  is kept loose, and the jumper leads  861  are flexible and can be permitted to be easily bended. 
         [0012]    However, in the described conventional board-to-board connector, the linking connector  801  includes the plurality of jumper leads  861 , and the plurality of jumper leads  861  are integrated with the housing  811  made of synthetic resin or the like. Therefore, in order to produce the connecting connector  801 , it is necessary to use a metallic-terminal die which has a function of holding the jumper leads  861  that are the metallic terminals, to form the housing  811 , by filling the metallic-terminal die with molten resin. However, costs for such metallic-terminal die are high because the structure thereof is generally complex, causing an increase in the manufacturing costs for the linking connector  801 . 
         [0013]    Moreover, since the jumper leads  861  bend when a location shift occurs between the first circuit board  991 A and the second circuit board  991 B, if, in particular, the pitch of the jumper leads  861  is small, the neighboring jumper leads  861  must contact with each other when they bend, which increase the possibility of occurrence of the so-called short-circuit between different leads. Hence, another component to avoid short-circuit between the leads is necessary to prevent the neighboring jumper leads  861  from being in contact with each other, and this causes an increase in the number of components, and the structure and arrangement become more complicated. 
         [0014]    Nevertheless, since FPC (flexible printed circuit) and FFC (flexible flat cable) inherently have flexibility, the FPC and FFC for high-speed transmission might be employable, instead of the conventional board-to-board connector, to connect the first circuit board  991 A and the second circuit board  991 B to one another. However, in this case, both ends of the flexible FPC or FFC have to be connected to connectors mounted on the first circuit board  991 A and the second circuit board  991 B one by one, and therefore it takes lots of effort and time to achieve the operation. 
       SUMMARY OF THE INVENTION 
       [0015]    Therefore, it is an object of the invention to solve the problems encountered by the conventional connector described above, and to provide a relay connector in which a three-dimensional conductive patterns are formed on surfaces of a body portion which is integrally formed of an insulating material, whereby an operation for fitting the connector to a mounted counterpart connector or connectors can be easily performed, any short-circuit between the conductive patterns do not occur, desired conductive patterns can be readily formed, a structure and an amendment is simple, the number of required components is small, and easy production as well as low production cost can be ensured. 
         [0016]    Therefore, a relay connector according to the present invention comprises a body portion provided with a plurality of fitting portions to be fitted to counterpart connectors, respectively, and integrally formed of an insulating material, and conductive patterns in three dimensions, which are formed on surfaces of the body portion, the conductive patterns being capable of coming into contact with counterpart terminals of the counterpart connectors, thereby connecting the plurality of counterpart connectors to one another. 
         [0017]    In the relay connector according to another embodiment of the present invention, the body portion is provided with a plate-like bridging portion, and the fitting portions are connected to the bridging portion at both ends of the bridging portion spaced apart in a direction in which the conductive patterns extend, the fitting portions extending, respectively, in a direction perpendicular to the bridging portion. 
         [0018]    In the relay connector according to a further embodiment of the present invention, the conductive patterns comprise first conductive patterns which include a first portion formed on a surface of the bridging portion, and second portions formed on surfaces of the fitting portions and connected to the first portion, and second conductive patterns which include a first portion formed on a rear surface of the bridging portion, and second portions formed on rear surfaces of the fitting portions and connected to the first portion. 
         [0019]    In the relay connector according to a still further embodiment of the present invention, the body portion further comprises chamfered portions formed in border portions between the surface of the bridging portion and the surfaces of the fitting portions, and chamfered portions formed in border portions between the rear surface of the bridging portion and the rear surfaces of the fitting portions. 
         [0020]    In the relay connector according to a still further embodiment of the present invention, the surfaces of the fitting portions include recessed surface portions on which the second portions of the first conductive patterns are formed, and projecting portions projecting further than the recessed surface portions, and the rear surfaces of the fitting portions include recessed surface portions on which the second portions of the second conductive patterns are formed, and projecting portions projecting further than the recessed surface portions. 
         [0021]    In the relay connector according to a still further embodiment of the present invention, at least one of the fitting portions is divided into a plurality of portions with respect to a direction of array of the conductive patterns, and the plurality of portions are arranged to be offset from one another with respect to a longitudinal direction of the conductive patterns. 
         [0022]    In the relay connector according to a still further embodiment of the present invention, the insulating material comprises a composite material obtained by mixing an organic metal with a base polymer, and the conductive patterns are formed of a metal plating film deposited on patterns formed by irradiating a beam of laser onto the surfaces of the body portion. 
         [0023]    In accordance with the present invention, the relay connector is formed with the conductive patterns in three dimensions on the surfaces of the body portion, which is integrally formed of an insulating material. Hence, an operation for fitting the relay connector to the counterpart connectors mounted on a substrate or a circuit board is performed easily, no short-circuit between the conductive patterns occurs, desired types of conductive patterns can be readily formed, the structure and arrangement can be simplified, the number of components required is reduced, production of the relay connector is made easier while achieving reduction in the production cost thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  is a perspective view illustrating a state where a relay connector according to a first embodiment of the present invention is fitted to counterpart connectors, and a cover member is attached thereto; 
           [0025]      FIG. 2  is a cross-sectional view, taken along the arrowed line A-A of  FIG. 1 , depicting the state where the relay connector according to the first embodiment of the present invention is fitted to the counterpart connectors; 
           [0026]      FIG. 3  is a perspective view illustrating the state where the relay connector according to the first embodiment of the present invention is fitted to the counterpart connectors; 
           [0027]      FIG. 4  is an exploded perspective view illustrating a relationship among the relay connector according to the first embodiment of the present invention, the counterpart connectors, and the cover member; 
           [0028]      FIG. 5  is a perspective view of the relay connector according to the first embodiment of the present invention; 
           [0029]      FIGS. 6A and 6B  are first views from the two different sides of the relay connector according to the first embodiment of the present invention, in which  FIG. 6A  is a top plan view thereof and  FIG. 6B  is a front view thereof; 
           [0030]      FIGS. 7A and 7B  are second views from the two different sides of the relay connector according to the first embodiment of the present invention, in which  FIG. 7A  is one side view thereof and  FIG. 7B  is a bottom view thereof; 
           [0031]      FIGS. 8A and 8B  are different cross-sectional views of the relay connector according to the first embodiment of the present invention, one ( FIG. 8B ) being a view taken along the arrowed line B-B of  FIG. 6B , and the other ( FIG. 8A ) being an enlarged view of portion “C” of  FIG. 8B ; 
           [0032]      FIGS. 9A and 9B  are views illustrating a state where a body portion of the relay connector according to the first embodiment of the present invention is irradiated with a beam of laser; 
           [0033]      FIG. 10  is a first perspective view of a relay connector according to a second embodiment of the present invention; 
           [0034]      FIG. 11  is a second perspective view of the relay connector according to the second embodiment of the present invention; 
           [0035]      FIGS. 12A to 12C  are three-sided views of the relay connector according to the second embodiment of the present invention, in which  FIG. 12A  is a top plan view thereof,  FIG. 12B  is a front view thereof, and  FIG. 12C  is a side view thereof; 
           [0036]      FIG. 13  is a bottom view of the relay connector according to the second embodiment of the present invention; 
           [0037]      FIG. 14  is a perspective view illustrating a state where the relay connector according to the second embodiment of the present invention is fitted to counterpart connectors; and 
           [0038]      FIG. 15  is a side view of a conventional board-to-board connector. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0039]    Preferred embodiments of the present invention will be described hereinbelow in detail with reference to the accompanying drawings. 
         [0040]      FIG. 1  is a perspective view illustrating a state where a relay connector according to a first embodiment of the present invention is fitted to counterpart connectors, and a cover member is attached thereto,  FIG. 2  is a cross-sectional view, taken along the arrowed line A-A of  FIG. 1 , depicting the state where the relay connector according to the first embodiment of the present invention is fitted to the counterpart connectors,  FIG. 3  is a perspective view illustrating the state where the relay connector according to the first embodiment of the present invention is fitted to the counterpart connectors, and  FIG. 4  is an exploded perspective view illustrating a relationship among the relay connector according to the first embodiment of the present invention, the counterpart connectors, and the cover member. 
         [0041]    In the drawing figures, reference numeral  1  generally denotes a connector as a relay connector according to the present first embodiment, and the relay connector  1  includes a body portion  11  formed of an insulating material such as synthetic resin, and conductive patterns  61  formed on surfaces of the body portion  11 , and can electrically connect a first substrate  91 A and a second substrate  91 B when both ends thereof are fitted to counterpart connectors  101  mounted on the first substrate  91 A and the second substrate  91 B, respectively. The conductive patterns  61  includes first conductive patterns  61 A formed on a first surface of the body portion  11 , namely, the uppermost surface of the body portion  11 , and later described second conductive patterns  61 B formed on a second surface of the body portion  11 , namely, the rear surface of the body portion  11  (refer to  FIG. 7B ), and, it is to be noted that when the first conductive patterns  61 A and the second conductive patterns  61 B are described collectively, both will be described as the conductive patterns  61 . The first substrate  91 A and the second substrate  91 B are, for example, printed circuit boards, but they may be any type of substrates as long as electric circuits are provided. 
         [0042]    In the present embodiment, representations of directions such as up, down, left, right, front, rear, and the like, used for explaining the structure and movement of each part of the connector  1 , and the like, are not absolute, but relative. These representations are appropriate when each part of the connector  1 , and the like, is in the position shown in the figures. If the position of the connector  1 , and the like, changes, however, it is assumed that these representations are to be changed according to the change in the position of the connector  1 , and the like. 
         [0043]    The body portion  11  is a member which is integrally formed of an insulating material such as synthetic resin, to be more specific, a composite material of thermoplastic resin containing organic metal, and includes a plate-like rectangular bridging portion  12 , and leg portions  13  as fitting portions extending in a direction perpendicular to the bridging portion  12  (the downward direction in  FIG. 2 ) in which the distal ends thereof are connected to both ends of the bridging portion  12 . As shown in  FIG. 2 , each of the leg portions  13  is provided with a fitting-recess portion  16  to be fitted to a center wall portion  122  of each of counterpart connectors  101 . Each of the fitting-recess portions  16  is a recess which is open on the bottom surface of each of the leg portions  13 , the cross section thereof extending in the array direction of the conductive patterns  61  (a direction connecting the right top and left bottom in  FIG. 1 ) is rectangle or trapezoidal, and both sides thereof are defined by an external wall portion  13   a  and an internal wall portion  13   b  of each of the leg portions  13 . 
         [0044]    As shown in  FIG. 3 , the plurality of first conductive patterns  61 A extending in a direction of connecting the leg portions  13  on both sides are formed so as to be parallel to each other on the surface of the body portion  11 . On the rear surface of the body portion  11 , a plurality of conductive patterns forming the later-described second conductive patterns  61 B are extending in the direction of connecting the legs portions  13  on both sides, similarly to the first conductive patterns  61 A, and formed so as to be parallel to each other. 
         [0045]    The connector  1  according to the present embodiment is so-called a MID (Molded Interconnect Device), in which the conductive patterns  61 , three-dimensional patterns, are integrally formed by plating on the surfaces of the body portion  11  which is formed of synthetic resin. In this case, the body portion  11  is formed of a composite material obtained by mixing a filler and organic metal with thermoplastic resin, which is base polymer, and is integrally molded into a desired shape by using a forming method such as an injection molding where a metallic die is used. Since the afore-mentioned organic metal is non-conductive, the composite material is an insulating material. Thereafter, the surfaces of the body portion  11  are radiated with a beam of laser for the patterning, and predetermined patterns, which correspond to the conductive patterns  61  are formed. Then, laser-radiated areas on the surfaces of the body portion  11  are activated, a physicochemical reaction of the organic metal is induced in these areas, and metal seeds are generated. Moreover, these areas are roughened by so-called laser abrasion. Since these areas have metal seeds and are roughened, deposition thereon of plating films can be high. 
         [0046]    When highly conductive metal such as copper is applied, by plating, onto the surfaces of the body portion  11  patterned as described above, plating films are securely deposited on the laser-illuminated areas, and the conductive patterns  61  are formed there. Therefore, for example, approximately 80 linearly extending conductive patterns  61  arrayed with a fine pitch of about 100 [μm] can be obtained. 
         [0047]    The conductive patterns  61  have a three-dimensional shape because they are formed along three-dimensional surfaces of the body portion  11 . As shown in  FIG. 5 , the first conductive patterns  61 A include a first portion  62 A formed on the surface of the bridging portion  12 , second portions  63 A formed on the surfaces of the leg portions  13  on both sides, in other words, on the external surfaces of the external wall portions  13   a , and one ends thereof are connected to both ends of the first portion  62 A, and later-described third portions  64 A formed on the side surfaces of the fitting-recess portions  16  on the external sides, namely, on the inner side surfaces of the external wall portions  13   a , and one ends thereof are connected to the other ends of the second portions  63 A (refer to  FIG. 7B ). Since the external side surface and the inner side surface of each of the external wall portions  13   a  are almost orthogonal to the surface of the bridging portion  12 , the second portions  63 A and the third portions  64 A extend in a direction almost orthogonal to the first portion  62 A. 
         [0048]    Moreover, similarly to the first conductive patterns  61 A, the second conductive patterns  61 B include a first portion  62 B formed on the rear surface of the bridging portion  12 , second portions  63 B formed on the rear surfaces of the leg portions  13  on both sides, namely, on the external side surfaces of the internal wall portions  13   b , and one ends thereof are connected to both ends of the first portion  62 B, and third portions  64 B formed on the internal surfaces of the internal wall portions  13   b , and one ends thereof are connected to the other ends of the second portions  63 B (refer to  FIG. 7B ). 
         [0049]    Once the leg portions  13  on both sides are fitted to the counterpart connectors  101  mounted on the first substrate  91 A and the second substrate  91 B, respectively, the first portion  63 A of the third conductive patterns  64 A of the first conductive patterns  61 A and the third portions  64 B of the second conductive patterns  61 B come into contact with counterpart terminals  161  of the counterpart connectors  101 . Therefore, the counterpart terminals  161  of the counterpart connectors  101  mounted on the first substrate  91 A and the second substrate  91 B, respectively, are electrically connected to one another via the first conductive patterns  61 A and the second conductive patterns  61 B. 
         [0050]    Here, the counterpart connector  101  is a so-called floating type connector, and includes an external housing  111  and an internal housing  121  integrally formed of an insulating material such as synthetic resin, and the plurality of counterpart terminals  161  formed of conductive metal and attached to the external housing  111  and the internal housing  121 . The internal housing  121  is accommodated in the external housing  111 . Because the external housing  111  and the internal housing  121  are independently formed members that are separate from each other, and connected to each other by the counterpart terminals  161 , the internal housing  121  is loosely restrained by the external housing  111  so as to be able to be displaced with respect to the external housing  111  as the counterpart terminals  161  are elastically deformed, that is to say, the internal housing  121  is in a floating state. 
         [0051]    The external housing  111  is a member which has a square tubular shape with a rectangular plane cross section, and includes side wall portions  112  which are in parallel with each other and extend in the longitudinal direction. The internal housing  121  is a member having a square columnar shape with a rectangular plane cross section, and includes the center wall portion  122 , two fitting wall portions  123  extending in the longitudinal direction, and two fitting groove portions  124  formed between the center wall portion  122  and the fitting wall portions  123  and extending in the longitudinal direction. 
         [0052]    The counterpart terminals  161  are arrayed with a predetermined pitch, forming two rows extending in the longitudinal direction of the counterpart connector  101 , mounted on the external housing  111  and the internal housing  121  so as to straddle over both housings, and exhibit a function of physically coupling the external housing  111  and the internal housing  121 . 
         [0053]    The external housings  111  are mounted and fixed onto the first substrate  91 A and the second substrate  91 B, respectively. In this case, the external housings  111  are fixed thereto, as tail portions  163  connected to one ends of the counterpart terminals  161  are connected to connecting pads which are coupled to non-illustrated conductive traces of the first substrate  91 A and the second substrate  91 B by soldering or the like, and additionally, auxiliary metallic bracket members  181  usually referred to as nail members are attached to the connecting pads or the like on the first substrate  91 A and the second substrate  91 B by soldering or the like so as to ensure the fixing of the external housings  111 . 
         [0054]    Moreover, contact portions  164  connected to the other ends of the counterpart terminals  161  are in a state of projecting into the fitting groove portions  124  from both sides of the center wall portion  122 . When the leg portions  13  on both sides of the connector  1  are fitted into the counterpart connectors  101 , the center wall portions  122  enter the fitting-recess portions  16 , and the external wall portions  13   a  and the internal wall portions  13   b  enter the fitting groove portions  124  arranged on both sides of the center wall portions  122 , as shown in  FIG. 2 . Accordingly, the contact portions  164  come into contact with the third portions  64 A and  64 B formed on the inner side surfaces of the external wall portions  13   a  and the internal wall portions  13   b , thus enabling the counterpart terminals  161  to be electrically conductive with the first conductive patterns  61 A and the second conductive patterns  61 B. 
         [0055]    Preferably, a cover member  41  is attached to the body portion  11  of the connector  1  to cover the top surface thereof as shown in  FIGS. 1 ,  2  and  4 . In the example depicted in these drawing figures, the cover member  41  includes a flat plate-like top plate portion  42 , which is approximately rectangle and covers the top surface of the body portion  11 , and opposite skirt portions  43  extending in the downward direction from the side edge of the top plate portion  42 . By covering the top surface of the body portion  11  with the cover member  41 , any foreign matters such as fine dusts in the air do not attach to the surface of the body portion  11 , preventing short-circuits from occurring between the neighboring first conductive patterns  61 A. Therefore, engagement holes  15  are formed in an area of the bridging portion  12  of the body portion  11  where the conductive patterns  61  are not formed, enabling the non-illustrated engagement projections provided in the cover member  41  to be engaged in the engagement holes  15 . 
         [0056]    Furthermore, it is desirable that manipulating recessed portions  14  are provided on both ends of the bridging portion  12  in the direction of array of the conductive patterns  61 . An operator can hold the body portion  11  easily and without failure by getting his/her fingers caught in the manipulating recessed portions  14  when carrying out diverse operations required for transporting the connector  1 , fitting the connector  1  to the counterpart connectors  101 , and the like. Moreover, it is desirable that manipulating recessed portions  46  having shapes corresponding to the manipulating recessed portions  14  are provided in the top plate portion  42  of the cover portion  41  at locations corresponding to the manipulating recessed portions  14 . 
         [0057]    Next, the structure of the connector  1  will be described in detail. 
         [0058]      FIG. 5  is a perspective view of the relay connector according to the first embodiment of the present invention,  FIGS. 6A and 6B  are first views from the two different sides of the relay connector according to the first embodiment of the present invention, in which  FIG. 6A  is a top plan view thereof and  FIG. 6B  is a front view thereof,  FIGS. 7A and 7B  are second views from the two different sides of the relay connector according to the first embodiment of the present invention, in which  FIG. 7A  is one side view thereof and  FIG. 7B  is a bottom view thereof,  FIGS. 8A and 8B  are different cross-sectional views of the relay connector according to the first embodiment of the present invention, one ( FIG. 8B ) being a view taken along the arrowed line B-B of  FIG. 6B , and the other ( FIG. 8A ) being an enlarged view of portion “C” of  FIG. 8B , and  FIGS. 9A and 9B  are views illustrating a state where a body portion of the relay connector according to the first embodiment of the present invention is irradiated with a beam of laser. 
         [0059]    As shown in  FIGS. 5 ,  8 A and  8 B, chamfered portions  12   a  are formed in corner portions which form border portions between the surface of the bridging portion  12  and the external side surfaces of the external wall portions  13   a . Therefore, in the first conductive patterns  61 A, an connecting angle between the first portion  62 A formed by plating on the surface of the bridging portion  12  and each of the second portions  63 A formed by plating on the external side surface of each of the external wall portions  13   a  becomes gentler, ensuring connection between the first portion  62 A and the second portions  63 A. This means that, if the angle of the border portion between the surface of the bridging portion  12  and the external side surface of each of the external wall portions  13   a  is as sharp as approximately 90 degrees, a plating film on the surface of the bridging portion  12  and a plating films on the external side surfaces of the external wall portions  13   a  may not become continuous with each other when forming the plating films, whereas provision of gentler angles of the boarder portions ensures that the both plating films are successfully continuous with each other. Moreover, when conducting the patterning by the laser beam radiation, if the angles of the boarder portions between the surface of the bridging portion  12  and the external side surfaces of the external wall portions  13   a  are as sharp as approximately 90 degrees, the patterns on the surface of the bridging portion  12  and the patterns on the external side surfaces of the external wall portions  13   a  may not be smoothly connected adequately, whereas both patterns are continuous with each other properly due to the gentler angles of the border portions. 
         [0060]    Furthermore, by forming the chamfered portions  12   a , in addition to ensuring continuity between the first portion  62 A and the second portions  63 A in a step of production of the first conductive patterns  61 A, the possibility of disconnection between both portions  62 A and  63 A is reduced even when any other object or the like abuts against the first portion  62 A and the second portions  63 A while mounting or using the connector  1 . In the example illustrated in the drawings, the chamfered portions  12   a  are inclined flat surfaces, but the chamfered portions  12   a  may be curved surfaces that connect the surface of the bridging portion  12  and the external side surfaces of the external wall portions  13   a.    
         [0061]    Further, as shown in  FIGS. 8A and 8B , chamfered portions  16   a  are also formed in corner portions which form border portions between the end portions of the fitting-recess portions  16  on the open side, in other words, the bottom surfaces of the leg portions  13 , and the inner side surfaces of the external wall portions  13   a . Since the chamfered portions  16   a  can exhibit functions similar to those exhibited by the chamfered portions  12   a , forming the chamfered portions  16   a  ensure continuity between the second portions  63 A formed by plating on the external side surfaces of the external wall portions  13   a  and the third portions  64 A formed by plating on the internal side surfaces of the external wall portions  13   a . Moreover, the possibility of disconnection between the second portions  63 A and the third portions  64 A is reduced. Furthermore, the chamfered portions  16   a  may be curved surfaces, in a manner similar to the chamfered portions  12   a.    
         [0062]    Although omitted in the example shown in the drawings, it is preferable that chamfered portions similar to the chamfered portions  16   a  are formed in corner portions which form border portions between the bottom surfaces of the leg portions  13  and the external side surfaces of the external wall portions  13   a . Accordingly, continuity between the second portions  63 A and the third portions  64 A is ensured even further, and the possibility of disconnection between the second portions  63 A and the third portions  64 A is further reduced. 
         [0063]    As shown in  FIGS. 8A and 8B , the chamfered portions  12   b  similar to the chamfered portions  12   a  are formed in corner portions which form border portions between the rear surface of the bridging portion  12  and the external side surfaces of the internal wall portions  13   b . Since the chamfered portions  12   b  can exhibit functions similar to those exhibited by the chamfered portions  12   a , forming the chamfered portions  12   b  ensures continuity in the second conductive patterns  61 B between the first portion  62 B formed by plating on the rear surface of the bridging portion  12  and the second portions  63 B formed by plating on the external side surfaces of the internal wall portions  13   b.    
         [0064]    When conducting the patterning by laser beam radiation in particular, if the angles of the border portions between the rear surface of the bridging portion  12  and the external side surfaces of the internal wall portions  13   b  are as sharp as nearly 90 degrees, it is difficult for the beam of laser to reach the border portions as they are narrow areas sandwiched by the inner surface of the bridging portion  12  and the external side surfaces of the inner wall portions  13   b , and which increases the likelihood that the patterns on the inner surface of the bridging portion  12  and the patterns on the external side surfaces of the internal wall portions  13   b  are not smoothly continuous with each other properly, whereas the gentler angles of the border portions makes it easier for the beam of laser to be radiated so as to reach the boarder portions, while enabling both patterns to be properly connected continuously with each other. 
         [0065]    In addition, the possibility of disconnection between the second portions  63 B and the third portions  64 B is certainly reduced. Similarly to the chamfered portions  12   a , the chamfered portions  12   b  may be curved surfaces. 
         [0066]    Yet further, the chamfered portions  16   b  similar to the chamfered portions  16   b  are formed in corner portions, which form border portions between the end portions of the fitting-recess portions  16  on the open side, in other words, the bottom surfaces of the leg portions  13 , and internal side surfaces of the internal wall portions  13   b . Similarly to the chamfered portions  16   a , forming the chamfered portions  16   b  ensures continuity in the second conductive patterns  61 B between the second portions  63 B formed by plating on the external side surfaces of the inner wall portions  13   b  and the third portions  64 B formed by plating on the internal side surfaces of the inner wall portions  13   b . In addition, the possibility of disconnection between the second portions  63 B and the third portions  64 B is reduced. Further, similarly to the chamfered portions  12   b , the chamfered portions  16   b  may be curved surfaces. 
         [0067]    Although omitted in the example shown in the drawings, it is desirable that chamfered portions similar to the chamfered portions  16   b  are formed in corner portions which form border portions between the bottom surfaces of the leg portions  13  and the external side surfaces of the internal wall portions  13   b . Accordingly, connection between the second portions  63 B and the third portions  64 B is ensured even further, and the possibility of disconnection between the second portions  63 B and the third portions  64 B is further reduced. 
         [0068]    As shown in  FIGS. 5 ,  7 A,  7 B,  8 A and  8 B, recessed surface portions  18 , and guard projecting portions  17  serving as projecting portions to define both ends of the first conductive patterns  61 A in the direction of array thereof in the recessed portions  18 , are formed on the external side surfaces of the external wall portions  13   a . The second portions  63 A of the first conductive patterns  61 A are formed on the recessed surface portions  18 . Similarly, recessed surface portions  21 , and guard projecting portions  22  serving as projecting portions to define both ends of the second conductive patterns  61 B in the direction of array thereof in the recessed surface portions, are formed on the external side surfaces of the inner wall portions  13   b . The second portions  63 B of the second conductive patterns  61 B are formed on the recessed surface portions  21 . 
         [0069]    As described above, since the guard projecting portions  17  and  22  projecting more outward than the recessed surface portions  18  and  21  are provided at both ends of the recessed portions  18  and  21 , respectively, the second portions  63 A of the first conductive patterns  61 A and the second portions  63 B of the second conductive patterns  61 B do not slidably contact the fitting wall portions  123  even if the external wall portions  13   a  and the internal wall portions  13   b  enter the fitting groove portions  124  on both sides of the respective center wall portions  122  when the leg portions  13  on both sides of the connector  1  are fitted to the counterpart connectors  101 . Therefore, even if the leg portions  13  are fitted to and withdrawn from the counterpart connectors  101  repeatedly, the second portions  63 A and  63 B are not damaged by slide contact with the fitting wall portions  123 . 
         [0070]    As described so far, in the present embodiment, the connector  1  is provided with the body portion  11  which is integrally formed of an insulating material and includes the plurality of leg portions  13  to be fitted to the counterpart connectors  101 , respectively, and the conductive patterns  61  in three-dimensions, which are formed on the surfaces of the body portion  11 , and the latter conductive patterns  61  always come into contact with the counterpart terminals  161  of the counterpart connectors  101 , thus establishing mutual connection among the plurality of the counterpart connectors  101 . To be more specific, the body portion  11  is provided with the plate-like bridging portion  12 , and the leg portions  13  are connected to both ends of the bridging portion  12  in the direction in which the conductive patterns  61  extend, and extend in the direction perpendicular to the bridging portion  12 . 
         [0071]    Further, in the present embodiment, forming dies used for forming the body portion  11  have a shape to be opened in the upward and downward directions in  FIGS. 8A and 8B , and form the leg portions  13  without forming any recessed shapes in the left and right directions in  FIGS. 8A and 8B  (i.e., the direction orthogonal to the opening direction of the die). In other words, the body portion  11  is formed without providing generally so-called undercuts in the injection molding, in the areas to form conductive patterns on the surfaces for the fitting-recess portions  16 , the recessed surfaces  18  and  21 , the guard projecting portions  17  and  22 , and the like. Therefore, laser beam radiation can readily definitely reach the surfaces of the areas where the conductive patterns of the connector  1  are to be formed. 
         [0072]    This means that, by having appropriate depths of the fitting-recess portions  16  and appropriate angles of the chamfered portions  12   a ,  12   b ,  16   a  and  16   b , the first conductive patterns  61 A and the second conductive patterns  61 B can be formed only with radiation from three directions indicated by the arrows D, E, and F in  FIG. 8B , and the body portion  11  can be produced with a small number of steps. 
         [0073]    Further, in the bridging portion  12 , it is preferred that the areas on the surface and rear surface of the bridging portion  12  where conductive patterns  61  are to be formed are flattened without any recesses or projections. This is because laser beam radiation in the direction of the arrow F may need to be divided into two directions depicted by the arrows F 1  and F 2  in  FIG. 8B  if, for example, a recessed portion is formed on the surface of the bridging portion  12 . In that case, however, radiation of the beam of laser needs to be applied from only four directions, and the body portion  11  can be still produced with a small number of steps. 
         [0074]    Furthermore, when the first conductive patterns  61 A and the second conductive patterns  61 B are formed in the body portion  11 , it is common to apply radiation of the beam of laser from a constant definite direction and to change the direction of the body portion  11 . 
         [0075]    At that time, there is usually employed a method in which plural body portions  11  are lined up in a direction (direction of arrow M) orthogonal to the direction of laser beam radiation (direction of arrow L), and a source of the laser beam radiation is moved to the direction of the arrayed body portions  11  (direction of arrow M), as shown in  FIGS. 9A and 9B . In this case, lining up the body portions  11  in a standing state against the direction of the laser beam radiation as much as possible, more numbers of body portions  11  can be lined up on a mounting surface thereof per a given unit area, and efficiency of the process is increased. 
         [0076]    Compared with the case where no chamfered portions are formed, with the chamfered portions  16   a  and  16   b  formed, it becomes possible to transfer the body portions  11  in the standing state when forming the conductive patterns with a given depth in the fitting-recess portions  16 .  FIGS. 9A and 9B  show a state where the body portions  11  are standing at 45 degrees against the direction of arrow M. 
         [0077]    Further, assuming that the tilt angle of the body portions  11  in the transferring state is constant, it becomes possible to form the conductive patterns in even deeper areas of the fitting-recess portions  16  by forming the chamfered portions  16   a  and  16   b , and the effective fitting length with the counterpart connectors can be extended. 
         [0078]    Accordingly, an operation for fitting the body portion  11  to the counterpart connectors can be performed easily. In addition, desired conductive patterns  61  can be obtained, and short-circuits between terminals due to contact between the neighboring conductive patterns  61  do not occur. Moreover, the structure is simplified, and the number of components is reduced. Also, manufacturing is easy, and costs can be curtailed. 
         [0079]    The conductive patterns  61  are provided with the first conductive patterns  61 A which include the first portion  62 A formed on the surface of the bridging portion  12  and the second portions  63 A formed on the surfaces of the leg portions  13  and connected to the first portion  62 A, and the second conductive patterns  61 B which include the first portion  62 B formed on the rear or inner surface of the bridging portion  12 , and the second portions  63 B formed on the rear surfaces of the leg portions  13  and connected to the first portion  62 B. Since the conductive patterns  61  are formed on both surfaces of the body portion  11  as described above, a number of conductive patterns  61  can be wired at a high density, and counterpart connectors  101  having a large number of electrodes can be connected to each other. 
         [0080]    Furthermore, the body portion  11  is provided with the chamfered portions  12   a  formed in the border portions between the surface of the bridging portion  12  and the surfaces of the leg portions  13 , and the chamfered portions  12   b  formed in the border portions between the rear surface of the bridging portion  12  and the rear surfaces of the leg portions  13 . Therefore, continuity is ensured between the first portion  62 A formed on the surface of the bridging portion  12  and the second portions  63 A formed on the surfaces of the leg portions  13 , and continuity is ensured between the first portion  62 B formed on the rear surface of the bridging portion  12  and the second portions  63 B formed on the rear surfaces of the leg portions  13 . 
         [0081]    Yet further, the surfaces of the leg portions  13  include the recessed surface portions  18  on which the second portions  63 A of the first conductive patterns  61 A are formed, and the guard projecting portions  17  projecting further than the recessed surface portions  18 , and the rear surfaces of the leg portions  13  include the recessed surface portions  21  on which the second portions  63 B of the second conductive patterns  61 B are formed, and the guard projecting portions  22  projecting further than the recessed surface portions  21 . Hence, when the leg portions  13  are fitted to the counterpart connectors  101 , the second portions  63 A of the first conductive patterns  61 A and the second portions  63 B of the second conductive patterns  61 B do not slidably contact the members of the counterpart connectors  101 . 
         [0082]    Yet further, the insulating material for the body portion  11  is made of a composite material in which organic metal is mixed in base polymer, and the conductive patterns  61  are formed of metal plating films deposited to the patterns formed by radiating a beam of laser onto the surfaces of the body portion  11 . Therefore, the complex conductive patterns  61  in three-dimension, which are arrayed with a fine pitch can be formed on the surfaces of the intricately-shaped body portion  11 . Even if the body portion  11  receives an external force and is deformed, short-circuits between terminals do not occur as the neighboring conductive patterns  61  do not come into contact with one another. 
         [0083]    Next, a second embodiment of the present invention will be described. The portions having the same structures as the first embodiment are designated by the same reference numerals, and that way the descriptions thereof are omitted. Also, descriptions of the same operations and effects as the first embodiment will be omitted as well for the simplicity sake. 
         [0084]      FIG. 10  is a first perspective view of a relay connector according to a second embodiment of the present invention,  FIG. 11  is a second perspective view of the relay connector according to the second embodiment of the present invention,  FIGS. 12A to 12C  are three-sided views of the relay connector according to the second embodiment of the present invention, in which  FIG. 12A  is a top plan view thereof,  FIG. 12B  is a front view thereof, and  FIG. 12C  is a side view thereof,  FIG. 13  is a bottom view of the relay connector according to the second embodiment of the present invention, and  FIG. 14  is a perspective view illustrating a state where the relay connector according to the second embodiment of the present invention is fitted to counterpart connectors. 
         [0085]    In the connector  1  of the present embodiment, one of the leg portions  13  is divided into two portions, a first leg portion  13 A and a second leg portion  13 B, with respect to a direction of array of the conductive patterns  61 , and are arranged to be offset so that the locations thereof differ from each other with respect to the longitudinal direction of the conductive patterns  61 . Note that the other leg portion  13  is one piece and is not divided. In this case, the bridging portion  12  is divided into two in the array direction of the conductive patterns  61  corresponding to the division of the leg portion  13  into the first leg portion  13 A and the second leg portion  13 B, and includes a shorter portion  12 A and a longer portion  12 B which have different lengths. 
         [0086]    One ends of the shorter portion  12 A and the longer portions  12 B are arranged to form the same straight line, and are located at the same positions with respect to the longitudinal direction of the conductive patterns  61 , so that the leg portion  13  is integrally connected to one ends of both of the shorter portion  12 A and the longer portion  12 B. The other ends of the shorter portion  12 A and the longer portion  12 B are at different locations relative to the longitudinal direction of the conductive patterns  61 , the first leg portion  13 A is integrally connected to the other end of the shorter portion  12 A, and the second leg portion  13 B is integrally connected to the other end of the longer portion  12 B. Therefore, the distance from the leg portion  13 , which is connected to one ends of both shorter portion  12 A and the longer portion  12 B, to the second leg portion  13 B is longer than the distance from the leg portion  13  to the first leg portion  13 A. Also, the first portion  62 A of the first conductive patterns  61 A formed on the surface of the longer portion  12 B and the first portion  62 B of the second conductive patterns  61 B formed on the rear surface of the longer portion  12 B are longer than the first portion  62 A of the first conductive patterns  61 A formed on the surface of the shorter portion  12 A and the first portion  62 B of the second conductive patterns  61 B formed on the rear surface of the shorter portion  12 A. 
         [0087]    Reference numeral  14 A represents a shorter manipulating recessed portion formed in the shorter portion  12 A, and reference numeral  14 B represents a longer manipulating recessed portion formed in the longer portion  12 B. In the example illustrated in the drawings, the shorter manipulating recessed portions  14 A and the longer manipulating recessed portions  14 B are structured to have different sizes to correspond to the shorter portion  12 A and the longer portion  12 B, but the sizes thereof may be the same. 
         [0088]    In the present invention, the leg portion  13 , the first leg portion  13 A and the second leg portion  13 B have different dimensions with respect to the direction of array of the conductive patterns  61  only, and the rest of dimensions and structures thereof are identical. Moreover, the leg portion  13 , the first leg portion  13 A and the second leg portion  13 B have structures similar to the legs portions  13  of the first embodiment. Further, the structure of the portions where the leg portion  13 , the first leg portion  13 A and the second leg portion  13 B are connected to the shorter portion  12 A and the longer portion  12 B is similar to the structure of the portions where the leg portions  13  are connected to the bridging portion  12  in the first embodiment. 
         [0089]    As shown in  FIG. 14 , a counterpart connector  101  to be fitted to the leg portion  13  is mounted on a first substrate  91 A, and a first counterpart connector  101 A and a second counterpart connector  101 B to be fitted to the first leg portion  13 A and the second leg portion  13 B are mounted on a second substrate  91 B. In this case, since the first counterpart connector  101 A and the second counterpart connector  101 B are mounted at locations corresponding to the first leg portion  13 A and the second leg portions  13 B, respectively, the first counterpart connector  101 A and the second counterpart connector  101 B are offset so that the locations thereof differ from each other with respect to the longitudinal direction of the conductive patterns  61 . 
         [0090]    Further, in the present embodiment, the counterpart connector  101 , the first counterpart connector  101 A and the second counterpart connector  101 B have different dimensions from each other with respect to the direction of array of the conductive patterns  61  only, and the rest of the dimensions and structures thereof are identical. In addition, the counterpart connector  101 , the first counterpart connector  101 A and the second counterpart connector  101 B have structures similar to the counterpart connectors  101  of the first embodiment. 
         [0091]    The rest of structures, the methods for manufacturing the conductive patterns  61  and the body portion  11 , how to fit the connector  1  to the counterpart connectors  101 , and so forth are similar to those of the first embodiment, and the descriptions thereof are thus omitted. 
         [0092]    In the present embodiment, such an example was described in which the leg portion  13  and the bridging portion  12  are divided into two in the array direction of the conductive patterns  61 , but the leg portion  13  and the bridging portion  12  can be divided into three or more in the array direction of the conductive patterns  61 . 
         [0093]    Also, in the present invention, the dimensions of the divided portions are approximately the same with respect to the array direction of the conductive patterns  61 , but the ratio of the dimensions of the divided portions with respect to the direction of array of the conductive patterns  61  may be set arbitrarily and optionally. 
         [0094]    Moreover, in the present invention, the example was described where only one of the leg portions  13  is divided and the other leg portion  13  is not divided and is a single piece, but the other leg portion  13  may be divided as well. 
         [0095]    As described above, in the present embodiment, at least one of the leg portions  13  is divided into a plurality of portions with respect to the array direction of the conductive patterns  61 , and the plurality of divided portions are offset so that the locations thereof are different from each other with respect to the longitudinal direction of the conductive patterns  61 . Therefore, the number and locations of the leg portions  13  can be set arbitrarily. Hence, even if the locations of the counterpart connectors  101  to be mounted on the first substrate  91 A and the second substrate  91 B are decided arbitrarily, the leg portions  13  can be arranged at locations corresponding to the locations of the counterpart connectors  101 , and counterpart connectors  101  can be connected to each other by the single connector  1 . 
         [0096]    The present invention is not limited to the above-described embodiments, and may be changed in various ways based on the gist of the present invention, and these changes are not eliminated from the scope of the present invention.

Technology Classification (CPC): 7