Patent Description:
In recent years, attention has been drawn to so-called smart clothes that can obtain user's biological data such as the heart rate and the body temperature only by being worn by the user. Such smart clothes have an electrode disposed at a measurement site and constituted of a flexible conductor, and when a wearable device serving as a measurement device is electrically connected to the electrode, biological data can be transmitted to the wearable device.

The electrode and the wearable device can be interconnected by, for instance, use of a connector connected to the flexible conductor.

However, when the wearable device is situated away from the measurement site, it is necessary to provide an electric path connecting the electrode disposed at the measurement site to the place where the connector is attached, and if such an electric path is formed from a flexible conductor, this causes higher electric resistance and higher cost.

To interconnect an electrode constituted of a flexible conductor and a wearable device by use of an electric wire that has low electric resistance and is inexpensive, it has been desired to develop a small-sized connector connecting the electric wire to the flexible conductor disposed on a garment.

As a connector for connecting an electric wire to a flexible conductor, for instance, <CIT> discloses a connector as shown in <FIG>. This connector includes a first connector <NUM> connected to an end of a substrate <NUM> and a second connector <NUM> attached to tips of electric wires <NUM>, and the electric wires <NUM> can be connected to a flexible conductor of the substrate <NUM> by fitting the second connector <NUM> to the first connector <NUM>.

However, the first connector <NUM> and the second connector <NUM> that are separately attached to the end of the substrate <NUM> and the tips of the electric wires <NUM> need to be fitted to each other in order to connect the electric wires <NUM> to the flexible conductor of the substrate <NUM>, and this causes a larger size of a device; and there is a separable connection portion between the first connector <NUM> and the second connector <NUM>, which impairs the reliability of electric connection.

From <CIT> a connection structure is known which is provided with: conductor exposing parts of the flat wiring material; conductor exposing parts of the flexible printed wiring material; and an overlapping connection means for connecting both exposing parts and to each other. The connection means is so composed as to connect both the exposing parts and with each other by overlaying a folded piece on the outside of the overlapping part of both the exposing parts and formed by superimposing, on the exposing parts with an upper insulating cover member removed, the exposing parts penetrating the folded piece folded back from the conductor tip side of a lower insulating cover member on the exposing part side.

From <CIT> a wiring connection is known, wherein end sections of circuit conductors of each flat cable mutually wiring-connected are exposed respectively, and the flat cables are inserted so that the exposed sides are faced oppositely into a case body. When a short piece-shaped flat-cable small piece is inserted into the case body together with the pressure-welding fitting section of a cover body <NUM> and each circuit conductor of the flat cables and the circuit conductors of the flat-cable small piece are brought into contact, the circuit conductors of the flat cables are wired and connected mutually in a mutually crossed shape through the circuit conductors of the flat-cable small piece.

The present invention has been made to solve the conventional problem as above and aims at providing a connector assembly that can electrically connect a conductor portion of an electric wire to a flexible conductor exposed on a surface of a sheet type conductive member with high reliability while its size can be reduced.

The present invention also aims at providing a connecting method for electrically connecting a conductor portion of an electric wire to a flexible conductor exposed on a surface of a sheet type conductive member.

A connector assembly according to the present invention comprises:.

A connecting method according to the present invention is one for connecting a conductor portion of an electric wire to a flexible conductor exposed on a surface of a sheet type conductive member, the method comprising:.

<FIG> shows a connector assembly according to Embodiment <NUM>. The connector assembly is obtained by connecting conductor portions 31A of a plurality of coated electric wires <NUM> to a sheet type conductive member <NUM> by means of a connector <NUM>.

The connector <NUM> includes a first insulator <NUM> and a second insulator <NUM> each made of an insulating resin material.

The sheet type conductive member <NUM> is obtained by forming a plurality of flexible conductors 21B on a surface of a sheet type insulating base 21A. The flexible conductors 21B are aligned in a predetermined alignment direction, separately form linearly extending patterns, and are exposed on a surface of the sheet type conductive member <NUM>.

The coated electric wires <NUM> are aligned in the predetermined alignment direction as with the flexible conductors 21B of the sheet type conductive member <NUM>, and each extend in parallel to the surface of the sheet type conductive member <NUM> and in a direction perpendicular to the alignment direction. Each coated electric wire <NUM> has a structure in which an outer periphery of the conductor portion 31A is covered with an insulating coating portion 31B. With the connector <NUM>, the conductor portions 31A of the covered electric wires <NUM> are electrically connected to the flexible conductors 21B exposed on the surface of the sheet type conductive member <NUM>. The conductor portion 31A of the coated electric wire <NUM> may be either a so-called solid wire constituted of one conductor or a so-called stranded wire constituted of plural conductors being stranded.

For convenience, the sheet type conductive member <NUM> is defined as extending along an XY plane, the predetermined alignment direction of the flexible conductors 21B and the coated electric wires <NUM> is referred to as "X direction," the direction in which each coated electric wire <NUM> extends toward the connector <NUM> is referred to as "+Y direction," and the direction orthogonal to an XY plane is referred to as "Z direction.

<FIG> shows an assembly view of the connector assembly according to Embodiment <NUM>. The sheet type conductive member <NUM> is disposed on the +Z direction side of the first insulator <NUM>, and the second insulator <NUM> is disposed on the +Z direction side of the sheet type conductive member <NUM>.

In addition, the coated electric wires <NUM> are each disposed in such a position as to extend in the Z direction on the -Y direction side of the sheet type conductive member <NUM>.

The first insulator <NUM> includes a flat plate portion 12A of rectangular shape extending along an XY plane, and a first retaining surface 12B of planar shape recessed in the -Z direction and facing in the +Z direction is formed at a +Y direction-side portion of the flat plate portion 12A. In addition, electric wire accommodating grooves 12C and 12D are formed on a -Y direction-side portion of the flat plate portion 12A, the electric wire accommodating grooves 12C extending in the Y direction from the first retaining surface 12B to a -Y directional end of the flat plate portion 12A, the electric wire accommodating grooves 12D being each disposed adjacent to the corresponding electric wire accommodating groove 12C on the +X direction side of the electric wire accommodating groove 12C, extending in the Y direction from the first retaining surface 12B, and terminating in front of the -Y directional end of the flat plate portion 12A.

These electric wire accommodating grooves 12C and 12D are opened toward the +Z direction and each have a groove width and a groove depth that allow the insulating coating portion 31B of the coated electric wire <NUM> to be accommodated in the grooves 12C and 12D. The adjacent electric wire accommodating grooves 12C and 12D form a pair, and a plurality of the pairs of electric wire accommodating grooves 12C and 12D corresponding to the coated electric wires <NUM> are formed in the flat plate portion 12A.

Further, the flat plate portion 12A is provided with a plurality of bosses 12E projecting in the +Z direction.

The second insulator <NUM> has a flat plate portion 13A of rectangular shape extending along an XY plane, and as with the first insulator <NUM>, a second retaining surface of planar shape (not shown) recessed in the +Z direction and facing in the -Z direction is formed at a +Y direction-side portion of the flat plate portion 13A. In addition, electric wire accommodating grooves 13C and electric wire accommodating grooves not shown are formed at a -Y direction-side portion and in a surface, facing in the -Z direction, of the flat plate portion 31A, the electric wire accommodating grooves 13C extending in the Y direction from the second retaining surface to a -Y directional end of the flat plate portion 13A, the electric wire accommodating grooves not shown being each disposed adjacent to the corresponding electric wire accommodating groove 13C on the +X direction side of the electric wire accommodating groove 13C, extending in the Y direction from the second retaining surface, and terminating in front of the -Y directional end of the flat plate portion 13A.

These electric wire accommodating grooves 13C and electric wire accommodating grooves not shown correspond to the electric wire accommodating grooves 12C and 12D of the first insulator <NUM>, are opened toward the -Z direction, and each have a groove width and a groove depth that allow the insulating coating portion 31B of the coated electric wire <NUM> to be accommodated in the groove 13C and the groove not shown.

Further, the flat plate portion 13A is provided with a plurality of fixing holes 13E penetrating the flat plate portion 13A in the Z direction. The fixing holes 13E separately correspond to the bosses 12E of the first insulator <NUM>.

The coated electric wires <NUM> in assembling the connector assembly are each disposed in such a position as to extend in the Z direction such that a tip portion P1 faces in the +Z direction and that a base end portion P2 faces in the -Z direction. In addition, a conductor exposed portion P3, in which the conductor portion 31A is exposed over a predetermined Z directional length by removing the insulating coating portion 31B, is formed at a position away from the tip portion P1 of each coated electric wire <NUM> by a predetermined distance in the -Z direction.

As shown in <FIG>, the sheet type conductive member <NUM> includes a first sheet portion <NUM> and a second sheet portion <NUM> disposed on the -Y direction side of the first sheet portion <NUM>. A retained portion 22A is disposed at a -Y direction-side portion of the first sheet portion <NUM>, and an extension portion 22B extending toward the +Y direction is disposed on the +Y direction side of the retained portion 22A. The second sheet portion <NUM> is joined to the retained portion 22A of the first sheet portion <NUM> via a folding-back line L extending in the X direction. The second sheet portion <NUM>, the retained portion 22A, and the extension portion 22B are integrally formed continuously in the Y direction.

The flexible conductors 21B exposed on the surface of the sheet type conductive member <NUM> on the +Z direction side are each disposed continuously from the second sheet portion <NUM> to the retained portion 22A and the extension portion 22B of the first sheet portion <NUM> beyond the folding-back line L. Each flexible conductor 21B has an electric wire connecting region 21C of substantially rectangular shape at a position overlapping the folding-back line L, and a pair of electric wire inserting holes 21D and 21E penetrating the sheet type conductive member <NUM> are separately formed on opposite sides in the X direction of the electric wire connecting region 21C on the folding-back line L. The pair of electric wire inserting holes 21D and 21E are each formed from a long hole that is sized so as to allow the insulating coating portion 31B of the coated electric wire <NUM> to pass through it. In addition, the pair of electric wire inserting holes 21D and 21E are separately situated to be in contact with the electric wire connecting region 21C on the opposite sides in the X direction of the electric wire connecting region 21C, and the flexible conductor 21B forming the electric wire connecting region 21C is disposed between the pair of electric wire inserting holes 21D and 21E.

A plurality of the pairs of electric wire inserting holes 21D and 21E as above are formed in the sheet type conductive member <NUM> to correspond to the coated electric wires <NUM>.

Further, a plurality of through-holes 21F corresponding to the plurality of bosses 12E of the first insulator <NUM> are formed in the retained portion 22A and the second sheet portion <NUM> of the sheet type conductive member <NUM>. One through-hole 21F formed in the retained portion 22A and another through hole 21F formed in the second sheet portion <NUM> are arranged symmetrically with respect to the folding-back line L.

When the connector assembly is assembled, first, as shown in <FIG>, each of the coated electric wires <NUM> is passed through the electric wire inserting hole 21D that is one of the corresponding pair of electric wire inserting holes 21D and 21E of the sheet type conductive member <NUM>. At this time, the coated electric wire <NUM> is disposed such that a part thereof from the conductor exposed portion P3 to the tip portion P1 is situated on the +Z direction side of the sheet type conductive member <NUM> and that a part thereof on the base end portion P2 side of the conductor exposed portion P3 is situated on the -Z direction side of the sheet type conductive member <NUM>.

Next, the conductor exposed portion P3 is bent, and the tip portion P1 of each of the coated electric wires <NUM> is passed through the electric wire inserting hole 21E that is the other of the corresponding pair of the electric wire inserting holes 21D and 21E from the +Z direction. When each of the coated electric wires <NUM> is sequentially passed through the pair of electric wire inserting holes 21D and 21E in this manner, as shown in <FIG>, the tip portion P1 of each of the coated electric wires <NUM> is situated on the -Z direction side of the sheet type conductive member <NUM>, and the conductor portion 31A exposed at the conductor exposed portion P3 is situated between the pair of electric wire inserting holes 21D and 21E on the surface of the sheet type conductive member <NUM> on the +Z direction side.

By folding back, in this state, the second sheet portion <NUM> of the sheet type conductive member <NUM> along the folding-back line L extending in the X direction that is the alignment direction of the coated electric wires <NUM> and the flexible conductors 21B, the second sheet portion <NUM> is rotated by <NUM> degrees around the folding-back line L so as to be superposed on the retained portion 22A of the first sheet portion <NUM> as shown in <FIG>. At this time, with folding back of the second sheet portion <NUM>, the coated electric wires <NUM> passed through the plurality of pairs of electric wire inserting holes 21D and 21E are rotated by <NUM> degrees around the folding-back line L, and the tip portion P1 and the base end portion P2 of each of the coated electric wires <NUM> extend from the sheet type conductive member <NUM> toward the -Y direction.

Since the through-holes 21F separately formed in the retained portion 22A and the second sheet portion <NUM> are arranged symmetrically with respect to the folding-back line L, when the second sheet portion <NUM> is folded back around the folding-back line L, the through-hole 21F formed in the second sheet portion <NUM> is superposed on the through-hole 21F formed in the retained portion 22A.

Then, with the bosses 12E of the first insulator <NUM> being passed through the through-holes 21F of the sheet type conductive member <NUM> from the -Z direction and further passed through the fixing holes 13E of the second insulator <NUM>, the sheet type conductive member <NUM> is sandwiched between the first insulator <NUM> and the second insulator <NUM> as shown in <FIG>. Consequently, the retained portion 22A of the first sheet portion <NUM> of the sheet type conductive member <NUM> faces the first retaining surface 12B of the first insulator <NUM>, and the second sheet portion <NUM> superposed on the retained portion 22A faces the second retaining surface of the second insulator <NUM>.

Tips of the bosses 12E projecting on the +Z direction side of the first insulator <NUM> are then thermally deformed, whereby the first insulator <NUM> and the second insulator <NUM> are fixed to each other to form the connector <NUM>. Thus, the assembling operation of the connector assembly shown in <FIG> is completed.

<FIG> shows the inside of the connector assembly. Since the electric wire connecting region 21C of the flexible conductor 21B is formed between the pair of the electric wire inserting holes 21D and 21E, with folding back of the second sheet portion <NUM>, the flexible conductor 21B forming the electric wire connecting region 21C is folded in two parts, and the conductor portion 31A exposed at the conductor exposed portion P3 situated between the pair of electric wire inserting holes 21D and 21E is sandwiched between the two parts of the flexible conductor 21B thus folded as shown in <FIG>. In this manner, the flexible conductor 21B makes contact with the conductor portion 31A of the coated electric wire <NUM> with predetermined contact pressure and is electrically connected to the conductor portion 31A.

Similarly, the plurality of flexible conductors 21B are electrically connected separately to the conductor portions 31A of the plurality of coated electric wires <NUM>.

As shown in <FIG>, the retained portion 22A of the first sheet portion <NUM> and the second sheet portion <NUM> of the sheet type conductive member <NUM> being superposed on each other are sandwiched between the first retaining surface 12B of the first insulator <NUM> and the second retaining surface 13B of the second insulator <NUM>.

In addition, as shown <FIG>, the tip portion P1 of the coated electric wire <NUM> projects in the -Y direction from the electric wire inserting hole 21E of the sheet type conductive member <NUM> and is accommodated in the electric wire accommodating groove 12D of the first insulator <NUM> and the electric wire accommodating groove not shown of the second insulator <NUM> in the connector <NUM>.

On the other hand, the part of the coated electric wire <NUM> on the base end portion P2 side projects in the -Y direction from the electric wire inserting hole 21D of the sheet type conductive member <NUM> and is accommodated in the electric wire accommodating groove 12C of the first insulator <NUM> and the electric wire accommodating groove 13C of the second insulator <NUM> and drawn from the connector <NUM> in the -Y direction as shown in <FIG>.

According to Embodiment <NUM>, the conductor portion 31A is sandwiched between the two parts of the flexible conductor 21B thus folded, thereby enabling to achieve a connector assembly that is small, specifically, thin, while electrically connecting the conductor portion 31A of the coated electric wire <NUM> to the flexible conductor 21B exposed on the surface of the sheet type conductive member <NUM> with high reliability.

<FIG> shows an assembly view of the connector assembly according to Embodiment <NUM>.

The first insulator <NUM> has the same configuration as that of the first insulator <NUM> used in Embodiment <NUM>. That is, the second insulator <NUM> includes a flat plate portion 42A of rectangular shape extending along an XY plane, and the first retaining surface 12B facing in the +Z direction is formed at a +Y direction-side portion of the flat plate portion 42A. A plurality of electric wire accommodating grooves 42C and 42D extending to the inside of the first retaining surface 12B are formed at a -Y direction-side portion of the flat plate portion 42A as with the electric wire accommodating grooves 12C and 12D of the first insulator <NUM>. The electric wire accommodating grooves 42C and 42D each have a groove width and a groove depth that allow the insulating coating portion 31B of the coated electric wire <NUM> to be accommodated in the grooves 42C and 42D.

In addition, the flat plate portion 42A is provided with the plurality of bosses 12E.

The second insulator <NUM> has the same configuration as that of the second insulator <NUM> used in Embodiment <NUM>. That is, the second insulator <NUM> includes a flat plate portion 43A of rectangular shape extending along an XY plane, and a second retaining surface (not shown) facing in the -Z direction is formed at a +Y direction-side portion of the flat plate portion 43A. In addition, a plurality of electric wire accommodating grooves 43C and a plurality of electric wire accommodating grooves (not shown) corresponding to the electric wire accommodating grooves 42C and 42D of the first insulator <NUM> are formed at a -Y direction-side portion and in the surface, facing in the -Z direction, of the flat plate portion 43A. The electric wire accommodating grooves 43C and the electric wire accommodating groove not shown each have a groove width and a groove depth that allow the insulating coating portion 31B of the coated electric wire <NUM> to be accommodated in the groove 43C and the groove not shown.

In addition, the flat plate portion 43A is provided with the plurality of fixing holes 13E.

The sheet type conductive member <NUM> is obtained by forming the plurality of flexible conductors 21B on the surface of the sheet type insulating base 21A as with the sheet type conductive member <NUM> in Embodiment <NUM>.

The coated electric wires <NUM> herein have the same configuration as that of the coated electric wires <NUM> used in Embodiment <NUM> except that the coated electric wires <NUM> herein each have the conductor exposed portion P3 longer in the Z direction than the conductor exposed portion P3 in the coated electric wire <NUM> used in Embodiment <NUM>.

As shown in <FIG>, the sheet type conductive member <NUM> includes a first sheet portion <NUM> and a second sheet portion <NUM> disposed on the -Y direction side of the first sheet portion <NUM>, a retained portion 52A is disposed at a -Y direction-side portion of the first sheet portion <NUM>, and an extension portion 52B extending toward the +Y direction is formed on the +Y direction side of the retained portion 52A. The second sheet portion <NUM> is joined to the retained portion 52A of the first sheet portion <NUM> via the folding-back line L extending in the X direction.

The flexible conductors 21B are formed only on a surface of the first sheet portion <NUM> on the +Z direction side and are not formed in the second sheet portion <NUM>.

Each flexible conductor 21B extends in the Y direction and is provided at its -Y directional end with an electric wire connecting region 51C of substantially rectangular shape disposed at the retained portion 52A. A pair of electric wire inserting holes 51D and 51E penetrating the sheet type conductive member <NUM> are formed on opposite sides in the X direction of the electric wire connecting region 51C near the folding-back line L. The pair of electric wire inserting holes 51D and 51E are disposed at positions inclined with respect to the folding-back line L, i.e., Y directional positions different from each other, and are each formed from a round hole that is sized so as to allow the insulating coating portion 31B of the coated electric wire <NUM> to pass through it.

The pair of electric wire inserting holes 51D and 51E are each sized to allow the insulating coating portion 31B of the coated electric wire <NUM> to pass through it. In addition, the pair of electric wire inserting holes 51D and 51E are situated to be in contact with the electric wire connecting region 51C on the opposite sides in the X direction of the electric wire connecting region 51C, and the flexible conductor 21B forming the electric wire connecting region 51C is disposed between the pair of electric wire inserting holes 51D and 51E.

A plurality of the pairs of electric wire inserting holes 51D and 51E as above are formed in the sheet type conductive member <NUM> to correspond to the coated electric wires <NUM>.

Further, the retained portion 52A and the second sheet portion <NUM> of the sheet type conducive member <NUM> are provided with the plurality of through-holes 21F.

When the connector assembly is assembled, first, as shown in <FIG>, each of the coated electric wires <NUM> is passed through the electric wire inserting hole 51D of the corresponding pair of the electric wire inserting holes 51D and 51E of the sheet type conductive member <NUM>. At this time, the coated electric wire <NUM> is disposed such that a part thereof from the conductor exposed portion P3 to the tip portion P1 is situated on the +Z direction side of the sheet type conductive member <NUM> and that a part thereof on the base end portion P2 side of the conductor exposed portion P3 is situated on the -Z direction side of the sheet type conductive member <NUM>.

Next, the conductor exposed portion P3 is bent, and the tip portion P1 of each of the coated electric wires <NUM> is passed through the electric wire inserting hole 51E that is the other of the corresponding pair of electric wire inserting holes 51D and 51E from the +Z direction. When each of the coated electric wires <NUM> is sequentially passed through the corresponding pair of electric wire inserting holes 51D and 51E in this manner, as shown in <FIG>, the tip portion P1 of each of the coated electric wires <NUM> is situated on the -Z direction side of the sheet type conductive member <NUM>, and the conductor portion 31A exposed at the conductor exposed portion P3 is situated between the pair of electric wire inserting holes 51D and 51E on the surface of the sheet type conductive member <NUM> on the +Z direction side.

By folding back, in this state, the second sheet portion <NUM> of the sheet type conductive member <NUM> along the folding-back line L extending in X direction, as shown in <FIG>, the second sheet portion <NUM> is rotated by <NUM> degrees around the folding-back line L so as to be superposed on the retained portion 52A of the first sheet portion <NUM>. At this time, with folding back of the second sheet portion <NUM>, the coated electric wires <NUM> passed through the plurality of pairs of electric wire inserting holes 51D and 51E are rotated by <NUM> degrees around the folding-back line L, and the tip portion P1 and the base end portion P2 of each of the coated electric wires <NUM> extend from the sheet type conductive member <NUM> toward the -Y direction.

Thereafter, with the bosses 12E of the first insulator <NUM> being separately passed through the through-holes 21F of the sheet type conductive member <NUM> from the -Z direction and further passed through the fixing holes 13E of the second insulator <NUM>, the sheet type conductive member <NUM> is sandwiched between the first insulator <NUM> and the second insulator <NUM> as shown in <FIG>.

Tips of the bosses 12E projecting on the +Z direction side of the second insulator <NUM> are then thermally deformed, whereby the first insulator <NUM> and the second insulator <NUM> are fixed to each other to form the connector <NUM>. Thus, the assembling operation of the connector assembly shown in <FIG> is completed.

<FIG> shows the inside of the connector assembly. Since the electric wire connecting region 51C of the flexible conductor 21B is formed between the pair of electric wire inserting holes 51D and 51E, the conductor portion 31A exposed at the conductor exposed portion P3 situated between the pair of electric wire inserting holes 51D and 51E is disposed on the electric wire connecting region 51C, and as shown in <FIG>, with folding back of the second sheet portion <NUM>, the retained portion 52A of the first sheet portion <NUM> and the second sheet portion <NUM> being superposed on each other are sandwiched between the first retaining surface 42B of the first insulator <NUM> and the second retaining surface 43B of the second insulator <NUM>. In this manner, the flexible conductor 21B forming the electric wire connecting region 51C makes contact with the conductor portion 31A of the coated electric wire <NUM> with predetermined contact pressure and is electrically connected to the conductor portion 31A.

In addition, as shown in <FIG>, the tip portion P1 of the coated electric wire <NUM> projects in the -Y direction from the electric wire inserting hole 51E of the sheet type conductive member <NUM> and is accommodated in the electric wire accommodating groove 42D of the first insulator <NUM> and the electric wire accommodating groove 43D of the second insulator <NUM> in the connector <NUM>.

On the other hand, the part of the coated electric wire <NUM> on the base end portion P2 side projects in the -Y direction from the electric wire inserting hole 51D of the sheet type conductive member <NUM> and is accommodated in the electric wire accommodating groove 42C of the first insulator <NUM> and the electric wire accommodating groove 43C of the second insulator <NUM> and drawn from the connector <NUM> in the -Y direction as shown in <FIG>.

Also in Embodiment <NUM>, the conductor portion 31A exposed at the conductor exposed portion P3 of the coated electric wire <NUM> makes contact with the electric wire connecting region 51C of the corresponding flexible conductor 21B, thereby enabling to achieve a connector assembly that is small, specifically, thin, while electrically connecting the conductor portion 31A of the coated electric wire <NUM> to the flexible conductor 21B exposed on the surface of the sheet type conductive member <NUM> with high reliability.

In addition, since the pair of electric wire inserting holes 51D and 51E of the sheet type conductive member <NUM> are disposed at the Y directional positions different from each other, the conductor portion 31A situated between the electric wire inserting holes 51D and 51E makes contact with the flexible conductor 21B over a distance longer than that in Embodiment <NUM>, thereby improving the reliability of electrical connection.

Further, in each of the plurality of pairs of the electric wire inserting holes 51D and 51E of the sheet type conductive member <NUM>, the electric wire inserting holes 51D and 51E are disposed at the positions inclined with respect to the folding-back line L, so that the conductor portions 31A of the adjacent coated electric wires <NUM> are disposed with a distance therebetween in the Y direction, whereby short-circuit between the conductor portions 31A can be effectively prevented. In addition, the alignment pitch in the X direction of the coated electric wires <NUM> can also be narrowed.

As with the first insulator <NUM> used in Embodiment <NUM>, the first insulator <NUM> includes a flat plate portion 62A of rectangular shape extending along an XY plane, and the first retaining surface 12B facing in the +Z direction is formed at a +Y direction-side portion of the flat plate portion 62A. A plurality of electric wire accommodating grooves 62C are formed at a -Y direction-side portion of the flat plate portion 62A to extend in the Y direction from the first retaining surface 12B and terminate in front of a -Y directional end of the flat plate portion 62A. The electric wire accommodating grooves 62C each have a groove width and a groove depth that allow the conductor portion 31A of the coated electric wire <NUM> to be accommodated in the groove 62C.

In addition, the flat plate portion 62A is provided with the plurality of bosses 12E.

Further, a plurality of ribs 62F are formed on the first retaining surface 12B to extend in the X direction and project in the +Z direction.

As with the second insulator <NUM> used in Embodiment <NUM>, the second insulator <NUM> includes a flat plate portion 63A of rectangular shape extending along an XY plane, and a second retaining surface (not shown) facing in the -Z direction is formed at a +Y direction-side portion of the flat plate portion 63A. In addition, a plurality of electric wire accommodating grooves (not shown) corresponding to the plurality of electric wire accommodating grooves 62C of the first insulator <NUM> are formed at a -Y direction-side portion and in a surface, facing in the -Z direction, of the flat plate portion 63A. These electric wire accommodating grooves not shown each have a groove width and a groove depth that allow the conductor portion 31A of the coated electric wire <NUM> to be accommodated in the groove not shown.

In addition, the flat plate portion 63A is provided with the plurality of fixing holes 13E.

Further, ribs (not shown) are formed on the second retaining surface to extend in the X direction and project in the -Z direction.

The coated electric wires <NUM> in assembling the connector assembly are each disposed in such a position as to extend in the Z direction such that the tip portion P1 faces in the -Z direction and that the base end portion P2 faces in the +Z direction. In addition, the conductor exposed portion P3 is formed to extend from the tip portion P1 of each of the coated electric wires <NUM> in the +Z direction over a predetermined Z directional length. At the conductor exposed portion P3, the insulating coating portion 31B is removed so that the conductor portion 31A is exposed.

As shown in <FIG>, the sheet type conductive member <NUM> includes a first sheet portion <NUM> and a second sheet portion <NUM> disposed on the -Y direction side of the first sheet portion <NUM>, a retained portion 72A is disposed in a -Y direction-side portion of the first sheet portion <NUM>, and an extension portion 72B is formed on the +Y direction side of the retained portion 72A to extend toward the +Y direction. The second sheet portion <NUM> is joined to the retained portion 72A of the first sheet portion <NUM> via the folding-back line L extending in the X direction.

The flexible conductors 21B are each disposed continuously from the second sheet portion <NUM> to the retained portion 72A and the extension portion 72B of the first sheet portion <NUM> beyond the folding-back line L.

Each flexible conductor 21B has the electric wire connecting region 21C of substantially rectangular shape at a position overlapping the folding-back line L, and one electric wire inserting hole 71D penetrating the sheet type conductive member <NUM> is formed at a center part of the electric wire connecting region 21C situated on the folding-back line L.

In addition, one electric wire guiding hole 71E is formed on the +X direction side of the electric wire connecting region 21C to penetrate the sheet type conductive member <NUM>. The electric wire guiding hole 71E extends in the Y direction from the second sheet portion <NUM> to the retained portion 72A beyond the folding-back line L.

Further, a slit type communication opening portion 71F penetrating the sheet type conductive member <NUM> is formed between the electric wire inserting hole 71D and the electric wire guiding hole 71E such that the electric wire inserting hole 71D and the electric wire guiding hole 71E communicate with each other in the X direction along the folding-back line L.

As shown in <FIG>, the electric wire inserting hole 71D is formed from a round hole having a size corresponding to the diameter of the conductor portion 31A of the coated electric wire <NUM>, specifically, a diameter S1 slightly larger than the diameter of the conductor portion 31A. The electric wire guiding hole 71E is formed from a long hole having a width S2 substantially equal to the diameter S1 of the electric wire inserting hole 71D. The communication opening portion 71F has an opening width S3 having a dimension smaller than the diameter of the conductor portion 31A of the coated electric wire <NUM>.

The communication opening portion 71F is connected to the electric wire guiding hole 71E, whereby a T-shaped opening is formed in the sheet type conductive member <NUM> so as to be in contact with a pair of corner portions <NUM> constituted of the sheet type conductive member <NUM>.

When the connector assembly is assembled, first, as shown in <FIG>, the conductor portion 31A of the conductor exposed portion P3 formed at the tip portion P1 of each of the coated electric wires <NUM> is passed through the corresponding electric wire guiding hole 71E of the sheet type conductive member <NUM> from the +Z direction. At this time, the conductor portion 31A is passed through the electric wire guiding hole 71E such that -Z and +Z direction-side portions of the conductor exposed portion P3 are situated on the -Z and +Z direction sides of the sheet type conductive member <NUM>, respectively.

Next, as shown in <FIG>, each of the coated electric wires <NUM> is slid in the -X direction relatively to the sheet type conductive member <NUM> along the corresponding communication opening portion 71F, whereby the conductor portion 31A exposed at the conductor exposed portion P3 of each of the coated electric wires <NUM> is passed through the corresponding electric wire inserting hole 71D.

At this time, while the communicating opening hole 71F has the opening width S3 having the dimension smaller than the diameter of the conductor portion 31A, part of the sheet type conductive member <NUM> around the communicating opening hole 71E is elastically bent, whereby the conductive portion 31A can be relatively slid to the electric wire inserting hole 71D.

By folding back, in this state, the second sheet portion <NUM> of the sheet type conductive member <NUM> along the folding-back line L extending in the X direction, the second sheet portion <NUM> is rotated by <NUM> degrees around the folding-back line L so as to be superposed on the retained portion 72A of the first sheet portion <NUM> as shown in <FIG>.

With folding back of the second sheet portion <NUM>, the coated electric wires <NUM> having the conductor portions 31A passed through the electric wire inserting holes 71D are rotated by <NUM> degrees around the folding-back line L, the tip portion P1 of each of the coated electric wires <NUM> projects from the sheet type conductive member <NUM> toward the -Y direction, and the base end portion P2 extends from the sheet type conductive member <NUM> toward the +Y direction.

<FIG> shows the inside of the connector assembly. Since the flexible conductor 21B has the electric wire connecting region 21C of substantially rectangular shape at the position overlapping the folding-back line L, with the second sheet portion <NUM> being folded back, the flexible conductor 21B forming the electric wire connecting region 21C is folded in two parts, and the conductor portion 31A exposed at the conductor exposed portion P3 of the coated electric wire <NUM> passed through the electric wire inserting hole 71D is sandwiched between the two parts of the flexible conductor 21B thus folded as shown in <FIG>. In this manner, the flexible conductor 21B forming the electric wire connecting region 21C makes contact with the conductor portion 31A of the coated electric wire <NUM> with predetermined contact pressure and is electrically connected to the conductor portion 31A.

The retained portion 72A of the first sheet portion <NUM> and the second sheet portion <NUM> of the sheet type conductive member <NUM> being superposed on each other are sandwiched between the first retaining surface 62B of the first insulator <NUM> and the second retaining surface 63B of the second insulator <NUM>, and the flexible conductor 21B forming the electric wire connecting region 21C is tightly attached to the conductor portion 31A by means of the ribs 62F formed on the first retaining surface 62B and the ribs 63F formed on the second retaining surface 63B. This improves the reliability of electric connection between the flexible conductor 21B and the conductor portion 31A.

In addition, the conductor portion 31A exposed at the tip portion P1 of the coated electric wire <NUM> projecting from the sheet type conductive member <NUM> toward the -Y direction is accommodated in the electric wire accommodating groove 62C of the first insulator <NUM> and the electric wire accommodating groove 63C of the second insulator <NUM> in the connector <NUM>.

On the other hand, a part of the coated electric wire <NUM> on the base end portion P2 side along with the sheet type conductive member <NUM> is drawn from the connector <NUM> in the +Y direction. At this time, as shown in <FIG>, the conductor portion 31A is bent in the Z direction at a +Y directional end of the connector <NUM>, whereby the insulating coating portion 31B of the coated electric wire <NUM> is situated on a +Z directional surface of the extension portion 72B of the sheet type conductive member <NUM>. That is, both the insulating coating portion 31B of the coated electric wire <NUM> and the extension portion 72B of the sheet type conductive member <NUM> can extend in the +Y direction without interfering with each other in the Z direction.

Thus, also in Embodiment <NUM>, the conductor portion 31A exposed at the conductor exposed portion P3 of the coated electric wire <NUM> makes contact with the electric wire connecting region 21C of the corresponding flexible conductor 21B, thereby enabling to achieve a connector assembly that is small, specifically, thin, while electrically connecting the conductor portion 31A of the coated electric wire <NUM> to the flexible conductor 21B exposed on the surface of the sheet type conductive member <NUM> with high reliability.

In addition, since the electric wire guiding hole 71E constituted of a long hole is formed to be connected to the electric wire inserting hole 71D of the sheet type conductive member <NUM> via the communication opening portion 71F, the conductor portion 31A of the coated electric wire <NUM> is passed through the electric wire guiding hole 71E and then slid along the communication opening portion 71F, whereby the conductor portion 31A can be passed through the electric wire inserting hole 71D, thus improving the operability in assembling the connector assembly.

The first insulator <NUM> is obtained by forming a plurality of electric wire accommodating grooves 82C in which the insulating coating portions 31B of the coated electric wires <NUM> are accommodated, instead of the plurality of electric wire accommodating grooves 62C in which the conductor portions 31A of the coated electric wires <NUM> are accommodated, in the flat plate portion 62A in the first insulator <NUM> used in Embodiment <NUM>, and otherwise has the same configuration as the first insulator <NUM> in Embodiment <NUM>.

The second insulator <NUM> is obtained by forming a plurality of electric wire accommodating grooves (not shown) in which the insulating coating portions 31B of the coated electric wires <NUM> are accommodated, instead of the plurality of electric wire accommodating grooves in which the conductor portions 31A of the coated electric wires <NUM> are accommodated, in the flat plate portion 63A in the second insulator <NUM> used in Embodiment <NUM>, and otherwise has the same configuration as the second insulator <NUM> in Embodiment <NUM>.

The sheet type conductive member <NUM> herein is the same as that used in Embodiment <NUM>.

Also in Embodiment <NUM>, as with Embodiment <NUM>, the coated electric wires <NUM> in assembling the connector assembly are each disposed in such a position as to extend in the Z direction such that the tip portion P1 faces in the -Z direction and that the base end portion P2 faces in the +Z direction. However, the insulating coating portion 31B is not removed and remains at the tip portion P1 of each coated electric wire <NUM>, and the conductor exposed portion P3, in which the conductor portion 31A is exposed over a predetermined Z directional length by removing the insulating coating portion 31B, is formed at a position away from the tip portion P1 in the +Z direction by a predetermined distance.

When the connector assembly is assembled, as with Embodiment <NUM>, first, the tip portion P1 of each of the coated electric wires <NUM> is passed through the corresponding electric wire guiding hole 71E of the sheet type conductive member <NUM> from the +Z direction. At this time, since the T-shaped opening is formed by connecting the communication opening portion 71F to the electric wire guiding hole 71E of the sheet type conductive member <NUM> as shown in <FIG>, when the tip portion P1 of the coated electric wire <NUM> having the insulating coating portion 31B having the diameter larger than that of the conductor portion 31A is pressed against the electric wire guiding hole 71E, the pair of corners <NUM> contacting the T-shaped opening are bent so that the tip portion P1 of the coated electric wire <NUM> is passed through the electric wire guiding hole 71E, and the conductor portion 31A exposed at the conductor exposed portion P3 can be situated at the electric wire guiding hole 71E.

As with Embodiment <NUM>, the conductor portion 31A of the conductor exposed portion P3 is then slid from the electric wire guiding hole 71E to the electric wire inserting hole 71D along the communication opening portion 71F, and the second sheet portion <NUM> of the sheet type conductive member <NUM> is folded back along the folding-back line L. In this manner, the tip portion P1 of each of the coated electric wires <NUM> projects from the sheet type conductive member <NUM> toward the -Y direction.

Thereafter, the bosses 12E of the first insulator <NUM> are passed through the through-holes 21F of the sheet type conductive member <NUM> from the -Z direction and further passed through the fixing holes 13E of the second insulator <NUM>, and the first insulator <NUM> and the second insulator <NUM> are fixed to each other to form the connector <NUM>. Thus, the assembling operation of the connector assembly shown in <FIG> is completed.

As shown in <FIG>, as with Embodiment <NUM>, the conductor portion 31A exposed at the conductor exposed portion P3 of the coated electric wire <NUM> is sandwiched between the two parts of the flexible conductor 21B thus folded. The flexible conductor 21B is then tightly attached and electrically connected to the conductor portion 31A by the ribs 62F formed on the first retaining surface 62B of the first insulator <NUM> and the ribs 63F formed on the second retaining surface 63B of the second insulator <NUM>.

The tip portion P1 of the coated electric wire <NUM> projecting from the sheet type conductive member <NUM> toward the -Y direction is accommodated in the electric wire accommodating groove 82C of the first insulator <NUM> and the electric wire accommodating groove 83C of the second insulator <NUM> in the connector <NUM>.

In addition, since the conductor portion 31A at the tip portion P1 of the coated electric wire <NUM> projecting from the sheet type conductive member <NUM> toward the -Y direction is covered with the insulating coating portion 31B, short-circuit between the conductor portions 31A of the adjacent coated electric wires <NUM> can be prevented. Further, even when the conductor portion 31A is formed from a so-called stranded wire constituted of plural conductors being stranded, the insulating coating portion 31B covering the tip portion P1 of the coated electric wire <NUM> prevents a tip of the stranded wire from spreading, so that not only short-circuit due to the spread conductors is prevented, but also the handleability of the coated electric wire <NUM> is improved.

Instead of covering, with the insulating coating portion 31B, the conductor portion 31A at the tip portion P1 of the coated electric wire <NUM> projecting from the sheet type conductive member <NUM> toward the -Y direction, the connector assembly may be configured such that the conductor portion 31A exposed by removing the insulating coating portion 31B projects from the sheet type conductive member <NUM> toward the -Y direction as the tip portion P1 and that the outer periphery of the projecting conductor portion 31A is covered with an insulating tape <NUM> as shown in <FIG>; even in this configuration, short-circuit of the conductor portions 31A of the adjacent coated electric wires <NUM> can be prevented.

In this case, as shown in <FIG>, it is necessary to use a first insulator <NUM> and a second insulator <NUM> each having a structure in which the conductor portions 31A covered with the insulating tape <NUM> can be accommodated.

While the three flexible conductors 21B exposed on the surface of the sheet type conductive member <NUM>, <NUM>, <NUM> are electrically connected to the conductor portions 31A of the three coated electric wires <NUM> in Embodiments <NUM> to <NUM> above, the invention is not limited thereto, and one or more flexible conductor(s) 21B can be electrically connected to a conductor portion(s) 31A of one or more coated electric wire(s) <NUM> in a similar manner.

Claim 1:
A connector assembly comprising:
a sheet type conductive member (<NUM>, <NUM>, <NUM>) having a flexible conductor (21B) exposed on a surface of the sheet type conductive member;
an electric wire (<NUM>) having a conductor portion (31A); and
a connector (<NUM>, <NUM>, <NUM>, <NUM>) connecting the conductor portion to the flexible conductor,
wherein the connector includes a first insulator (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having a first retaining surface (12B) and a second insulator (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having a second retaining surface (13B) facing the first retaining surface,
wherein the sheet type conductive member includes a first sheet portion (<NUM>, <NUM>, <NUM>) having a retained portion (22A, 52A, 72A) disposed to face the first retaining surface, a second sheet portion (<NUM>, <NUM>, <NUM>) joined to the retained portion via a folding-back line (L) and disposed to face the second retaining surface with the second sheet portion being folded back onto the retained portion along the folding-back line, and at least one electric wire inserting hole (21D, 21E, 51D, 51E, 71D) formed in at least one of the retained portion and the second sheet portion and penetrating the sheet type conductive member,
wherein the flexible conductor is exposed at least on a surface of the retained portion,
wherein the conductor portion of the electric wire is passed through the electric wire inserting hole and disposed between the retained portion and the second sheet portion, and
wherein the first insulator and the second insulator are fixed with each other such that the retained portion and the second sheet portion are superposed on each other and disposed between the first retaining surface and the second retaining surface, whereby the flexible conductor (21B) makes contact with and is electrically connected to the conductor portion (31A) of the electric wire.