Patent Document

BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to a terminal and a connector, and more particularly to an improved press-contacting terminal having a wire press-contacting portion with which a wire is press-contacted in such a manner that the wire extends in a direction perpendicular to a terminal fitting direction.  
         [0002]     Also, this invention relates to a connector having a housing in which a plurality of terminals, connected respectively to wires, are received, and more particularly to such a connector in which an electrical connection of each terminal can be checked by bringing a probe of a tester into contact with the terminal from the outside of the housing.  
         [0003]     One related press-contacting metal terminal is formed by cutting and bending an electrically-conductive metal sheet, and this metal terminal has a narrow, elongated box-like body having a uniform width over an entire length thereof (see, for example, JP-A-10-294138, especially, pages 2 and 3, FIG. 1).  
         [0004]     As shown in  FIG. 23 , a front portion (left-side portion in  FIG. 23 ) of such a press-contacting metal terminal  100  is formed into a terminal connecting portion  110  for connection to a mating metal terminal, while a rear portion thereof (right-side portion in  FIG. 23 ) is formed into a wire press-contacting portion  120  with which a wire D can be press-contacted.  
         [0005]     The terminal connecting portion  110  is formed by winding a relevant portion of a metal sheet into a rectangular tubular shape having four corner portions  111 , with end portions of this metal sheet portion superposed together at a top wall portion of this terminal connecting portion. A resilient contact piece portion  112  for resilient contact with a mating connection metal terminal is provided within this terminal connecting portion.  
         [0006]     The wire press-contacting portion  120  is also formed by winding a relevant portion of the metal sheet into a rectangular tubular shape having four corner portions  121 . Grooves  123  are formed respectively in rear end portions of upper and lower plates  122 U and  122 L to respectively provide a pair of press-contacting blades  124  with which the wire D can be press-contacted. A blade width of the pair of press-contacting blades  124  is generally equal to the width of the rectangular tubular body.  
         [0007]     There is known a related press-contacting connector which includes a plurality of press-contacting metal terminals as described above, and a connector housing for receiving these press-contacting metal terminals (see, for example, JP-A-11-191443, especially, pages 2 and 3, FIG. 8.  
         [0008]     As shown in  FIG. 24 , such a press-contacting connector  130  includes a plurality of press-contacting metal terminals  100  as described above, and a connector housing  140  for receiving the press-contacting metal terminals  100 .  
         [0009]     The connector housing  140  includes a plurality of terminal receiving chambers  141  for respectively receiving the press-contacting metal terminals  140  in a juxtaposed manner. Reception portions  142   a  and  142   b  are formed within each terminal receiving chamber  141 , and are disposed at a generally central portion of the terminal receiving chamber  141  in a terminal inserting direction (in a left-hand direction in  FIG. 24 ).  
         [0010]     When the wire D is press-contacted with the pair of press-contacting blades  124  of the press-contacting metal terminal  100  inserted in the terminal receiving chamber  141 , abutment portions  101   a  and  101   b , formed respectively at the upper and lower plates  122 U and  122 L of the press-contacting metal terminal  100 , are brought into abutting engagement with the reception portions  142   a  and  142   b , respectively, so that a pushing force is received.  
         [0011]     Therefore, the deformation of the press-contacting metal terminal  100  is prevented as compared with the case where such a pushing force is received by a front end portion of a press-contacting metal terminal.  
         [0012]     In recent years, with a compact design of electrical parts, a compact design of the press-contacting metal terminal  100  as well as a compact design of the press-contacting connector  130  has been desired. However, the blade width of the pair of press-contacting blades  124  is equal to the width of the press-contacting metal terminal  100  as described above, and the compact design is limited in connection with the size of the wire D to be press-contacted with the press-contacting metal terminal.  
         [0013]     And besides, there is encountered a problem that the strength of the press-contacting blades decreases with the compact design of the press-contacting metal terminal, so that the press-contacting force is lowered.  
         [0014]     Furthermore, when forming the press-contacting metal terminal  100  having the box-like shape as described above, those portions of the metal sheet which are to be formed respectively into the corner portions  121  are integrally bent in parallel relation to the adjacent grooves  123 , so that the grooves  123  are spread, which invites a problem that the precision of working of the press-contacting blades  124  is lowered.  
         [0015]     In the press-contacting connector  130 , when the wire D is press-contacted with the pair of press-contacting blades  124 , the abutment portions  101   a  and  101   b  of the press-contacting metal terminal  100  abut respectively against the reception portions  142   a  and  142   b  of the connector housing  140 , and are supported by them, respectively. However, the thickness of the abutment portions  101   a  and  101   b  can only be made equal to or about twice larger than the sheet thickness, and therefore there is a possibility that upon application of the pushing force, the abutment portions  101   a  and  101   b  cut into the reception portions  142   a  and  142   b , respectively, so that the connector housing  140  is subjected to chipping, deformation or the like.  
         [0016]     Also, heretofore, electrical parts, electrical devices, control boards, etc., mounted on a vehicle or the like in spaced relation to each other, are electrically connected by a wire harness including a plurality of wire groups in which predetermined connectors are beforehand attached to predetermined ones of these wires.  
         [0017]     In such a wire harness, when a trouble develops in any of the connectors, this connector, together with its outwardly-extending wires, is cut off from the wire harness, and an exchange-purpose connector, having wires beforehand extended outwardly therefrom, is used, in which case the wires of the exchange-purpose connector are connected respectively to corresponding wires of the wire harness, thereby achieving the recovery. In such a case, it is necessary to confirm whether or not the original wires of the wire harness are properly connected respectively to the wires of the exchange-purpose connector.  
         [0018]     In recent years, with the use of an increased number of electrical parts and control circuits, there is a tendency for connectors to receive an increased number of terminals therein, and the receiving density increases, and therefore a strict dimensional control has now been imposed on the terminals.  
         [0019]     Therefore, for example, when checking an electrical connection of the terminal, it is necessary to avoid bringing a probe of a tester into direct contact with an electrical contact portion of the terminal. Therefore, there has been proposed the type of connector in which an electrical connection of each terminal can be checked without bringing such a probe into contact with the electrical contact portion.  
         [0020]     In a connector  201  shown in  FIG. 25 , detection holes  209 , corresponding respectively to cavities  207 , are formed through a rear portion of a lower wall  205  of a housing  203 . A lower metal wall (lower surface plate)  213  of each press-contacting terminal  211  is opposed to the corresponding detection hole  209 , and the inner side of the detection hole  9  is closed by the lower surface plate  213  of the press-contacting terminal  211 .  
         [0021]     In this connector  201 , a tester rod T can be inserted into the detection hole  209  in the housing  203 , and can be brought into abutting engagement with the lower surface plate  213  of the press-contacting terminal  211  for checking an electrical connection of the terminal (refer to JP-A-11-204227).  
         [0022]     In many cases, connectors, used for a wire harness, are molded of a resin material since in addition to insulating properties, an impact resistance, moldability and a lightweight design can be obtained. Therefore, there are occasions when the configuration of the connector is limited by the direction of removal of the molded connector from a mold.  
         [0023]     The direction of connection of the above related connector  201  to a mating connector and the direction of insertion of the terminals into the connector  101  coincide with each other, that is, are the same direction indicated by arrow “a” in  FIG. 25 . Therefore, the direction of removal of the connector from the mold is the same direction “a”.  
         [0024]     In the above connector, however, the detection holes  9 , corresponding respectively to the cavities, are formed through the wall in a direction perpendicular to the mold-removing direction. Therefore, because of its structure, the mold need to include a slide mold, and therefore is complicated in structure. As a result, there was a disadvantage that the cost of the mold increased.  
         [0025]     To deal with this problem, for example, the provision of the detection holes was omitted, and a tester rod was inserted through a wire lead-out hole in the rear end of the connector, and was brought into abutting engagement with the metal terminal so as to effect an electrical connection check. In this case, however, the wire interfered with the tester rod, and therefore the operation was difficult.  
         [0026]     Particularly when each wire was bent into a crank-shape at the wire lead-out hole by an attached cover as in the connector of  FIG. 25 , the test rod could not be inserted into the wire lead-out hole, and therefore must be inserted into a cavity opening formed in the front end of the connector, and as a result there was a fear that the terminal was damaged.  
       SUMMARY OF THE INVENTION  
       [0027]     It is therefore an object of the present invention to provide a compact design of a press-contacting metal terminal and a compact design of a press-contacting connector and also to provide the good press-contacting metal terminal and press-contacting connector, in which the reliability of the press-contacting connection is enhanced.  
         [0028]     Also, an another object of the present invention is to provide a connector in which a housing, having holes for the purpose of an electrical connection check, can be molded by the use of a mold of a simple structure, so that the cost of the mold can be made low.  
         [0029]     In order to achieve the above object, according to the present invention, there is provided a terminal, comprising:  
         [0030]     a terminal connecting portion, having a tubular shape, and receiving a mating terminal;  
         [0031]     a wire press-contacting portion, including a press-contacting blade for press-contacting a wire, and the press-contacting blade having a blade width larger than a width of the terminal connecting portion; and  
         [0032]     an interconnecting portion, connecting the terminal connection portion and a wire press-contacting portion,  
         [0033]     wherein a press-contacting direction in which the wire is press-contacted with the wire press-contacting portion is parallel to a terminal fitting direction of the terminal connecting portion.  
         [0034]     In the above configuration, the wire press-contacting portion has the press-contacting blade having the blade width larger than the width of the terminal connecting portion, and therefore even when the terminal connecting portion is formed into a compact design as a result of forming the press-contacting terminal into a compact design, the reliability of the press-contacting connection by the press-contacting blade will not be lowered.  
         [0035]     The press-contacting blade of the press-contacting terminal, which is connected by the interconnecting portion to the terminal connecting portion in parallel relation thereto, is formed independently of the terminal connecting portion.  
         [0036]     Therefore, the precision of working of the press-contacting blade will not be lowered by the influence of the terminal connecting portion-forming operation.  
         [0037]     Preferably, the interconnecting portion has a press-contact receiving face for receiving a press-contacting force acting on the press-contacting blade. The press-contact receiving face abuts against an inner wall of a connector housing so that the press-contacting force is received by the inner wall of the connector housing through the press-contact receiving face when the wire is press-contacted with the press-contacting blade. Here, it is preferable that, the press-contact receiving face is formed at a rear side of the press-contacting blade.  
         [0038]     In the above configuration, the press-contacting force for press-contacting the wire with the press-contacting blade is received by the inner wall of the connector housing through the press-contact receiving face formed at the rear side of the press-contacting blade.  
         [0039]     Therefore, the bearing pressure of the press-contacting terminal, acting on the inner wall of the connector housing during the press-contacting operation, can be reduced, and the chipping and deformation of the connector housing are prevented. And besides, the press-contacting force will not act on the terminal connecting portion, and therefore the terminal connecting portion is prevented from deformation.  
         [0040]     Preferably, the press-contacting blade is formed by a flat plate having a groove with which the wire is press-contacted.  
         [0041]     Preferably, the wire press-contacting portion is spaced a prescribed distance from the terminal connecting portion in a direction perpendicular to the press-contacting direction.  
         [0042]     According to the present invention, there is also provided a connector, comprising:  
         [0043]     a plurality of terminals; and  
         [0044]     a connector housing, receiving the terminals, each of the terminals, including: 
        a terminal connecting portion, having a tubular shape, and receiving a mating terminal;     a wire press-contacting portion, including a press-contacting blade for press-contacting a wire, and the press-contacting blade having a blade width larger than a width of the terminal connecting portion; and     an interconnecting portion, connecting the terminal connection portion and a wire press-contacting portion,        
 
         [0048]     wherein a press-contacting direction in which the wire is press-contacted with the wire press-contacting portion is parallel to a terminal fitting direction of the terminal connecting portion; and  
         [0049]     wherein the terminal connecting portions of the terminals are received in the connector housing in parallel so that the press-contacting blades are arranged in a staggered manner.  
         [0050]     In the above configuration, the terminal connecting portions of the plurality of press-contacting terminals (each having the wire press-contacting portion and the terminal connecting portion which are interconnected by the interconnecting portion in such a manner that the press-contacting direction of the wire press-contacting portion is parallel to the terminal fitting direction of the terminal connecting portion) are received in the connector housing in such a juxtaposed manner that the press-contacting blades of the press-contacting terminals are arranged in a staggered manner. Therefore, even in the case where the terminal connecting portions of the press-contacting terminals are received in the connector housing in juxtaposed, closely-spaced relation to one another, the adjacent press-contacting blades are prevented from interfering with each other.  
         [0051]     Therefore, the blade width of the press-contacting blades can be increased so as to increase the strength thereof without increasing the pitch of the juxtaposed press-contacting terminals. And besides, the connector housing can be formed into a compact design by reducing the pitch of the juxtaposed press-contacting terminals, so that the press-contacting connector can be formed into the compact design.  
         [0052]     Preferably, the interconnecting portion has a press-contact receiving face which abuts against an inner wall of the connector housing so that a press-contacting force acting on the press-contacting blade is received by the inner wall of the connector housing when the wire is press-contacted with the press-contacting blade. The connector housing has a support jig-inserting portion into which a support jig for receiving the press-contacting force through the inner face of the connector housing is inserted.  
         [0053]     In the above configuration, the press-contacting force, supported through the press-contact receiving face formed, is received by the support jig inserted in the support jig-inserting portion of the connector housing. Therefore, the connector housing and the terminal are prevented from being deformed during the press-contacting operation, and besides the wire can be easily and positively press-contacted with the press-contacting blade.  
         [0054]     According to the present invention, there is also provided a connector, comprising:  
         [0055]     a housing; and  
         [0056]     a terminal, received in the housing, and having a wire connecting portion which connects a wire and an extension portion which is extended from the wire connecting portion,  
         [0057]     wherein the extension portion has a conductive portion which is formed in a direction intersecting a direction in which the terminal is inserted into the housing; and  
         [0058]     wherein the housing has an exposure hole through which at least part of the conductive portion is exposed to an exterior.  
         [0059]     Here, one example of the connector housing is molded of a synthetic resin, and a plurality of terminal receiving chambers (division sections) for respectively receiving the terminals are formed within the housing.  
         [0060]     One example of the terminal is a press-contacting terminal which includes an electrical contact portion formed at a front end thereof, and the press-contacting portion at a rear end thereof. One example of the conductive portion is an upstanding piece portion which is bent perpendicularly relative to the extension portion extending between the electrical contact portion and the press-contacting portion.  
         [0061]     In the above configuration, the terminal has the conductive portion formed, for example, projecting in an upstanding manner in the direction intersecting the direction of insertion of the terminal, and therefore the exposure hole (that is, an opening or hole for the purpose of an electrical connection check) for exposing the conductive portion can be formed in the direction of removal of a mold. Therefore, there is no need to use a complicated mold with a slide mold or the like as used in the related construction in which the holes for checking the electrical connection are formed in the direction perpendicular to the direction of removal of the mold, and therefore the structure of the mold can be simplified, so that the cost of the mold can be made low.  
         [0062]     Therefore, this connector solves the problems of the related construction, that is, the complicated structure of the mold and the increased cost of the mold.  
         [0063]     Preferably, the exposure hole is open in a direction in which the housing is fitted into a mating housing.  
         [0064]     In the above configuration, a probe of a tester and the terminal to be checked for its electrical connection can be viewed from the same direction at a position close to them, and the failure to direct the probe to the proper terminal to be checked for its electrical connection hardly occurs, so that the electrical connection check can be effected easily.  
         [0065]     Preferably, the conductive portion is electrically connected to the wire through the wire connecting portion.  
         [0066]     Preferably, the connector the extension portion is comprised of a conductive plate. The conductive portion is formed by folding the conductive plate. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0067]     The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:  
         [0068]      FIG. 1  is a perspective view showing the whole of a first embodiment of a press-contacting metal terminal of the invention;  
         [0069]      FIG. 2  is a developed view of the press-contacting metal terminal of  FIG. 1 ;  
         [0070]      FIG. 3  is an exploded, perspective view of the first embodiment of a press-contacting connector of the invention as seen from the front side thereof;  
         [0071]      FIG. 4  is an exploded, perspective view of the press-contacting connector of  FIG. 3  as seen from the rear side thereof;  
         [0072]      FIG. 5  is a perspective view showing a condition in which the press-contacting metal terminals are to be inserted into a connector housing of  FIG. 4 ;  
         [0073]      FIG. 6  is a perspective view showing a condition in which the press-contacting metal terminals are received in the connector housing of  FIG. 5 ;  
         [0074]      FIG. 7  is a perspective, cross-sectional view taken along the line VII-VII of  FIG. 6 ;  
         [0075]      FIG. 8  is a cross-sectional view taken along the line VIII-VIII of  FIG. 6 ;  
         [0076]      FIG. 9  is a cross-sectional view taken along the line IX-IX of  FIG. 6 ;  
         [0077]      FIG. 10  is a perspective view of the connector housing with which the wires are press-contacted;  
         [0078]      FIG. 11  is a longitudinal cross-sectional view of the press-contacting connector with which the wires are press-contacted;  
         [0079]      FIG. 12  is a longitudinal cross-sectional view of the press-contacting connector with which the wires are press-contacted;  
         [0080]      FIG. 13  is a perspective view of a connector according to a second embodiment of the invention as seen from a lower front side thereof, showing a condition of an electrical connection check;  
         [0081]      FIG. 14  is an exploded, perspective view of the connector of  FIG. 13 ;  
         [0082]      FIG. 15  is a perspective view of a terminal shown in  FIG. 14 ;  
         [0083]      FIG. 16  is a developed view showing the process of forming the terminals of  FIG. 15  from a metal sheet;  
         [0084]      FIG. 17  is an enlarged view of an important portion of the terminal of  FIG. 15 ;  
         [0085]      FIG. 18  is an exploded, perspective view of the connector of  FIG. 13  as seen from an upper front side thereof;  
         [0086]      FIG. 19  is a perspective view of the connector, having wires connected thereto, as seen from a rear side thereof;  
         [0087]      FIG. 20  is a longitudinal cross-sectional view showing an electrical connection check for the terminal received in a lower receiving chamber;  
         [0088]      FIG. 21  is a longitudinal cross-sectional view showing an electrical connection check for the terminal received in an upper receiving chamber;  
         [0089]      FIGS. 22A  to  22 C are perspective views showing modified terminals, respectively;  
         [0090]      FIG. 23  is a perspective view showing the whole of a related press-contacting metal terminal;  
         [0091]      FIG. 24  is a longitudinal cross-sectional view showing a related press-contacting connector; and  
         [0092]      FIG. 25  is a cross-sectional view of a related connector having detection holes. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0093]     A first embodiment of a press-contacting metal terminal and a press-contacting connector of the invention, will now be described in detail with reference to the accompanying drawings.  
         [0094]      FIG. 1  is a perspective view showing the whole of the first embodiment of the press-contacting metal terminal of the invention, and  FIG. 2  is a developed view of the press-contacting metal terminal of  FIG. 1 .  
         [0095]     As shown in  FIG. 1 , the press-contacting metal terminal  10  of this embodiment includes a terminal connecting portion  20  of a tubular shape formed at one end of a base plate  21 L formed of an electrically-conductive metal sheet, and a wire press-contacting portion  30  formed at the other end of the base plate  21 L, and a wire D can be press-contacted with this wire press-contacting portion  30  in such a manner that the wire D extends in a direction perpendicular to a terminal fitting direction (in a direction of arrow A in  FIG. 1 ).  
         [0096]     The wire press-contacting portion  30  and the terminal connecting portion  20  are interconnected by an interconnecting portion  40  in such a manner that the press-contacting direction of the wire press-contacting portion  30  is parallel to the terminal fitting direction of the terminal connecting portion  20 .  
         [0097]     Referring to  FIGS. 1 and 2 , the terminal connecting portion  20  is formed by blanking a sheet piece from an electrically-conductive metal sheet (sheet material)  11  and then by bending this sheet piece into a tubular body of a rectangular cross-section having a superposed upper plate  21 U. A mating terminal is inserted into an internal space  22  within this terminal connecting portion  20 .  
         [0098]     In order to positively electrically connect this metal terminal to the mating terminal, there is provided a resilient contact piece portion  23  (which can be resiliently deformed) which is folded back, and is disposed within the internal space  22 . A resiliently-deformable lock piece portion  24  is formed on the upper plate  21 U, and when the metal terminal is inserted in a connector housing  60  (see  FIG. 4 ) described later, this lock piece portion  24  prevents the withdrawal of the metal terminal.  
         [0099]     The interconnecting portion  40  has an L-shape, and includes a horizontal portion  41  formed integrally with and extending from the base plate  21 L of the terminal connecting portion  20 , and a vertical portion  42  extending vertically upwardly from a rear end of this horizontal portion  41 . The wire press-contacting portion  30  is formed integrally at an upper end of the vertical portion  42 .  
         [0100]     Therefore, the press-contacting direction of the wire press-contacting portion  30  is parallel to the terminal fitting direction of the terminal connecting portion  20 , and the wire press-contacting portion  30  is spaced a predetermined distance H from a centerline (axis) CL 1  of the terminal connecting portion  20 .  
         [0101]     The interconnecting portion  40  can be shaped to have only the vertical portion extending vertically upwardly from the rear end of the base plate  21 L of the terminal connecting portion  20 .  
         [0102]     Two (upper and lower) flat plate-like press-contacting blades  31  are formed at the wire press-contacting portion  30 , and a groove  32  for press-contacting with the wire D is formed in a widthwise-central portion of each press-contacting blade  31 .  
         [0103]     A blade width “B” of the press-contacting blades  31  is larger than a width “b” of the terminal connecting portion  20 , and a sufficient strength of the press-contacting blade  31  is secured so that a sufficient press-contacting force can be obtained.  
         [0104]     A press-contact receiving face  33  is formed at a rear side (left side in  FIG. 1 ) of the press-contacting blades  31 , and when the wire D is press-contacted with the press-contacting blades  31 , this press-contact receiving face  33  abuts against an inner wall of the connector housing so that a press-contacting force, acting on the press-contacting blades  31 , can be supported by the inner wall of the connector housing.  
         [0105]     In the press-contacting metal terminal  10  of this embodiment, the wire press-contacting portion  30  has the press-contacting blades  31  having the blade width “B” larger than the width “b” of the terminal connecting portion  20 . Therefore, when the terminal connecting portion  20  is formed into a compact design as a result of a compact design of the press-contacting metal terminal  10 , the reliability of the press-contacting connection by the press-contacting blades  31  will not be lowered.  
         [0106]     The press-contacting blades  31  of the wire press-contacting portion  30 , connected by the interconnecting portion  40  to the terminal connecting portion  20  in parallel relation thereto, are formed independently of the terminal connecting portion  20 .  
         [0107]     Namely, when the blanking of the sheet material  11  is effected in such a manner that the grooves  32 , formed respectively in the press-contacting blades  31 , are spaced a predetermined distance from the terminal connecting portion  20 , these grooves  32  will not be influenced at the time of forming the terminal connecting portion  20  by a bending operation at a later stage. And besides, when bending the pair of press-contacting blades  31 , any portion is not bent in parallel relation to the grooves  32 , and therefore the lowered working precision of the press-contacting blades  31 , such as the spreading of the grooves  32 , will not occur.  
         [0108]     Next, the first embodiment of the press-contacting connector of the invention will be described in detail with reference to the accompanying drawings.  
         [0109]      FIGS. 3 and 4  are exploded, perspective views of the first embodiment of the press-contacting connector of the invention as seen respectively from the front side and the rear side.  
         [0110]     As shown in  FIGS. 3 and 4 , the press-contacting connector  50  of this embodiment includes the connector housing  60  for receiving the terminal connecting portions  20  of a plurality of the press-contacting metal terminals  10  in such a juxtaposed manner that the pairs of press-contacting blades  31  of the press-contacting metal terminals  10  are arranged in a staggered manner, and a cover  70  attached to a rear end of the connector housing  60  to cover those portions of the wires D press-contacted with the press-contacting blades  31 .  
         [0111]     The connector housing  60  of a generally rectangular parallelepiped shape is made of an insulative resin, and a plurality of terminal receiving chambers  61  for respectively receiving the terminal connecting portions  20  of the plurality of press-contacting metal terminals  10  in a juxtaposed manner are formed in a lower section of an internal space of this connector housing. Terminal insertion ports  61   a  are formed in a front surface (left side surface in  FIG. 3 ) of the connector housing, and mating terminals are inserted into these terminal insertion ports  61   a , respectively.  
         [0112]     Support portion-inserting portions  62  (serving as a support jig-inserting portion) for receiving a support jig  80  (see  FIG. 9 ) described later are formed in an upper section of the internal space of the connector housing  60 . Support portion-inserting ports  62   b  for the insertion of support portions  82   a  of the support jig  80  therethrough are formed in the front surface of the connector housing.  
         [0113]     A support portion-sliding surface  63  (serving as a support jig-inserting portion) for guiding a sliding movement of a support portion  82   b  of the support jig  80  is formed on a lower surface of the connector housing  60 .  
         [0114]     A plurality of juxtaposed guide recesses  64 U are formed in a rear end (left end in  FIG. 4 ) of a top plate  60 U of the connector housing  60 , while a plurality of juxtaposed guide recesses  64 L are formed in a rear end (left end in  FIG. 4 ) of a bottom plate  60 L of the connector housing, and theses recesses  64 U and  64 L guide and hold the insulated conductors (wires) D extending vertically. Partition walls  65  for separating the plurality of wires D from one another are formed at the rear end surface of the connector housing  60 , and are disposed between the row of upper guide recesses  64 U and the row of lower guide recesses  64 L, and extend vertically.  
         [0115]     An elastically-deformable lock arm  66  is formed on an upper surface of the top plate  60 U of the connector housing  60 , and when the press-contacting connector  50  is attached to a mating connector portion such for example as an electric box, this lock arm  66  prevents the connector  50  from being disengaged from the mating connector portion. Retaining projections  68  are formed respectively on outer surfaces of opposite side plates  67  of the connector housing  60 , and when the cover  70  is attached to the connector housing, these retaining projections  68  retain the cover  70 .  
         [0116]     As shown in  FIGS. 3 and 4 , the cover  70  has a generally flat plate-like shape, and lock arms  71  are formed on and project respectively from right and left sides of this cover. These lock arms  71  are retainingly engaged respectively with the retaining projections  68  of the connector housing  60 , thereby preventing the cover  70  from being disengaged from the connector housing  60 .  
         [0117]     Guide ribs  51   a , corresponding to the guide recesses  64 U, are formed in an upper surface of the cover  70  so as to guide the wires D rearwardly, while guide ribs  51   a , corresponding to the guide recesses  64 L, are formed in a lower surface of the cover  70  so as to guide the wires D rearwardly, these guide ribs  51   a  extending in the forward-rearward direction. Pressing projections  72  for respectively pressing the insulated conductors (wires) D in the press-contacting direction are formed on an inner surface of the cover  70 .  
         [0118]     Next, a method of inserting the press-contacting metal terminals  10  into the connector housing  60  will be described.  
         [0119]     As described in detail with reference to  FIG. 1 , the blade width “B” of the press-contacting blades  31  of the press-contacting metal terminal  10  is larger than the width “b” of the terminal connecting portion  20 , and therefore if all of the press-contacting metal terminals  10  are juxtaposed to one another in the same posture in a closely-spaced manner, the press-contacting blades  31  of the adjacent press-contacting metal terminals  10  interfere with each other.  
         [0120]     Therefore, the press-contacting metal terminals  10  to be juxtaposed to one another are alternately inverted (that is, turned upside down about the centerlines CL 1  of the corresponding terminal connecting portions  20 ) as shown in  FIG. 5 , and then the terminal connecting portions  20  of these press-contacting metal terminals  10  are inserted respectively into the terminal receiving chambers  61  of the connector housing  60 . The press-contacting metal terminals  10  are inserted into the connector housing  60  in such a manner that their terminal connecting portions  20  are inserted respectively into the terminal receiving chambers  61  from the rear side (left side in  FIG. 5 ) of the connector housing  60 .  
         [0121]     Namely, although the terminal connecting portions  20  of the plurality of press-contacting metal terminals  10  are received in a juxtaposed manner in the connector housing  60 , the wire press-contacting portions  30  (each of which is not aligned with the terminal connecting portion  20 ) are disposed in a staggered manner, that is, disposed alternately close to the top plate  60  and bottom plate  60 L of the connector housing  60  as shown in FIGS.  6  to  8 .  
         [0122]     Therefore, the wire press-contacting portion  30  is disposed parallel to the terminal fitting direction of the terminal connecting portion  20  as a result of the provision of the interconnecting portion  40  of the press-contacting metal terminal  10 , and the wire press-contacting portion  30  is spaced the predetermined distance H from the centerline (axis) CL 1  of the terminal connecting portion  20 . The wire press-contacting portions  30  are arranged to abut alternately against the inner sides of the upper and lower guide recesses  64 U and  64 L in the connector housing  60 . With this arrangement, the press-contacting blades  31  of any two adjacent press-contacting metal terminals  10  are spaced a sufficient distance from each other.  
         [0123]     Therefore, in the press-contacting connector  50  of this embodiment, the plurality of press-contacting metal terminals  10  are alternately inverted, so that their press-contacting blades  31  are disposed alternately at the upper position and lower position, and with this arrangement the sufficient space is provided between the adjacent press-contacting blades  31 . Therefore, even in the case where the terminal connecting portions  20  of the press-contacting metal terminals  10  are received in the connector housing in juxtaposed, closely-spaced relation to one another, the adjacent press-contacting blades  31  are prevented from interfering with each other. Therefore, the compact design of the press-contacting metal terminal  10 , as well as the compact design of the press-contacting connector  50 , can be achieved.  
         [0124]     Next, the operation for press-contacting the wires D with the press-contacting blades  31  in the press-contacting connector  50  will be described.  
         [0125]     First, the support jig  80  is inserted along the support portion-inserting portions  62  and the support portion-sliding surface  63  of the connector housing  60  as shown in  FIG. 9 .  
         [0126]     The support jig  80  includes a plate-like base portion  81 , the four juxtaposed narrow support portions  82   a  extending perpendicularly from the base portion  81  so as to be inserted into the support portion-inserting portions  62 , and the wide support portion  82   b  extending perpendicularly from the base portion  81  in parallel relation to the support portions  82   a  so as to slide along the support portion-sliding surface  63 .  
         [0127]     A distal end of each inserted support portion  82   a  abuts against a bottom wall surface  62   a  of the corresponding support portion-inserting portion  62 , and a distal end of the support portion  82   b  abuts against an abutment surface  63   a  formed at a rear end of the support portion-sliding surface  63 .  
         [0128]     The bottom wall surfaces  62   a  and the abutment surface  63   a , formed at the connector housing  60 , are arranged to correspond to the wire press-contacting portions  30  of the press-contacting metal terminals  10  received in the connector housing  60 , and the distal ends of the support portions  82   a  are opposed respectively to the press-contact receiving faces  33  of the corresponding wire press-contacting portions  30  through the inner wall of the connector housing, while the distal end of the support portion  82   b  is opposed to the press-contact receiving faces  33  of the corresponding wire press-contacting portions  30  through the inner wall of the connector housing.  
         [0129]     By the use of a press-contacting machine (not shown), each wire D is press-fitted into the press-contacting blades  31  of the corresponding press-contacting metal terminal  10  in the connector housing  60  set on the support jig  80 , and by doing so, the wire D is press-contacted with the press-contacting blades  31 .  
         [0130]     At this time, the press-contacting force, supported by the inner wall of the connector housing through the press-contact receiving face  33  formed at the rear side of the press-contacting blades  33  of each press-contacting metal terminal  10 , is received by the corresponding support portion  82   a  (inserted along the support portion-inserting portion  62  of the connector housing  60 ) or support portion  82   b  (inserted along the support portion-sliding surface  63  of the connector housing  60 ) of the support jig  80 .  
         [0131]     Therefore, the press-contacting metal terminal  10  and the connector housing  60  are prevented from being deformed by the press-contacting load, and the wire D can be easily and positively press-contacted with the press-contacting blades  31 .  
         [0132]     Therefore, variations in height of sheathes of the wires D relative to the press-contacting blades  31  are reduced, so that the reliability of the press-contacting connection is enhanced.  
         [0133]     As shown in  FIG. 10 , the press-contacting blades  31  of the juxtaposed press-contacting metal terminals  10  are alternately inverted, and therefore the press-contacting blades  31  of the juxtaposed terminals  10 , press-contacted with the respective wires D, are disposed alternately at the upper position and the lower position, and the plurality of juxtaposed wires D can be press-contacted at a pitch smaller than the blade width “B” of the press-contacting blades  31 .  
         [0134]     After the wires D are press-contacted with the press-contacting metal terminals, respectively, the cover  70  is fitted on the rear end of the connector housing  60  as shown in  FIGS. 11 and 12 , and the lock arms  71  are locked respectively to the retaining projections  68  of the connector housing  60 , so that the wires D are held in a bent condition between the cover  70  and the connector housing  60 .  
         [0135]     Then, opposite lead-out portions of each wire D, extending respectively in the upward and downward directions, are guided reawardly by the guide ribs  51   a  of the cover  70 , respectively, and are bundled together by a binding member  73  such as an insulating tape.  FIG. 11  shows the wire D press-contacted with the press-contacting blades  31  disposed at the upper portion of the connector, and  FIG. 12  shows the wire D press-contacted with the press-contacting blades  31  disposed at the lower portion of the connector.  
         [0136]     Therefore, when each wire D is press-contacted with the corresponding press-contacting blades  31  in the press-contacting connector  50 , an excessive press-contacting force will not act on the connector housing  60  and the terminal connecting portion  20  of the press-contacting metal terminal  10 , and the press-contacting metal terminals  10  and the connector housing  60  are prevented from being deformed, and besides each wire D can be easily and positively press-contacted with the corresponding press-contacting blades  31 .  
         [0137]     The press-contacting metal terminal and the press-contacting connector of the invention are not limited to the above embodiment, and can take various forms on the basis of the subject matter of the invention.  
         [0138]     For example, in the above embodiment, the plurality of sheathed wires are used as the wires to be press-contacted with the terminals, there can be used a plurality of separate insulated conductors obtained by suitably dividing a flat wire comprising the plurality of juxtaposed conductors covered with an insulating material.  
         [0139]     Next, a second embodiment of the present invention will now be described in detail with reference to the drawings.  
         [0140]     As shown in  FIGS. 13 and 14 , the connector  121  of this embodiment includes a housing  123  molded of a synthetic resin, the plurality of terminals  125  received in the housing  123 , and a wire retaining member (retainer) which will be described later.  
         [0141]     As shown in  FIG. 15 , the terminal  125  is formed by bending an electrically-conductive sheet material, and this terminal  125  has a box-like electrical contact portion  127  formed at its front portion. A resilient contact piece portion  129  for contact with a mating male terminal (not shown) is formed by bending, and is received within the electrical contact portion  127 .  
         [0142]     A retaining piece portion  131  is formed by bending on an upper outer surface of the electrical contact portion  127 , and extends toward the rear end of the terminal in a slanting manner. When the terminal  125  is inserted into the housing  123 , the retaining piece portion  131  is brought into retaining engagement with a retaining portion (not shown) within the housing  123  to prevent the withdrawal of the terminal  125 .  
         [0143]     An extension portion  133  is formed at a rear portion of the terminal  125 , and extends rearwardly from a bottom plate portion of the box-like body, and a press-contacting portion  135  is formed at a rear end of the extension portion  133 . The press-contacting portion  135  includes a pair of parallel press-contacting blades  137 , and each of the press-contacting blades  137  has a groove  139  in the form of a slit extending from a rear edge thereof to a central portion thereof.  
         [0144]     When a sheathed wire is press-fitted into the press-contacting blades  137 , a sheath of the sheathed wire is cut by blade portions (defined respectively by opposed side edges of each groove  139 ), so that the press-contacting portion  135  is electrically connected to a conductor provided within the sheathed wire.  
         [0145]     The extension portion  133  has an upstanding piece portion (bent portion)  141  formed between the electrical contact portion  127  and the press-contacting portion  135 , and this bent portion  141  projects in an upstanding manner in a direction intersecting (that is, “perpendicular to” in this embodiment) a direction of insertion of the terminal  125 . The press-contacting portion  135  is provided at an upper end of this bent portion  141 , and extends rearwardly.  
         [0146]     Therefore, the wire, connected to the press-contacting portion  135 , is disposed perpendicular to the direction of insertion of the terminal  125 .  
         [0147]     As shown in  FIG. 16 , the terminal  125  is formed by bending (sheet metal working) of one developed member  143  blanked by pressing or the like from a metal sheet. Reference numerals in  FIG. 16  denote the various portions of the terminal  125  in the form of the developed member  143 .  
         [0148]     In this developed member  143 , the press-contacting portion  135  is connected to the extension portion  133  by a connecting portion  145  extending laterally from the rear end portion of the extension portion  133 . The pair of press-contacting blades  137  are formed respectively at front and rear edges of a base plate  147  (of the press-contacting portion) extending from the connecting portion  145 .  
         [0149]     Therefore, the press-contacting portion  135  is formed by sheet metal working as follows. First, the connecting portion  145  is bent rearwardly relative to the extension portion  133 , and then the pair of upper and lower press-contacting blades  137  are perpendicularly bent rearwardly relative to the base plate  147  (of the press-contacting portion) disposed parallel to the extension portion  133 , as shown in  FIG. 17 .  
         [0150]     That surface  149  of the extension portion  133 , facing away from this press-contacting portion  135 , serves as a tester probe-contacting surface as described later. Thus, a probe is adapted to be brought into contact with the surface  149  of the extension portion  133 , and therefore the probe will not be brought into direct contact with the press-contacting portion  135 .  
         [0151]     The extension portion  133  and the base plate  147  of the press-contacting portion  135  jointly provide a double-wall structure in which these two plate portions are disposed in contiguous relation to each other, and therefore a higher strength is obtained as compared with the case where this portion is formed by a single plate portion.  
         [0152]     As shown in  FIG. 18 , the housing  123  has a hollow portion which is divided into two (upper and lower) sections. A plurality of juxtaposed terminal receiving chambers  151  for respectively receiving the terminals  125  are formed in the lower hollow section, and are arranged in a row.  
         [0153]     The upper hollow section is divided by a partition wall  153  into insertion ports  155  each corresponding to a predetermined number of terminal receiving chambers  151 .  
         [0154]     As shown in  FIG. 14 , each of the terminal receiving chambers  151  is open to the rear side of the housing  123 , and the terminal  125  is inserted into the terminal receiving chamber through this rear opening  157 . In the housing  123  of this embodiment, the terminals  125  are mounted respectively in the terminal receiving chambers  151  in such a manner that the juxtaposed terminals  125  are alternately inverted (that is, turned upside down).  
         [0155]     Therefore, the press-contacting portions  135 , formed respectively at the rear ends of the juxtaposed terminals  125 , are arranged in the rear portion of the housing  123  in such a manner that the press-contacting portions  135  of any two adjacent terminals  125  are disposed in reversed relation to each other as shown in  FIG. 18 .  
         [0156]     The wires are press-fitted respectively into the press-contacting portions  135  located in the rear portion of the housing  123 . After the press-fitting of the wires, the retainer  159  is attached to the rear end of the housing  123 , the retainer  159  having such a configuration that it can press those portions of the wires held respectively in the press-contacting portions  135 .  
         [0157]     The retainer  159  has retaining frames  161  of a generally rectangular shape formed respectively at opposite ends thereof, and these retaining frames  161  are retainingly engaged respectively with projections  163  formed respectively on opposite side surfaces of the housing  123 , thereby fixing the retainer  159  to the rear end of the housing  123  as shown in  FIG. 19 .  
         [0158]     The retainer  159  is thus fixed to the rear end of the housing  123 , thereby preventing the wires  165  (press-contacted respectively with the press-contacting portions  135 ) from moving relative to the respective grooves  139  in the withdrawing direction so as to maintain the good electrically-connected condition.  
         [0159]     The wires  165 , retained by the retainer  159 , extend rearwardly along the upper and lower surfaces of the retainer  159 , and are bundled together, for example, into a flat configuration by a binding band  167  or the like.  
         [0160]     Upper recesses  169   a  for respectively holding the corresponding press-contacting portions  135 , as well as lower recesses  169   b  for respectively holding the corresponding press-contacting portions  135 , are formed in the rear end portion of the housing  123  as shown in  FIGS. 20 and 21 , and the plurality of upper recesses  169   a  and the plurality of lower recesses  169   b  are arranged in two (upper and lower) rows in such a manner that these recesses  169   a  and  169   b  correspond to the terminals  125 , respectively. Each of the upper recesses  169   a  communicates with the insertion port  155  through a corresponding through hole  171 .  
         [0161]     Each of the lower recesses  169   b  is open toward the front side of the housing  123  through a corresponding exposure hole  173  formed in the fitting direction.  
         [0162]     With respect to those terminals  125  having the upwardly-directed press-contacting portions  135 , respectively, these press-contacting portions  135  are received in the upper recesses  169   a , respectively, as shown in  FIG. 20 . With respect to those terminals  125  having the downwardly-directed press-contacting portions  135 , respectively, these press-contacting portions  135  are received in the lower recesses  169   b , respectively, as shown in  FIG. 21 .  
         [0163]     Therefore, with respect to those terminals  125  whose press-contacting portions  135  are received respectively in the upper recesses  169   a , the surface  149  of the bent portion  141  of each terminal  125  is exposed to the front side of the housing  123  through the corresponding through hole  171  and the insertion port  155 . With respect to those terminals  125  whose press-contacting portions  135  are received respectively in the lower recesses  169   b , the surface  149  of the bent portion  141  of each terminal  125  is exposed to the front side of the housing  123  through the corresponding exposure hole  173 .  
         [0164]     The through holes  171  and the exposure holes  173  perform a similar function to the function of the detection holes used in the related construction. Namely, when checking the electrical connection of each of those terminals  125  whose press-contacting portions  135  are received respectively in the upper recesses  169   a , the probe P is inserted into the corresponding through hole  171 , disposed just above the terminal  125  to be checked, and is brought into contact with the surface  149  of the bent portion  141  of this terminal as shown in  FIG. 20 .  
         [0165]     When checking the electrical connection of each of those terminals  125  whose press-contacting portions  135  are received respectively in the lower recesses  169   b , the probe P is inserted into the corresponding exposure hole  173 , disposed just beneath the terminal  125  to be checked, and is brought into contact with the surface  149  of the bent portion  141  of this terminal as shown in  FIG. 21 .  
         [0166]     In this connector  121 , each terminal  125  has the bent portion  141  projecting in an upstanding manner in the direction intersecting the direction of insertion of the terminal  125 , and therefore the exposure holes  173  each for exposing the corresponding bent portion  141  can be formed in the direction of removal of a mold.  
         [0167]     Therefore, there is no need to use a complicated mold with a slide mold or the like as used in the related construction in which the holes for checking the electrical connection are formed in the direction perpendicular to the direction of removal of the mold, and therefore the structure of the mold can be simplified, so that the cost of the mold can be made low.  
         [0168]     And besides, the exposure holes  173  are open in the direction of fitting of the housing into the mating housing (that is, open toward the front side), and therefore the probe P of the tester and the terminal  125  to be checked for its electrical connection can be viewed from the same direction at a position close to them, and the failure to direct the probe to the proper terminal  125  to be checked for its electrical connection hardly occurs, so that the electrical connection check can be effected easily.  
         [0169]     The connector of the present invention is not limited to the second embodiment, and suitable modifications and improvements can be made.  
         [0170]     For example, in the second embodiment, the extension portion  133  is bent into an L-shape, thereby forming the bent portion  141 . In the connector of the invention, however, any suitable bent portion can be adopted in so far as the bent portion  141 , projecting in an upstanding manner in a direction intersecting the direction of insertion of the terminal  125 , can be formed at the extension portion  133 , and the bent portion is not limited to the L-shape. For example, a bent portion may be an intermediate piece portion  181  formed by bending an extension portion  133  into a crank-shape as shown in  FIG. 22A .  
         [0171]     A bent portion may be a hanging piece portion  183  formed by bending a central portion of an extension portion  133  into a generally U-shape as shown in  FIG. 22B .  
         [0172]     As shown in  FIG. 22C , there may be adopted a structure in which an extension portion  133  is bent upwardly, and then is folded or bent at an angle of 45 degrees along a folding line  185 , and further is folded back through an angle of 180 degrees along a vertical folding line  187 , and further is folded along a folding line extending in the same direction as that of the folding line  185 , thereby forming a bent portion  189  projecting laterally from the extension portion  133 .  
         [0173]     In the above embodiment, the configuration, dimensions, number, arrangement, etc., of the illustrated insertion ports  155 , through holes  171 , exposure holes  173 , retainer  159  and so on are arbitrary, and are not limited in so far as the present invention can be achieved.

Technology Category: 4