ELECTRIC CONNECTOR AND MANUFACTURING METHOD THEREOF

TECHNICAL FIELD

The present disclosure relates to an electrical connector and manufacturing method thereof.

BACKGROUND

An electrical connector having a plurality of contacts is known as a type of electrical connector. For example, the following Patent Literature 1 discloses a technique for forming an electrically insulating housing by insert molding for integration with a plurality of contacts.

CITATION LIST
Patent Literature

Patent Literature 1: Japanese Unexamined Patent Publication No. 2012-59540

SUMMARY OF INVENTION
Technical Problem

Also known as an electrical connector is an electrical connector (such as a USB Type-C connector) provided with a mid-plate (conductive member having a plate shape), in which a plurality of first contacts disposed on one surface of the mid-plate and a plurality of second contacts disposed on the other surface of the mid-plate are overlapped each other in the thickness direction of the mid-plate.

The inventors have found that the contacts may undergo a flexural deformation during the insert molding that is disclosed in Patent Literature 1 in a case where the insert molding is applied to the electrical connector in which the plurality of contacts overlap each other via the mid-plate. In the event of the flexural contact deformation, the relative positional accuracy between the mid-plate and the contact decreases, and then resin leakage to the surface of the contact may arise during the insert molding and problems such as a conduction failure may arise during connection with an opposite connector.

An object of the present disclosure is to provide electrical connector and manufacturing method thereof with which the relative positional accuracy between a plate-shaped conductive member and a contact can be improved.

Solution to Problem

An electrical connector according to an aspect of the present disclosure includes a connecting portion made of resin and configured to be connected with an opposite connector, a main body portion positioned behind the connecting portion in a direction of connection with the opposite connector, a conductive member having a plate shape and extending along the direction of connection with the opposite connector and having a part held by the connecting portion, a plurality of first contacts having conductivity and extending along the direction the connection with the opposite connector with at least a part held by the connecting portion on one surface of the connecting portion and the other part held by the main body portion, and a plurality of second contacts having conductivity and extending along the direction of connection with the opposite connector with at least a part held by the connecting portion on the other surface of the connecting portion and the other part held by the main body portion. The connecting portion includes a first resin portion holding the first contact and a second resin portion holding the second contact, the second resin portion separate from the first resin portion. The connector further comprises a third resin portion covering the first resin portion and the second resin portion, the third resin portion separate from the first resin portion and the second resin portion.

A method for manufacturing an electrical connector according to an aspect of the present disclosure is a method for manufacturing an electrical connector comprising a connecting portion made of resin and configured to be connected with an opposite connector, a main body portion positioned behind the connecting portion in a direction of connection with the opposite connector, a conductive member having a plate shape and extending along the direction of connection with the opposite connector and having a part held by the connecting portion, a plurality of first contacts having conductivity and extending along the direction of connection with the opposite connector with at least a part held by the connecting portion on one surface of the connecting portion and the other part held by the main body portion, and a plurality of second contacts having conductivity and extending along the direction of connection with the opposite connector with at least a part held by the connecting portion on the other surface of the connecting portion and the other part held by the main body portion. The method includes of forming a first molded body, the first contact is held by the connecting portion on one surface of the conductive member by a first resin portion of the connecting portion in the first molded body, a step of forming a second molded body, the second contact is held by a second resin portion of the connecting portion separate from the first resin portion in the second molded body, and a step of covering a molded body set with a third resin portion of the connecting portion separate from the first resin portion and the second resin portion, the second molded body disposed on the other surface of the conductive member held by the first molded body in the molded body set.

In the electrical connector and manufacturing method thereof, the first molded body in which the first contact is held by the conductive member on one surface of the conductive member by the first resin portion of the connecting portion can be formed by insert molding. During the insert molding, deflection of the first contact can be suppressed by means of a predetermined mold. Likewise, the second molded body in which the second contact is held by the second resin portion of the connecting portion can be formed by insert molding. Also during the insert molding, deflection of the second contact can be suppressed by means of a predetermined mold. By carrying out the first molded body molding step and the second molded body molding step separately as the above, the disposition and the shape of the mold in each molding step can be changed. As a result, deflection of the first contact and the second contact can be suppressed, and then the relative positional accuracy of the first contact and the second contact with respect to the plate-shaped conductive member increases.

Advantageous Effects of Invention

According to the present disclosure, an electrical connector and manufacturing method thereof with which the relative positional accuracy between a plate-shaped conductive member and a contact can be improved are provided.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view illustrating an electrical connector according to an embodiment of the present disclosure.

FIG. 2 is a cross-sectional view taken along line II-II of the electrical connector in FIG. 1.

FIG. 3 is a perspective view illustrating a connector main body of the electrical connector in FIG. 1.

FIG. 4 is a cross-sectional view taken along line IV-IV of the connector main body in FIG. 3.

FIG. 5 is a front view in which the connector main body in FIG. 3 is viewed from a direction of connection X.

FIG. 6 is a perspective view illustrating an intermediate ground plate in FIG. 3.

FIG. 7 is a perspective view illustrating an upper ground plate in FIG. 3.

FIG. 8 is a perspective view illustrating a lower ground plate in FIG. 3.

FIG. 9 is a perspective view illustrating a back ground plate in FIG. 3.

FIG. 10 is a plan view of the connector main body in FIG. 3.

FIG. 11 is a bottom view of the connector main body in FIG. 3.

FIG. 12 is a flowchart illustrating a procedure for manufacturing the connector main body in FIG. 3.

FIG. 13 is a perspective view illustrating a first molded body obtained by first insert molding.

FIG. 14 is a cross-sectional view taken along line XIV-XIV of the first molded body in FIG. 13.

FIG. 15 is a perspective view illustrating a second molded body obtained by second insert molding.

FIG. 16 is a cross-sectional view taken along line XVI-XVI of the second molded body in FIG. 15.

FIG. 17 is a perspective view illustrating a state where the back ground plate is disposed in a molded body set in which the first molded body in FIG. 13 and the second molded body in FIG. 15 overlap each other.

FIG. 18 is a cross-sectional view taken along line XVIII-XVIII of the molded body set in FIG. 17.

FIG. 19 is a perspective view illustrating how a shell is attached to the connector main body in FIG. 3.

FIG. 20 is a diagram illustrating fitting between a tube portion of the shell and a main body portion of the connector main body.

FIG. 21 is a diagram illustrating joining between an extending portion of the shell and a spring portion.

DESCRIPTION OF EMBODIMENTS

Hereinafter, an embodiment of the present disclosure will be described in detail with reference to accompanying drawings. In the description, the same reference numerals are used for the same elements or elements having the same functions so that the same description does not have to be repeated.

First, an electrical connector 1 according to the present embodiment will be described with reference to FIGS. 1 and 2.

The electrical connector 1 is a receptacle connector attached to an electronic device 2 such as a portable device and an information technology device. As illustrated in FIG. 2, the electrical connector 1 is accommodated in an accommodating space C of the electronic device 2, is fixed to a substrate 3 of the electronic device 2 by solder connection or the like, and is electrically connected to the substrate 3. By inserting a plug connector (not illustrated) as an opposite connector into the electrical connector 1, it is possible to perform electric power supply and electrical signal transmission between the plug connector and the substrate 3. In the present embodiment, the electrical connector 1 is a USB Type-C connector.

The electrical connector 1 and the plug connector are interconnected along a predetermined direction. As illustrated in FIG. 3, in the following description, the direction in which the electrical connector 1 and the plug connector are interconnected will be referred to as an X direction. In addition, in the X direction, the direction toward the plug connector will be referred to as forward and the direction away from the plug connector will be referred to as rearward. The X-direction front part of each member will be referred to as a front portion and the X-direction rear part of each member will be referred to as a rear portion.

As illustrated in FIG. 1, the electrical connector 1 is configured to include a shell 10, a waterproof member 20, and a connector assembly 30.

Hereinafter, the configuration of the connector assembly 30 will be described with reference to FIGS. 3 to 5.

As illustrated in FIG. 3, the connector assembly 30 has a plurality of conductive contacts 40, a plurality of conductive ground plates 50, and a resin molded body 60 integrally bonding the contact 40 and the ground plate 50 to each other.

Each of the plurality of contacts 40 is an elongated member extending along the direction in which the electrical connector 1 and the plug connector are interconnected (X direction). A metal material such as Cu constitutes each of the plurality of contacts 40. As illustrated in FIGS. 4 and 5, the plurality of contacts 40 include a plurality of contacts 42 parallel in a direction orthogonal to the X direction. In the present embodiment, 12 contacts 42 are parallel in a direction orthogonal to the X direction. In the following description, the direction in which the contacts 42 are parallel will be referred to as a Y direction for convenience of description. As illustrated in FIG. 4, each of the contacts 42 has a bent portion 42a in which the rear portion in the X direction is bent toward the substrate 3 and a substrate connecting portion 42b extending from the lower end portion of the bent portion 42a along a main surface 3a of the substrate 3 in the surface direction. The substrate connecting portion 42b is electrically connected by solder connection or the like to, for example, a signal terminal (not illustrated) disposed on the main surface 3a of the substrate 3.

As illustrated in FIGS. 4 and 5, the plurality of contacts 40 include 12 contacts 44 as well as the 12 contacts 42. The contacts 44 are separated by a predetermined distance in a Z direction, which is orthogonal to the X direction and the Y direction, and extend in the X direction so as to overlap the contacts 42. The contacts 44 are disposed in parallel in the Y direction. In the following description, the direction orthogonal to the X direction and the Y direction will be referred to as the Z direction for convenience of description. In addition, in the Z direction, the side that is far from the substrate 3 will be referred to as an upper side and the side that is close to the substrate 3 will be referred to as a lower side with reference to the main surface 3a of the substrate 3. For example, the contact 42 on the side far from the substrate 3 in the Z direction will be referred to as an upper contact and the contact 44 on the side close to the substrate 3 in the Z direction will be referred to as a lower contact. As illustrated in FIG. 5, the X-direction front portions of the upper contact 42 (second contact) and the lower contact 44 (first contact) overlap each other in the Z direction (thickness direction of an intermediate ground plate 52 to be described later). As in the case of the upper contact 42, the lower contact 44 has a bent portion 44a in which the rear portion in the X direction is bent toward the substrate 3 and a substrate connecting portion 44b extending from the lower end portion of the bent portion 44a along the main surface 3a of the substrate 3 in the surface direction. The substrate connecting portion 44b is electrically connected by solder connection or the like to, for example, the signal terminal (not illustrated) disposed on the main surface 3a of the substrate 3.

As illustrated in FIG. 4, the plurality of ground plates 50 include the intermediate ground plate (conductive member having a plate shape) 52, an upper ground plate 54, a lower ground plate 56, and a back ground plate 58, all of which are at ground potential.

As illustrated in FIG. 6, the intermediate ground plate 52 has a plate-shaped portion 52a disposed in the front in the X direction, two arm portions 52b extending rearward from the plate-shaped portion 52a, and a substrate connecting portion 52c descending toward the substrate 3 from the rear end of the arm portion 52b. The plate-shaped portion 52a of the intermediate ground plate 52 is a part extending in parallel to the upper contact 42 and the lower contact 44 between the upper contact 42 and the lower contact 44. A plurality of through holes 53 are provided at the parts of the plate-shaped portion 52a where, the upper contact 42 and the lower contact 44 overlap each other in the Z direction. Each of the through holes 53 is used so that each of the lower contacts 44 is held with a mold when the intermediate ground plate 52 and the lower contact 44 are disposed in the mold by first insert molding to be described later. The lower end of the substrate connecting portion 52c of the intermediate ground plate 52 extends to a position reaching a ground terminal disposed on the main surface 3a of the substrate 3.

As illustrated in FIG. 7, the upper ground plate 54 has a plate-shaped portion 54a disposed in the front in the X direction, five bridge portions 54b extending rearward from the plate-shaped portion 54a at predetermined intervals in the Y direction, a belt-shaped portion 54c extending in the Y direction so as to be connected to all of the five bridge portions 54b, and a joining portion 54d extending rearward from both Y-direction ends of the belt-shaped portion 54c and joined to the back ground plate 58 to be described later. The plate-shaped portion 54a of the upper ground plate 54 is a part extending in parallel to the intermediate ground plate 52 in a state where the upper contact 42 is interposed between the plate-shaped portion 54a and the intermediate ground plate 52.

As illustrated in FIG. 8, the lower ground plate 56 has a plate-shaped portion 56a disposed in the front in the X direction, five bridge portions 56b extending rearward from the plate-shaped portion 56a at predetermined intervals in the Y direction, a belt-shaped portion 56c extending in the Y direction so as to be connected to all of the five bridge portions 56b, and a substrate connecting portion 56d descending toward the substrate 3 from both Y-direction ends of the belt-shaped portion 56c. The plate-shaped portion 56a of the lower ground plate 56 is a part extending in parallel to the intermediate ground plate 52 in a state where the lower contact 44 is interposed between the plate-shaped portion 56a and the intermediate ground plate 52.

As illustrated in FIGS. 4 and 9, the back ground plate 58 has a plate-shaped portion 58a extending in parallel to the upper ground plate 54 behind the upper ground plate 54 and joined to the joining portion 54d of the upper ground plate 54, a plate-shaped descending portion 58b descending toward the substrate 3 from the rear end of the plate-shaped portion 58a, and three substrate connecting portions 58c extending from the lower end of the descending portion 58b to a position reaching the ground terminal (not illustrated) disposed on the main surface 3a of the substrate 3. The back ground plate 58 covers the bent portion 42a of the upper contact 42 and the bent portion 44a of the lower contact 44. By means of the back ground plate 58, it is possible to suppress a situation in which the upper contact 42 and the lower contact 44 are affected by electromagnetic waves from the outside and a situation in which electromagnetic wave noise generated in the upper contact 42 and the lower contact 44 affects an electronic device around the electrical connector 1.

A spring portion 59 connected to extending portions 14A and 14B of the shell 10 to be described later is provided in both Y-direction end portions of the plate-shaped portion 58a of the back ground plate 58.

An insulating resin constitutes the resin molded body 60. As illustrated in FIG. 4, the resin molded body 60 holds and fixes each of the plurality of contacts 40 and the plurality of ground plates 50 described above at a predetermined position.

The resin molded body 60 has a connecting portion 70 and a main body portion 80. The connecting portion 70 is a part to be connected with the opposite connector and is positioned in the front of the resin molded body 60 with regard to the direction of connection. The main body portion 80 is a part to be fixed to the substrate 3 of the electronic device 2 and is positioned behind the connecting portion 70 in the direction of connection with the opposite connector.

The connecting portion 70 holds the front portion (a part) of each contact 40 with regard to the direction of connection. Specifically, the connecting portion 70 holds the upper contact 42 on one surface (surface) of the plate-shaped portion 52a of the intermediate ground plate 52 such that the upper contact 42 is separated by a predetermined distance from the plate-shaped portion 52a of the intermediate ground plate 52. In addition, the connecting portion 70 holds the lower contact 44 on the other surface (back surface) of the plate-shaped portion 52a of the intermediate ground plate 52 such that the lower contact 44 is separated by a predetermined distance from the plate-shaped portion 52a of the intermediate ground plate 52.

The connecting portion 70 holds the plate-shaped portion 54a of the upper ground plate 54 in a state where the upper contact 42 is interposed on one surface of the plate-shaped portion 52a of the intermediate ground plate 52. Likewise, the connecting portion 70 holds the plate-shaped portion 56a of the lower ground plate 56 in a state where the lower contact 44 is interposed on the other surface of the plate-shaped portion 52a of the intermediate ground plate 52. In other words, the plurality of contacts 40 (upper contact 42 and lower contact 44) are disposed on both sides of the intermediate ground plate 52 (conductive member having a plate shape) in a state of being electrically insulated from the intermediate ground plate 52 and with at least one part held by the connecting portion 70 and the other part held by the main body portion 80.

The main body portion 80 holds the rear portion (the other part) of each contact 40 and each ground plate 50 with regard to the X direction. As illustrated in FIGS. 4 and 10, the main body portion 80 has an opening portion 82 penetrating the main body portion 80 in the Z direction. The cross-sectional shape of the opening portion 82 is a rectangular shape extending in the Y direction. A part of the rear portion of each contact 40 and a part of each ground plate 50 are exposed in the opening portion 82. In other words, a part of the rear portion of the upper contact 42 and a part of the rear portion of the lower contact 44 are exposed from the opening portion 82 as exposed portions 42c and 44c, respectively. With regard to the intermediate ground plate 52, the two arm portions 52b are partially exposed from the opening portion 82. With regard to the upper ground plate 54 and the lower ground plate 56, a part of each bridge portion 54b and a part of each bridge portion 56b are exposed from the opening portion 82.

As illustrated in FIGS. 3 and 5, the main body portion 80 has a pair of flange portions 84A and 84B disposed at positions sandwiching the opening portion 82 from the Y direction. Each of the flange portions 84A and 84B extends away from the opening portion 82 along the Y direction. Each of the flange portions 84A and 84B is provided with a through hole 84a, and the extending portions 14A and 14B of the shell 10 to be described later are inserted through the through holes 84a.

Next, a procedure for manufacturing the connector assembly 30 will be described with reference to FIGS. 12 to 18.

Initially during the manufacturing of the connector assembly 30, the intermediate ground plate 52, the lower contact 44, and the lower ground plate 56 are disposed at predetermined positions in a predetermined mold and the members are integrated by means of a first resin 62 as the first insert molding (Step S1 in FIG. 12). A first molded body 32 as illustrated in FIG. 13 is obtained as a result of the first insert molding. In the first molded body 32, the lower contact 44 and the lower ground plate 56 are held and fixed on the other surface of the intermediate ground plate 52 via the first resin 62.

As illustrated in FIG. 14, the first resin 62 is formed between the intermediate ground plate 52 and the lower contact 44 and between the lower contact 44 and the lower ground plate 56. The first resin 62 is not formed in the exposed portion 44c of the lower contact 44, a part of the arm portion 52b of the intermediate ground plate 52, and a part of each bridge portion 56b of the lower ground plate 56 that are exposed in the opening portion 82 described above.

During the first insert molding, a part of the mold is inserted from above through the through hole 53 provided in the intermediate ground plate 52 and the lower contact 44 and the lower ground plate 56 are held by the part of the mold. Then, a situation in which the lower contact 44 and the lower ground plate 56 deflect toward the intermediate ground plate during the insert molding is suppressed.

After the first insert molding, the upper contact 42 and the upper ground plate 54 are disposed at predetermined positions in the predetermined mold and the members are integrated by means of a second resin 64 as second insert molding (Step S2 in FIG. 12). A second molded body 34 as illustrated in FIG. 15 is obtained as a result of the second insert molding. As illustrated in FIG. 16, in the second molded body 34, the second resin 64 is formed between the upper contact 42 and the upper ground plate 54 and on the lower side of the upper contact 42. The second resin 64 is not formed in the exposed portion 42c of the upper contact 42 and a part of each bridge portion 54b of the upper ground plate 54 that are exposed in the opening portion 82 described above.

After the second insert molding, a molded body set 36 in which the second molded body 34 is disposed on the first molded body 32 is formed as illustrated in FIGS. 17 and 18. As a result, the upper contact 42 and the upper ground plate 54 are disposed on one surface of the intermediate ground plate 52 via the second resin 64. Then, the molded body set 36 and the back ground plate 58 are disposed at predetermined positions in the predetermined mold and third insert molding is performed by means of a third resin 66 (Step S3 in FIG. 12). As a result, the connector assembly 30 described above is obtained.

In other words, the first resin 62, the second resin 64, and the third resin 66 described above constitute the resin molded body 60 of the connector assembly 30.

As illustrated in FIG. 19, the shell 10 has a tubular shape with both ends open and a conductive metal material constitutes the shell 10. The shell 10 has a tube portion 12 and the two extending portions 14A and 14B.

The tube portion 12 has a flat shape having an elliptical and annular cross section and extends along the X direction. The tube portion 12 covers the whole of the connecting portion 70 of the connector assembly 30, and the rear end portion of the tube portion 12 is fitted to the main body portion 80.

The fitting between the tube portion 12 and the main body portion 80 will be described with reference to FIG. 20.

As illustrated in FIG. 20, a part 86 (hereinafter, referred to as the front main body portion 86) of the main body portion 80 that is positioned in front of the opening portion 82 is designed such that the outer diameter of the front end of the front main body portion 86 is equal in dimension to the inner diameter of the tube portion 12 or slightly smaller in dimension than the inner diameter of the tube portion and the front main body portion 86 has an outer shape dimension gradually expanding from the front end toward the rear in the X direction. As illustrated in FIG. 20, which is a cross-sectional view, the front main body portion 86 to be joined to the rear end portion of the tube portion 12 is formed such that the entire circumferential surface that includes an upper end surface 86a and a lower end surface 86b is inclined by an angle θ with respect to an axis parallel to the X direction.

Accordingly, the stress and the frictional force with respect to an inner peripheral surface 12a of the tube portion 12 increase from the front main body portion 86 and the tube portion 12 is thinly fitted to the front main body portion 86 once the tube portion 12 is press-fitted to the front main body portion 86 along the X direction after the tube portion 12 is disposed so as to come into contact with the outer periphery of the front main body portion 86. As illustrated in FIGS. 5, 10, 11, and 19, the main body portion 80 is provided with four abutting portions 84b abutting against the rear end portion of the tube portion 12. The position at which the abutting portion 84b and the rear end portion of the tube portion 12 abut against each other is the rear end position of the front main body portion 86 (or a position in front of the position), and the tube portion is not press-fitted behind the position. In other words, a situation in which the tube portion 12 blocks the opening portion 82 of the main body portion 80 is avoided by means of the abutting portion 84b.

The extending portions 14A and 14B of the shell 10 extend from one end of the shell 10 toward the main body portion 80. Specifically, the extending portions 14A and 14B extend toward the main body portion 80 along the X direction from both Y-direction end portions of the rear end portion of the tube portion 12.

The extending portions 14A and 14B are elongated and equal in width to each other. The extending portions 14A and 14B are inserted through the through holes 84a provided in the flange portions 84A and 84B of the main body portion 80, respectively. The flange portions 84A and 84B are positioned in front of spring portions 59A and 59B in the X direction and shield the spring portions 59A and 59B when viewed from the front in the X direction, respectively. As illustrated in FIG. 21, a tip portion 14a of the extending portion 14A reaches the spring portion 59A provided on the back ground plate 58 held by the main body portion 80 via the through hole 84a of the flange portion 84A. The tip portion 14a of the extending portion 14A is elastically joined to the spring portion 59A. Specifically, the tip portion 14a of the extending portion 14A is accommodated in a U-shaped recessed portion 59a of the spring portion 59A and is urged in the Y direction and clamped between a base body portion 59b and an urging portion 59c of the spring portion 59A. The shell 10 reaches ground potential by the tip portion 14a of the extending portion 14A coming into contact with the spring portion 59A. Although not illustrated, a tip portion 14b of the extending portion 14B reaches the spring portion 59B via the through hole 84a of the flange portion 84B and is elastically joined to the spring portion 59B as in the case of the tip portion 14a of the extending portion 14A described above. Description of the manner of joining the tip portion 14b of the extending portion 14B and the spring portion 59B to each other, which is similar to the manner of joining the tip portion 14a of the extending portion 14A and the spring portion 59A to each other, will be omitted. In the present embodiment, each of the extending portions 14A and 14B may be bonded by welding or the like although no permanent bonding is performed between the spring portions 59A and 59B and the back ground plate 58.

By means of the conductive shell 10 described above, it is possible to suppress a situation in which the connector assembly 30 is affected by electromagnetic waves from the outside and a situation in which electromagnetic wave noise generated in the connector assembly 30 affects an electronic device around the electrical connector 1.

As illustrated in FIG. 2, the waterproof member 20 has an internal waterproof portion 22 and an external waterproof portion 24 configured to be integrated with each other. The waterproof member 20 is obtained by the connector assembly 30 to which the shell 10 is attached being disposed in a predetermined mold, the opening portion 82 of the main body portion 80 being filled with an insulating resin, and molding being performed such that the outer periphery of the main body portion 80 is surrounded. The resin that is used for the waterproof member 20 may be elastic to some extent. The resin is, for example, silicone rubber.

The internal waterproof portion 22 is a part with which the opening portion 82 of the main body portion 80 is filled. The internal waterproof portion 22 covers the part of each contact 40 and each ground plate 50 that is exposed from the opening portion 82 of the main body portion 80. Specifically, as illustrated in FIGS. 2 and 4, the internal waterproof portion 22 covers the exposed portions 42c and 44c of the upper contact 42 and the lower contact 44, a part of the arm portion 52b of the intermediate ground plate 52, a part of the bridge portion 54b of the upper ground plate 54, and a part of the bridge portion 56b of the lower ground plate 56. In this manner, the internal waterproof portion 22 covers all of the contact 40 and the ground plate 50 held by both the connecting portion 70 and the main body portion 80 in the opening portion 82, and thus a situation in which moisture reaches the rear end of the main body portion 80 from the connecting portion 70 through the contact 40 and the ground plate 50 is suppressed.

As illustrated in FIG. 1, the external waterproof portion 24 is an annular part that surrounds the entire circumference of the main body portion 80 which is perpendicular to the X direction. As illustrated in FIG. 2, the external waterproof portion 24 has a substantially triangular cross section tapered away from the main body portion 80 in the Z direction. In terms of dimension and shape, the external waterproof portion 24 is designed such that a top portion 24a of the external waterproof portion 24 is capable of abutting against an inner wall 4 of the accommodating space C of the electronic device 2 over the entire circumference.

The external waterproof portion 24 has a thin film portion 24b that thinly covers the surface of the rear end portion of the tube portion 12 of the shell 10. The thin film portion 24b is provided integrally with respect to the external waterproof portion 24 and covers an interface B between the rear end surface of the tube portion 12 and the waterproof member 20 over the entire circumference.

As described above, the electrical connector 1 is provided with the waterproof member 20 having the internal waterproof portion 22 and the external waterproof portion 24 in the main body portion 80, and the internal waterproof portion 22 and the external waterproof portion 24 are integrated with each other. Accordingly, the internal waterproof portion 22 covers the exposed portions 42c and 44c of the upper contact 42 and the lower contact 44 in the opening portion 82 of the main body portion 80, and rearward water immersion of the main body portion 80 along the upper contact 42 and the lower contact 44 is prevented. In addition, the external waterproof portion 24 surrounds the entire circumference of the main body portion 80 and prevents water immersion between the electrical connector 1 and the inner wall 4 of the accommodating space C of the electronic device 2. Since the internal waterproof portion 22 and the external waterproof portion 24 are integrated as described above, both internal waterproofing and external waterproofing can be realized with the simple configuration of the single waterproof member 20 in the electrical connector 1 described above.

Accordingly, assembly work can be simpler than in a case where an internal waterproofing member and an external waterproofing member are combined with each other so that both internal waterproofing and external waterproofing are realized. As a result, manufacturing cost reduction and manufacturing facility efficiency improvement can be achieved.

It should be noted that the waterproof member 20 does not necessarily have to be made of a single material and a configuration using a plurality of materials (such as two-color molding) may be adopted for the waterproof member 20 insofar as the internal waterproof portion 22 and the external waterproof portion 24 are integrated with each other in the configuration.

The electrical connector 1 described above does not necessarily have to be provided with both the upper contact 42 and the lower contact 44. The electrical connector 1 described above may be configured to be provided with either the upper contact 42 or the lower contact 44. In addition, in the electrical connector 1, the number of contacts constituting the upper contact 42 and the lower contact 44 can be appropriately increased or decreased. Further, each of the ground plates 50 is optional and a configuration lacking, for example, the intermediate ground plate 52 can be adopted as well. Also, the electrical connector 1 may be configured without the shell 10.

In the electrical connector 1, the tube portion 12 is firmly fitted to the front main body portion 86 of the main body portion 80 by the rear end portion of the shell 10 being fitted to the front end portion (front main body portion 86) of the main body portion 80 with the front main body portion 86 inclined such that the outer shape dimension of the front main body portion 86 to be joined to the rear end portion of the tube portion 12 of the shell 10 expands rearward from the front in the direction of connection (X direction).

The thin film portion 24b of the external waterproof portion 24 covers the interface B between the rear end surface of the tube portion 12 and the waterproof member 20 over the entire circumference, and thus a situation in which water intrudes into the electrical connector 1 from the interface B is significantly suppressed. In addition, the water immersion path that reaches the interface B can be extended to the same extent as the width (X-direction length) of the thin film portion 24b, and thus no water is likely to intrude into the electrical connector 1.

In the electrical connector 1, the connecting portion 70 has the first resin 62 (first resin portion) holding the lower contact 44 with respect to the intermediate ground plate 52 and the second resin 64 (second resin portion) holding the upper contact 42 with respect to the intermediate ground plate 52 and separate from the first resin 62. Also provided is the third resin 66 (third resin portion) covering the first resin 62 and the second resin 64 and separate from the first resin 62 and the second resin 64.

As described above, the first resin 62 is formed by the first insert molding (Step S1 in FIG. 12) and the second resin 64 is formed by the second insert molding (Step S2 in FIG. 12).

Deflection of the lower contact 44 can be suppressed by a predetermined mold being used during the first insert molding. Specifically, a situation in which the lower contact 44 deflects toward the intermediate ground plate 52 is suppressed by a mold that has a part which can be inserted through the through hole 53 provided in the intermediate ground plate 52 being used and insert molding being performed in a state where the lower contact 44 is held by the mold. Also during the second insert molding, deflection of the upper contact 42 can be suppressed by a predetermined mold being used. During the second insert molding, the intermediate ground plate 52 is not integrated, and thus the upper contact 42 is unlikely to deflect.

The disposition and the shape of the mold that is used for each molding step can be appropriately changed based on the above-described division into the first insert molding (step for molding the first molded body 32) and the second insert molding (step for molding the second molded body 34). As a result, deflection of the upper contact 42 and the lower contact 44 can be suppressed. Accordingly, the upper contact 42 and the lower contact 44 are capable of realizing a high level of relative positional accuracy with respect to the intermediate ground plate 52.

During the first insert molding, a part of the mold is inserted from above through the through hole 53 provided in the plate-shaped portion 52a of the intermediate ground plate 52 and the lower contact 44 can be held so as not to deflect upward. In a case where the intermediate ground plate 52 is integrated during the second insert molding without being integrated during the first insert molding, the upper contact 42 can be held so as not to deflect downward by a part of the mold being inserted from below through the through hole 53 during the second insert molding.

The first resin 62, the second resin 64, and the third resin 66 may be resin materials of the same type or resin materials of different types.

In the electrical connector 1, the shell 10 has the tube portion 12 and the extending portions 14A and 14B. The extending portions 14A and 14B are elastically connected to the spring portion 59 by extending to the spring portion 59 (ground member) of the back ground plate 58 of the main body portion 80.

The shell 10 and the back ground plate 58 can be electrically connected to each other by the extending portions 14A and 14B of the shell 10 being elastically joined to the spring portion 59 of the back ground plate 58. In other words, the shell 10 and the back ground plate 58 can be electrically interconnected with a simple configuration without welding. As a result, the electrical connector 1 can be relatively inexpensive. In the electrical connector according to the related art, electrical connection between a shell and a back shell (back ground plate) is realized by welding, and thus pre-welding electrical connection is insufficient and initial electrical connection is possible after the welding. Accordingly, in the electrical connector according to the related art, insufficient electrical connection may arise in the event of a shell-back shell welding problem. In the electrical connector 1 described above, in contrast, insufficient electrical connection attributable to a welding problem does not occur and the shell 10 and the back ground plate 58 can be electrically interconnected with reliability.

In the electrical connector 1, the shell 10 and the back ground plate 58 are not welded to each other, and thus no welding facility is necessary and manufacturing cost reduction can be achieved. In addition, welding work-related labor and time can be reduced and manufacturing efficiency improvement can be achieved.

REFERENCE SIGNS LIST

1: electrical connector, 2: electronic device, 3: substrate, 4: inner wall, 10: shell, 12: tube portion, 14A, 14B: extending portion, 20: waterproof member, 22: internal waterproof portion, 24: external waterproof portion, 30: connector assembly, 32: first molded body, 34: second molded body, 36: molded body set, 40, 42, 44: contact, 42c, 44c: exposed portion, 50, 52, 54, 56, 58: ground plate, 59, 59A, 59B: spring portion, 60: resin molded body, 62: first resin, 64: second resin, 66: third resin, 70: connecting portion, 80: main body portion, 82: opening portion, 84A, 84B: flange portion, 84a: through hole, C: accommodating space.

ELECTRIC CONNECTOR AND MANUFACTURING METHOD THEREOF

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