Pressure contact type connector and manufacturing method of the same

Abstract

A pressure contact type connector includes: an upper flat plate portion; a lower flat plate portion which is disposed below the upper flat plate portion; a first spring portion which connects the upper and lower flat plate portions; and a second spring portion which extends upward from the lower flat plate portion and applies a resilient force to the upper flat plate portion, in which the first and second spring portions are wound about the upper flat plate portion when viewed from above in a plan view, and extend so that the spring portions do not interfere with each other when being compressed and extended in the vertical direction, the first spring portion is formed to be bent so that a width dimension is larger than a thickness dimension, and the second spring portion is formed to be bent so that a width dimension is larger than a thickness dimension.

Claims

1. A pressure contact type connector comprising: a base portion that is formed of metal; a contact point portion that is formed of metal; a first spring portion that couples the base portion to the contact point portion and is wound; a support portion that is provided between the contact point portion and the base portion; and a second spring portion that couples the base portion and the support portion and is wound, wherein the first spring portion and the second spring portion are wound in the same direction about the contact point portion in a plan view from an upper side.

2. A pressure contact type connector comprising: a base portion that is formed of metal; a contact point portion that is formed of metal; a first spring portion that couples the base portion and the contact point portion and is wound; a support portion; and a second spring portion that couples the base portion and the support portion and is wound; wherein the first spring portion and the second spring portion are wound in the same direction about the contact point portion in a plan view from an upper side, and wherein when the contact point portion is pressed toward the side of the base portion, restoring force is generated in the first spring portion and the second spring portion.

3. The pressure contact type connector according to claim 1, wherein the contact point portion has a plate shape.

4. The pressure contact type connector according to claim 2, wherein the contact point portion has a plate shape.

5. The pressure contact type connector according to claim 1, wherein the contact point portion is provided with a protrusion.

6. The pressure contact type connector according to claim 1, wherein the support portion has a plate shape.

7. The pressure contact type connector according to claim 1, wherein a stopper is provided outside the first spring portion or the second spring portion.

8. The pressure contact type connector according to claim 7, wherein the stopper portion is connected to the base portion.

9. The pressure contact type connector according to claim 1, wherein the first spring portion and the second spring portion or either the first spring portion or the second spring portion is formed by being bent into an L shape.

10. The pressure contact type connector according to claim 9, wherein the first spring portion and the second spring portion has the same number of portions bent into the L shapes.

11. The pressure contact type connector according to claim 1, wherein the width of the first spring portion is narrower on the side of the contact point portion than on the side of the base portion.

12. The pressure contact type connector according to claim 1, wherein the base portion, the first spring portion, the second spring portion, the contact point portion, and the support portion are formed by bending one punched metal plate.

13. The pressure contact type connector according to claim 1, wherein an edge of the contact point portion has a rounded portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view showing an outline of a pressure contact type connector according to an example embodiment.

(2) FIGS. 2A and 2B are views showing the pressure contact type connector according to an example embodiment, FIG. 2A is a plan view showing the pressure contact type connector when viewed from a Z1 direction side shown in FIG. 1, and FIG. 2B is a side view showing the pressure contact type connector when viewed from a Y2 direction side shown in FIG. 1.

(3) FIGS. 3A and 3B are views showing the pressure contact type connector according to an example embodiment, FIG. 3A is a sectional view showing a section taken along line A-A shown in FIG. 2A, and FIG. 3B is a sectional view showing a section taken along line B-B shown in FIG. 2A.

(4) FIGS. 4A and 4B are schematic views for explaining an operation of the pressure contact type connector according to an example embodiment, FIG. 4A is a schematic sectional view showing an initial state of the pressure contact type connector, and FIG. 4B is a schematic sectional view showing an operation state of the pressure contact type connector.

(5) FIG. 5 is a flow chart showing a process of a manufacturing method of the pressure contact type connector according to an example embodiment.

(6) FIGS. 6A and 6B are views showing the pressure contact type connector according to an example embodiment, FIG. 6A is a perspective view showing an outline of the pressure contact type connector, and FIG. 6B is a perspective view showing the pressure contact type connector when viewed from an X1 direction side shown in FIG. 6A.

(7) FIGS. 7A and 7B are views showing the pressure contact type connector according to an example embodiment, FIG. 7A is a plan view showing the pressure contact type connector when viewed from a Z1 direction side shown in FIGS. 6A and 6B, and FIG. 7B is a side view showing the pressure contact type connector when viewed from a Y2 direction side shown in FIGS. 6A and 6B.

(8) FIG. 8 is a sectional view showing a section of the pressure contact type connector according to an example embodiment taken along line C-C shown in FIGS. 7A and 7B.

(9) FIGS. 9A and 9B are schematic views for explaining an operation of the pressure contact type connector according to an example embodiment, FIG. 9A is a schematic sectional view showing an initial state of the pressure contact type connector, and FIG. 9B is a schematic sectional view showing an operation state of the pressure contact type connector.

(10) FIG. 10 is a flow chart showing a process of a manufacturing method of the pressure contact type connector according to an example embodiment.

(11) FIGS. 11A and 11B are views showing a pressure contact type connector according to an example embodiment, FIG. 11A is a plan view showing an outline of the pressure contact type connector, and FIG. 11B is a sectional view showing a section taken along line D-D shown in FIG. 11A.

(12) FIGS. 12A and 12B are views showing a pressure contact type connector according to an example embodiment, FIG. 12A is a perspective view showing an outline of the pressure contact type connector, and FIG. 12B is an exploded perspective view showing a configuration of the pressure contact type connector.

(13) FIGS. 13A and 13B are views showing a structure of a connection terminal of a pressure contact type connector disclosed in Japanese Unexamined Patent Application Publication No. 2010-118256, FIG. 13A is a plan view showing an outline of the connection terminal, and FIG. 13B is a sectional view showing a section taken along line Z-Z shown in FIG. 13A.

DETAILED DESCRIPTION OF THE DISCLOSURE

(14) The following description is intended to convey a thorough understanding of the embodiments described by providing a number of specific embodiments and details involving a pressure contact type connector and manufacturing method of the same. It should be appreciated, however, that the present invention is not limited to these specific embodiments and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending on specific design and other needs.

(15) First, a configuration of a pressure contact type connector 1 according to an example embodiment will be described with reference to FIGS. 1 to 3B. FIG. 1 is a perspective view showing an outline of the pressure contact type connector 1 according to the example embodiment. FIGS. 2A and 2B are views showing the pressure contact type connector 1 according to the first embodiment, FIG. 2A is a plan view showing the pressure contact type connector 1 when viewed from a Z1 direction side shown in FIG. 1, and FIG. 2B is a side view showing the pressure contact type connector 1 when viewed from a Y2 direction side shown in FIG. 1. FIGS. 3A and 3B are views showing the pressure contact type connector 1 according to the example embodiment, FIG. 3A is a sectional view showing a section taken along line A-A shown in FIG. 2A, and FIG. 3B is a sectional view showing a section taken along line B-B shown in FIG. 2A.

(16) As shown in FIG. 1, the pressure contact type connector 1 may be formed of a metal plate, which may include an L-shaped portion 1n which may include an upper plate portion 1k extending along a vertical direction (Z1-Z1 direction) and having a bent tip and an intermediate plate portion 1m connected to the lower side of the upper plate portion 1k and extending along a first direction (X1-X2 direction and one direction with respect to the upper plate portion 1k), and an L-shaped portion 1q which may include a lower plate portion 1p extending along the vertical direction and having a bent tip and an intermediate plate portion 1r connected to the upper side of the lower plate portion 1p and extending along a second direction (Y1-Y2 direction and one direction with respect to the lower plate portion 1p) in a horizontal direction. In addition, the pressure contact type connector 1 may include an upper flat plate portion 1a which may be formed by bending the upper plate portion 1k so as to extend along the other direction (second direction) which is the horizontal direction and is orthogonal to the first direction (one direction with respect to the upper plate portion 1k), and a lower flat plate portion 1b which is formed by bending the lower plate portion 1p so as to extend along the other direction (first direction) which is the horizontal direction and is orthogonal to the second direction (one direction with respect to the lower plate portion 1p). That is, the pressure contact type connector 1 may include the upper flat plate portion 1a which may extend in a flat plate shape along the horizontal direction including the X1-X2 direction and the Y1-Y2 direction, and the lower flat plate portion 1b which may extend in a flat plate shape along the horizontal direction and may be disposed below the upper flat plate portion 1a. In addition, as shown in FIGS. 2A and 2B, the upper flat plate portion 1a and the lower flat plate portion 1b may be disposed so that the upper flat plate portion 1a overlaps with the lower flat plate portion 1b in the vicinity of the center portion of the lower flat plate portion 1b when the pressure contact type connector 1 is viewed from above (Z1 direction side) in a plan view.

(17) In addition, a first spring portion 1c or a second spring portion 1d may be formed by bending the intermediate plate portions 1m and 1r of a metal plate having the L-shaped portions 1n and 1q so as to be wound around a virtual center line which is set along the vertical direction, and the intermediate plate portion 1m extending from the upper plate portion 1k and the intermediate plate portion 1r from the lower plate portion 1p are integrally formed so as to be connected to each other. In addition, in such an embodiment, in the first spring portion 1c and the second spring portion 1d, the intermediate plate portion 1m extending from the upper plate portion 1k and the intermediate plate portion 1r extending from the lower plate portion 1p may be formed so as to be bent and wound around the virtual center line set along the vertical direction, and are connected to each other so as to be integrally formed. That is, the pressure contact type connector 1 may include the first spring portion 1c which may connect one end portion (Y1 direction side end portion) of the upper flat plate portion 1a and one end portion (X1 direction side end portion) of the lower flat plate portion 1b and may have elasticity in the vertical direction, and the second spring portion 1d which may extend from the other end portion (X2 direction side end) of the lower flat plate portion 1b toward the upper flat plate portion 1a, may have elasticity in the vertical direction, and may apply a resilient force to the upper flat plate portion 1a. In addition, in such an embodiment, the second spring portion 1d may extend upward from the other end portion of the lower flat plate portion 1b and may not be connected to the upper flat plate portion 1a. However, the second spring portion 1d may be formed so that the second spring portion 1d extends downward toward the lower flat plate portion 1b from the other end portion (Y2 direction side end portion) of the upper flat plate portion 1a and may not be connected to the lower flat plate portion 1b, or may be formed so that the second spring portion 1d is connected to the lower flat plate portion 1b. In an example embodiment, when the pressure contact type connector 1 is viewed from above in a plan view, the first spring portion 1c and the second spring portion 1d may be wound in the same direction about the upper flat plate portion 1a, and extends so that the spring portions 1c and 1d do not interfere with each other when being compressed and extended in the vertical direction. In addition, the first spring portion 1c and the second spring portion 1d may come into slide-contact with each other when being compressed and extended in the vertical direction, and may be positioned so that the operations in the vertical direction are not hindered.

(18) In addition, an auxiliary upper flat plate portion 1h may be disposed below the upper flat plate portion 1a, the upper flat plate portion 1a may extend from the first spring portion 1c, the auxiliary upper flat plate portion 1h may extend from the second spring portion 1d, and the upper flat plate portion 1a may be disposed above the auxiliary upper flat plate portion 1h. The upper flat plate portion 1a and the auxiliary upper flat plate portion 1h may be disposed so as to be separated from each other in the vertical direction in a contactable manner. In such an embodiment, the end portion of the upper side (Z1 direction side) of the second spring portion 1d may be connected to the other end portion (Y2 direction side end portion) of the auxiliary upper flat plate portion 1h. The first spring portion 1c may be formed so as to be bent with respect to the upper flat plate portion 1a and the lower flat plate portion 1b, and the first spring portion 1c may protrude upward from the one end portion (a position near the Y1 direction on the X1 direction side) of the lower flat plate portion 1b and may be bent so as to be wound at the upper side of the lower flat plate portion 1b. In addition, the second spring portion 1d may be formed so as to be bent with respect to at least one of the upper flat plate portion 1a and the lower flat plate portion 1b, and, the second spring portion 1d may be formed so as to be bent with respect to the upper flat plate portion 1a and the lower flat plate portion 1b, protrudes from one (a position near the Y2 direction on the X2 direction side) of the other end portion of the auxiliary upper flat plate portion 1h and the other end portion of the lower flat plate portion 1b toward the other, and is bent so as to be wound at the upper side of the lower flat plate portion 1b.

(19) Moreover, the first spring portion 1c and the second spring portion 1d may be formed so that a width dimension W of a material in the vertical direction is larger than a thickness dimension T in the horizontal direction, and the width dimension W in the vertical direction of each of the first spring portion 1c and the second spring portion 1d decreases from the lower side toward the upper side in the entirety thereof. For example, as shown by W11, W12, W13, and W14 in FIGS. 3A and 3B, the width dimensions W in the vertical direction of the first spring portion 1c may be different from one another according to the location. When W11, W12, W13, and W14 are arranged in a location order close to the lower side (lower flat plate portion 1b), W11, W12, W13, and W14 are positioned in this order, and a magnitude relationship of W11>W12>W13>W14 is satisfied. Also in the second spring portion 1d, as shown by W21, W22, W23, and W24, the width dimensions W in the vertical direction are different from one another according to the location. When W21, W22, W23, and W24 are arranged in a location order close to the lower side (lower flat plate portion 1b), W21, W22, W23, and W24 are positioned in this order, and a magnitude relationship of W21>W22>W23>W24 is satisfied. In addition, as shown in FIGS. 2A and 2B, stopper portions 1e which may be formed to protrude upward are connected to the lower flat plate portion 1b at locations of noninterference with the first spring portion 1c and the second spring portion 1d. The stopper portion 1e may be provided outside the first spring portion 1c and the second spring portion 1d, and in FIGS. 2A and 2B, the stopper portions 1e may be provided at the position near the X2 direction at the Y1 direction side end portion of the lower flat plate portion 1b, and at the position near the X1 direction at the Y2 direction side end portion. A height dimension H of each of the stopper portions 1e may be the same as a height dimension h of each of the base portions if of the first spring portion 1c and the second spring portion 1d on the lower flat plate portion 1b.

(20) In addition, in the pressure contact type connector 1 of an example embodiment, the height dimension H may be the same as the height dimension h. However, the height dimension H may be equal to or more than the height dimension h, or may be equal to or more than the width dimension in the vertical direction.

(21) Next, an operation of the pressure contact type connector 1 will be described with reference to FIGS. 4A and 4B. FIGS. 4A and 4B are schematic views for explaining the operation of the pressure contact type connector 1 according to an example embodiment, FIG. 4A is a schematic sectional view showing an initial state of the pressure contact type connector 1, and FIG. 4B is a schematic sectional view showing the operation state of the pressure contact type connector 1.

(22) When the pressure contact type connector 1 is actually used, as shown in FIGS. 4A and 4B, the pressure contact type connector 1 may be used for connection between a wiring pattern PT1 on a circuit substrate of a mounted electric device and a wiring pattern PT2 of a different circuit substrate, or the like. In descriptions below, a case where the pressure contact type connector 1 is disposed on the wiring pattern PT1 and the wiring pattern PT2 is disposed so as to overlap the pressure contact type connector 1 is described. However, the present invention is not limited to this.

(23) The pressure contact type connector 1 disposed on the wiring pattern PT1 may be disposed so that the lower flat plate portion 1b comes into contact with the wiring pattern PT1, and the pressure contact type connector 1 and the wiring pattern PT1 are electrically connected to each other. In the initial state in which the wiring pattern PT2 may not be disposed on the pressure contact type connector 1, as shown in FIG. 4A, the upper flat plate portion 1a of the pressure contact type connector 1 may protrude upward by elastic forces of the first spring portion 1c and the second spring portion 1d. In addition, the upper flat plate portion 1a and the auxiliary upper flat plate portion 1h may be separated from each other.

(24) When the wiring pattern PT2 may be disposed on the pressure contact type connector 1, as shown in FIG. 4B, the upper flat plate portion 1a and the auxiliary upper flat plate portion 1h come into contact with each other, and in a state where the second spring portion 1d assists the first spring portion 1c, the first spring portion 1c and the second spring portion 1d may be bent downward (to the Z2 direction). In this case, the pressure contact type connector 1 and the wiring pattern PT2 come into pressure-contact with each other, and thus, the pressure contact type connector 1 and the wiring pattern PT2 are electrically and stably connected to each other. That is, the wiring substrate including the wiring pattern PT1 and the wiring substrate including the wiring pattern PT2 may be electrically connected to each other via the pressure contact type connector 1.

(25) The pressure contact type connector 1 may include: the upper flat plate portion 1a which extends in a flat plate shape along the horizontal direction; the lower flat plate portion 1b which extends in a flat plate shape along the horizontal direction and is disposed below the upper flat plate portion 1a; the first spring portion 1c which connects the one end portion of the upper flat plate portion 1a and the one end portion of the lower flat plate portion 1b and has elasticity in the vertical direction; and a second spring portion 1d which extends from the other end portion of the lower flat plate portion 1b toward the upper flat plate portion 1a, includes elasticity in the vertical direction, and is configured to apply a resilient force to the upper flat plate portion 1a, in which the first spring portion 1c and the second spring portion 1d are wound in the same direction about the upper flat plate portion 1a when viewed from above in a plan view, and extend so that the first spring portion and the second spring portion do not interfere with each other when the spring portions are compressed and extended in the vertical direction, the first spring portion 1c is formed so as to be bent with respect to the upper flat plate portion 1a and the lower flat plate portion 1b so that the width dimension W in the vertical direction is larger than the thickness dimension T in the horizontal direction, and the second spring portion 1d is formed so as to be bent with respect to at least one of the upper flat plate portion 1a and the lower flat plate portion 1b so that the width dimension W in the vertical direction is larger than the thickness dimension T in the horizontal direction.

(26) Accordingly, the first spring portion 1c and the second spring portion 1d may be formed so that the thickness direction of the first spring portion 1c and the thickness direction of the second spring portion 1d are the horizontal directions, and thus, a reduction in the size of the pressure contact type connector in the horizontal direction is achieved. In addition, when viewed from the side, since it is possible to increase width dimensions of the first spring portion 1c and the second spring portion 1d with respect to the directions in which the first spring portion 1c and the second spring portion 1d are wound, it is possible to obtain a large elastic force. Accordingly, it is possible to provide the pressure contact type connector capable of having a reduced mounting area and obtaining a large elastic force. Moreover, it is possible to securely connect the pressure contact type connector and a contacted portion by the upper flat plate portion, the lower flat plate portion, the first spring, and the second spring.

(27) In addition, in the pressure contact type connector 1 of such an embodiment, the upper flat plate portion 1a may be formed by bending the upper plate portion 1k of a metal plate having the L-shaped portion 1n, which includes the upper plate portion 1k extending along the vertical direction and the intermediate plate portion 1m connected to the lower side of the upper plate portion 1k and extending in one direction in the horizontal direction, so as to extend along the other direction which is the horizontal direction and is orthogonal to the one direction, and the first spring portion 1c or the second spring portion 1d may be formed by bending the intermediate plate portion 1m of metal plate having the L-shaped portion 1n so as to be wound around a virtual center line which is set along the vertical direction.

(28) Accordingly, the upper plate portion 1k of a metal plate having the L-shaped portion 1n extending along the one direction in the horizontal direction may be formed so as to be bent to extend along the other direction in the horizontal direction, and thus, it is possible to easily configure the upper flat plate portion 1a by bending it once.

(29) Moreover, in the pressure contact type connector 1 of an example embodiment, the lower flat plate portion 1b may be formed by bending the lower plate portion 1p of a metal plate having the L-shaped portion 1q, which includes the lower plate portion 1p extending along the vertical direction and the intermediate plate portion 1r connected to the upper side of the lower plate portion 1p and extending in one direction in the horizontal direction, so as to extend along the other direction which is the horizontal direction and is orthogonal to the one direction, and the first spring portion 1c or the second spring portion 1d may be formed by bending the intermediate plate portion 1r of a metal plate having the L-shaped portion 1q so as to be wound around a virtual center line which is set along the vertical direction.

(30) Accordingly, the lower plate portion 1p of metal plate having the L-shaped portion 1q extending along the one direction in the horizontal direction may be formed so as to be bent to extend along the other direction in the horizontal direction, and thus, it is possible to easily configure the lower flat plate portion 1b by bending it once.

(31) Moreover, in the pressure contact type connector 1 of such an embodiment, the first spring portion 1c may protrude upward from the one end portion of the lower flat plate portion 1b and may be bent so as to be wound at the upper side of the lower flat plate portion 1b, and the second spring portion 1d may protrude from the other end portion of the lower flat plate portion 1b toward the upper flat plate portion 1a, and may be bent so as to be wound at the upper side of the lower flat plate portion 1b.

(32) Accordingly, when viewed from above in a plan view, since the lower flat plate portion 1b does not protrude from the first spring portion 1c and the second spring portion 1d in at least the one end portion (X1 direction side end portion) of the lower flat plate portion 1b and the other end portion (X2 direction side end portion) of the lower flat plate portion 1b, it is possible to decrease the mounting area. Moreover, also in the Y1 direction side end portion and the Y2 direction side end portion of the lower flat plate portion 1b, since the lower flat plate portion 1b does not protrude outside from the first spring portion 1c and the second spring portion 1d, it is possible to further decrease the mounting area.

(33) In addition, in the pressure contact type connector 1, the stopper portion 1e, which may be formed to protrude upward at a location of noninterference with the first spring portion 1c and the second spring portion 1d, may be connected to the lower flat plate portion 1b, and the height dimension H of the stopper portion 1e may be the same as the height dimension h of the base portion if of each of the first spring portion 1c and the second spring portion 1d on the lower flat plate portion 1b.

(34) Accordingly, when the first spring portion 1c and the second spring portion 1d are pressed downward more than necessary via the upper flat plate portion 1a by a part A such as an electronic device, since the stopper portion 1e comes into contact with the part A, it is possible to limit the displacement amount in the vertical direction of each of the first spring portion 1c and the second spring portion 1d, and thus, it is possible to prevent the first spring portion 1c and the second spring portion 1d from being damaged. Moreover, since the height dimension H of the stopper portion 1e is the same as the height dimension h of the base portion if of each of the first spring portion 1c and the second spring portion 1d on the lower flat plate portion 1b, it is possible to more securely prevent the first spring portion 1c and the second spring portion 1d from being plastically deformed.

(35) In the pressure contact type connector 1, the stopper portion 1e may be provided outside the first spring portion 1c and the second spring portion 1d.

(36) Accordingly, when the pressure contact type connector 1 is viewed from above in a plan view, since the stopper portion 1e is provided outside the first spring portion 1c and the second spring portion 1d, it is possible to prevent a finger or the like from coming into direct-contact with the first spring portion 1c and the second spring portion 1d from the side. Therefore, it is possible to prevent the first spring portion 1c and the second spring portion 1d from being damaged. Moreover, when the first spring portion 1c and the second spring portion 1d extend and contract in the vertical direction, the stopper can function as a guide.

(37) In addition, in the pressure contact type connector 1, the width dimension in the vertical direction of each of the first spring portion 1c and the second spring portion 1d may decrease from the lower side toward the upper side in the entirety thereof.

(38) Accordingly, since the width dimension W in the vertical direction of each of the first spring portion 1c and the second spring portion 1d decreases from the lower side toward the upper side, it is possible to obtain an elastic force required for a stable electrical connection, and it is possible to lengthen strokes of (to easily bent) the first spring portion 1c and the second spring portion 1d. Moreover, the width dimension may decrease from the lower side toward the upper side in the entirety thereof, and the width may partially increase.

(39) In the pressure contact type connector 1, the second spring portion 1d may be connected to the other end portion of the lower flat plate portion 1b, and the auxiliary upper flat plate portion 1h extending from the second spring portion 1d may be provided on the lower side of the upper flat plate portion 1a.

(40) Accordingly, the upper flat plate portion 1a may be configured to be disposed to overlap the auxiliary upper flat plate portion 1h, and thus, the pressure applied to the upper flat plate portion 1a may be equally applied to the first spring portion 1c and the second spring portion 1d. Therefore, when the first spring portion 1c and the second spring portion 1d are pressed, the first spring portion 1c and the second spring portion 1d are not easily inclined, a predetermined elastic force can be obtained, and disadvantages such as deformation due to inclination do not easily occur.

(41) In the pressure contact type connector 1, the upper flat plate portion 1a and the auxiliary upper flat plate portion 1h may be disposed so as to be separated from each other in the vertical direction in a contactable manner.

(42) Accordingly, since the upper flat plate portion 1a and the auxiliary upper flat plate portion 1h are disposed so as to be separated from each other, when a surface treatment such as plating is performed after the shape of the pressure contact type connector 1 is formed, the surface treatment is also performed on the lower surface of the upper flat plate portion 1a and the upper surface of the auxiliary upper flat plate portion 1h, and thus, it is possible to prevent corrosion.

(43) In addition, in the pressure contact type connector 1, when viewed from above, since the first spring portion 1c and the second spring portion 1d are disposed to oppose each other while the upper flat plate portion 1a is interposed therebetween, the upper flat plate portion 1a is not easily inclined when being pressed and can easily move along the vertical direction.

(44) Hereinafter, a manufacturing method MP of the pressure contact type connector 1 according to an example embodiment will be described with reference to FIG. 5. FIG. 5 is a flow chart showing a process of the manufacturing method MP of the pressure contact type connector 1 according to an example embodiment. The manufacturing method MP includes a punching step MP1, a first winding step MP2, a second winding step MP3, a third bending step MP4, a second bending step MP5, and a first bending step MP6. As shown in FIG. 5, first, the punching step MP1 is performed. In the punching step MP1, a punched body 5 (not shown), which may include the lower flat plate portion 1b, the first spring portion 1c extending from the one end portion of the lower flat plate portion 1b integrally with the upper flat plate portion 1a, and the second spring portion 1d extending from the other end portion of the lower flat plate portion 1b, may be formed in an integral flat plate shape from one metal plate. After the punching step MP1, the first winding step MP2 may be performed. In the first winding step MP2, the punched body 5 may be formed so as to be bent and wound the first spring portion 1c. After the first winding step MP2, the second winding step MP3 may be performed. In the second winding step MP3, the punched body 5 may be formed so as to be bent to wind the second spring portion 1d. In addition, the second winding step MP3 may be performed after the punching step MP1, and thereafter, the first winding step MP2 may be performed. After the second winding step MP3, the third bending step MP4 may be performed. In the third bending step MP4, the punched body 5 may be formed so as to be bent to extend the stopper portion 1e upward. After the third bending step MP4, the second bending step MP5 may be performed. In the second bending step MP5, the second spring portion 1d may be bent so as to stand upright with respect to the lower flat plate portion 1b. After the second bending step MP5, the first bending step MP6 may be performed. In the first bending step MP6, the first spring portion 1c stands upright with respect to the lower flat plate portion 1b so that the first spring portion 1c does not interfere with the second spring portion 1d. According to the manufacturing processes, the pressure contact type connector 1 is completed. Moreover, the manufacturing process is described in which the third bending step MP4 is performed after the first winding step MP2 and the second winding step MP3. However, for example, the second bending step MP5 and the first bending step MP6 may be performed after the first winding step MP2 and the second winding step MP3, and thereafter, the third bending step MP4 may be performed. In addition, the upper flat plate portion 1a is formed at the first winding step MP2, and the auxiliary upper flat plate portion 1h is formed at the second winding step MP3.

(45) The manufacturing method MP of the pressure contact type connector 1, may include: the punching step MP1 of forming the punched body 5, which includes the lower flat plate portion 1b, the first spring portion 1c extending from one end portion of the lower flat plate portion 1b integrally with the upper flat plate portion 1a, and the second spring portion 1d extending from the other end portion of the lower flat plate portion 1b opposing the one end portion of the lower flat plate portion 1b while interposing the lower flat plate portion 1b, in an integral flat plate shape from one metal plate; the first winding step MP2 of bendingly forming the first spring portion 1c so as to be wound after the punching step MP1; the second winding step MP3 of bendingly forming the second spring portion 1d so as to be wound after the punching step MP1; the second bending step MP5 of bending the second spring portion 1d so as to stand upright with respect to the lower flat plate portion 1b after the second winding step MP3; and the first bending step MP6 of bending the first spring portion 1c so as to stand upright with respect to the lower flat plate portion 1b so that the first spring portion 1c does not interfere with the second spring portion 1d after the first winding step MP2 and the second bending step MP5.

(46) Accordingly, since it is possible to form the pressure contact type connector from one metal plate, it is possible to decrease the number of parts.

(47) In the embodiment described above, the integrated intermediate portions 1m and 1r may be bent three times by approximately 90, and are formed within a range of approximately 270 in a plan view. However, the intermediate portions may be formed in a spiral shape in which arcs are formed, and the formation range may be 90 or more, and preferably, may be 180 or more.

(48) A configuration of a pressure contact type connector 2 an example embodiment will be described with reference to FIGS. 6A to 8. FIGS. 6A and 6B are views showing the pressure contact type connector 2 according to the second embodiment, FIG. 6A is a perspective view showing an outline of the pressure contact type connector 2, and FIG. 6B is a perspective view showing the pressure contact type connector 2 when viewed from the X1 direction side shown in FIG. 6A. FIGS. 7A and 7B are views showing the pressure contact type connector 2 according to the second embodiment, FIG. 7A is a plan view showing the pressure contact type connector 2 when viewed from the Z1 direction side shown in FIGS. 6A and 6B, and FIG. 7B is a side view showing the pressure contact type connector 2 when viewed from the Y2 direction side shown in FIGS. 6A and 6B. FIG. 8 is a sectional view showing a section of the pressure contact type connector 2 according to the second embodiment taken along line C-C shown in FIGS. 7A and 7B.

(49) As shown in FIGS. 6A and 6B, the pressure contact type connector 2 may include: an upper flat plate portion 2a which may extend along the horizontal direction including the X1-X2 direction and the Y1-Y2 direction and has a flat plate shape; a lower flat plate portion 2b which may extend along the horizontal direction, may have a flat plate shape and may be disposed below the upper flat plate portion 2a; and a spring portion 2c which may connect one end portion (end portion of the X2 direction side) of the upper flat plate portion 2a and one end portion (end portion of the X1 direction side) of the lower flat plate portion 2b and has elasticity in the vertical direction (Z1-Z2 direction). The pressure contact type connector 2 may be formed of a metal plate, which may include an L-shaped portion 2f which may include an upper plate portion 2d extending along the vertical direction and having a bent tip and an intermediate plate portion 2e connected to the lower side (Z2 direction side) of the upper plate portion 2d and extending along one direction (Y1-Y2 direction) in the horizontal direction, and an L-shaped portion 2m which includes a lower plate portion 2g extending along the vertical direction and an intermediate plate portion 2n connected to the upper side (Z1 direction side) of the lower plate portion 2g and extending along one direction in the horizontal direction. The upper flat plate portion 2a may be formed by bending the upper plate portion 2d so as to extend along the other direction (X1-X2 direction) which is the horizontal direction and is orthogonal to the one direction, and the lower flat plate portion 2b is formed by bending the lower plate portion 2g so as to extend along the other direction which is the horizontal direction and is orthogonal to the one direction.

(50) As shown in FIGS. 7A and 7B, the spring portion 2c may be formed so as to be bent with respect to the upper flat plate portion 2a and the lower flat plate portion 2b, and may be formed by bending the intermediate plate portions 2e and 2n of a metal plate having the L-shaped portions 2f and 2m so as to be wound around the virtual center line set along the vertical direction and by connecting the intermediate plate portion 2e extending downward from the upper plate portion 2d and the intermediate plate portion 2n extending upward from the lower plate portion 2g. In addition, the width dimension W of a material in the vertical direction of the spring portion 2c is larger than the thickness dimension T in the horizontal direction. As shown in FIG. 8, the width dimension W in the vertical direction of the spring portion 2c may decrease from the lower side toward the upper side in the entirety thereof. For example, as shown by W1, W2, and W3 in FIG. 8, the width dimensions W in the vertical direction of the spring portion 2c are different from one another according to the location. When W1, W2, and W3 are arranged in a location order close to the lower side (lower flat plate portion 2b), W1, W2, and W3 are positioned in this order, and a magnitude relationship of W1>W2>W3> is satisfied.

(51) In addition, as shown in FIGS. 7A and 7B, stopper portions 2h which are formed to protrude upward may be connected to the lower flat plate portion 2b at locations of noninterference with the spring portion 2c. The stopper portions 2h may be provided outside the spring portions 2c when viewed from above in a plan view. In addition, the stopper portions 2h may be formed so as to protrude upward from the end portions of the X2 direction side, the Y1 direction side, and the Y2 directions side of the lower flat plate portion 2b. A height dimension h of each of the stopper portions 2h may be the same as a height dimension H of a base portion 2k of each of the spring portions 2c connected to the lower flat plate portion 2b. In addition, the height dimension h may be the same as the height dimension H. However, the height dimension h of the stopper portion 2h may be equal to or more than the height dimension H of the base portion 2k or equal to or more than the width dimension in the vertical direction of the spring portion 2c.

(52) Next, the operation of the pressure contact type connector 2 will be described with reference to FIGS. 9A and 9B. FIGS. 9A and 9B are schematic views for explaining the operation of the pressure contact type connector 2 according to an example embodiment, FIG. 9A is a schematic sectional view showing an initial state of the pressure contact type connector 2, and FIG. 9B is a schematic sectional view showing the operation state of the pressure contact type connector 1.

(53) When the pressure contact type connector 2 is actually used, as shown in FIGS. 9A and 9B, the pressure contact type connector 1 may be used for connection between the wiring pattern PT1 on a circuit substrate of the mounted electric device and the wiring pattern PT2 of a different circuit substrate, or the like. In descriptions below, a case where the pressure contact type connector 2 is disposed on the wiring pattern PT1 and the wiring pattern PT2 may be disposed so as to overlap the pressure contact type connector 2 is described. However, the present invention is not limited to this.

(54) The pressure contact type connector 2 disposed on the wiring pattern PT1 may be disposed so that the lower flat plate portion 2b comes into contact with the wiring pattern PT1, and the pressure contact type connector 2 and the wiring pattern PT2 are electrically connected to each other. In the initial state in which the wiring pattern PT2 is not disposed on the pressure contact type connector 2, as shown in FIG. 9A, the upper flat plate portion 2a of the pressure contact type connector 1 protrudes upward by the elastic force of the spring portion 2c.

(55) When the wiring pattern PT2 is disposed on the pressure contact type connector 2, as shown in FIG. 9B, the pressure contact type connector 2 may be bent downward (Z2 direction). In this case, the pressure contact type connector 2 and the wiring pattern PT2 come into pressure-contact with each other, and thus, the pressure contact type connector 2 and the wiring pattern PT2 may be electrically and stably connected to each other. That is, the wiring substrate including the wiring pattern PT1 and the wiring substrate including the wiring pattern PT2 may be electrically connected to each other via the pressure contact type connector 2.

(56) In the pressure contact type connector 2 may include: the upper flat plate portion 2a which extends in a flat plate shape along the horizontal direction; the lower flat plate portion 2b which extends in a flat plate shape along the horizontal direction and is disposed below the upper flat plate portion 2a; and the spring portion 2c which connects one end portion of the upper flat plate portion 2a and one end portion of the lower flat plate portion 2b and has elasticity in the vertical direction, in which the spring portion 2c is formed so as to be bent with respect to the upper flat plate portion 2a and the lower flat plate portion 2b so that the width dimension in the vertical direction is larger than the thickness dimension in the horizontal direction.

(57) Accordingly, the spring portion 2c may be formed so that the thickness direction of the spring portion 2c is the horizontal direction, and thus, a reduction in the size of the pressure contact type connector in the horizontal direction is achieved. In addition, when viewed from the side, since it is possible to increase the width dimension of the spring portion 2c with respect to the directions in which the spring portion 2c are wound, it is possible to obtain a large elastic force. Accordingly, it is possible to provide the pressure contact type connector capable of having a reduced mounting area and obtaining a large elastic force.

(58) In addition, in the pressure contact type connector 2, the upper flat plate portion 2a may be formed by bending the upper plate portion 2d of a metal plate having the L-shaped portion 2f, which may include the upper plate portion 2d extending along the vertical direction and an intermediate plate portion 2e connected to the lower side of the upper plate portion 2d and extending in one direction in the horizontal direction, to extend along the other direction which is the horizontal direction and is orthogonal to the one direction, and the spring portion 2c may be formed by bending the intermediate plate portion 2e of a metal plate having the L-shaped portion 2f so as to be wound around a virtual center line which may be set along the vertical direction.

(59) Accordingly, the upper plate portion 2d of a metal plate having the L-shaped portion 2f extending along the one direction in the horizontal direction may be formed so as to be bent to extend along the other direction in the horizontal direction, and thus, it is possible to easily configure the upper flat plate portion 2a by bending it once.

(60) In addition, in the pressure contact type connector 2, the lower flat plate portion 2b may be formed by bending the lower plate portion 2g of a metal plate having the L-shaped portion 2m, which may include the lower plate portion 2g extending along the vertical direction and the intermediate plate portion 2n connected to the upper side of the lower plate portion 2g and extending in one direction in the horizontal direction, so as to extend along the other direction which is the horizontal direction and is orthogonal to the one direction, and the spring portion 2c may be formed by bending the intermediate plate portion 2n of a metal plate having the L-shaped portion 2m so as to be wound around a virtual center line which is set along the vertical direction.

(61) Accordingly, the lower plate portion 2g of a metal plate having the L-shaped portion 2m extending along the one direction in the horizontal direction may be formed so as to be bent to extend along the other direction in the horizontal direction, and thus, it is possible to easily configure the lower flat plate portion 2b by bending it once.

(62) Moreover, in the pressure contact type connector 2, the stopper portion 2h, which is formed to protrude upward at a location of noninterference with the spring portion 2c, may be connected to the lower flat plate portion 2b.

(63) Accordingly, since the stopper portion 2h may be connected to the lower flat plate portion 2b, it is possible to limit a displacement amount in the vertical direction, and it possible to prevent the spring portion 2c from being damaged.

(64) In addition, in the pressure contact type connector 2, the height dimension of the stopper portion 2h may be equal to or more than the height dimension of the base portion 2k of the spring portion 2c connected to the lower flat plate portion 2b.

(65) Accordingly, since the height dimension of the stopper portion 2h may be equal to or more than the height dimension of the base portion 2k, it is possible to limit the displacement amount in the vertical direction within a range in which the spring portion 2c is elastically deformed, and it is possible to securely prevent the spring portion 2c from being damaged.

(66) Moreover, in the pressure contact type connector 2, the stopper portion 2h may be provided outside the spring portion 2c.

(67) Accordingly, since the stopper portion 2h may be provided outside the spring portion 2c, it is possible to prevent a finger or the like from coming into contact with the spring portions from the side and to prevent the spring portion 2c being damaged. In addition, when the spring portion 2c extends and contracts in the vertical direction, the stopper portion 2h can function as a guide.

(68) In the pressure contact type connector 2, the width dimension in the vertical direction of the spring portion 2c may decrease from the lower side toward the upper side in the entirety thereof.

(69) Accordingly, since the width dimension in the vertical direction of the spring portion 2c may decrease from the lower side toward the upper side, it is possible to obtain an elastic force required for a stable electrical connection, and it is possible to lengthen the stroke of the spring portion 2c. Moreover, the width dimension may decrease from the lower side toward the upper side in the entirety thereof, and the width may partially increase.

(70) Hereinafter, a manufacturing method mp of the pressure contact type connector 2 will be described with reference to FIG. 10. FIG. 10 is a flow chart showing a process of the manufacturing method mp of the pressure contact type connector 2 according to an example embodiment. The manufacturing method mp may include a punching step mp1, an upper flat plate portion forming step mp2, a lower flat plate portion forming step mp3, and a spring portion forming step mp4. As shown in FIG. 10, first, the punching step mp1 may be performed. In the punching step mp1, a crank-shaped punched portion 6 (not shown), which includes the intermediate plate portion 2e extending in the horizontal direction, the upper plate portion 2d connected upward to the one end portion of the intermediate plate portion 2e, and the lower plate portion 2g connected downward to the other end portion of the intermediate plate portion 2e, may be formed in an integral flat plate shape from one metal plate. After the punching step mp1, the upper flat plate portion forming step mp2 may be performed. In the upper flat plate portion forming step mp2, the upper plate portion 2d of the crank-shaped punched portion 6 may be bent to form the upper flat plate portion 2a. After the upper flat plate portion forming step mp2, the lower flat plate portion forming step mp3 may be performed. In the lower flat plate portion forming step mp3, the lower plate portion 2g of the crank-shaped punched portion 6 may be bent to form the lower flat plate portion 2b. In addition, the lower flat plate portion forming step mp3 may be performed after the punching step mp1, and thereafter, the upper flat plate portion forming step mp2 may be performed. After the lower flat plate portion forming step mp3, the spring portion forming step mp4 may be performed. In the spring portion forming step mp4, the intermediate plate portion 2e of the crank-shaped punched portion 6 may be bent so as to be wound to form the spring portion 2c. According to the manufacturing processes, the pressure contact type connector 2 may be completed.

(71) The manufacturing method mp of the pressure contact type connector 2 may include: the punching step mp1 of forming the crank-shaped punched portion 6, which includes the integral intermediate plate portions 2e and 2m extending in the horizontal direction, the upper plate portion 2d connected upward to the one end portion of the intermediate plate portions 2e and 2m, and the lower plate portion 2g connected downward to the other end portion of the intermediate plate portion 2e, in an integral flat plate shape from one metal plate; the upper flat plate portion forming step mp2 of forming the upper flat plate portion 2a by bending the upper plate portion 2d after the punching step mp1; the lower flat plate portion forming step mp3 of forming the lower flat plate portion 2b by bending the lower plate portion 2g after the punching step mp1; and the spring portion forming step mp4 of forming the spring portion 2c by bending the intermediate plate portions 2e and 2m so as to be wound after the punching step mp1.

(72) Accordingly, since it is possible to form the pressure contact type connector from one metal plate, it is possible to decrease the number of parts.

(73) Hereinbefore, the pressure contact type connectors according to embodiments of the present invention and the manufacturing methods thereof are described. However, the present invention is not limited to the above-described embodiments, and various modifications may be performed within the scope which does not depart from the gist of the invention. For example, the present invention may be modified as follows, and the modified embodiments are also included in the present invention. Moreover, in descriptions with respect to the following embodiments, pressure contact type connectors having shapes different from the shape of the pressure contact type connector 1 according to the first embodiment will be described. However, for easy explanation, names of parts, reference numerals, or the like used for explanations of the pressure contact type connector 1 according to the first embodiment are used for names of parts, reference numerals, or the like of the following embodiments. In addition, FIGS. 11A and 11B used for the explanations are views showing the pressure contact type connector 1 according to an example embodiment, FIG. 11A is a plan view showing an outline of the pressure contact type connector 1, and FIG. 11B is a sectional view showing a section taken along line D-D shown in FIG. 11A. FIGS. 12A and 12B are views showing the pressure contact type connector 1 according to a fifth embodiment, FIG. 12A is a perspective view showing an outline of the pressure contact type connector 1, and FIG. 12B is an exploded perspective view showing a configuration of the pressure contact type connector 1.

(74) In an above-described embodiment, the upper flat plate portion 1a may include the upper flat plate portion 1a and the auxiliary upper flat plate portion 1h. The upper flat plate portion 1a may be configured to include only the upper flat plate portion 1a according to the first embodiment, and the lower surface of the upper flat plate portion 1a may be held by the tip portion of the upper side of the second spring portion 1d.

(75) In the above-described embodiments, the stopper portion 1e may be provided outside the first spring portion 1c and the second spring portion 1d. However, as shown in FIGS. 11A and 11B, the stopper portion 1e may be provided inside the first spring portion 1c and the second spring portion 1d and below the upper flat plate portion 1a. Accordingly, when the first spring portion 1c and the second spring portion 1d may be pressed downward more than necessary via the upper flat plate portion 1a by the part A, since the stopper portion 1e comes into contact with the part A via the upper flat plate portion 1a, it is possible to limit the displacement amount in the vertical direction of each of the first spring portion 1c and the second spring portion 1d, and thus, it is possible to prevent the first spring portion 1c and the second spring portion 1d from being damaged.

(76) In the above described embodiments, the pressure contact type connector 1 may be a single body. However, for example, as shown in FIGS. 12A and 12B, the periphery of the pressure contact type connector 1 may be covered by a protective cover 7. Since the protective cover 7 is provided, when a finger unintentionally comes into contact with the pressure contact type connector, the force in the horizontal direction is not easily transmitted to the first spring portion 1c and the second spring portion 1d, and it is possible to prevent the pressure contact type connector 1 from being damaged. In addition, since the protective cover 7 is guided along the outline of the pressure contact type connector 1, the protective cover is not easily inclined and easily moves in the vertical direction.

(77) It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims of the equivalents thereof.

(78) The embodiments of the present inventions are not to be limited in scope by the specific embodiments described herein. Further, although some of the embodiments of the present disclosure have been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art should recognize that its usefulness is not limited thereto and that the embodiments of the present inventions can be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the embodiments of the present inventions as disclosed herein. While the foregoing description includes many details and specificities, it is to be understood that these have been included for purposes of explanation only, and are not to be interpreted as limitations of the invention. Many modifications to the embodiments described above can be made without departing from the spirit and scope of the invention.