Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-06-11
2001-04-24
Young, Lee (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S874000, C029S876000, C029S884000, C264S273000, C264S279100, C264S275000, C264S272110, C439S736000
Reexamination Certificate
active
06219913
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a connector producing method and to a connector produced by insert molding.
2. Description of the Prior Art
A prior art connector produced by insert molding is disclosed in Japanese Unexamined Utility Model Publication No. 7-11771 and is illustrated in
FIG. 7
herein. As shown in
FIG. 7
, this connector is constructed such that a group of terminal fittings a, b are assembled into a housing c by insert molding, and male connector portions d, e are provided at the opposite ends. This connector is used as an intermediate connector or the like.
In producing such a connector by insert molding, the housing c may be molded according to the following method. A group of terminal fittings a, b are accommodated in a cavity of a mold and the ends thereof are inserted into mount grooves formed in the wall surface of the cavity. The housing c then is molded by injecting the cavity with synthetic resin. However, if the above method is adopted, particularly when the terminal fittings a, b have a long length, the terminal fittings a, b are elastically deformed upon being subjected to an injection pressure of the resin, with the result that the lengths of the terminal fittings a, b projecting in the male connector portions d, e may vary and, in an extreme case, the terminal fittings a, b may be brought into contact with each other.
As a countermeasure, the respective terminal fittings a, b are formed with intermediate members f, g for preventing a deformation by insert molding as shown in FIG.
8
. The housing c is produced by insert molding using an assembly of the intermediate members f, g and the terminal fittings a, b as a core material. This prevents the terminal fittings a, b from being elastically deformed during the insert molding of the housing c.
On the other hand, the connector is required to have a smaller thickness for a space-saving purpose. However, if the connector is produced according to the prior art method, there is a limit in suppressing the thickness of the connector as a whole since there is the thickness of the intermediate members f, g surrounding the respective terminal fittings a, b in addition to that of the housing c.
The present invention was developed in view of the above problems, and an object thereof is to enable the production of a connector having a smaller thickness.
SUMMARY OF THE INVENTION
According to the invention there is provided a method for producing a connector by assembling a plurality of terminal fittings into a housing preferably of a synthetic resin by insert molding. The method comprises the steps of forming a core member by securing the terminal fittings on surfaces of a nonconductive mount plate, and performing insert molding using the core member as a core material.
Accordingly, insert molding can be performed with the outer surfaces of the male terminal fittings preferably opposite from those secured to the mount plate exposed. Accordingly, only the thickness of the housing is added at the outer surfaces of the male terminal fittings, with the result that the thickness of the connector as a whole can be reduced or suppressed. Furthermore the displacement of the terminal fittings during the insert molding of the housing can be securely prevented.
According to a preferred embodiment of the invention, there is provided a method for producing a connector by assembling a plurality of terminal fittings which are not in contact with each other into a housing of a synthetic resin by insert molding. As part of the method, a core member is formed by securing the terminal fittings on the opposite surfaces of a nonconductive mount plate, and insert molding is performed using the core member as a core material.
Preferably, the securing step of the terminal fittings comprises engaging mount holes preferably formed in the terminal fittings, with projections preferably formed on the mount plate. In other words, the terminal fittings are secured by engaging mount holes formed in the terminal fittings with projections formed on the mount plate. Accordingly, the terminal fittings are secured to the mount plate by the engagement of the projections and the mount holes.
Further preferably, the terminal fittings are secured to the mount plate while being connected with each other via a carrier and separated or cut from each other after being secured. Accordingly, the plurality of terminal fittings can be integrally or unitarily secured to the mount plate, enabling an efficient securing operation.
Still further preferably, the method further comprises the step of orienting or mounting the terminal fittings on the mount plate by or in or on mount grooves provided thereon. Accordingly a correct positioning and/or orientation of the terminal fittings with respect to each other or with respect to the housing itself can be easily achieved.
Most preferably, the securing of the terminal fittings on the mount plate is performed by means of press fitting and/or ultrasonic welding and/or gluing and/or clamping. Accordingly the terminal fittings are securely fixed to the mount plate such that their position remains substantially unchanged during the subsequent step of insert molding to form the housing.
According to the invention, there is further provided a connector, preferably produced by a method according to the invention, comprising: a nonconductive mount plate, a plurality of terminal fittings secured to surfaces of the mount plate, and a housing formed by insert molding using the terminal fittings mounted on the mount plate as a core material.
According to a preferred embodiment of the invention, there is provided a connector produced by assembling a plurality of terminal fittings which are not in contact with each other into a housing of a synthetic resin by insert molding. The connector comprises a nonconductive mount plate, a plurality of terminal fittings secured to the opposite surfaces of the mount plate, and a housing formed by insert molding using the terminal fittings mounted on the mount plate as a core material.
Preferably, the connector further comprises mount holes, preferably formed in the terminal fittings, and projections preferably formed on the mount plate, being engageable with each other to secure the terminal fittings on the mount plate. Accordingly, the terminal fittings can be easily secured to the mount plate.
Further preferably, the mount plate is made out of the same material, in particular the same synthetic resin as the housing and preferably comprises mount grooves into which the terminal fittings are insertable. Accordingly, the terminal fittings can be easily oriented and held in a preferred orientation during the insert molding and/or curing of the housing.
Still further preferably, the terminal fittings are secured or fixed to the mount plate by press fit and/or and/or ultrasonic welding and/or gluing and/or clamping.
Most preferably, the mount plate comprises at least one opening preferably formed as a through hole, into which the material, preferably the synthetic resin of the housing is insertable or fillable upon forming the housing by insert molding. Accordingly the housing and the mount plate carrying the terminal fittings are even more intimately connected and fixed to each other.
Most preferably, at least two projections are provided for each terminal fitting.
According to the invention, there is further provided a use of a connector according to the invention, as or for a socket for an electric or electronic component or equipment such as a bulb, a fuse, a transistor, a resistor, an IC chip or the like, wherein at least one terminal fitting is provided for the connection with the electric or electronic component and wherein at least one further terminal is provided for an electric connection with an electric circuit.
These and other objects, features and advantages of the present invention will become more apparent upon a reading of the following detailed description and accompanying drawings.
REFERENCES:
patent: 4579404 (1986-04-01),
Casella Anthony J.
Chang Rick Kiltae
Hespos Gerald E.
Porco Michael J.
Sumitomo Wiring Systems Ltd.
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