Connector

An applicant claims priority under 35 U.S.C. §119 of Japanese Patent Application No. JP2013-245042 filed Nov. 27, 2013 and Japanese Patent Application No. JP2014-133000 filed Jun. 27, 2014.

This invention relates to a connector with a structure which prevents a finger of a user from being in contact with a tip of a contact.

As shown in FIG. 29( a ) , a connector 100 of JP 3,575,295B comprises a contact 101 , a holding member 102 holding the contact 101 , and a contact prevention member 103 attached to the contact 101 . The contact 101 has a held portion 104 and a main portion 105 . The held portion 104 is held by the holding member 102 . The main portion 105 roughly has a tubular shape and extends from the held portion 104 in a predetermined direction (PD). As shown in FIG. 29( b ) , the main portion 105 is formed with holes 106 , each of which pierces the main portion 105 in a radius direction perpendicular to the predetermined direction. The contact prevention member 103 has a head portion 107 , a shaft portion 108 and resilient portions 109 . The head portion 107 is larger than an inner shape of the main portion 105 . The shaft portion 108 has a shape corresponding to the inner shape of the main portion 105 . Each of the resilient portions 109 extends from the shaft portion 108 . An end of each resilient portion 109 is formed with an engagement portion 110 which projects outwards beyond the shaft portion 108 in the radius direction. When the contact prevention member 103 is inserted into the contact 101 , the engagement portions 110 of the contact prevention member 103 are engaged with the holes 106 of the main portion 105 . Thus, the contact prevention member 103 is attached to the contact 101 . The head portion 107 of the contact prevention member 103 projects over the tip of the contact 101 and prevents a finger 111 of a user from being in contact with the tip of the contact 101 .

The contact sometimes receives a force obliquely to the predetermined direction when the connector is mated with a mating connector. The connector of JP 3,575,295B has a problem that the contact might buckle when the contact receives the oblique force.

It is an object of the present invention to provide a connector with a structure which prevents a finger of a user from being in contact with a tip of a contact and according to which the contact buckles hardly even if the contact receives oblique force.

One aspect of the present invention provides a connector which is mateable with a mating connector along a predetermined direction (PD). The connector comprises a holding member, a plurality of contacts and a plurality of contact prevention members. The holding member includes a holding portion. The plurality of contacts include held portions and main portions, respectively. The held portions are held by the holding portion. The main portions extend from the held portions, respectively, in the predetermined direction. The main portions project over the holding portion in the predetermined direction. Each of the main portions has a tubular shape. Each of the contact prevention members is made of insulator. The contact prevention members occupy insides of the main portions, respectively. The contact prevention members project over the main portions, respectively, in the predetermined direction.

The contact prevention member occupies the inside of the main portion and projects over the main portion. Since the contact prevention member projects over the main portion, a finger of a user can be prevented from being in contact with the tip of the contact. Since the main portion is reinforced from inside thereof by the contact prevention member, the contact buckles hardly.

An appreciation of the objectives of the present invention and a more complete understanding of its structure may be had by studying the following description of the preferred embodiment and by referring to the accompanying drawings.

FIG. 1 is a perspective view showing a connector according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view showing the connector of FIG. 1 .

FIG. 3 is a perspective view showing a contact and a contact prevention member which are included in the connector of FIG. 1 .

FIG. 4 is a cross-sectional view showing the contact and the contact prevention member of FIG. 3 . The contact is not yet formed with a crimped portion.

FIG. 5 is a perspective view showing a state before assembling the contact and the contact prevention member of FIG. 3 .

FIG. 6 is a perspective view showing the contact and the contact prevention member of FIG. 5 . The contact prevention member is inserted into the contact. The contact is not yet formed with the crimped portion.

FIG. 7 is a perspective view showing a connector according to a second embodiment of the present invention.

FIG. 8 is a cross-sectional view showing the connector of FIG. 7 .

FIG. 9 is a perspective view showing a contact and a contact prevention member which are included in the connector of FIG. 7 .

FIG. 10 is a cross-sectional view showing the contact and the contact prevention member of FIG. 9 . The contact is not yet formed with the crimped portion.

FIG. 11 is a perspective view showing a state before assembling the contact and the contact prevention member of FIG. 9 .

FIG. 12 is a perspective view showing the contact and the contact prevention member of FIG. 11 . The contact prevention member is inserted into the contact. The contact is not yet formed with the crimped portion.

FIG. 13 is a perspective view showing a connector according to a third embodiment of the present invention.

FIG. 14 is a cross-sectional view showing the connector of FIG. 13 .

FIG. 15 is a perspective view showing a contact and a contact prevention member which are included in the connector of FIG. 13 .

FIG. 16 is a cross-sectional view showing the contact and the contact prevention member of FIG. 15 . The contact is not yet formed with the crimped portion.

FIG. 17 is a perspective view showing a state before assembling the contact and the contact prevention member of FIG. 15 . The contact is in a state of an intermediate member.

FIG. 18 is a perspective view showing the intermediate member and the contact prevention member of FIG. 17 . The contact prevention member is mounted on the intermediate member.

FIG. 19 is a perspective view showing the intermediate member and the contact prevention member of FIG. 18 . The intermediate member is wound on the contact prevention member.

FIG. 20 is a perspective view showing a connector according to a modification in which a surrounding portion of the connector of FIG. 1 is formed of an insulator.

FIG. 21 is a cross-sectional view showing the connector of FIG. 20 .

FIG. 22 is a perspective view showing a connector according to a fourth embodiment of the present invention.

FIG. 23 is a cross-sectional view showing the connector of FIG. 22 .

FIG. 24 is a perspective view showing a contact and a contact prevention member which are included in the connector of FIG. 22 .

FIG. 25 is a cross-sectional view showing the contact and the contact prevention member of FIG. 24 .

FIG. 26 is an enlarged, cross-sectional view showing a tip of the contact and the contact prevention member of FIG. 25 .

FIG. 27 is a perspective view showing a state before assembling the contact and the contact prevention member of FIG. 24 . The contact prevention member is not yet formed with a large shape portion.

FIG. 28 is a perspective view showing a state following the state of FIG. 27 . The contact is formed with the crimped portion.

FIG. 29 is a cross-sectional view showing a connector of JP 3,575,295B. FIG. 29 ( a ) is a cross-sectional view showing the connector. FIG. 29 ( b ) is an enlarged, cross-sectional view showing the contact and the contact prevention member of FIG. 29 ( a ) .

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

Referring to FIGS. 1 and 2 , a connector 10 according to a first embodiment of the present invention is mateable with a mating connector (not shown) along a predetermined direction (front-rear direction, PD). The connector 10 has a mating end 12 and a receiving portion 14 . The mating end 12 is mateable with the mating connector. The receiving portion 14 receives a part of the mating connector. The mating end 12 is positioned at a front end of the connector 10 . The receiving portion 14 is positioned rearward of the mating end 12 . Specifically, the receiving portion 14 is recessed rearward from the mating end 12 .

The illustrated connector 10 comprises a holding member 20 , a plurality of contacts 30 , a plurality of contact prevention members 50 and a shell 60 . The holding member 20 is made of insulator. Each of the contacts 30 is made of conductor. Each of the contact prevention members 50 is made of insulator. The shell 60 is made of metal.

As shown in FIG. 2 , the holding member 20 includes a holding portion 22 which consists of two blocks, a front block 24 and a rear block 26 . The holding portion 22 may consist of one block.

As shown in FIGS. 1 to 4 , each of the contacts 30 includes a held portion 32 and a main portion 36 . The held portion 32 is held by the holding portion 22 . The main portion 36 projects over the held portion 32 in the predetermined direction. In detail, the main portion 36 of the present embodiment extends frontward so as to project over the holding portion 22 in the predetermined direction. As shown in FIGS. 2 to 4 , the held portion 32 is formed with a stopper portion 34 projecting in a radial direction. In the present embodiment, the stopper portion 34 is caught by the front block 24 and the rear block 26 as shown in FIG. 2 , so that the held portion 32 is held by the holding portion 22 . Furthermore, the stopper portion 34 is provided with a plane portion 34 ′, so that the contact 30 can be prevented from being rotated. The main portion 36 has a tubular shape. Especially, the main portion 36 of the present embodiment has a cross-sectional shape uniform in a plane perpendicular to the predetermined direction.

The main portion 36 of the contact 30 is a part which is connected to a mating contact (not shown) of the mating connector (not shown). On the other hand, a rear part (including the held portion 32 ) of the contact 30 is a connection portion which is connected to a signal line. Although the main portion 36 of the present embodiment has a cylindrical tubular shape, the present invention is not limited thereto. Depending upon a shape or the like of the mating contact (not shown) of the mating connector (not shown), the main portion 36 may have a square tubular shape. In addition, as understood from FIG. 4 , each of the contacts 30 of the present embodiment has a hollow structure in which a hole pierces it from its front end 30 F to its rear end 30 R. However, the present invention is not limited thereto. For example, each of the contacts 30 may have a partition wall which separates the main portion 36 from the connection portion (the rear part of the contact 30 ).

Unlike the connector of JP 3,575,295B, each of the main portions 36 of the present embodiment is formed with no hole which connects between an inside and an outside of the main portion 36 , as understood from FIGS. 3 and 4 . Accordingly, when the signal line is connected to the contact 30 by soldering, molten solder flowing through an inside of the connection portion cannot flow out to an outer surface of the main portion 36 as a contact portion which connects the mating contact (not shown). Although each of the contacts 30 of the present embodiment is formed with no hole which connects between the outside and the inside thereof, each of the connection portions of the contacts 30 may be formed with the hole if each of the main portions 36 of the contacts 30 is formed with no hole.

As shown in FIGS. 4 and 5 , each of the contact prevention members 50 of the present embodiment has a head portion 52 and a shaft portion 54 . The shaft portion 54 extends along the predetermined direction (front-rear direction). Except a portion which is crimped to be deformed as described later, the shaft portion 54 has a bar-like shape having a size uniform in the plane perpendicular to the predetermined direction. The head portion 52 is formed at a front end of the shaft portion 54 . The head portion 52 has a shape (large shape portion) larger than the shaft portion 54 in the plane perpendicular to the predetermined direction. In detail, as understood from FIGS. 3 and 4 , a maximum size of the head portion 52 is almost same as an outer peripheral size of the main portion 36 . Specifically, the head portions (large shape portions) 52 project outwards beyond shapes which are defined by inner walls of the main portions 36 in the plane perpendicular to the predetermined direction, respectively. The shaft portions 54 are accommodated in the contacts 30 , respectively. The head portions 52 project frontward from the front ends 30 F of the main portions 36 , respectively.

As best illustrated in FIG. 3 , each of parts of the contacts 30 is crimped to be formed with crimped portions 40 , so that the contact prevention members 50 of the present embodiment are attached to the contacts 30 , respectively. In detail, as understood from FIGS. 5 and 6 , the shaft portions 54 are inserted from the front ends 30 F of the contacts 30 into the main portions 36 , respectively, and regions 42 are then crimped to be deformed, so that the crimped portions 40 are formed (see FIG. 3 ). By the formation of the crimped portions 40 , parts of the shaft portions 54 are deformed so as to occupy inside of the crimped portions 40 , respectively. Accordingly, the contact prevention members 50 are held by the contacts 30 , respectively.

As understood from FIGS. 5 and 6 , each of the contact prevention members 50 of the present embodiment is provided with the large shape portion (head portion 52 ), which is larger than the shaft portion 54 , only at one end of the shaft portion 54 . Accordingly, when the shaft portions 54 are inserted into the main portions 36 , respectively, unnecessary loads are not applied to the contact prevention members 50 and the contacts 30 , respectively, so that unintended deformations of the contact prevention members 50 and the contacts 30 can be prevented.

In addition, as understood from FIGS. 2 and 4 , the shaft portions 54 of the contact prevention members 50 occupy insides of the main portions 36 , respectively. In other words, insides of the main portions 36 of the contacts 30 are reinforced by the shaft portions 54 , respectively. Thus, the contacts 30 of the present embodiment buckle hardly.

As understood from FIGS. 2 and 3 , each of the crimped portions 40 of the present embodiment is formed on the held portions 32 . Accordingly, as shown in FIG. 1 , the crimped portions 40 are not exposed in the receiving portion 14 . Since each of the main portions 36 has a uniform shape as shown in FIGS. 2 and 3 , the contacts 30 of the present embodiment buckle hardly. However, the present invention is not limited thereto. Each of the crimped portions 40 may be formed so as to extend over from the held portion 32 to the main portion 36 . In other words, each crimped portion 40 may be formed to bridge the held portion 32 and the main portion 36 .

As shown in FIGS. 1 and 2 , the shell 60 partly covers the holding member 20 . The shell 60 has a surrounding portion 62 which surrounds the main portions 36 of the plurality of contacts 30 altogether in the plane perpendicular to the predetermined direction. The surrounding portion 62 of the present embodiment defines the receiving portion 14 while an end of the surrounding portion 62 forms the mating end 12 . Although the surrounding portion 62 is formed as a part of the shell 60 in the present embodiment, the surrounding portion 62 may be formed as a part of the holding member 20 . The surrounding portion 62 may be provided on both the holding member 20 and the shell 60 .

For example, with reference to FIGS. 20 and 21 , a variation of the connector 10 C comprises, instead of the shell 60 of the above-described embodiment, a surrounding portion 62 C made of insulator. Specifically, the connector 10 C comprises the plurality of contacts 30 , the holding member 20 , the surrounding portion 62 C made of insulator. Each of the contacts 30 has a structure same as the contact 30 of the above-described embodiment and is held by the holding member 20 as described above. The surrounding portion 62 C surrounds the main portions 36 of the plurality of contacts 30 altogether in the plane perpendicular to the predetermined direction. As understood from FIGS. 1 and 20 , similar to the surrounding portion 62 of the above-described embodiment, the surrounding portion 62 C of the present embodiment defines a receiving portion 14 C and an end of the surrounding portion 62 C forms a mating end 12 C. Specifically, similar to the receiving portion 14 of the above-described embodiment, the main portions 36 of the contacts 30 are positioned in the receiving portion 14 C which is defined by the surrounding portion 62 C of this variation. In addition, the surrounding portion 62 C may be formed integrally with the holding member 20 .

With reference to FIGS. 7 and 8 , a connector 10 A according to a second embodiment of the present invention is a variation example of the connector 10 of the above-described first embodiment. In FIGS. 7 and 8 , components which are same as those of the connector 10 shown in FIGS. 1 and 2 are referred by using reference signs same as those of the connector 10 . As understood from FIGS. 7 and 8 , the holding member 20 and the shell 60 of the present embodiment are same as the holding member 20 and the shell 60 of the first embodiment. Accordingly, detailed explanation about those components is not made. With reference to FIGS. 5 and 11 , each of contacts 30 A which is not yet crimped has a structure same as the contact 30 of the first embodiment which is not yet crimped. Accordingly, with reference to FIGS. 9 to 12 , a structure of a contact prevention member 50 A and an attachment method of the contact prevention member 50 A to the contact 30 A are mainly described below.

As shown in FIGS. 10 and 11 , each of the contact prevention members 50 A of the present embodiment has a shaft portion 54 A and a large shape portion 56 A. The shaft portion 54 A extends along the predetermined direction (front-rear direction). The shaft portion 54 A has a length longer than the shaft portion 54 of the above-described first embodiment in the predetermined direction. The shaft portion 54 A has a bar-like shape having a size uniform in the plane perpendicular to the predetermined direction. Parts of the shaft portions 54 A of the present embodiment project from the front ends 30 F of the contacts 30 A, respectively. The remaining parts of the shaft portions 54 A of the present embodiment are accommodated in the contacts 30 A, respectively. The large shape portion 56 A is provided on a rear end of the shaft portion 54 A. The large shape portion 56 A has a shape larger than the shaft portion 54 A in the plane perpendicular to the predetermined direction. The large shape portions 56 A are accommodated in the contacts 30 A, respectively.

As best illustrated in FIG. 9 , each of parts of the contacts 30 A is crimped to be formed with a crimped portion 40 A, so that contact prevention members 50 A of the present embodiment are attached to the contacts 30 A, respectively. In detail, as understood from FIGS. 11 and 12 , the shaft portions 54 A are inserted from the rear ends 30 R of the contacts 30 A into the main portions 36 , respectively, and regions 42 A are then crimped to be deformed, so that the crimped portions 40 A are formed (see FIG. 9 ). By the formation of the crimped portions 40 A, parts of the large shape portion 56 A are deformed to occupy insides of the crimped portions 40 A, respectively, so that the contact prevention members 50 A are held by the contacts 30 A, respectively. In addition, as shown in FIG. 3 of the first embodiment, each of the crimped portions 40 A may be formed at a part which is positioned frontward of the stopper portion 34 .

As understood from FIGS. 11 and 12 , each of the contact prevention members 50 A of the present embodiment is provided with the large shape portion 56 A, which is larger than the shaft portion 54 A, only at one end of the shaft portion 54 A. Accordingly, when the shaft portions 54 A are inserted into the contacts 30 A, respectively, unnecessary loads are not applied to the contact prevention members 50 A and the contacts 30 A, respectively, so that unintended deformations of the contact prevention members 50 A and the contacts 30 A can be prevented.

In addition, as understood from FIGS. 8 and 10 , the shaft portions 54 A of the contact prevention members 50 A occupy insides of the main portions 36 of the contacts 30 A, respectively. In other words, insides of the main portions 36 of the contacts 30 A are reinforced by the shaft portions 54 A, respectively. Thus, the contacts 30 A of the present embodiment buckle hardly.

As understood from FIGS. 8 and 9 , each of the crimped portions 40 A of the present embodiment is formed on the held portion 32 A. Each of the main portions 36 of the present embodiment has a uniform shape. Accordingly, the contacts 30 A of the present embodiment buckle hardly.

In the above-described first and second embodiment, the contacts 30 , 30 A are formed by cutting and the like. However, the present invention is not limited thereto. For example, in a third embodiment, each of contacts may be formed cylindrically by rolling a blank which is obtained by pressing a metal plate. The third embodiment is described below.

With reference to FIGS. 13 and 14 , a connector 10 B according to the third embodiment of the present invention is a variation example of the connector 10 of the above-described first embodiment. In FIGS. 13 and 14 , the portions which are same as those of the connector 10 shown in FIGS. 1 and 2 are referred by using reference signs same as those of the connector 10 . As understood from FIGS. 13 and 14 , the holding member 20 and the shell 60 of the present embodiment are same as the holding member 20 and the shell 60 of the first embodiment. Accordingly, detailed explanation about those portions is not made.

Although, as understood from FIGS. 14 to 16 , a main function of contacts 30 B is same as the above-described contacts 30 , 30 A, a manufacturing method of the contacts 30 B is different from those of the contacts 30 , 30 A. Because of the difference of the manufacturing methods, a structural detail of each of the contacts 30 B is different from those of the contacts 30 , 30 A.

As understood from FIGS. 15 to 19 , the contacts 30 B of the present embodiment are formed by winding intermediate members 70 , which are obtained by pressing metal plates, around contact prevention members 50 B, respectively. The intermediate members 70 are wound around the contact prevention members 50 B, respectively, so that the contact prevention members 50 B are held by the contacts 30 B, respectively.

With reference to FIGS. 16 to 18 , each of the contact prevention members 50 B of the present embodiment has a structure which has both features of the contact prevention member 50 B and the contact prevention member 50 A as described above. Each of the contact prevention members 50 B has a head portion (large shape portion) 52 B, a shaft portion 54 B and a large shape portion 56 B. The head portion 52 B corresponds to the head portion 52 of the contact prevention member 50 B of the first embodiment. The head portion 52 B is positioned frontward of the shaft portion 54 B. The large shape portion 56 B corresponds to the large shape portion 56 A of the contact prevention member 50 A of the second embodiment. The large shape portion 56 B is positioned rearward of the shaft portion 54 B. Specifically, in the predetermined direction, each of the contact prevention members 50 B of the present embodiment has the large shape portion 52 B on one end of the shaft portion 54 B and the large shape portion 56 B on the other end thereof. The large shape portions 52 B and 56 B have shapes each of which is larger than a shape of the shaft portion 54 B in the plane perpendicular to the predetermined direction.

As shown in FIG. 17 , each of the intermediate members 70 is formed with a portion 34 B′ which becomes a stopper portion 34 B. The illustrated intermediate member 70 is under a state where the intermediate member 70 is connected to a carrier 72 . As shown in FIG. 18 , the contact prevention members 50 B are mounted on the intermediate members 70 so that the head portions 52 B project from front ends 30 F′ of the intermediate members 70 , respectively, and that the large shape portions 56 B extend rearward from the portions 34 B′, respectively. Specifically, the contact prevention members 50 B are mounted on the intermediate members 70 so that the shaft portions 54 B are positioned between the front ends 30 F′ and the portions 34 B′, respectively. Next, as shown in FIG. 19 , the intermediate members 70 are wound around the contact prevention members 50 B, respectively. Thus, the contact prevention members 50 B are held by the contacts 30 B, respectively. After that, the carriers 72 are separated from the contacts 30 B, respectively, so that the contact 30 B and the contact prevention member 50 B as shown in FIG. 15 are obtained.

By the above-described manufacturing method, each of the contacts 30 B has a joint 30 C. As shown in FIG. 16 , the shaft portions 54 B of the contact prevention members 50 B occupy insides of the main portions 36 B, respectively, and each of the contacts 30 B is formed with no hole which connects between an inside and an outside thereof. Accordingly, similar to the first embodiment and the second embodiment, molten solder cannot flow out to an outer surface of the contact 30 B when the signal line is connected to the contact 30 B by soldering. In addition, in the present embodiment, each of the connection portions of the contacts 30 B may be formed with the hole if each of the main portions 36 B of the contacts 30 B is not formed with the hole.

With reference to FIG. 16 , a space exists between the stopper portion 34 B and the large shape portion 56 B of the present embodiment. As shown in FIG. 14 , the stopper portion 34 B is a part of the held portion 32 B which is held by the holding portion 22 . Thus, the contacts 30 B buckle hardly even if the spaces exist. However, the present invention is not limited thereto. Each of the contact prevention members 50 B may be modified so that each of the spaces does not exist between the stopper portion 34 B and the contact prevention member 50 B.

By the above-described manufacturing method, the large shape portions 52 B and 56 B having shapes each of which is larger than an inner shape of the main portion 36 B can be provided at opposite ends of the tubular main portion 36 B, respectively. Accordingly, the contact prevention member 50 B are prevented from coming off from the contacts 30 B, respectively.

In the present embodiment, each of the contact prevention members 50 B having a size slightly larger than a normal size may be pressed to be compressed and deformed when the intermediate member 70 is wound therearound. In that case, the contacts 30 B are engaged with the surface of the contact prevention members 50 B by winding the intermediate members 70 , respectively, so that the contact prevention members 50 B are held by the contacts 30 B, respectively. Accordingly, at least one of the head portion 52 B and the large shape portion 56 B can be omitted. In addition, similar to the first and second embodiment, at least one of the crimped portions 40 , 40 A may be formed on the contact 30 B.

With reference to FIGS. 22 and 23 , the connector 10 D according to a fourth embodiment of the present invention is a variation example of the connector 10 of the above-described first embodiment. In FIGS. 22 and 23 , components which are same as those of the connector 10 shown in FIGS. 1 and 2 are referred by using reference signs same as those of the connector 10 . As understood from FIGS. 22 and 23 , the holding member 20 and the shell 60 of the present embodiment are same as the holding member 20 and the shell 60 of the first embodiment. Accordingly, detailed explanation about those components is not made.

As understood from FIGS. 24 and 25 , each of the contacts 30 D of the present embodiment is obtained by pressing a metal plate followed by bending it. Each of the contacts 30 D of the present embodiment has a joint 30 C similar to the contact 30 B (see FIG. 15 ) of the above-described embodiment. However, the present invention is not limited thereto. Each of the contacts 30 D may be formed by cutting and the like.

Specifically, as shown in FIGS. 24 and 25 , each of the contacts 30 D has a held portion 32 D and a main portion 36 D. The held portion 32 D is held by the holding portion 22 . The main portion 36 D extends from the held portion 32 D in the predetermined direction. In detail, the main portion 36 D of the present embodiment extends frontward so as to project over the holding portion 22 in the predetermined direction. As shown in FIGS. 23 to 25 , the held portion 32 D is formed with a stopper portion 34 D projecting in the radial direction. In the present embodiment, as shown in FIG. 23 , the stopper portion 34 D is caught by the front block 24 and the rear block 26 as shown in FIG. 23 , so that the held portion 32 D is held by the holding portion 22 . The main portion 36 D has a tubular shape. Except a portion which is crimped to be deformed as described later, the main portion 36 D of the present embodiment has a cross-sectional shape uniform in the plane perpendicular to the predetermined direction. As best illustrated in FIG. 25 , each of the contacts 30 D is formed with a partition portion 44 D which separates solder from the contact prevention member 50 D so that the solder is prevented from being adhered to the contact prevention member 50 D when the signal line is connected to the contact 30 D by soldering. Each of the contact prevention members 50 D is described later. In the present embodiment, the partition portion 44 D is positioned rearward of the stopper portion 34 D.

As shown in FIGS. 25 and 26 , each of the contact prevention members 50 D of the present embodiment has a head portion (large shape portion) 52 D, an inner fit portion 56 D and a shaft portion 54 D. The shaft portion 54 D extends along the predetermined direction (front-rear direction). Except a portion which is crimped to be deformed as described later, the shaft portion 54 D has a bar-like shape having a size uniform in the plane perpendicular to the predetermined direction. Especially, in the plane (perpendicular plane) perpendicular to the predetermined direction, the shaft portion 54 D of the present embodiment has a size smaller than a shape which is defined by an inner wall 38 D of the main portion 36 D of the contact 30 D. Accordingly, as shown in FIG. 26 , a slight space exists between the inner wall 38 D of the main portion 36 D and the shaft portion 54 D, and the shaft portion 54 D is not closely fit on the inner wall 38 D. The inner fit portion 56 D is provided on a front end of the shaft portion 54 D. The inner fit portion 56 D has a size larger than the shaft portion 54 D in the perpendicular plane. In other words, the shaft portion 54 D has a size smaller than the inner fit portion 56 D in the perpendicular plane. Specifically, the inner fit portion 56 D is closely fit on the whole inner wall 38 D of the main portion 36 D in the perpendicular plane. The head portion 52 D is provided on a front end of the inner fit portion 56 D. Specifically, the inner fit portion 56 D is positioned between the head portion 52 D and the shaft portion 54 D in the predetermined direction. The head portion 52 D of the present embodiment is in contact with the main portion 36 D without any gaps in the predetermined direction. In other words, the head portion 52 D is in contact with a whole circumference of an end of the main portion 36 D. Furthermore, the head portion 52 D has a size larger than the inner fit portion 56 D in the perpendicular plane. Specifically, the head portion 52 D has a size larger than the shaft portion 54 D in the perpendicular plane. In detail, as understood from FIGS. 25 and 26 , the head portion (large shape portion) 52 D projects outwards beyond a shape which is defined by the inner wall 38 D of the main portion 36 D in the perpendicular plane. The inner fit portion 56 D and the shaft portion 54 D are accommodated in the contact 30 D. The head portion 52 D projects frontward from the front end 30 F of the main portion 36 D.

In the present embodiment, the shaft portion 54 D has the bar-like shape having a cross-sectional shape uniform in the perpendicular plane. Accordingly, an end of each of the contact prevention members 50 D of the present embodiment opposite to the head portion 52 D thereof has a size smaller than a shape which is defined by the inner wall 38 D of the main portion 36 D in the perpendicular plane. Specifically, each of the contact prevention members 50 D of the present embodiment is formed with a large shape portion (head portion 52 D) only at one end in the predetermine direction, wherein the large shape portion (head portion 52 D) projects outwards beyond a shape which is defined by the inner wall 38 D of the main portion 36 D in the perpendicular plane.

As shown in FIGS. 27 and 28 , each of the contact prevention members 50 D of the present embodiment is formed by thermally welding a rod material 54 D 1 made of resin by use of a jig 80 . The illustrated contact 30 D is connected to the carrier 72 . The carrier 72 holds the contact 30 D upon formation of the contact prevention member 50 D.

In detail, with reference to FIG. 27 , after a continuously-formed, long rod material 54 D 1 is inserted into the main portion 36 D of the contact 30 D, the rod material 54 D 1 is cut so as to have a predetermined length. Alternatively, the rod material 54 D 1 may be first cut to have the predetermined length, and then may be inserted into the main portion 36 D of the contact 30 D. Thereafter, a part of the contact 30 D is crimped to form a crimped portion 40 D, so that the rod material 54 D 1 is fixed so as not to be moved in the predetermined direction. In this state, as shown in FIG. 28 , an end of the rod material 54 D 1 projects frontward from the front end 30 F of the contact 30 D, and the head portion 52 D is then formed by using the jig 80 . The jig 80 is formed with a recess 82 which has a shape corresponding to a shape of the head portion 52 D. After the jig 80 is heated over a melting point of the rod material 54 D 1 , the heated jig 80 is pressed against the end of the rod material 54 D 1 . Accordingly, the head portion 52 D is formed while an excess resin is pushed into the main portion 36 D so that the inner fit portion 56 D is formed. In other words, the contact prevention member 50 D is formed by the above-described process. After that, the carrier 72 is separated from the contact 30 D.

In the above-described heating process with using the jig 80 , the head portion 52 D is closely fit on the front end 30 F of the contact 30 D in the predetermined direction while the inner fit portion 56 D is closely fit on the inner wall 38 D of the main portion 36 D. Accordingly, looseness of the contact prevention member 50 D (especially, the head portions 52 D and the vicinities thereof) against the contact 30 D can be suppressed.

In the above-described manufacturing method, the rod material 54 D 1 is inserted into the contact 30 D and then a part of the contact 30 D is crimped so that a position of the rod material 54 D 1 with respect to the contact 30 D is fixed. However, the present invention is not limited thereto. For example, the contact 30 D may be provided with a projection on its inside, and then the rod material 54 D 1 may be press-fitted into the contact 30 D so that a position of the rod material 54 D 1 with respect to the contact 30 D is fixed.

Instead of the rod material 54 D 1 having a simple shape, for example, a premolded insulator, such as the contact prevention member 50 A as shown in FIG. 11 , can be used. In that case, after the insulator is inserted into the contact 30 A as shown in FIG. 12 , the crimped portion 40 A (see FIG. 9 ) is formed, and the jig 80 is then pressed against the insulator as shown in FIG. 28 , so that the head portion 52 D (large shape portion) is formed. In the above-described process, instead of forming the crimped portion 40 A and pressing the jig 80 against the insulator, the jig 80 may be pressed against the insulator as shown in FIG. 28 in a state where movement of the insulator is restricted by pressing a rear part of the large shape portion 56 A (see FIG. 11 ). In this case, similar to the third embodiment, the large shape portions are formed at opposite ends of the contact prevention member, respectively. Nonetheless, the contact prevention member 50 D has the large shape portion only at one end thereof. The contact prevention member 50 D can be formed by using a resin rod having a simple shape and can be formed by the above-described manufacturing method suitable for automatization. Accordingly, the contact 30 D including the contact prevention member 50 D having the large shape portion only at one end thereof is advantageous in cost.

The above-described connectors 10 , 10 A, 10 B and 10 D are especially useful for a medical equipment which requires that a finger of a user is prevented from being brought into contact with tips of the contacts 30 , 30 A, 30 B and 30 D whose diameters are small.

The present application is based on Japanese patent applications of JP2013-245042 and JP2014-133000 filed before the Japan Patent Office on Nov. 27, 2013 and Jun. 27, 2014, respectively, the contents of which are incorporated herein by references.

While there has been described what is believed to be the preferred embodiment of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such embodiments that fall within the true scope of the invention.