Electrical Connector Assist Lever Mechanism
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Solution Overview
Problem
The increasing number of electrical components in vehicles requires a compact electrical connector that can accommodate more terminals while maintaining ease of use and reducing the force required for mating, as existing connectors often necessitate excessive force and separate tools.
Innovation Solution
An electrical connector design featuring a first housing with a movable second housing and a lever that rotates to move linearly, engaging guide elements for alignment and leverage, with a lock to retain the lever in position, allowing for efficient mating and disconnection without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrical terminals are placed in a connector to connect multiple wires simultaneously, then the number of electrical connections increases, but the amount of force required to mate the connectors increases
Solution Approach 1:
The patent employs a lever mechanism that transforms rotational motion into linear motion to mate the connector housings. The lever provides mechanical advantage, allowing the operator to mate multiple terminals with reduced manual force by utilizing the lever's rotational movement rather than direct linear force application.
Solution Approach 2:
The lever acts as an intermediary between the operator and the connector housings. Instead of directly applying force to mate the housings, the operator moves the lever, which then translates this motion into the force needed to bring the housings together, reducing the perceived effort required.
2Volume of moving object
If the connector size is reduced to fit more connections in confined spaces, then the space required decreases, but the ease of operation may be compromised
Solution Approach 1:
The lever mechanism allows for compact connector design while maintaining ease of operation. The rotational movement of the lever requires minimal space compared to traditional manual mating methods, and the mechanical advantage provided by the lever ensures that even in a compact configuration, the operator can mate the connector with reduced force.
Solution Approach 2:
The lever mechanism introduces a rotational dimension to the mating process. Instead of requiring linear force application along the connector axis, the lever allows the operator to apply force through rotational movement, effectively utilizing a different dimensional approach to achieve mating in compact spaces.
3Force
If a lever mechanism is added to reduce mating force, then the force required decreases, but the device complexity increases
Solution Approach 1:
The lever is integrated into the connector housing structure itself, serving both as a structural component and as the mating mechanism. The lever is mounted on the first housing and engages with the second housing, combining the functions of structural support and force multiplication in a single element, thereby minimizing the increase in device complexity.
Solution Approach 2:
The lever mechanism is merged with the connector housing design. The lever is mounted on the first housing and directly engages the second housing, combining the housing structure with the mating mechanism. This integration reduces the number of separate components and simplifies the overall device complexity while still providing the force reduction benefit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables a higher number of terminals to be fitted in a smaller space, reducing the force needed for mating and ensuring proper alignment, while maintaining operator ease and tool-free operation.
Implementation Method 1
A lever is mounted on the first housing for relative rotational movement. The lever can move between a pre-stage position and a final position. The lever engages the second housing to move the second housing linearly between a pre-stage position and a seated position relative to the first housing.
Data Source
AI summary
An electrical connector includes a first housing. A second housing is movable relative to the first housing. A lever is mounted on the first housing for relative rotational movement. The lever can move between a pre-stage position and a final position. The lever engages the second housing to move the second housing linearly between a pre-stage position and a seated position relative to the first housing. A lock on the first housing retains the lever in the final position relative to the first housing.