Electrical Connector Crank Lever Locking Mechanism
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Solution Overview
Problem
Existing electrical connectors face challenges in securely locking small printed substrates during strong vibrations and hinder packaging density due to the ejector mechanism occupying space on the main printed substrate.
Innovation Solution
The electrical connector features a housing with a locking mechanism that includes a pair of crank levers converting translatory movement into rotational movement, paired with clip arms that securely lock the substrate by moving in a direction opposite to the insertion, and a cam mechanism to prevent detachment, allowing for improved packaging density by eliminating the need for outwardly opening ejectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pair of ejectors opens outwardly at both wings of the housing to release the small printed substrate, then the small printed substrate can be released from the electrical connector, but the pair of ejectors occupies packaging area on the main printed substrate, hindering improvement in packaging density
Solution Approach 1:
The patent combines the ejector function with the housing structure by integrating ejector arms into the housing walls. The ejector arms are formed as integral parts of the housing, eliminating the need for separate outwardly opening ejector components. This merging allows the release function to be achieved while minimizing the occupied packaging area on the main printed substrate.
Solution Approach 2:
Instead of having ejectors open outwardly from the housing wings, the patent inverts the approach by having ejector arms move inwardly or laterally within the housing structure. The ejector arms are positioned to engage the substrate from within the housing boundaries, reversing the traditional outward-opening configuration and thereby preserving packaging area.
2Reliability
If projections are engaged with through holes at both wings of the small printed substrate to prevent detachment, then the small printed substrate is secured, but under strong vibrations the projections may cross over the through holes causing the small printed substrate to detach
Solution Approach 1:
The patent changes the geometric parameters of the locking mechanism by providing projections with enlarged head portions that extend beyond the through holes in the lateral direction. This parameter change creates an interference fit that prevents the projections from crossing over the through holes during vibration, thereby maintaining reliable substrate locking under harsh conditions.
Solution Approach 2:
The patent incorporates a vibration-resistant design by pre-configuring the projections with lateral extensions that anticipate and counteract the harmful effects of vibration. The enlarged head portions act as a cushioning mechanism that absorbs and dissipates vibrational forces before they can cause the projections to disengage from the through holes.
3Length of stationary object
If the electrical connector is designed with a compact structure to minimize height and improve packaging density, then the electrical connector size is reduced, but the locking mechanism may not provide sufficient reliability under strong vibrations
Solution Approach 1:
The patent employs a nested design where the ejector arms are integrated within the housing walls, and the projections are formed as part of the header structure. This nesting allows the locking mechanism to be compact in height while maintaining sufficient engagement depth to provide reliable vibration resistance. The multi-level integration of components achieves both compactness and reliability.
Solution Approach 2:
The patent utilizes composite construction by integrating multiple functional elements (housing, headers, ejector arms, projections) into a unified structure with distributed locking points. This composite approach allows the connector to achieve high vibration resistance through multiple engagement points while maintaining compact overall dimensions, as the locking function is distributed throughout the structure rather than concentrated in a single tall component.
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 connector effectively secures the small printed substrate against detachment due to vibrations and enhances packaging density by eliminating the space occupied by the ejector mechanism, allowing for better integration of electrical components on the main printed substrate.
Implementation Method 1
a pair of crank levers that are held to freely swing at the base end portion of the pair of the headers; a pair of ejectors that is held at a pair of the headers to freely advance and retract by a swinging movement of a pair of the crank levers being converted to translatory movement
Data Source
AI summary
A connector includes a housing, a pair of headers, a pair of crank levers, a pair of ejectors, and a pair of clip arms. When a printed substrate is inserted into the housing, the pair of crank levers is caused to pivot so as to raise the pair of ejectors. Then, by moving the pair of clip arms from a third groove to a second groove at which the width is narrower, a pair of projections fits a pair of locking holes so as to sandwich both sides of the printed substrate. The connector can securely lock the printed substrate since the header prevents widening of the distance of the pair of projections even in a case in which a force aimed to detach the printed substrate from the housing works is acting thereon.