Connector Lever Assembly for High Axial Force
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Solution Overview
Problem
Existing connector assemblies require excessive manual force for coupling, especially in limited spaces, and known solutions involving gears are costly and complex to manufacture.
Innovation Solution
A connector assembly with a lever assembly comprising a pivotally arranged inner and outer lever member, where the inner lever engages the mating connector, allowing for high axial force with minimal manual effort and designed for easy manufacturing and compact installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a thread and coupling nut gear mechanism is used, then gear function is achieved, but tool requirement and space requirement increase
Solution Approach 1:
The invention extracts the essential gear function from the complex thread and coupling nut mechanism, retaining only the lever arm and pivot point elements that provide mechanical advantage, thereby eliminating the need for additional tools while maintaining the force multiplication effect
Solution Approach 2:
The lever assembly is designed to be self-contained with the lever pivoting directly on the connector housing, using the connector's own structure as the fulcrum, thereby eliminating the need for external tools and making the system self-sufficient
2Reliability
If insulation displacement contact is used, then connection capability is improved, but plug-in force increases
Solution Approach 1:
The lever assembly acts as a force counterbalance, where the user applies a small force on the lever arm and the system counteracts the large plug-in force required for insulation displacement contacts through mechanical advantage, making the connection process feasible
3Adaptability or versatility
If multiple contact pins are used, then connection functionality is improved, but plug-in force increases
Solution Approach 1:
The lever assembly segments the force application, allowing the user to apply force at a distance from the pivot point rather than directly at the connector interface, thereby distributing and reducing the required plug-in force while maintaining the ability to connect multiple contact pins
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
Enables coupling of connectors with limited manual force even in small spaces, reducing manufacturing costs and minimizing wear and fatigue, while maintaining a simple and efficient design.
Implementation Method 1
The lever assembly comprises at least one lever, the lever being arranged on the connector pivotally about a pivot axis
Implementation Method 2
configured to provide a lever gear ratio allowing a user to couple the connector to a mating connector with a limited manual force
Data Source
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AI summary
The invention relates to a connector assembly (1) comprising a connector (3), a mating connector (5) adapted to be coupled to the connector (3) in a mating direction (9), and a lever assembly (7). Connector assemblies (1) of the art have the disadvantage that they do not provide a sufficiently high axial force and may not be manipulated within a limited mounting space. The inventive connector assembly (1) solves this problem in that the lever assembly (7) comprising at least one lever (11), the lever (11) being arranged on the connector (3) pivotably about a pivot axis (35), the pivot axis (35) being oriented essentially perpendicular to the mating direction (9), the lever (11) at least partly covering the mating connector (5) in a coupled state (91) of the connector assembly (1), the lever (11) comprising an inner lever member (15) and an outer lever member (13), the inner lever member (15) being connected to the outer lever member (13) at a position distal from the pivot axis (35), the inner lever member (15) being arranged between the outer lever member (13) and the mating connector (5) in the coupled state (91) of the connector assembly (1), and the inner lever member (15) engaging the mating connector (5), at least in the mating direction (9).