Electrical Connector Lever Gear Mechanism for Binding Reduction
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Solution Overview
Problem
Electrical connectors with levers require significant initial torque and can bind due to the initial contact angle and angular spacing of gear teeth, leading to unused rotary travel and potential misalignment issues.
Innovation Solution
The connector assembly features a lever with gear teeth that mesh with complementary teeth on the header, allowing rotation to draw the plug assembly into engagement and a cam mechanism for easy insertion and removal, minimizing binding and ensuring proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gear teeth are spaced apart to allow receiving area between teeth, then the lever can be properly oriented for engagement, but unused rotary travel increases
Solution Approach 1:
The patent modifies the geometric parameters of the gear teeth, specifically the angle and spacing, to optimize the engagement process. By changing the tooth geometry parameters, the lever achieves proper orientation with minimal unused rotary travel.
2Ease of operation
If the initial contact angle between lever tooth and header tooth is used, then gear engagement is achieved, but initial torque required may be great and binding may occur
Solution Approach 1:
The patent optimizes the contact angle parameter between the lever tooth and header tooth. By adjusting this angular parameter, the initial torque required for engagement is reduced and binding is prevented while maintaining effective gear engagement.
3Ease of operation
If two gear teeth are used on the lever, then proper angular spacing can be achieved, but device complexity increases
Solution Approach 1:
The patent divides the engagement function into two separate components: the lever with its gear teeth for engagement, and the lifting member with its cam surface for disengagement. This segmentation allows each component to have optimized simplicity while achieving the overall functional requirement.
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
This design reduces the initial torque required for engagement, prevents binding, and allows for easy insertion and removal of the plug assembly, ensuring reliable electrical connections while preventing damage from incorrect insertion.
Implementation Method 1
A cam portion is cooperable with the post for moving the plug housing upon counter rotation of the lever locking member
Implementation Method 2
the lever has at least one gear tooth cooperable with the header gear tooth, such that rotation of the lever causes engagement of the header gear tooth and the plug housing gear tooth, drawing the plug member into the cavity
Data Source
AI summary
An electrical connector assembly includes a plug assembly for mating with a header. The plug assembly includes a plug housing and a lever, where the lever includes gear teeth which cooperate with a tooth on the header in a rack and pinion fashion. The lever is locked to the plug housing when the lever is poised for the plug housing to be inserted into the header. A release member on the header releases the lever from the locked position allowing the lever to be rotated to the position where the lever gear teeth mesh with the header tooth, to draw the plug assembly into the header. A cam on the lever also contacts a contact surface in the header, which pre-lifts the plug assembly during disconnection.