Electrical Connector Lever Locking Mechanism Design
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Solution Overview
Problem
Large electrical connectors require significant force to combine with mating connectors, leading to deformation of the lever locking mechanism over time, causing unreliable connections due to interference with wiring harnesses.
Innovation Solution
A lever-supported electrical connector with a pivotally mounted locking mechanism featuring a recess for a mating connector's boss and a flexible latching detent that engages with the housing, reducing insertion force and preventing rotational disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lever locking mechanism is used to reduce insertion force for large connectors, then ease of operation is improved, but reliability deteriorates due to deformation from interference with wiring harnesses
Solution Approach 1:
The locking mechanism is divided into two independent parts: a lever component for insertion assistance and a separate locking component with a latching detent for securing the connection. This segmentation allows each component to perform its specific function without interfering with wiring harnesses, resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
A boss on the housing acts as an intermediary element that engages with the locking component. This intermediary structure provides a stable engagement point that is not affected by lever deformation, ensuring reliable locking even when the lever is subjected to external forces from wiring harnesses.
2Reliability
If the lever locking mechanism is positioned to avoid wiring harness interference, then reliability is improved, but device complexity increases
Solution Approach 1:
The locking component is integrated into the existing lever structure, with the latching detent formed as part of the lever assembly. This merging approach maintains reliability by ensuring proper engagement while avoiding the need for completely separate components, thus limiting the increase in device complexity.
3Ease of manufacture
If a snap-latch design is used for the locking mechanism, then ease of manufacture is improved, but reliability deteriorates due to excessive force on the lever
Solution Approach 1:
The latching detent is designed with specific local geometric features that concentrate the locking force at precise engagement points. This local quality optimization ensures stable latching engagement while minimizing the overall force required from the lever, maintaining reliability without complicating manufacturing.
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 solution ensures a reliable and durable connection by maintaining the fit of the mating connectors, even when the lever locking portion is subjected to deformation from wiring harnesses, preventing unintentional disconnection.
Implementation Method 1
a lever (14) supported pivotally on at least one pivot (13) disposed on the housing (11). The lever (14) rotates on the pivot (13) within a range from a pre-engagement position to a final engagement position
Implementation Method 2
a latching detent (173) configured to engage with the engaging portion (18) of the housing (11) at the second position, and thereby rotational movement of the lever (14) is restrained at the final engagement position
Data Source
AI summary
An electrical connector includes a housing and a lever supported pivotally on at least one pivot disposed on the housing. The lever rotates on the pivot within a range from a pre-engagement position to a final engagement position. The lever also has a recess configured to fit a boss disposed on a mating connector therein in accordance with rotational movement of the lever. Further, the lever includes a locking portion disposed on a beam thereof. The locking portion includes a base portion extending downward from the beam, a latching arm extending from the base portion in a direction substantially tangent to the rotational movement; and a latching detent disposed in proximity of a free end of the latching arm. The latching detent is configured to engage with the engaging portion of the housing at the second position, and thereby rotational movement of the lever is restrained at the final engagement position.