High-Voltage Connector Lever Locking for Accurate Vibration-Safe Mating

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Solution Overview

Problem

Existing electrical connectors face challenges in accurately and easily connecting components, as they are not designed to provide an improved electrical connector that allows components to be connected accurately and easily connected components, as they are not designed to provide an improved electrical connector that allows components to be connected accurately and easily.

Innovation Solution

The electrical connector includes an inner housing with a terminal cavity, a terminal position assurance, an outer housing with a lever, and a connector position assurance, which facilitate relative movements to ensure secure and easy connection of electrical terminals and cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If existing electrical connectors are used, then components can be connected, but the connection is not accurate and easy

Engineering Contradiction:

Improveease of connectionVSAvoidconnection accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The terminal position assurance is pre-configured in the housing to automatically guide and secure the terminal in the correct position during insertion, eliminating the need for precise manual alignment and ensuring accurate connection without requiring operator skill

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The terminal position assurance acts as an intermediary component between the terminal and the housing, providing a mechanical guide and retention mechanism that ensures proper positioning and secure connection of the terminal within the housing

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If existing electrical connectors are used, then components can be connected, but the connection is not secure against vibrations

Engineering Contradiction:

Improveconnection securityVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector position assurance is pre-configured to automatically engage with the housing and secure the connector in place during the insertion process, providing vibration resistance without requiring additional complex locking mechanisms or multiple assembly steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connector position assurance is integrated within the housing structure, with the leg and trigger mechanism nested within the housing cavity, providing a compact design that secures the connector without adding external complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20260005471A1High Voltage Electrical Connector

Publication Date: 2026.01.01 LEAR CORP

AI summary

An electrical connector includes an inner housing. The inner housing defines a terminal cavity that is adapted to accommodate an electrical terminal. A terminal position assurance is attached to the inner housing for relative movement between an open position and a closed position. The terminal position assurance extends into the terminal cavity when in the closed position. The electrical connector includes an outer housing with an outer body that defines an outer housing cavity. The outer body also defines an outer housing opening. The inner housing is retained in the outer housing cavity. A lever is connected to the outer housing for relative movement between a pre-mate position and a mated position. The lever defines a lever opening. The outer housing opening is located between the terminal position assurance and the lever opening.