Connector Lever Locking Mechanism for Transport Stability
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Solution Overview
Problem
Existing electrical connector assemblies with mate assist levers often experience unintended movement from the preliminary mating position to the fully mated position when no counter connector is present, requiring an additional manual step to correct the lever position for successful mating, which is inefficient and prone to damage during transport.
Innovation Solution
An electrical connector assembly with a pivotable lever featuring a locking mechanism that securely holds the lever in transport and preliminary mating positions, utilizing a flexible locking arm and latching projection, and a cam groove system with limiting protrusions and a curved tilt surface to guide the lever into the correct positions, ensuring secure locking and easy mating with a corresponding counter connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mate assist lever is provided without a locking mechanism, then the lever can be easily moved during operation, but the lever may move unintentionally during transport causing damage and requiring additional manual correction steps
Solution Approach 1:
The locking mechanism is engaged in advance during transport to secure the lever in a predetermined position. The holding means (latching projection and locking arm) are designed to automatically lock the lever before operation begins, preventing any unintended movement during transportation while allowing easy release when needed for mating operations
2Reliability
If a locking mechanism is added to secure the lever during transport, then the lever position stability is improved, but the device complexity increases
Solution Approach 1:
The locking mechanism is merged with the existing lever structure by integrating the locking arm as part of the lever assembly and the latching projection as part of the housing structure. This combination approach allows the locking function to be achieved without adding completely separate components, thereby reducing overall device complexity while maintaining reliability
Solution Approach 2:
The locking mechanism is designed to be self-activating through the natural movement of the lever. When the lever is in its retracted position, the locking arm automatically engages with the latching projection without requiring external actuation. The mechanism serves itself by using the lever's own position to trigger the locking action, eliminating the need for additional control systems
3Productivity
If the lever is designed to move freely during mating operation, then the mating process is facilitated, but the lever may move beyond the intended position when no counter connector is present requiring manual correction
Solution Approach 1:
The locking mechanism provides positional feedback through the engagement state of the locking arm and latching projection. When the lever reaches its intended position during mating, the mechanism provides feedback by maintaining locked engagement, preventing the lever from moving beyond the correct position. This feedback system ensures the lever stops at the proper location without requiring manual intervention to correct overshooting
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Electrical connector assembly (10) comprising a connector housing (200), a cap (30) and a mate assist mechanism, comprising a lever (100) pivotably arranged on the cap(30); the lever (100) being movable from a transport position to a preliminary mating position and further to a fully mated position, and wherein the connector assembly (10) comprises a first holding means to releasably hold the lever (100) in the transport position and a second holding means to releasably hold the lever (100) in the preliminary mating position, said first holding means comprises a locking arm (40) arranged on the lever (100) and a corresponding latching projection (50) arranged on the cap (30), latching said locking arm (40) when the lever (100) is in the transport position, wherein the connector housing (200) has a wall (210) extending opposite the mating direction (Y) towards the cap (30) and configured to release the locking arm (40) from the latching projection (50) and move the lever (100) towards the preliminary mating position, said second holding means comprises a locking protrusion (222) and a corresponding locking reception (120) receiving said locking protrusion (222) when the lever (100) is in the preliminary mating position; wherein the locking protrusion (222) is arranged on the connector housing (200); wherein the locking reception (120) is arranged on the lever (100); and wherein, upon mating with a corresponding mating connector (300), the mating connector (300) displaces the locking protrusion (222) to release the lever (100).