Extendable Lever Connector Assembly for High-Force Coupling
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Solution Overview
Problem
Existing connectors require high plug-in force for coupling, making them difficult to use in limited spaces and increasing the physical effort required, especially when dealing with insulation displacement connectors where high force is necessary.
Innovation Solution
A connector assembly with a lever assembly comprising two pivotable levers and extendable extensions that allow for a longer lever arm, reducing the physical effort needed for coupling by converting torque into axial force, while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lever assembly with extended lever arm is used, then the physical effort required for coupling is reduced, but the space occupied by the connector increases
Solution Approach 1:
The lever assembly incorporates an extension that can be moved between an extended state during coupling operations and a retracted state for compact storage. This dynamic configuration allows the lever arm length to be adjusted based on operational needs, reducing physical effort when extended and minimizing space when retracted
Solution Approach 2:
The extension is designed to be nested within or attached to the lever assembly structure. When retracted, the extension folds into or alongside the main lever body, allowing the connector to maintain a compact form factor while still providing the option for extended lever arm functionality when needed
2Power
If the lever assembly is extended to reduce physical effort, then the torque conversion capability improves, but the compactness of the connector is compromised
Solution Approach 1:
The lever assembly allows dynamic adjustment of the lever arm length through the movable extension. During coupling operations requiring high torque, the extension is deployed to increase the lever arm and thus the torque conversion capability. When not in use, the extension is retracted to maintain connector compactness
Solution Approach 2:
The lever assembly is divided into the main lever body and a separate movable extension component. This segmentation allows the extension to be independently controlled and positioned, enabling the system to optimize between torque capability and compactness based on operational requirements
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 enables easy coupling with minimal physical effort in limited spaces, achieving high axial force with lower effort and minimizing space usage, making it suitable for applications where space is constrained.
Implementation Method 1
a higher torque, which can be converted into a high axial force in the coupling direction during coupling with a complementary connector, can be achieved with lower physical effort
Data Source
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AI summary
The invention relates to a connector (1) with a coupling side (23) for coupling with a complementary connector (11) along a connection direction (22), a connector housing (2) and with a lever assembly (4) that comprises at least one lever (6) for coupling with the complementary connector (11), the lever (6) being held pivotable around an axis of rotation (20) on the connector housing (2), wherein the axis of rotation (20) runs essentially perpendicular to the connection direction (22) and wherein the at least one lever (6) extends in at least one position in the connection direction (22) away from the axis of rotation (20). In order to gain a high force transmission with constrained space, and to obtain a compact connector (1) when coupled with the complementary connector (11), the lever assembly (4) is provided with at least one extension (6) that is moveable relative to the at least one lever (6), and that extends the lever assembly (4) in the extended state (38) in the direction away from the axis of rotation (20). Furthermore, the invention relates to a connector assembly (150) comprising such a connector (1) and a complementary connector (11) with an end face (120) facing the coupling side (23), the complementary connection (11) being adapted to be at least partially inserted into the connector housing (2) in the connection direction (22).