Lever-Actuated Electrical Connector for Reduced Mating Force
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Solution Overview
Problem
The increasing number of electrical components in vehicles requires a compact electrical connector that can accommodate more terminals while maintaining ease of use and reducing the force needed to mate connectors, as existing connectors often require excessive force and separate tools.
Innovation Solution
An electrical connector design featuring a lever that rotates to move a second housing linearly into position, with a lock and connector position assurance mechanism to secure the lever in place, allowing for easy mating and disconnection while providing improved leverage and alignment guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrical terminals are placed in a connector to increase the number of electrical connections, then the quantity of electrical connections is improved, but the force required to mate the connectors increases excessively
Solution Approach 1:
The connector employs a lever mechanism that rotates between a pre-stage position and a final position to dynamically apply force during mating. The lever engages the second housing to move it linearly between positions, allowing the operator to control the mating process in stages rather than requiring excessive force all at once.
Solution Approach 2:
The lever acts as an intermediary mechanical element between the operator and the connector housing. By introducing this intermediate component, the direct force application is transformed into a leveraged rotational motion that engages the housing gradually, reducing the peak force requirement while maintaining the ability to mate multiple terminals.
2Volume of moving object
If the connector size is reduced to fit confined spaces, then the volume is improved, but the ease of operation deteriorates
Solution Approach 1:
The lever provides an operational dimension perpendicular to the compact connector body. While the connector housing maintains a small volume for confined spaces, the lever extends outward to provide a convenient hand engagement point, allowing easy operation without increasing the main connector volume.
Solution Approach 2:
The connector is segmented into distinct functional components: a compact housing containing the terminals and a separate lever mechanism for operation. This segmentation allows the housing to remain small for confined spaces while the lever can be optimally sized for ease of operation.
3Ease of operation
If a lever mechanism is added to reduce mating force, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The lever is integrated with the connector housing through direct engagement features. The lever engages the second housing to move it linearly, combining the lever mechanism with the housing structure rather than adding a completely separate assembly, thereby reducing overall complexity.
Solution Approach 2:
The lever serves multiple functions: it provides mechanical advantage to reduce mating force, guides the second housing into proper alignment during insertion, and can be used to disengage the connector for removal. This multi-functionality reduces the need for additional separate components.
4Ease of operation
If the connector is designed for easy removal without tools, then the ease of operation is improved, but the reliability of the connection may deteriorate
Solution Approach 1:
The lever mechanism provides dynamic control over the connection state. When the lever is in the final position, the lock retains it securely to ensure reliable connection. To remove, the operator simply moves the lever back to the pre-stage position, which automatically disengages the locking feature, providing easy tool-free removal while maintaining connection reliability during operation.
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
Enables a higher density of electrical terminals in confined spaces with reduced operator effort, ensuring proper alignment and secure connections, and allowing for easy operation without separate tools.
Implementation Method 1
The electrical connector includes a lever. The lever is mounted on the first housing for relative rotational movement between a pre-stage position and a final position. The lever engages the second housing to move the second housing linearly between a pre-stage position and a seated position relative to the first housing.
Data Source
AI summary
An electrical connector includes a first housing. A second housing is movable relative to the first housing. The electrical connector includes a lever that is mounted on the first housing for relative rotational movement between a pre-stage position and a final position. The lever engages the second housing to move the second housing linearly between a pre-stage position and a seated position relative to the first housing. The electrical connector includes a lock that retains the lever in the final position relative to the first housing. The electrical connector also includes a connector position assurance. The connector position assurance is mounted on the first housing for relative movement between an initial position and an assurance position. When the lever is in the final position and the connector position assurance is in the assurance position, the connector position assurance engages the lever and prevents the lever from being moved away from the final position.