Lever-Assisted Electrical Connector for Robust Partial-to-Full Mating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for motor vehicles are prone to damage during manufacturing, storage, and assembly due to shocks and unintentional stresses, leading to potential loss of parts or subassemblies and increased time in the overall process.
Innovation Solution
The design incorporates a lever with a retention element on its internal face, which provides a direct push on electrical contacts for secure mating and includes a retention protrusion to prevent the lever from spreading or being lost, thus enhancing robustness and manufacturing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lever is provided to assist mating and provide locking function, then the connector becomes more robust and reliable, but the device complexity increases
Solution Approach 1:
The patent combines the mating assistance function and the locking function into a single lever mechanism. The lever's movement simultaneously engages the contact elements for mating and activates the locking element to secure the connector, thereby reducing the number of separate components while maintaining reliability.
Solution Approach 2:
The lever is designed to perform multiple functions: it assists in the mating process by applying force to engage contacts, and it also serves as a locking mechanism when positioned in the locked state. This multi-functionality reduces overall device complexity while improving reliability through integrated design.
2Power
If the connector is designed to transmit large amounts of energy through high intensity or high voltage, then the electrical connection becomes more robust, but the manufacturing precision requirements increase
Solution Approach 1:
The lever is designed to apply a preliminary pushing force on the contact elements during the mating process, ensuring that the contacts are fully engaged and achieve the required overlap length before final locking occurs. This preliminary action compensates for tolerance variations and ensures consistent contact engagement for high power applications.
3Strength
If the connector and counter-connector are mated with substantive effort, then the electrical connection becomes more stable, but the ease of operation decreases
Solution Approach 1:
The lever mechanism provides dynamic assistance during the mating process. As the lever is moved into the locked position, it progressively applies force to push the contact elements together, reducing the manual effort required from the operator while still achieving a stable, strong connection. The mechanical advantage provided by the lever system makes the mating process easier without compromising connection strength.
Data Source
AI summary
A connector system includes a connector housing with electrical contacts for engaging counter-contacts of a counter-connector. The system features a lever mechanism with a lever arm connected to the housing via a joint, enabling movement between open and closed positions. In the open position, the counter-connector can be partially mated, while in the closed position, full mating is achieved. The lever includes a securing portion extending through an opening in the housing wall to secure the lever in place. This design facilitates the mating process between the connector and counter-connector, ensuring a reliable and secure electrical connection.