Lever-Assisted Electrical Connector With Contact-Module Retention
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Solution Overview
Problem
Existing electrical connectors for motor vehicles are prone to damage and reliability issues during manufacturing, storage, and assembly due to shocks and unintentional stresses, which can lead to loss of parts or subassemblies and increased time in the assembly process.
Innovation Solution
A connector design featuring a securing portion that serves both as a completion and retention element, allowing for a direct push on electrical contacts for enhanced mating and providing a retention mechanism that prevents lever arms from detaching from the housing, thus improving robustness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a connector is provided with a lever for mating assistance and locking, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent combines the mating assistance function and the locking function into a single integrated lever mechanism. The lever simultaneously provides the pushing motion needed for mating and the locking action to secure the connector, thereby improving ease of operation while minimizing the increase in device complexity.
Solution Approach 2:
The lever is designed to perform multiple functions: it acts as both a mating assistance tool (pushing the connectors together) and a locking mechanism (securing the mated connectors). This multi-functionality reduces the need for separate components, addressing the contradiction between operational ease and structural complexity.
2Productivity
If the connector is handled during manufacturing, storage, and assembly, then the productivity is improved, but the reliability deteriorates due to shocks and unintentional stresses
Solution Approach 1:
The connector is pre-assembled with its counter-connector in a controlled manufacturing environment before delivery. This preliminary assembly ensures that the connection is already established and secured, reducing the risk of damage during subsequent handling, storage, and assembly operations, thereby maintaining reliability while enabling efficient productivity.
Solution Approach 2:
The design incorporates features that protect the connector from shocks and unintentional stresses during handling. The robust construction and secure locking mechanism provide inherent protection against damage, cushioning the connector against the harmful effects of mechanical stress before such stress can cause reliability issues.
3Power
If power connector transmits large amount of energy under high voltage, then the power capability is improved, but the manufacturing precision requirement increases to ensure proper contact overlap
Solution Approach 1:
The patent specifies a minimum contact overlap length parameter (more than 1mm) to ensure proper electrical connection. By defining this critical dimension parameter, the design ensures sufficient contact area for high power transmission while providing a clear manufacturing target that balances precision requirements with practical manufacturability.
Data Source
Figure 1~2b
Figure 3~5b
Figure 6a~7b
AI summary
The present disclosure relates to an electrical connector (1) comprising an assisting and/or locking lever, adapted and arranged for mating with a counter connector(9). According to the disclosure, the lever(3) further comprises a securing portion(33) that extends towards and through an opening(22) of a wall(21) of the connector housing for providing a securing interaction(P39,2232-229) between said lever(3) and said housing(2,22) or its content(4), typically in a position that is off-centered from said joint(29,39). Securing portion is preferably arranged for, together and in a same member, providing a retention function of the lever arms to the housing and a completion action on the contacts(52) or contact module(4). Retention is provided by a transverse protrusion(332) prolonging the extension(331), with edges that exceed the opening. Same transverse protrusion also comes in contact with a ridge(43) of the module(4) in the last part(L23b) of the lever course, thus pushing(P39) in supplement on the contact module, together with a self-locking effect.