Compact Lever Connector with Longitudinal Cam Mechanism
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Solution Overview
Problem
Conventional lever connectors with high contact density become difficult or impossible to manually connect due to their bulkiness, which prevents their use on circuits with multiple printed circuit boards where space is limited.
Innovation Solution
A set of lever connectors featuring a cam mechanism with a lever that remains circumscribed within the connector's perimeter, allowing for relative movement between connector parts using a pivotally mounted plate and rod system, enabling connection and disconnection without extending beyond the connector's dimensions, thus maintaining manipulability even when in contact with other elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional lever connectors are used with high contact density, then electrical connection capability is improved, but manual operability deteriorates due to bulkiness
Solution Approach 1:
The lever is repositioned from a lateral mounting configuration to a longitudinal configuration that extends along the coupling direction (Z-axis) rather than perpendicular to it. This dimensional reorientation allows the lever to operate within the connector's footprint, enabling high contact density while maintaining manual operability in crowded PCB environments.
2Area of stationary object
If lever connectors are mounted in close proximity on circuit boards, then space utilization is improved, but lever manipulability deteriorates due to lateral extension
Solution Approach 1:
The lever mechanism is reconfigured to extend along the coupling direction (longitudinal axis) rather than laterally. This allows multiple connectors to be mounted in close proximity without lateral lever extension interfering with adjacent components, while the lever remains fully manipulable along the Z-axis coupling direction.
Solution Approach 2:
Instead of mounting the lever laterally on the connector body, the invention inverts the mounting approach by attaching the lever to the movable part and having it extend longitudinally. This inversion resolves the conflict between compact footprint and lever manipulability.
3Ease of operation
If lever extends beyond connector perimeter, then lever operation range is improved, but connector integration deteriorates due to excessive dimensions
Solution Approach 1:
The lever's operational range is achieved by extending it along the coupling direction (Z-axis) rather than laterally. This allows full lever operation for connection and disconnection while keeping the lever within the connector's lateral footprint, maintaining proper integration with the connector body.
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 efficient electrical connection and disconnection of high-density conductor bundles on printed circuit boards without the need for excessive manual force, ensuring reliable operation and compact integration within crowded circuit board layouts.
Implementation Method 1
a cam mechanism capable of moving the movable part between disconnection and connection positions of the plug sets
Data Source
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AI summary
A lever connector comprising a first part (3) forming a base and a second part (2) movable relative to the base, the first and second parts internally receiving first and second sets of opposing contacts, respectively male and female, each provided at one end of conductors to be connected, and a cam mechanism (10, 15) adapted to move the movable part (3) between a first position of complete disconnection of the contact sets and a second active position of electrical connection of the contact sets. The cam mechanism includes a lever (10) shaped so as not to extend laterally beyond the perimeter of the connector.