Lever-Actuated Connector Assembly for High-Pressure Contact Mating
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Solution Overview
Problem
Existing connector assemblies face challenges in maintaining contact reliability between connectors due to increased contact force, which complicates fitting operations and can cause damage, especially in environments with external forces like vibration.
Innovation Solution
A connector assembly design featuring a lever member with a rotational shaft member and cam mechanism that allows for easy fitting by rotating the lever from an initial to a first rotation position, moving the insulators relative to each other, and then pressing the contacts together with a predetermined contact pressure, ensuring reliable electrical connection without surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact force between the first contact and the second contact is increased to improve contact reliability, then the contact reliability improves, but the insertion force required for fitting the connectors increases and the contacts may be damaged
Solution Approach 1:
The lever member transitions from a non-rotating state to a rotating state, and the rotational shaft member transitions from a non-pressing state to a pressing state, dynamically adjusting the contact force during the fitting operation to achieve both easy operation and reliable contact
Solution Approach 2:
The cam surface is pre-configured on the rotational shaft member to automatically apply pressing force when the lever member rotates to a specific position, preliminarily establishing the contact pressure before final connection is completed
2Reliability
If the contact force between the first contact and the second contact is increased to improve contact reliability, then the contact reliability improves, but the contacts may be damaged due to excessive force
Solution Approach 1:
The cam surface is designed with specific geometric parameters that control the pressing force magnitude, changing the force parameter to achieve optimal contact pressure that ensures reliability without causing damage
Solution Approach 2:
The rotational shaft member acts as an intermediary mechanism between the lever member and the contacts, mediating the force transmission through its cam surface to provide controlled pressing action
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 design enables easy fitting of connectors with high contact pressure, maintaining reliable electrical connection even under external forces, and prevents contact damage while ensuring waterproof sealing.
Implementation Method 1
a cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member
Implementation Method 2
the first contact and the second contact are brought into contact with each other with a predetermined contact pressure due to the cam surface of the rotational shaft member
Data Source
AI summary
A connector assembly includes a first connector having a first insulator and a first contact, a second connector having a second insulator and a second contact and being fitted to the first connector along a fitting direction; a lever member held by one of the first insulator and the second insulator in a rotatable manner about a rotational axis, a rotational shaft member extending along the rotational axis and rotating in accordance with rotation of the lever member, the rotational shaft member having a cam surface for pressing the first contact and the second contact against each other, and a cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member.