Lever Connector Cover Alignment via Positioning Mechanism
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Solution Overview
Problem
Lever-type connectors face issues with misalignment of the cover with respect to the connector housing, which can prevent smooth completion of the connecting operation due to interference and misalignment of locking mechanisms, especially when the cover is misaligned during assembly or due to restoring forces of bent wires.
Innovation Solution
Incorporation of positioning portions on the cover and corresponding receiving portions on the lever, which contact each other at the connection end position to ensure proper alignment and secure the cover in place, allowing the lever to be held at the predetermined connection end position, thereby facilitating smooth completion of the connecting operation. Additionally, an accommodation recess reduces the projecting amount of the lever, and the use of reinforcing ribs and lightening holes for positioning without drastic design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the cover is assembled to cover the wire extending from the connector housing, then the wire is protected, but misalignment of the cover with respect to the connector housing occurs causing interference with the lever
Solution Approach 1:
A positioning portion is introduced as an intermediary element between the cover and the lever. This positioning portion includes a positioning protrusion on the cover that engages with a positioning recess on the lever, serving as a mediator to ensure precise alignment and prevent misalignment during assembly and operation.
Solution Approach 2:
The positioning portion is pre-configured on both the cover and lever before assembly. The positioning protrusion and positioning recess are designed in advance to guide the cover into the correct position relative to the connector housing, preventing misalignment before it occurs.
2Ease of operation
If the lock and lock receiving portion are used to secure the lever at the connection end position, then the connecting operation can be completed, but misalignment prevents the lock and lock receiving portion from engaging
Solution Approach 1:
The positioning portion acts as an intermediary that ensures the lock and lock receiving portion are properly aligned. By establishing the correct relative position between the cover and lever through the positioning protrusion and recess, the locking mechanism can engage reliably without misalignment issues.
Solution Approach 2:
The positioning portion is configured in advance to guide the cover and lever into proper alignment before the locking action occurs. This preliminary positioning ensures that when the lever reaches the connection end position, the lock and lock receiving portion are correctly aligned for engagement.
3Shape
If the cover holds the wire in a bent state, then the wire is organized, but the restoring force of the bent wire causes misalignment of the cover
Solution Approach 1:
The positioning portion provides a counteracting constraint that balances the restoring force of the bent wire. The positioning protrusion engaged with the positioning recess creates a stabilizing force that counteracts the misalignment tendency caused by the wire's restoring force, maintaining proper cover alignment.
Solution Approach 2:
The positioning portion serves as an intermediary that mediates between the bent wire's restoring force and the cover's position. It provides a mechanical constraint that prevents the cover from misaligning due to the wire's elastic recovery, while still allowing the wire to remain in its organized bent state.
Data Source
AI summary
A lever-type connector (1) is provided with a connector housing (10) including a wire holding portion (11). Wires W have end parts held in the wire holding portion (11) and extend from the connector housing (10). A lever (20) is assembled with the connector housing (10) and is rotatable from a connection start position to a connection end position. A cover (50) covers the wires W extending from the connector housing (10) by being assembled with the connector housing (10). The cover 50 includes positioning portions (55A), and the lever (20) includes positioning receiving portions for positioning the cover (50) at a proper mounting position by contacting the positioning portions (55A) when the lever (20) is at the connection end position.