Lever Connector Clamping Mechanism for Lower Opening Force
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Solution Overview
Problem
Current lever connectors for electrical conductors face challenges such as high lever opening forces, limited shipping configurations, and larger size, which hinder their efficiency and versatility in electrical connection applications.
Innovation Solution
The development of lever connectors with improved lever opening forces, the ability to be shipped with levers in the open configuration, and a smaller size, including a housing design with insulating materials, a busbar with conductive arms, a lever mechanism with a lifting mechanism, and a resilient member with a fixed and clamping section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional lever connectors are used, then reliable electrical connection is achieved, but lever opening force becomes excessively high
Solution Approach 1:
The connector is divided into a housing and a separate lever assembly that can be independently manipulated. The lever acts as an independent actuating mechanism that translates user input force into clamping force on the conductor, separating the high-force clamping function from the low-force actuation function.
Solution Approach 2:
The lever mechanism incorporates dynamic movement through defined travel paths and pivot points. The lever rotates about a pivot axis within the housing, converting rotational motion into linear clamping motion that engages the conductor with controlled force progression rather than static high force.
2Stability of the object's composition
If lever connectors are designed for closed configuration, then structural stability is improved, but shipping and storage flexibility is reduced
Solution Approach 1:
The lever is designed as a movable component that can transition between open and closed positions. During shipping, the lever remains in the open position allowing compact stacking and reduced risk of damage. During installation, the lever is actuated to the closed position to provide structural stability and secure electrical connection.
Solution Approach 2:
The lever is extracted as a separate actuating component from the main housing body. This allows the housing to be shipped in a stable, compact state while the lever can be independently positioned or even removed if needed, providing flexibility for different shipping and storage scenarios.
3Productivity
If traditional lever connector designs are used, then functional requirements are met, but device size becomes larger
Solution Approach 1:
The lever mechanism is nested within the housing structure, with the lever rotating about a pivot point that is integrated into the housing body. The resilient member is positioned within the same housing space, and all components are arranged to utilize the available volume efficiently, creating a compact integrated assembly.
Solution Approach 2:
The lever mechanism utilizes rotational motion in a plane perpendicular to the conductor insertion direction. This dimensional approach allows the lever to achieve full actuation travel within a compact footprint, reducing the overall size of the connector while maintaining functional effectiveness.
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 improved lever connectors achieve reduced lever opening forces, enhanced shipping flexibility, and a more compact design, facilitating easier integration and use in various electrical connection applications.
Implementation Method 1
a resilient member (170) located within the housing (110) that includes a fixed section (172) connected to the busbar bridge (134) and a clamping section (174) connected to the lifting mechanism (154)
Data Source
AI summary
A lever connector includes a housing, a busbar located within the housing, lever mechanisms, and resilient members that connect the lever mechanisms to the busbar. Each lever mechanism includes a lever located on a near side of the busbar bridge and a lifting mechanism located on a far side of the busbar bridge opposite the near side of the busbar bridge. Each resilient member includes a fixed section connected to the busbar bridge and a clamping section connected to the lifting mechanism. When the lever is actuated and lifted upwards and away from the housing, the lifting mechanism moves the clamping section of the resilient member to release away from the busbar base surf ace. When the lever is closed and pushed downward toward the housing, the lifting mechanism moves the clamping section of the resilient member downward to push the electrical conductor against the busbar base surface.