Lever-Type Connector Assembly via Rear Insertion and Rotation
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Solution Overview
Problem
The existing lever-type connectors face difficulties in assembly due to limited lateral space, which can lead to interference with wires and potential deformation or scraping of components during the assembly process.
Innovation Solution
A U-shaped lever with ridge pieces and a lever guide system that includes front and rear rails, allowing the lever to be assembled from behind the housing while avoiding wires, with a lock mechanism to prevent deformation and ensure smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lever is arranged laterally to the housing for assembly, then the lever can be assembled with the housing, but the lever is laterally long and the assembling operation is difficult if sufficient lateral space is not available
Solution Approach 1:
The patent changes the assembly direction from lateral (horizontal) to longitudinal (from behind the housing). The lever is inserted from the rear surface of the housing through the wire passage in the longitudinal direction, then rotated into its final position. This dimensional change eliminates the need for sufficient lateral space while maintaining assembly feasibility.
2Ease of manufacture
If the lever is inserted laterally into the housing, then the lever can be assembled, but the lever may interfere with wires pulled out rearward from the housing
Solution Approach 1:
The patent performs preliminary routing of wires through the housing before lever assembly. Wires are pulled out rearward from the housing and positioned within the wire passage structure. The lever is then inserted from behind through this pre-prepared wire passage, ensuring wires are already in position and will not be interfered with during lever insertion or rotation.
3Object-affected harmful factors
If the lever is assembled from behind the housing, then wires are avoided during assembly, but the lever must be laterally long to reach from behind to the connection position
Solution Approach 1:
The patent employs a dynamic two-stage assembly process. First, the lever is inserted in the longitudinal direction from behind the housing through the wire passage to a temporary initial position. Second, the lever is rotated about a pivot point to reach its final connection position. This dynamic transformation from linear insertion to rotational movement allows the lever to reach its destination without requiring excessive initial length.
4Productivity
If the lever is inserted laterally, then assembly can proceed, but deformation or scraping of components may occur due to limited lateral space
Solution Approach 1:
The patent introduces a wire passage structure as an intermediary guide path. This passage serves as a mediator that directs the lever from its insertion point behind the housing to its final position. The guided path ensures proper alignment and prevents lateral deviations that could cause deformation or scraping of components, while still allowing efficient assembly progression.
Data Source
AI summary
A connector includes a housing (10) that is connectable to a mating connector by rotating a lever (40) from an initial position to a connection position on the housing (10). The lever (40) has two arm plates (41) coupled by an operating portion (42). Ridge pieces (44) are on facing surfaces of the arm plates (41). Front and rear rails (22A, 22B) extend perpendicular to a pull-out direction of wires to guide the ridge piece (44) laterally. An introducing portion (26) is open on one end of the rear rail (22B) to receive the ridge piece (44) between the rails (22A, 22B) from a position behind the housing (10). An escaping portion enables the ridge piece (44) to rotate from a position between the rails to the position behind the housing (10) as the lever (40) is rotated from the connection position to the initial position.