Lever Connector Assembly With Spring-Cam Contact Locking
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Solution Overview
Problem
Conventional connector assemblies face challenges in maintaining contact reliability between first and second contacts when subjected to external forces, such as vibration, due to the need for thicker wires to handle increased electric current, which can lead to poor contact and increased insertion force requirements.
Innovation Solution
The connector assembly incorporates a contact spring member with a pressing portion that elastically deforms to press the first contact against the second contact, and a rotational shaft member with a cam surface that interacts with the contact spring member to facilitate easy fitting and locking of the connectors, ensuring reliable contact without excessive insertion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If thicker electric wires are used to handle increased electric current, then the current carrying capacity is improved, but the contact reliability deteriorates due to transmission of external forces such as vibration to the contact points
Solution Approach 1:
The patent introduces a contact spring member as an intermediary element between the first contact and second contact. This spring member absorbs external forces such as vibration through its elastic deformation, preventing these forces from being transmitted to the contact points. The spring member maintains reliable electrical contact while allowing the use of thicker wires for high current carrying capacity.
2Reliability
If increased contact force is applied between the first contact and the second contact to improve contact reliability, then the contact reliability is improved, but the insertion force required for fitting increases making the operation difficult
Solution Approach 1:
The patent employs a dynamic contact spring member that can elastically deform to provide the necessary contact force. During the fitting operation, the lever member rotates to insert the contacts, and the spring member naturally provides contact force through its elasticity without requiring excessive insertion force. The spring member dynamically adjusts to maintain optimal contact force while allowing easy fitting operation.
3Reliability
If increased contact force is applied between the first contact and the second contact, then the contact reliability is improved, but the contact surfaces may be damaged leading to lower contact reliability
Solution Approach 1:
The contact spring member serves as a mediator that provides the necessary contact force through elastic deformation rather than direct rigid contact. This elastic interaction prevents damage to the contact surfaces while maintaining sufficient contact force for reliable electrical connection. The spring member absorbs the stress that would otherwise damage the contact surfaces.
4Ease of operation
If a lever member with rotation mechanism is used to ease the fitting operation, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The lever member is designed to perform multiple functions: it serves as both the operating handle for insertion and the mechanical linkage that actuates the contact spring member. The rotation mechanism of the lever member simultaneously controls the insertion motion and the engagement of the contact spring, reducing the need for separate components and minimizing overall device complexity while maintaining ease of operation.
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
This solution enhances contact reliability between the first and second contacts while allowing for easy fitting and detachment of the connectors, even under conditions of increased electric current and external vibrations, thus providing a reliable electrical connection.
Implementation Method 1
a contact spring member attached to the second contact and including a pressing portion configured to press the first contact against the second contact to bring the first contact and the second contact into contact with each other
Implementation Method 2
a rotational shaft member held by the second insulator to rotate about the rotational axis along with rotation of the lever member and including a cam surface configured to elastically deform the contact spring member
Data Source
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AI summary
The 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 contact spring member attached to the second contact and pressing the first contact against the second contact, a lever member held by the second insulator and being rotatable about a rotational axis between a first rotational position and a second rotational position, a rotational shaft member held by the second insulator to rotate about the rotational axis with rotation of the lever member and having a cam surface configured to elastically deform the contact spring member, and a fitting cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member.