Lever Connector Layout for Narrower Width Without Housing Changes
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Solution Overview
Problem
Existing connectors face challenges in size reduction due to the restriction of the lever's width dimension by the housing, making it difficult to reduce the connector's size when the number of terminal fittings is less than usual.
Innovation Solution
The connector design allows the lever to be positioned apart from the housing side surface portions, enabling independent reduction of the cover and lever width dimensions without altering the housing, with the lever's side portions facing each other and connected by a connecting portion, and the cover having inner side surface portions that determine the lever's width dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the width dimension of the cover and lever are reduced to decrease connector size, then the connector size is reduced, but the lever cannot be properly supported by the housing side surface portions
Solution Approach 1:
The lever is repositioned from overlapping with the housing side surface portions to being apart from them in the arrangement direction. This spatial reconfiguration in the width direction allows the lever width to be independently reduced without compromising its support stability, as the lever is now supported by the cover structure rather than requiring overlap with the housing sides.
2Quantity of substance
If the number of terminal fittings is reduced, then the connector can be smaller, but the lever width cannot be reduced due to housing constraints
Solution Approach 1:
The connector structure is segmented into distinct functional zones: the cover with its side surface portions that support the lever, and the housing with its side surface portions that maintain structural integrity. This segmentation allows the lever width to be independently optimized based on the actual number of terminal fittings, while the housing maintains its structural requirements.
3Volume of moving object
If the lever width is reduced to match a smaller cover, then the connector size is reduced, but the lever may deform during rotation
Solution Approach 1:
The cover acts as an intermediary structure that provides support to the lever. The cover side surface portions are positioned to support the lever during rotation, compensating for the reduced lever width. This intermediary support mechanism allows the lever to be narrower without sacrificing its resistance to deformation during operation.
Data Source
AI summary
A lever (70) has a pair of side portions (72) facing each other in a width direction, and a connecting portion (71) connecting the pair of side portions (72). A cover (50) includes a pair of cover side surface portions (51) located on an inner side of the pair of side portions (72) in the width direction. A housing (11) includes a pair of housing side surface portions (22) arranged side by side with the pair of cover side surface portions (51), at positions opposite the pair of cover side surface portions (51) with an outer periphery of a drawing-out surface (27) as a boundary. The lever (70) is apart from the housing side surface portions (22) in an arrangement direction of the cover side surface portions (51) and the housing side surface portions (22).