Lever Fitting Connector Size Reduction via Extraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lever fitting-type connectors in electric vehicles have a size issue due to the arrangement of the lock portion, which increases the connector's size in the Y direction, making it difficult to safely and smoothly install.
Innovation Solution
A lever fitting-type connector design that eliminates the need for a lock portion by using a rotatable lever with holes for projections, an engagement receiving portion, and abutment receiving portions to maintain the non-fitting position, reducing the connector's size and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock portion is arranged in the conventional lever fitting-type connector to maintain the lever in the non-fitting position, then the lever can be securely held in place, but the size of the connector becomes large in the Y direction
Solution Approach 1:
The patent removes the lock portion from the connector structure entirely. Instead of using a separate locking mechanism, the invention uses the engagement receiving portion and engaging portion that work together with the lever's inherent movement to maintain positioning. This extraction of the lock portion directly reduces the connector size in the Y direction while maintaining functional reliability through the simplified engagement mechanism.
Solution Approach 2:
The engagement receiving portion serves multiple functions: it receives the engaging portion of the lever, maintains the lever in the non-fitting position, and guides the lever's rotational movement. By making this component multi-functional, the patent eliminates the need for a separate lock portion, thereby reducing the connector's Y-direction size while preserving the lever positioning reliability.
2Reliability
If a lock portion with projection and U-shaped groove is provided in the conventional connector, then the lever can be maintained in the non-fitting position, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent extracts the lock portion entirely from the connector design. The engagement receiving portion and engaging portion work together to achieve the same positioning function without requiring the complex projection and U-shaped groove structure. This simplification directly reduces manufacturing complexity and production time while maintaining the reliability of lever positioning through the streamlined engagement mechanism.
Solution Approach 2:
The invention changes the structural parameters of the positioning mechanism by replacing the lock portion's projection and U-shaped groove with a simpler engagement receiving portion and engaging portion configuration. This parameter change simplifies the manufacturing process, reduces the number of machining operations required, and decreases production time while preserving the essential function of maintaining the lever in the non-fitting position.
3Reliability
If the lock portion is arranged in the conventional connector to ensure safe operation, then the lever positioning is reliable, but the connector size increases making installation difficult
Solution Approach 1:
The patent removes the lock portion that caused the size increase, making the connector more compact and easier to install. The engagement receiving portion and engaging portion maintain the necessary reliability for safe operation while allowing for a more compact design that facilitates easier installation in confined spaces.
Solution Approach 2:
Instead of adding a lock portion to ensure reliability (which increased size), the invention inverts the approach by using a simplified engagement mechanism that achieves reliability through the lever's own movement and the engagement receiving portion's design. This inverted approach maintains safety while reducing size and improving installation ease.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A lever fitting-type connecter of the present invention has housing having a main body and a pair of projections; a lever having holes into which the projections are inserted, the lever rotated in a state that the projections are inserted into the holes from a non-fitting position before being fitted to another connector to a fitting position fitted to the other connector by rotating around the projection; an engagement receiving portion arranged in the projection so as to sandwich the lever between the main body and the engagement receiving portion; a first overlapping position arranged in the lever and overlapped with the engagement receiving portion at the non-fitting position; a second overlapping position arranged in the lever and overlapped with the engagement receiving portion at the fitting position; and an engaging portion arranged between the first and second overlapping positions and engaged to the engagement receiving portion.