Lever-Lock Electrical Connector with CPA Secondary Locking
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Solution Overview
Problem
Existing electrical connectors in automotive and aerospace applications are difficult to install efficiently and lack sufficient resistance to unintentional decoupling during use, transport, maintenance, or assembly processes.
Innovation Solution
The electrical connector design includes a first housing portion with a lever-rotatable first lock and a connector position assurance (CPA) device with a second lock, which secures the first and second housing portions in seated alignment, preventing unintentional decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single lock mechanism is used, then the device complexity is reduced, but the resistance to unintentional decoupling is insufficient
Solution Approach 1:
The lock mechanism is segmented into two distinct locks: a first lock with a lever that rotates between unlocked and locked positions, and a second lock that is staged and locked. This segmentation allows each lock to perform its specific function independently, providing enhanced decoupling resistance while maintaining manageable complexity through functional specialization.
Solution Approach 2:
The second lock is staged in advance before final engagement. The CPA device stages the second lock into position, and upon lever actuation, the second lock transitions to a locked state that provides additional securing. This preliminary action ensures that the second lock is ready to engage and provide immediate additional resistance to decoupling.
2Ease of operation
If a lever-rotatable lock is used, then the ease of operation is improved, but the reliability against unintentional decoupling is insufficient
Solution Approach 1:
The first lock and second lock are merged into a coordinated system where the lever actuation of the first lock triggers the engagement of the second lock. This merging allows a single simple lever operation to simultaneously activate both locking mechanisms, maintaining ease of operation while achieving enhanced reliability through the combined securing action of both locks.
Solution Approach 2:
The CPA device automatically stages and positions the second lock without requiring separate manual intervention. When the lever is actuated, the system self-coordinates to engage both locks, providing enhanced reliability while maintaining simple operation. The second lock serves itself by being staged and locked through the same lever action that operates the first lock.
Data Source
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AI summary
An electrical connector (100), comprising: a first housing portion (110) configured to receive a second housing portion (120) in seated alignment to form a housing of the electrical connector (100); the first housing (110) comprising a lever (130) rotatable between an unlocked position where the second housing portion (120) is removable from the first housing portion (110), and a locked position that secures the first and second housing portions (110, 120) in seated alignment; a connector position assurance device (140) that, in a staged position, engages with the lever (130) to maintain it in the locked position; the connector positioning assurance device (140) comprising a second lock (150) that, in the staged position, further secures the first and second housing portions (110, 120) in seated alignment.