Lever-Locked Electrical Connector Assembly for Blind Mating
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Solution Overview
Problem
Existing electrical connector assemblies require screws or bolts for mating, which are cumbersome, difficult to assemble, and prone to loosening under vibration, necessitating multiple operators and increasing assembly time and cost, while also making it challenging to ensure proper mating in blind connector situations.
Innovation Solution
The electrical connector assembly employs a lever mechanism with a movable shaft and retaining means, eliminating the need for screws or bolts, allowing for a robust, single-operator assembly with visual indicators for proper locking, and utilizing snap-fit connections for quick and secure mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws or bolts are used for mating the electrical connector assembly, then the assembly can be securely fixed, but the assembly process becomes cumbersome, requiring multiple operators and increasing assembly time
Solution Approach 1:
The invention extracts and eliminates the screws or bolts from the electrical connector assembly, replacing them with a lever-based latching mechanism. The lever (18) with its shaft (34) engages with the coupling hook portion (62) of the retaining means (58) to secure the mating connection without requiring any fastening screws, thus simplifying the assembly process while maintaining secure fixation.
Solution Approach 2:
The invention introduces a dynamic lever mechanism that can be easily moved between positions to achieve and release the mated state. The lever (18) is movable about a shaft (34) and can be positioned to engage or disengage from the coupling hook portion (62), allowing single-operator assembly and quick reconfiguration without the need for tightening or loosening screws.
2Reliability
If screws are used for fixing the assembly, then the connection can be maintained, but the screws may loosen under vibration during use, causing damage
Solution Approach 1:
The invention removes screws entirely from the assembly, replacing them with a lever-based latching system. The lever (18) with shaft (34) engages with the coupling hook portion (62) in a positive locking manner that is inherently resistant to vibration-induced loosening, as there are no threaded connections to gradually unwind under vibrational stress.
Solution Approach 2:
The lever mechanism is designed with a coupling hook portion (62) that engages the shaft (34) in a way that prevents loosening before vibration even occurs. The geometry of the coupling hook and shaft creates a mechanical interlock that actively resists the forces that would cause loosening, rather than merely relying on friction or torque as screw connections do.
3Productivity
If a lever mechanism is used instead of screws, then assembly time is reduced and single-operator assembly is enabled, but the coupling effort is localised at protrusions, weakening the lever after restricted operations
Solution Approach 1:
The invention segments the coupling function across multiple structural elements: the lever (18), its shaft (34), the coupling hook portion (62), and the retaining means (58). This distribution of the coupling effort across multiple points and components prevents excessive stress concentration at a single location, thereby improving the lever's durability while maintaining quick assembly capabilities.
Solution Approach 2:
The invention merges the lever mechanism with the retaining means structure, where the coupling hook portion (62) is integrated into the retaining means (58). This integration allows the coupling effort to be shared between the lever-shaft assembly and the housing structures, distributing the mechanical stress and preventing premature wear or failure of the lever while preserving the rapid assembly advantage.
4Ease of operation
If blind mating is used, then the connector can be assembled without visual alignment, but it is difficult to ensure proper and complete coupling of the mating housings and terminals
Solution Approach 1:
The invention incorporates feedback through the lever mechanism itself. As the lever (18) is moved into position and the shaft (34) engages with the coupling hook portion (62), the operator receives tactile feedback indicating proper engagement. The lever's movement resistance and final positioned state provide sensory confirmation that the mating housings are properly coupled, enabling blind mating with assured precision.
Solution Approach 2:
The dynamic lever mechanism provides progressive engagement feedback during the mating process. As the lever moves toward its engaged position, the shaft progressively engages with the coupling hook, creating varying resistance that guides the operator through proper alignment and coupling, ensuring manufacturing precision even without visual confirmation.
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The present invention relates to an electrical connector assembly comprising a plug housing (12) configured to be mated and locked with a receptacle housing (14); the plug housing comprising a lever (18) movable from a first position, wherein the plug housing (12) and the receptacle housing (14) are unlocked, to a second position wherein the plug housing (12) is locked with the receptacle housing (14); characterised in that the lever (18) is rotatably mounted about a shaft (34) arranged in and passing through the plug housing (12); and the receptacle housing (14) comprises a retaining means (58) with a coupling hook portion (62), the coupling hook portion (62) being configured to engage with the shaft (34) of the plug housing (12); such that in the second position, the shaft (34) is in abutment in the coupling hook portion (62) of the retaining means (58) thereby maintaining the plug housing (12) and the receptacle housing (14) together by positive locking.