Lever-Locked Electrical Connector for Narrow-Space Installation
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Solution Overview
Problem
Existing lever-type electrical connection systems face limitations in flexible application due to narrow installation spaces, particularly in vehicles, where assembly is constrained by the environment.
Innovation Solution
An electrical connector design featuring a housing with a pivotally mounted locking lever and a connector position assurance member with a channel and locking edge, allowing for flexible insertion and locking without increasing the connector's size, enabling secure locking in a compact form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lever-type locking system is used to ensure connection reliability, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The patent combines the position retention function and lever locking function into a single integrated structure. The position retention member is formed as one piece with the locking lever, eliminating the need for separate retention mechanisms while maintaining both position locking and lever retention capabilities. This merging reduces device complexity while preserving connection reliability.
Solution Approach 2:
The locking lever serves multiple functions: it provides the primary locking action, retains the position retention member, and ensures connection reliability. The position retention member integrated with the lever acts as both a position lock and a lever retention mechanism. This multi-functionality reduces the number of components while maintaining reliable connection.
2Reliability
If existing lever-locked electrical connection systems are used, then connection reliability is improved, but the adaptability to narrow installation spaces deteriorates
Solution Approach 1:
The locking lever is designed to pivot between different positions (locked and unlocked states) and the position retention member can move along the lever. This dynamic design allows the system to adapt to different installation configurations and narrow spaces while maintaining reliable locking when engaged. The flexible movement capability enables installation in constrained environments.
Solution Approach 2:
The locking mechanism is divided into functional segments: the locking lever for primary engagement, the position retention member for securing the lever position, and the integrated connection between them. This segmentation allows each component to be optimized for its specific function while fitting within narrow installation spaces, improving adaptability without compromising reliability.
3Reliability
If the connector position assurance member is inserted into the channel, then the locking reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The position retention member is designed to be self-retaining within the channel through its integrated structure with the locking lever. The lever's movement automatically secures the position retention member in place, eliminating the need for high-precision external retention mechanisms. This self-service approach maintains locking reliability while reducing manufacturing precision requirements.
Solution Approach 2:
The position retention member and locking lever are formed as one piece, creating an integrated assembly that simplifies the insertion and locking process. This merging reduces the number of separate components that would require precise alignment and manufacturing tolerances, thereby maintaining locking reliability while reducing manufacturing precision requirements.
Data Source
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AI summary
Disclosed is an electrical connector with a position holding structure. The connector comprises: a housing provided with a locking portion; a locking lever, which has a first arm and a second arm connected to opposite sides of the housing, and a beam portion extending between the first arm and the second arm, with a channel being provided in the beam portion; and a connector position assurance member, the connector position assurance member having a locking edge, the connector position assurance member being inserted into the channel from an open end of the channel, and the connector position assurance member having a pre-installed position and a locked position in the channel, wherein when the locking lever pivots to the second position and the connector position assurance member enters into the locked position, the locking edge abuts against the locking portion in the channel, thereby locking a rotational motion of the locking lever. The electrical connector according to the present invention has a simple structure and high installation flexibility.