Lever-Type Plug Connector Elastic Locking Mechanism
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Solution Overview
Problem
Existing plug connectors can be damaged when a locked lever is attempted to be opened without releasing the locking mechanism first, leading to incorrect operation and potential damage to the locking mechanism and the entire connector.
Innovation Solution
A plug connector with a locking device that is elastically movable from a blocking position into a release position and an overload position, allowing the lever to be unlocked even if the locking device has not been previously released, using a latch projection and reinforcing ribs to prevent damage by distributing forces and maintaining elastic deformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to lock the lever in the closed position, then the reliability of the plug connector is improved, but the device complexity increases
Solution Approach 1:
The locking device is integrated into the cap structure, merging the locking function with the existing cap component. The locking device includes a locking projection that engages with a receiving structure on the housing, and is actuated by the lever itself, combining multiple functions into a unified structure.
Solution Approach 2:
The lever serves dual functions: it both closes the housing and actuates the locking mechanism. When the lever is moved to the closed position, it automatically engages the locking projection with the receiving structure, locking itself without requiring a separate locking action.
2Reliability
If the locking device is made rigid to ensure reliable locking, then the reliability is improved, but the risk of damage from incorrect operation increases
Solution Approach 1:
The locking device is designed with elastic properties, allowing it to deform under excessive force. The locking projection can be elastically displaced from the engaged position when excessive force is applied, preventing permanent damage while maintaining reliable locking under normal conditions. This changes the mechanical parameter from rigid to elastic.
Solution Approach 2:
The elastic nature of the locking device acts as a cushion against excessive forces. When incorrect operation applies excessive force, the elastic material absorbs the energy through deformation, preventing damage to the lever or housing while still allowing the locking function to operate reliably under normal conditions.
3Object-affected harmful factors
If the locking device is made elastic to prevent damage, then the resistance to harmful factors is improved, but the locking reliability may be compromised
Solution Approach 1:
The elastic material and geometry are specifically designed so that the force required to elastically displace the locking projection exceeds the normal operating forces but remains below the threshold for permanent deformation. This creates a clear distinction between normal operation (reliable locking) and abnormal conditions (elastic deformation prevents damage).
Solution Approach 2:
The locking projection and receiving structure are designed with curved surfaces that guide the engagement and disengagement motions. The curved geometry ensures smooth engagement while allowing controlled elastic deformation, maintaining reliable locking during normal operation while preventing damage under excessive force.
4Reliability
If a separate unlocking action is required before opening, then the reliability is improved, but the ease of operation decreases
Solution Approach 1:
The lever automatically actuates the locking and unlocking mechanisms through its own motion. When moved to the closed position, it engages the locking projection. When moved to the open position, it automatically disengages the locking projection, eliminating the need for a separate unlocking action while maintaining reliable locking during normal operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution prevents damage to the locking device and other components by allowing the lever to be released from its locked position without prior unlocking, ensuring the connector remains functional even after incorrect operation, and reduces the risk of inelastic deformation.
Implementation Method 1
the locking device is elastically movable out of its blocking position into a release position in order to unlock the lever in the second position
Implementation Method 2
the reinforcing rib can advantageously partially dissipate forces acting on the locking device into the area around the locking device, which advantageously effectively prevents damage to the locking device
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A plug connector has a housing with a cap, the cap having a lever which can adopt a first position and a second position. In this case, the housing is opened in the first position of the lever and closed in the second position of the lever. Furthermore, the plug connector has a locking device 300 which can adopt a blocking position which is intended to lock the lever in the second position. The locking device is elastically movable out of its blocking position into a release position in order to unlock the lever in the second position. Furthermore, the locking device is elastically movable out of its blocking position into an overload position in order to unlock the lever in the second position if a force exerted on the lever exceeds a set value. In this case, the overload position differs from the release position.