Mating Assist Lever With Axial CPA For Constrained Space
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Solution Overview
Problem
Lever arm electrical connection systems face challenges in constrained space environments, where limited mating space and obstructions hinder easy mating and unmating of connector housings, particularly in vehicular applications.
Innovation Solution
The electrical connection system incorporates a mating assist lever (MAL) with a locking means and a connector position assurance (CPA) member, allowing for secure mating and unmating in limited spaces by rotating the MAL to a CLOSED position and applying forces to latch the locking means and position the CPA member, ensuring secure connections without unintended disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional lever arm electrical connection system is used, then the connector housings can be easily mated and unmated in open spaces, but the system becomes difficult to operate in constrained space environments with limited mating space
Solution Approach 1:
The patent repositions the CPA member from a traditional lateral access configuration to an axial access configuration along the mating axis. This dimensional change allows the CPA member to be accessed and operated from the front or rear of the connector housing, enabling mating operations in constrained spaces where lateral access is blocked by vehicle structures or other components.
Solution Approach 2:
The patent inverts the conventional approach by placing the CPA member on the opposite end of the lever arm mechanism, allowing access from the mating axis direction rather than from the side. This inversion enables operators to access the CPA member from the front or rear of the connector, reversing the traditional access pattern to accommodate constrained space environments.
2Ease of operation
If the mating assist lever is designed for full rotation, then the locking means and CPA member are easily accessible, but the rotation space requirement increases which is not suitable for compact environments
Solution Approach 1:
The patent segments the lever arm's rotation path into distinct functional zones: an initial rotation phase that engages the locking means, and a subsequent phase that positions the CPA member for axial access. This segmentation allows the lever to achieve full functional capability through a limited rotation arc, reducing the overall rotation space required while maintaining accessibility to both the locking means and CPA member.
Solution Approach 2:
The patent implements a dynamic lever arm mechanism that changes its functional configuration during rotation. The lever arm transitions from a state where it primarily engages the locking means to a state where it positions the CPA member for access. This dynamic behavior allows the system to maximize functionality within a reduced rotation space by adapting the lever's position and function throughout its limited arc of motion.
Data Source
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AI summary
An electrical connection system and method includes a first connector housing (12) matable to a second connector housing (14) along a mating axis. The first connector housing (12) contains a mating assist lever that rotationally pivots between an inoperative position (17) and a closed position (19) and includes a locking means. When the mating assist lever is positionally rotatable (F1) to the closed position the first connector housing (12) and the second connector housing (14) are mated together such that the locking means are disposed adjacent an external surface (30) of the second connector housing (14). A sufficiently applied force against the locking means actuates the locking means so that the locking means latchingly secures the first connector housing (12) to the second connector housing (14). A connector position assurance member (20), also disposed on the mating assist lever, slidingly communicates with the latched locking means transverse to the mating axis and ensures the latched locking means does not become unlatched so that electrical connection system remains mated.