Plug Connector Buckling Lever Lockout for Reliable Mating
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Solution Overview
Problem
Conventional electrical connector assemblies lack a structure to ensure the position of the buckling lever, leading to potential mistaken touching and failure of the plug connector to connect with the socket connector, which can result in damage to the assembly.
Innovation Solution
The electrical connector assembly includes a socket connector and a plug connector with a buckling lever, limiting blocks, and torsion springs. The buckling lever has a grip and buckling portions, with buckling slots and blocking slots that prevent the buckling lever from being mistakenly touched by blocking it when the plug connector is unconnected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the buckling lever is provided without position assurance structure, then the plug connector can be easily plugged or unplugged, but the buckling lever may be mistakenly touched causing connection failure or damage
Solution Approach 1:
The blocking slots are pre-formed in the plug connector body at positions that will block the buckling lever during the insertion process. Before the buckling lever can be accidentally actuated, the limiting blocks with blocking ends physically prevent its movement, thereby eliminating the risk of mistaken touching while preserving easy operation.
Solution Approach 2:
The limiting blocks serve as intermediary elements between the buckling lever and the operator. These limiting blocks with blocking ends act as mechanical mediators that intercept and prevent unintended actuation of the buckling lever, while still allowing intentional operation when needed.
2Reliability
If blocking slots and limiting blocks are added to prevent mistaken touching, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The limiting blocks are integrated into the plug connector assembly, merging the blocking function with the existing connector structure. The blocking slots are directly formed in the plug connector body, combining the protective function with the connector housing rather than adding separate external components.
Solution Approach 2:
The limiting blocks serve multiple functions: they guide the insertion process, prevent mistaken touching of the buckling lever, and maintain structural integrity of the plug connector. The blocking slots simultaneously serve as protective features and as part of the overall connector geometry.
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
This design effectively prevents the buckling lever from being mistakenly touched, ensuring successful connection between the plug and socket connectors and preventing potential damage to the assembly.
Implementation Method 1
Each torsion spring is connected between one limiting block and the one buckling portion. The two torsion springs exert two forces on the two blocking ends of the two limiting blocks to make the two blocking ends of the two limiting blocks be blocked in the two blocking slots.
Data Source
AI summary
An electrical connector assembly includes a socket connector, and a plug connector connected with the socket connector. The socket connector includes a base body, two socket terminals mounted in the base body, and two buckling blocks disposed at two outer side surfaces of the base body. The plug connector includes a main body, two plug terminals mounted in the main body, a buckling lever, two buckling slots, two blocking slots, two limiting blocks and two torsion springs. The buckling lever has two buckling portions rotatably connected to the main body. The two buckling slots are disposed at the two buckling portions. The two blocking slots are disposed at two sides of an outer surface of the main body. The two limiting blocks are movable pivoted to the two buckling portions. The limiting blocks in initial position serve to prevent mistaken movement of the buckling lever and to allow such movement of the buckling lever when appropriate for mating with a socket.