Plug Connector Lever Assembly for Low-Force Multi-Contact Mating
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Solution Overview
Problem
Existing plug connectors require high operating forces for connection and disconnection due to increased number of contact elements, leading to complex designs and space requirements.
Innovation Solution
A plug connector with a lever system that reduces operating forces by mechanical advantage through a combination of guide systems and rotatable arms, allowing efficient force transmission and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plug connector with multiple contact elements is used, then the electrical connection capability is improved, but the operating force required for plugging and releasing increases
Solution Approach 1:
The plug connector is divided into multiple independent contact elements (socket elements crimped to cable lines) that can be connected simultaneously through a single plug-in action. This segmentation allows the electrical connection capability to be scaled by adding more contacts without proportionally increasing the operating force, as the force is distributed across the connection process.
Solution Approach 2:
A lever system is introduced as an intermediary mechanical advantage device between the user's hand and the plug connector. The lever system with its pivot point and arm structure amplifies the user's input force, enabling connection of multiple contact elements while keeping the actual operating force below 75 N. The lever acts as a force multiplier that resolves the contradiction between connection capability and operating force.
2Ease of operation
If a lever system is added to reduce operating forces, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The lever system is merged with the plug connector housing structure, where the lever pivot point is integrated into the housing and the lever arm works in conjunction with existing guide slots. This merging approach reduces the need for separate, complex mechanical assemblies while achieving the force reduction goal. The guide systems and engagement elements are combined with the lever mechanism to create a unified structure that maintains simplicity.
Solution Approach 2:
Instead of making the plug connector itself complex to achieve force reduction, the solution inverts the approach by adding a simple lever mechanism that provides mechanical advantage externally. The complexity is minimized by using a basic lever-and-pivot configuration rather than complex internal mechanisms within the connector body.
3Ease of operation
If a slider system is used to reduce operating forces, then the ease of operation is improved, but the space requirement increases
Solution Approach 1:
The lever system provides dynamic force multiplication during the plug-in operation. The mechanical advantage varies during the lever's rotation, providing maximum force reduction when needed most (during the feed-in peak when contact lamellae are displaced). This dynamic approach achieves force reduction without requiring the large transverse space that a slider system would need for its linear displacement mechanism.
4Adaptability or versatility
If the number of contact elements is increased, then the electrical connection capability is improved, but the plug-in force increases
Solution Approach 1:
The lever system is positioned and pre-configured before the plug-in operation begins. The engagement elements are already in place to engage with counter elements on the mating connector. This preliminary arrangement allows the lever to immediately provide mechanical advantage when the plug-in force is needed to overcome the feed-in peak, preventing the plug-in force from becoming excessively high even with multiple contact elements.
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 lever system enables secure plug-in and release with reduced operating forces below 75 N, minimizing design space and operating travel, while preventing tilting and jamming.
Implementation Method 1
A plug connector (1) includes a lever system (5, 15) which enables a reduction of operating forces when the plug connector (1) is plugged into and/or released from a mating plug connector (20)
Data Source
AI summary
A plug connector to be plugged along a plug-in direction into a mating plug connector having a mating plug connector housing. The plug connector includes a plug connector housing; electrical contact elements, which are situated in the plug connector housing; a first lever system to reduce an operating force when the plug connector is plugged into and/or released from the mating plug connector, the first lever system being rotatably supported on the plug connector housing, the first lever system having: first and second arms, the second arm being pivotably situated on the first arm using a first joint pin, the first joint pin being movable in the plug connector housing in a first guide slot, which essentially extends along the plug-in direction, a first guide system between the first arm and the plug connector housing, and a second guide system between the second arm and the plug connector housing.