Plug Connector Locking Lever Structure for Tensile Load Reliability
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Solution Overview
Problem
Existing electrical plug connectors with locking systems connected to the housing via a web are prone to plastic deformation when tensile forces are applied, leading to unreliable fixation and potential unintentional loosening.
Innovation Solution
A locking system featuring a locking lever configured as a bending bar that creates a spring force, connected to the housing via a supporting web and actuating lever, which absorbs tensile forces and prevents deformation by distributing them over a longer length, ensuring secure fixation and easy operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the locking system is connected to the housing via a web, then the device complexity is reduced, but the reliability deteriorates due to plastic deformation under tensile forces
Solution Approach 1:
The locking system is divided into two separate connection paths: one through the web and another through the locking lever itself. The locking lever is designed as a bending bar that extends from the housing and connects to the actuating lever, creating an independent load-bearing structure that segments the force transmission paths and prevents concentrated stress on the web.
Solution Approach 2:
The locking lever is designed as a flexible bending bar that can elastically deform under tensile forces. This dynamic element absorbs and distributes loads through elastic deformation, preventing permanent plastic deformation of the web while maintaining reliable fixation. The bending bar's flexibility allows it to adapt to force applications and return to its original position.
2Ease of operation
If the locking lever is actuated by pressing the actuating area, then the ease of operation is improved, but the stability deteriorates due to potential unintentional loosening
Solution Approach 1:
The locking lever is designed as a curved bending bar with specific geometric contours. The curvature of the bending bar creates a mechanical advantage that amplifies the actuating force while maintaining a stable locked position. The curved geometry ensures that small actuating movements produce sufficient force to release the latch, while the overall structure remains stable 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 provides a secure and reliable locking mechanism that withstands tensile forces without deformation, allowing for easy actuation and secure engagement with a connector strip, maintaining the plug connector's position even under tension.
Implementation Method 1
The locking lever 5 is a bending bar which creates a spring effect in a direction of the housing 3
Implementation Method 2
When the actuating lever is pressed in the actuating area, it rotates about the web so that the latching element moves away from the housing
Data Source
AI summary
A plug connector includes a housing and a locking system arranged on the housing. The locking system has an actuating lever and a locking lever. The locking lever has a latching element. The actuating lever and the locking lever are connected to one another at a first end of the locking lever. The locking lever is a bending bar that creates a spring force in a direction of the housing. The locking lever extends to a second end along a plug-in direction from the housing. The actuating lever is connected to the housing by a supporting web and projects beyond the supporting web in a direction opposite the plug-in direction.