Retained Lever Connector Structure for Shock-Resistant Assembly
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Solution Overview
Problem
Existing connectors, particularly in the automotive sector, are prone to damage and disassembly during handling and assembly processes, leading to inefficiencies and increased costs due to lost or damaged parts.
Innovation Solution
A connector design featuring a lever with a retention element that is integral to the lever arm, rather than being external and exposed, providing enhanced retention and resilience against shocks and stresses during handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the retention element is made external and exposed on the connector housing, then the assembly process is simplified, but the connector becomes vulnerable to shocks and unintentional stresses causing damage and disassembly
Solution Approach 1:
The retention element is nested within the lever arm structure, forming an integral part that extends through the retention opening. This nesting protects the retention element from external shocks while maintaining its function for lever retention and release.
Solution Approach 2:
The retention element is merged with the lever arm to form a single integral structure. This combination ensures that the retention element moves with the lever arm and is protected from external damage, while still allowing the lever to be retained or released as needed.
2Reliability
If the retention element is integrated into the lever arm, then the connector becomes more robust against damage, but the manufacturing complexity increases
Solution Approach 1:
The retention element and lever arm are merged into a single integral structure, which can be manufactured as one piece using injection molding or other suitable processes. This merging provides robustness while avoiding the complexity of separate components and assembly steps.
Solution Approach 2:
The design allows for parameter changes in the lever arm structure, such as varying the shape and position of the retention element, to optimize both robustness and manufacturability for different application requirements.
3Reliability
If the retention opening has a narrow shape, then the retention element is securely held, but the lever cannot be easily inserted or removed
Solution Approach 1:
The retention opening is designed with dynamic characteristics, having a narrow section for secure retention and a wider insertion section for easy lever placement. The lever arm can be inserted through the wider section and then retained by the narrow section, providing both ease of operation and security.
Solution Approach 2:
The retention opening is segmented into different sections with different functions: a wider insertion hole for easy lever placement and a narrower retention section for secure holding. This segmentation allows the opening to fulfill multiple functions within a single structural feature.
Data Source
Figure 1~2b
Figure 3~5b
Figure 6a~7b
AI summary
The disclosure relates to a connector (1) provided with a lever (3), such as for coupling aid or a locking function. Lever is jointed on connector housing (2), and mobile between at least an open position (P2) and a closed position (P3). The lever carries a retention element (33) extending through a retention opening (22) of the housing (2), and retained therein by a transverse retention protrusion (332) both in the open position (P2) and in the closed position (P3). Preferably, lever has two arms, pivotally mounted on both sides of the housing, and retention opening (22) has a shape in arc of circle concentric therewith, and has an insertion hole (221) with it edges wider than the rest of its retention edges (229), for inserting the retention element (33) in a position (P1) different from both open and closed positions. Disclosure also encompasses a method for manufacturing such a connector, and a method for using it in connecting a cable it is mounted on with by mating with a counter connector.