Sealed Connector Lever Layout for Low-Force Symmetrical Mating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lever-type electrical connectors require high mating forces, are difficult to use by hand, and lack sealing capabilities due to complex mechanics and lever positioning, making them unsuitable for sealed connections.
Innovation Solution
A sealed electrical connector assembly with a U-shaped lever mounted between inner and outer sidewalls, featuring gear wheel elements that distribute mating forces symmetrically and allow for a symmetrical, straight mating process, while incorporating a sealing mechanism to ensure a tight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a lever-type electrical connector uses complex mechanics with cam grooves and followers to achieve mating, then the connector can handle large forces, but the device complexity increases and sealing becomes difficult
Solution Approach 1:
The patent replaces the complex cam groove and follower mechanical system with a simpler lever mechanism that directly engages the counter connector. The lever pivots on the housing and uses a lever arm to apply force to the counter connector housing, eliminating the need for cam grooves, followers, and associated complex mechanics while still achieving the required mating force
Solution Approach 2:
The patent extracts and removes the unnecessary cam groove and follower components from the connector assembly, keeping only the essential lever mechanism. This simplification reduces device complexity while maintaining the force transmission capability needed for mating high pin count connectors
2Force
If the lever is positioned outside the housing to provide leverage, then the mating force is amplified, but sealing between connectors becomes impossible
Solution Approach 1:
The patent nests the lever mechanism within the housing structure by positioning the lever pivot inside the housing and having the lever arm extend through or alongside the housing walls. The lever arm interacts with the counter connector housing in a nested arrangement that allows force amplification while maintaining the sealed interface between the two connector housings
Solution Approach 2:
The lever acts as an intermediary element that transmits force from the user's manual operation to the counter connector housing. By positioning the lever pivot inside the sealed housing and having the lever arm engage the counter connector, the system achieves force amplification without compromising the seal, as the lever mediates the force transmission through the housing structure rather than requiring external positioning
3Reliability
If high mating forces are required for 90+ pin connectors, then the connection is reliable, but the ease of operation decreases requiring more than 75 N user force
Solution Approach 1:
The lever mechanism provides a mechanical advantage that counteracts the high frictional forces and mating resistance encountered during connector engagement. By using a lever arm with appropriate length ratios, the system reduces the user input force requirement from potentially hundreds of newtons to within the 75 N limit specified by automotive standards, making manual operation feasible while maintaining reliable connection
Solution Approach 2:
The lever is designed to pivot and rotate dynamically during the mating process, allowing the user to apply force in a rotational motion rather than direct linear force. This dynamic action enables the user to overcome frictional forces and achieve mating with reduced effort, as the lever's rotational movement amplifies the applied force and controls the engagement sequence
4Volume of moving object
If the lever structure uses thin-walled sidebars for compactness, then the footprint is reduced, but the structural strength decreases making assembly difficult
Solution Approach 1:
The lever is constructed from polymer material that provides both the required structural strength and compact form factor. The polymer construction allows the lever to maintain adequate wall thickness for strength while keeping the overall footprint small, avoiding the need for thin-walled metal sidebars that would compromise structural integrity
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 reduces the required mating force, ensures easy assembly, provides a reliable and sealed connection, and maintains a compact footprint, addressing the challenges of high force requirements and sealing issues in prior art connectors.
Implementation Method 1
A mate assist lever is pivotally connected to the housing. The lever comprises a first gear wheel element
Data Source
Figure 1a~1c
Figure 2~3
Figure 4~5
AI summary
The present disclosure relates to an electrical connector assembly comprising a sealed connector housing, with a side wall comprising an inner side wall and a parallel outer side wall, defining a gap therebetween; and a mate assist lever comprising at least a first gear wheel element. The lever is mounted between the inner side wall and the outer side wall on the inner side of the outer side wall, such that a clearance remains between the lever and the outer side of the inner side wall, the clearance being adapted to allow insertion of a part of a housing of a counter connector assembly.