Split Lever Connector Assembly With Dynamic Sealing
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Solution Overview
Problem
Existing electrical connector assemblies for automotive applications face challenges such as high assembly force requirements, potential misalignment during assembly, lack of sealing functionality, and complexity in manufacturing, leading to reliability issues due to moisture and dust ingress.
Innovation Solution
A connector assembly featuring a split, symmetrical lever with interlocking means and a sealing member, where the lever arms are identical and pivotably mounted to the connector housing, providing a mate assist function and ensuring a sealed connection through a 2K injection molded seal, reducing manufacturing complexity and assembly confusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional slider connector is used, then the connector can be assembled, but a substantial force is required to mate the connector housings together, increasing assembly complexity and risk of incorrect assembly
Solution Approach 1:
The connector employs a dynamic lever mechanism that rotates from an open to a closed position, transforming the static high-force sliding action into a dynamic rotational motion. This lever action mechanically amplifies the operator's input force, reducing the substantial force previously required to mate the connector housings together while simplifying the assembly process
2Reliability
If a lever with sealing arrangement is added, then waterproof and dustproof protection is provided, but the sealing arrangement may hinder the rotational movement of the lever
Solution Approach 1:
The connector utilizes a flexible sealing member in the form of a lip seal that can deform elastically during the lever's rotational movement. This flexible membrane maintains the waterproof and dustproof barrier while accommodating the dynamic motion of the lever, preventing hindrance to rotational operation
Solution Approach 2:
The sealing arrangement is designed to be dynamic rather than static, allowing the sealing member to move and deform with the lever's rotation. This dynamic sealing approach maintains protection against moisture and dust while enabling full range of motion for the lever mechanism
3Strength
If a U-shaped lever is used, then the lever can withstand the force required for mate assist function, but the lever is difficult to install as it must be sufficiently rigid yet sufficiently flexible for secure fitting
Solution Approach 1:
The lever is divided into multiple segments or components that can be assembled together. This segmentation allows each part to be optimized for its specific function - some portions can be rigid to withstand forces while other portions can be flexible to facilitate installation through resilient deformation during the fitting process
4Ease of manufacture
If multiple parts are used to construct the lever, then the lever can be assembled on the connector, but confusion and potential incorrect orientation occur during assembly
Solution Approach 1:
The lever components incorporate asymmetric features such as unique shapes, keyed interfaces, or directional markings that provide visual and mechanical guidance for correct orientation. This asymmetry eliminates confusion during assembly by making it physically impossible or visually obvious how each part should be positioned, ensuring precise assembly without requiring complex instructions or training
Data Source
Figure 1
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Figure 3a~3b
AI summary
The present disclosure provides a connector assembly. The connector assembly comprises a connector housing adapted to engage with a corresponding counter connector housing. A lever comprising a first lever arm and a second lever arm is pivotably and sealingly mounted to the connector housing. Each lever arm comprises interlocking means for connecting the first lever arm to the second lever arm at a first location. The interlocking means of each of the first lever arm and the second lever arm are configured to define complementary symmetrical surfaces that interlock with one another when the lever arms are pivotably mounted to the connector housing. On mounting the lever arms to the connector housing, the lever is configured to move about the connector housing between an open state and a closed state to secure the counter connector housing to the connector housing.