Waterproof Connector Lever Feedback for Sealing State

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Solution Overview

Problem

Conventional waterproof connectors face challenges in reliably transitioning the rear holder from a partially locked to a fully locked state, which is crucial for maintaining high sealing performance, and there is a risk of overlooking this transition during assembly.

Innovation Solution

A waterproof connector design that incorporates a lever and movement limiting portions on the rear holder, allowing the lever to move freely when fully locked but be limited when partially locked, along with projections that resiliently widen the rubber plug's insertion holes, ensuring easy visual differentiation between states and reducing the force required for full locking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the rear holder is set in the partially locked state during terminal fitting insertion, then the terminal fitting can be accommodated, but the sealing performance deteriorates if the fully locked state is not achieved

Engineering Contradiction:

Improveterminal fitting insertionVSAvoidsealing performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The lever provides tactile and visual feedback to indicate the locking state. When the rear holder is in the partially locked state, the lever can be operated; when in the fully locked state, the lever becomes inoperable. This feedback mechanism ensures operators can confirm the sealing state without additional inspection steps.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system transitions from a static locking mechanism to a dynamic one where the lever's operability changes based on the rear holder's position. The movement limiting portion dynamically restricts lever movement only when the rear holder reaches the fully locked state, creating a self-indicating system.

Inventive Principle:

Principle #15Dynamics

2Difficulty of detecting and measuring

If the rear holder is made to project from the housing rear end to indicate locking state, then visual distinction between states is improved, but the device dimensions increase

Engineering Contradiction:

Improvelocking state detectionVSAvoidhousing rear end dimension

Core Design Contradiction:

Difficulty of detecting and measuringVSLength of stationary object

Solution Approach 1:

The lever serves as an intermediary indicator mechanism. Instead of the rear holder itself projecting to indicate state, the lever's operability (movable vs. fixed position) mediates the indication of locking state. This avoids increasing housing dimensions while maintaining clear state detection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the lever is allowed to move freely in the fully locked state, then operability for connection assistance is maintained, but the locking state cannot be confirmed

Engineering Contradiction:

Improvelever operabilityVSAvoidlocking state confirmation

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

Instead of allowing lever movement to indicate locking state (traditional approach), this invention inverts the logic: the lever becomes inoperable (fixed position) to indicate the fully locked state. This inversion provides clear state confirmation while maintaining connection assistance functionality when needed.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If the wire clamping hole moves to overlap the insertion hole center during locking, then wire movement is restricted and sealing is improved, but the structure becomes more complex

Engineering Contradiction:

Improvesealing performanceVSAvoidrear holder structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wire clamping function and sealing function are merged into a single structural feature. The movement of the wire clamping hole relative to the insertion hole center simultaneously achieves wire restriction and sealing enhancement, eliminating the need for separate mechanisms and reducing overall structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

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

This design ensures the rear holder is reliably set in the fully locked state, enhancing sealing performance while maintaining operability and allowing easy visual confirmation of the locking state, thus preventing misassembly and ensuring a watertight connection.

Implementation Method 1

The projection may press the insertion hole in a diameter reducing direction by being fit into the recess in a manner to resiliently push and widen the recess

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9231348B2Waterproof connector

Publication Date: 2016.01.05 SUMITOMO WIRING SYSTEMS LTD

AI summary

A waterproof connector includes a housing (20) that accommodates terminal fittings (12). A rubber plug (40) is fit in the housing (20) and a rear holder (50) is mounted behind the rubber plug (40). The rear holder (50) is set in a partially locked state while inserting the terminal fittings (12) and is set in a fully locked state after the terminal fittings (12) are accommodated completely. A lever (80) is assembled with the housing (20) and is moved to assist a connection to a mating connector (90). Movement limiting portions (70) are retracted from a movable range of the lever (80) to permit movement of the lever (80) when the rear holder (50) is in the fully locked state, but are in the movable range of the lever (80) to limit movement of the lever (80) when the rear holder (50) is in the partially locked state.