Waterproof Electrical Connector Lever Latch Mechanism
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Solution Overview
Problem
Conventional electrical connectors with latch mechanisms are not suitable for waterproof applications due to design limitations that prevent the incorporation of a latch mechanism on the housing surface and the inability of pre-lock latches to be released by the male housing when the female housing is covered.
Innovation Solution
A waterproof electrical connector design featuring a pivotally connected lever that moves between two fixed positions, with a locking mechanism that captures bosses within recesses and a pair of latch mechanisms that transition from a latched to a release state to secure the connection, allowing for a matable connection with a workpiece connector while preventing back movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a latch mechanism is disposed on the housing surface for non-waterproof connectors, then the latch mechanism can engage with the mating connector, but the latch mechanism cannot be incorporated on a waterproof connector because the mating connector is covered by the housing
Solution Approach 1:
The latch mechanism is moved from a surface-level engagement (2D plane on housing surface) to an internal engagement mechanism (3D space within connector cavity). The latch projections engage with guide rails from within the connector cavity, transitioning the engagement dimension from external surface to internal volume, enabling waterproof application while maintaining latching function.
Solution Approach 2:
Guide rails are introduced as intermediary elements between the latch mechanism and the mating connector. The guide rails extend from the mating connector and engage with latch projections internally, serving as a mediator that transmits the locking action while allowing the housing to remain closed for waterproofing.
2Reliability
If a pre-lock latch is designed on the female housing, then the latch can secure the connection, but the pre-lock latch cannot be released by the male housing which is covered by the female housing
Solution Approach 1:
Instead of the male housing actively releasing the latch from the outside, the design inverts the approach: the latch mechanism is positioned internally so that the mating connector itself, during insertion, automatically triggers the release of latch projections from their engaged positions on the guide rails. The release action occurs through the natural insertion motion rather than requiring external manipulation.
Solution Approach 2:
The insertion process itself serves to release the latch mechanism. As the mating connector is inserted, its guide rails interact with the latch projections, causing them to automatically move from the engaged to the released state without requiring separate release actions or external intervention.
3Device complexity
If the lever is not seated between the housing and the mating connector, then the connector structure is simpler, but the connector cannot provide waterproof protection
Solution Approach 1:
The lever is nested within the connector housing structure, positioned inside the connector cavity rather than externally. The lever, latch mechanisms, and guide rails are all contained within the housing volume, creating a nested arrangement where the lever engages with internal features while the housing provides the outer waterproof barrier, eliminating the need for external sealing structures.
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
Enables a secure, waterproof electrical connection by ensuring the lever remains locked in a boss-capture position, preventing back movement and maintaining the connection, thus addressing the limitations of conventional connectors in waterproof applications.
Implementation Method 1
the pair of locking mechanisms in the normally relaxed state move to a flexed state and then return to the normally relaxed state thereby locking the lever in a final boss-capture position
Implementation Method 2
the lever is pivotally connected to the connector housing and is operative to move from a first fixed position to a second fixed position
Data Source
AI summary
An electrical connector includes a generally box-shaped connector housing and a lever. The lever is pivotally connected to the connector housing and is operative to move from a first fixed position to a second fixed position. In the first fixed position, the lever is releasably connected to the connector housing to prevent the lever from moving towards the second fixed position. In the second fixed position, the lever is releasably connected to the connector housing to prevent the lever from moving towards the first fixed position. Upon releasing the lever from the first fixed position, the lever is operative to pivotally move from the first fixed position to the second fixed position. The electrical connector is adapted for matable connection with a workpiece connector.