EP2654134A1

EP2654134A1 - Lever structures for electrical connectors

Info

Publication number: EP2654134A1
Application number: EP12164647.5A
Authority: EP
Inventors: Alessandro Genta; Robert Baker; Thomas REISSNEGGER; Ralf Schwan
Original assignee: Tyco Electronics AMP GmbH; Tyco Electronics UK Ltd; Tyco Electronics AMP Italia SpA
Current assignee: TE Connectivity Germany GmbH; Tyco Electronics UK Ltd; TE Connectivity Italia Distribution SRL
Priority date: 2012-04-18
Filing date: 2012-04-18
Publication date: 2013-10-23
Anticipated expiration: 2032-04-18
Also published as: EP2654134B1; WO2013156427A1

Abstract

The present invention relates to a connector housing designed to have a first and a second lever structure mountable on a mounting face of the first connector housing and opposing each other. The first and second lever structures can be operated simultaneously so as to cancel the reaction force perpendicular to the mating direction during mating of the connector. Moreover, the connector housing of the present invention allows to respectively lock the first and second lever structures to the first and second connector housings so as to keep the latter under tension, when the connector is fully mated.

Description

The present invention relates to a first connector housing for accommodating electrical contacts and in particular to lever structures pivotally mountable on a side face of the first connector housing and adapted to be engaged with a counterpart on a mating second connector housing so as to excite a pressure on at least one of the two mating connector houses. The present invention further relates to a second housing for accommodating electrical contacts adapted to be mated, through the lever structures, to the first connector housing. Finally, the present invention relates to a connector housing including a first and second housing for electrical contacts and lever structures for assisting mating of the connector and holding the connector in a connected state.
Common connectors are mated by pressing a first connector housing, such as a plug, against a second connector housing or header, such as a socket, until a certain minimum contact pressure and/or a minimum contact surface between the electrical contacts accommodated in the plug and socket housings is reached. This configuration should be stable over time so as to assure a reliable electrical connection. Moreover, especially for connector assemblies of large dimensions, the contact pressure necessary to assure a reliable connection causes a certain amount of friction when the two connector parts are mated and un-mated. The friction force to be overcome when coupling and uncoupling the connector becomes quite significant in the case of multi-conductor connectors containing a large number of individual contacts.
Prior art connectors include a handle or lever mechanism that facilitate the connection of the plug and socket housings. An example of such a mechanism is schematically illustrated in figure 31.
Figure 31 shows a portion of a connector assembly 300 including a lever 310, a first connector housing and a header or second connector housing 301. The lever 310 includes an engaging element 311, such as a toothed head, adapted to be engaged with a corresponding toothed portion 302, such as a rack, on the first housing 301. By operating the lever 310, such as by pivoting the lever 310 around a pivotal axis or pivot 312, the rotational movement of the lever 310 is transferred to the second connector housing 301, which is moved with respect to the first connector housing along a mating direction of the connector assembly 300.
However, because of the reaction force perpendicular to the mating direction resulting from the gear pressure angle of single lever 310 and rack 302 mating assist designs, coupled with the sliding friction of the pinion bearing on its axle 312, the system efficiency is reduced.
For example, in a configuration as that depicted in figure 31, the load on the pivotal axle 312 of the lever 310 is the total force needed to mate/un-mate the connector housings. The friction on the axle 312 can de derived as the mating force divided by the lever ratio times the friction coefficient: $Friction = \frac{Mating_Force}{Lever_Ratio \cdot Friction_Coefficient}$
The applied mating force will be given by the force applied by the lever 310 times the cosine of the gear pressure angle on the teeth of the rack 302. Considering a normalized lever force, or in other words a lever force of 1 F where F is a constant with the dimensions of a Force, and a gear pressure angle of 20 deg., the mating force applied will be 0.94 F.
Equation (1) above may be used for calculating the friction effect on the axle. For a lever ratio of 25 and a friction coefficient of 0.5, considering an applied mating force of 0.94 as calculated above, the friction force on the axle 312 will be approximatively 0.07 F.
The perpendicular reaction force will be given by the component of the lever force perpendicular to the mating force times the friction coefficient. This is given by: 1F. sin(20deg) = 0.34F, where 20 deg. is the gear pressure angle.
In the case of a unitary force applied by the lever for a friction coefficient of 0.5, for a gear pressure angle of 20 deg., the reaction force due to the friction between the connector housings to be overcome is given by the perpendicular reaction force times the friction coefficient: 0.34F · 0.5 =0.17F, where F is a constant having the dimensions of a Force.
Summarizing, the extra torque required on the lever to compensate for mechanical inefficiencies due to axle friction and reaction force or pressure angle losses is 0.17 (pressure angle loss) plus 0.07 (axle friction), for a total loss of 0.24. The force to be applied to the lever for connecting/disconnecting the first and second housings results to be 24% more than for a frictionless system.
Simple transverse slide and cam track mate assist designs suffer significant frictional losses. This is due to the fact that the mating force has to be reacted on a transverse flat bearing surface between the slide and the mating connector housing, and between the slide cam track and the mating header engagement structure, which usually takes the form of a peg. Apart from very shallow cam angles to increase mechanical advantage, the frictional losses can be addressed by constructing the mechanism from low sliding friction materials, or the application of lubricant grease.
There are however practical limits to this approach. In particular, low friction materials can be expensive and difficult to process, as well a having potentially reduced mechanical properties. Consequently, indentation of the sliding surfaces could occur at high loads, leading to system failure. This effect is known as 'Brinelling'. On the other hand, grease application is expensive and difficult to control. Further grease attracts dust and other undesirable debris. Moreover, it can melt away at high temperatures, freeze at low temperatures and degrade over time, thereby leading to a reduced functionality of the mate assist structure..
In addition, once the plug and socket housings are fully mated, the connector assembly may be exposed to high mechanical stress and vibrations, especially in automotive applications. Another problem of common connectors, such as those described above is that, once connected and put in place, the connector parts (i.e. the plug and socket housings) may move apart from each other due to high vibrations, thereby mining the reliability of the electrical connection. Moreover, relative movement of the connector housings during operation may expose the electrical contacts and the connector housings to mechanical stresses, such as side stresses, which said parts are not designed to withstand. This may cause failures and ruptures that may in the worst case, require the replacement of the entire connector. Finally, also a cable mounted in the connector housings may suffer from excessive vibration levels and movement of the cable with respect to the connector housing, especially in a position proximate to the entering side of the cable into the connector housing, may result in a faster deterioration of the cable and therefore in a shorter life of the connector.
The object of the present invention is therefore to provide a mating design for an electrical connector that overcomes the drawbacks described above. In particular, it is an object of the present invention to provide a design for a connector housing that allows reducing the frictional losses during mating and un-mating operations due to the reaction force as described above.
Further, the present invention aims at providing a design for an electrical connector including a fixing structure that provides for tolerance removal for housing and wire against heightened vibration levels. In particular, it is an object of the present invention to provide a connector that can withstand high vibration levels and that can assure a reliable connection in applications where the connector is exposed to high vibration levels, such as establishing electrical connection for parts of a vehicle close to the engine.
It is the particular approach of the present invention to add a second lever system opposing to the lever system of a common connector design to be operated together so as to cancel out the reaction force due to the component of the force applied to the lever perpendicular to the mating force. In addition or in alternative, the so obtained twin lever system may be adapted to fix the first and second housing in the mated configuration so as to withstand high vibration levels.
According to a first aspect of the present invention, it is provided a first connector housing for accommodating electrical contacts and adapted to be connected to a mating second connector housing. The first connector housing comprises a first lever structure including a first lever portion pivotally engageable with a first engaging member on a side face of the first connector housing. Further, a second lever structure includes a first lever portion pivotally engageable with a second engaging member on a side face of the first connector housing so as to be opposing the first lever structure. Each of the first lever structure and the second lever structure is further adapted to be respectively engaged to a corresponding first and second engaging element on the mating second connector housing, wherein at least one of the first and second lever structures is adapted to excite a pressure on at least one of the first connector housing and the second connector housing.
In other words, each of the first and second lever structures comprises a first lever portion adapted to be respectively pivotally engaged with the first and second engaging element on the side face or mounting face of the first connector housing so as to pivotally mount the first and second lever structures to the first connector housing.
The first second lever structure may further include a second lever portion or first lever body pivotally movable with respect to the first lever portion. Similarly, the second lever structure may as well include a second lever portion or second lever body pivotally movable with respect to the first lever portion. The second lever portion is adapted to be respectively engaged to the corresponding first and second engaging element on the mating second connector housing.
The first and second lever bodies may include on two side faces thereof a curved cam groove adapted to be engaged with a cam portion on a side face of the second lever portion. This provides a constraint that reduces the movement of the first lever portion with respect to the second lever portion.
According to a further aspect, the first lever structure may comprise a first synchronization element adapted to engage a corresponding second synchronization element of the second lever structure. The first and second synchronization elements are adapted to synchronize the relative pivotal movement of the first and second lever structures. This configuration allows transferring the rotational movement of one of the first and second lever structures to the opposing one. This configuration assures an over-centre mating of the first and second connector housings, thereby avoiding exerting side pressures on the contacts due to an uneven operation of the lever structures.
According to a further aspect of the present invention, the first and second synchronization elements are a gear members included in the first lever portion.
According to a further aspect of the present invention, the first and second lever structures are adapted to respectively engage a top edge of the first and second face of the first connector housing so as to lock to the first connector housing relative to the second connector housing.
According to a further aspect of the present invention, the gear member of at least one of the first and second lever structures is adapted to engage a corresponding toothed element on a side face of the second connector housing, the toothed element being one of the first or second engaging element on the second connector housing.
According to an aspect of the present invention, the gear member of the first lever structure is a circular pinion adapted to engage, on a first side thereof the corresponding toothed element and on a second side the gear element of the second lever structure.
According to a further aspect of the present invention, the gear elements are integrally formed with the first and second lever structures.
Alternatively, the gear elements, which may be toothed heads, may be mountable on the first and second lever structures so as to rotate with respect to the first and second housings together with the first and second lever structures.
Each of the gear elements may be pivotably mountable on the side face of the first connector housing mounting the respective first or second lever structures and further fixed to the respective lever structure. Accordingly, existing connector housings might be modified to include a synchronization mechanism.
According to a further aspect, the gear element may comprise at least two gear teeth of different lengths, so that the lever ratio corresponding to the first tooth is higher than the lever ratio corresponding to the second tooth.
The gear elements may be made of plastic or any suitable material with the necessary stiffness for withstanding the forces applied to the first and second lever structures in order to mate and un-mate the first and second connector housings.
According to a further aspect of the present invention, the first lever structure is adapted to be pivoted simultaneously with the second lever structure, respectively so as to move the first connector housing toward the second connector housing.
According to a further aspect of the present invention, the first and second lever structures are mounted on the same face of the first connector housing. More specifically, each of the first and second lever structures may be pivotally engageable with two opposing mounting side faces of the first connector housing.
The first connector housing may also include a guard element adapted to be mounted on a mounting side face of the first connector housing on which the first and second lever assembly are mounted. The guard element is positioned so as to cover the gear elements of the first and second lever assembly and to keep them against the mounting side face. The guard element has the function of keeping the gear elements of the first and second lever assembly aligned and correctly engaged, and to prevent accidental disengagement of said gear elements.
According to a further aspect of the present invention, for each of the first and second lever structures the first lever portion or cover portion is a cover adapted to at least partially cover an upper portion of the first connector housing and a portion of an electric cable in proximity of a top surface of the first connector housing, the top surface being a surface through which the cable enters the first connector housing.
According to a further aspect of the invention, the cover portion of the first lever structure or first cover portion may include latching elements adapted to be latched to corresponding mating latching elements on the cover portion of the second lever structure or second cover portion.
According to a further aspect of the present invention, in a closed state of the first and second lever structures, the cover of the first and second lever structures are locked to each other and enclose the upper portion of the first connection housing and the portion of the electric cable in proximity of the top surface.
According to a further aspect of the present invention, the second lever portion is a clip element pivotally mounted on the respective cover and adapted to be latched to a hook member on a side face of the second connector housing.
According to a further aspect of the present invention, in a closed state the first and second lever structures are adapted to excite a tension on the first connector housing and on the second connector housing.
According to still another aspect of the present invention, it is provided a second connector housing for accommodating electrical contacts. The second connector housing is adapted to be connected to a mating first connector housing, such as the first connector housing described above. The second connector housing comprises a first engaging element on a first side face of the second connector housing, said first engaging element being adapted to be engaged to a corresponding first lever structure on a mating first connector housing. The first engaging element is such that the first lever structure is adapted to excite a pressure on the first connector housing and the second connector housing through the first engaging element.
The second connector housing may further comprise a second engaging element on a second side face opposing the first side face, said second engaging element being adapted to be engaged to a corresponding second lever structure on the mating first connector housing. The first and second engaging element are such that at least one of the first and second lever structures is adapted to excite a pressure on at least one of the first connector housing and the second connector housing.
The first engaging element may comprise a tooth adapted to be engaged with a gear element on the first lever structure. Similarly, the second engaging element may comprise a toothed element adapted to be engaged with a gear on the second lever structure.
According to a further development, a first tooth of the toothed element may be chosen so that the lever ratio defined by the first tooth is higher than the level ratio defined by a second tooth of the toothed element.
According to an aspect of the present invention, the toothed element may be a rack adapted to be engaged with a circular pinion on the first and/or second lever structure.
According to a further aspect of the present invention the rack is parallel to the mating direction of the connector. In particular, according to a further development, the gear element, such as the circular pinion, comprises at least two gear or pinion teeth of different lengths, wherein each gear tooth is arranged so as to be adapted to engage a rack tooth of a corresponding rack so as to provide a high initial gear ratio and a lower final gear ratio, respectively. In this manner, engagement of the first pinion tooth with the corresponding rack tooth with a high gear ratio allows to overcome peak mating forces, while the second and further gear teeth engaged with the corresponding second and further rack teeth with a lower gear ratio serves to complete mating in the required lever angular rotation. Here, the high gear ratio of the first gear and rack teeth is defined relative to the gear ratio of the second and further gear and rack teeth.
The corresponding rack tooth may have a form adapted to be mated and to cooperate to the corresponding gear tooth,
According to a further development, the rack angle of a first rack tooth is chosen so that the lever ratio defined by the first rack tooth is higher than the level ratio defined by the second rack tooth. In alternative to the rack any other toothed element adapted to co-operate with the gear element on the first and second lever structures may be used.
The rack may alternatively be at an angle with respect to the mating direction of the first connector housing with the second connector housing. Such a configuration would eliminate the perpendicular reaction load upon mating of the first and second connector housings.
According to an aspect of the present invention, a first rack tooth of the rack may be at an angle so that rotation of the lever is at a higher level ratio when the gear element engages the first rack tooth. This design creates a mechanical advantage during initial mating.
The present invention further relates to a connector system for establishing an electrical connection. The connector system may include a first connector housing for accommodating electrical contacts and a second connector housing for accommodating electrical contacts. The first and second connector housings may be designed as described in the previous paragraphs. The second connector housing is adapted to be connected to the first connector housing so as to establish an electrical contact.
The accompanying drawings are incorporated into and form a part of a specification to illustrate several embodiments of the present invention. These drawings together with the description serve to explain the principles of the invention. The drawings are only for the purpose of illustrating preferred and alternative examples of how the invention can be made and used, and are not to be construed as limiting the invention to only the illustrated and described in the embodiments. Further features and advantages will become clear from the following and more particular description of the various embodiments of the invention, as illustrated in the accompanying drawings, in which the same reference numbers refer to the same elements and wherein:

Figure 1 is a perspective view of a connector assembly including a first and a second housing according to the present invention;
Figure 2 shows a perspective view of a connector assembly including a first and a second housing according to a further embodiment of the present invention;
Figures 3 to 5 show different perspective views of a particular mate-assist mechanism for a connecting assembly according to the embodiment of figure 2; figures 3 and 5 are longitudinal cuts along a side of a guard member;
Figures 6 and 7 respectively show a second and a first lever portion of a lever structure according to an embodiment of the present invention;
Figure 8 shows a particular of the lever structure according to an embodiment of the present invention;
Figures 9 and 10 show a perspective view of a connection between a connector housing and a lever structure according to the present invention and a section thereof, respectively;
Figures 11 and 12 show the connector assembly of figure 2 in an open and a closed position, respectively;
Figures 13 and 14 show a connector assembly including a lever structure according to an embodiment of the present invention in an open and closed position, respectively;
Figures 15 to 17 show a connector assembly including a lever structure according to a further embodiment of the present invention in an open and in two intermediate positions;
Figure 18 shows a schematic drawing illustrating the working principle of the lever structure according to an embodiment of the present invention;
Figure 19 shows the working principle of a meting design according to a further embodiment of the present invention;
Figure 20 is a schematic drawing illustrating a particular of a lever pinion and rack mating mechanism according to an embodiment of the present invention;
Figures 21 and 22 show a connector assembly including a first and a second lever structure according to a further embodiment of the present invention;
Figures 23 to 26 illustrate a sequence of an operation for closing the first and second lever structures on a fully connected connector assembly;
Figures 27 to 29 show a top view of the closing sequence described with reference to figures 23 to 26;
Figure 30 shows a side view of a fully connected connector assembly according to an embodiment of the present invention;
Figure 31 shows a schematic drawing illustrating a mate-assist structure according to the prior art.

In the following description, for explanatory purposes, specific details are set forth in order to provide a thorough understanding of the principle of the invention. It may be evident, however, that the present invention can be practiced without these specific details. Furthermore, well known structures and devices are only described in a more general form in order to facilitate the description.
In the following description, the expression "lever structure" or "lever assembly" is used to indicate a structure adapted to assist the mating of first and second connector housings; in addition or alternatively, the lever structure may be a structure for keeping the first and second connector housings under tension when connected.
Furthermore, the terms "first connector housing" and "second connector housing" are used to indicate a housing for receiving electrical contacts, such as a plug housing, and a corresponding mating housing, such as a socket housing, of a connector assembly. These terms are interchangeable.
The problem underlying the present invention is based on the observation that common connector assemblies are not specifically designed for withstanding high vibration levels, such as those experienced by those parts of a car that are close to the engine. Moreover, the present invention is based on the further observation that electrical connectors operated by a single lever structure, especially those having big dimensions, require a high-applied force for fully connecting the connector housings. This is due to the reaction force perpendicular to the mating direction resulting from the operation of the lever structure, coupled with the sliding friction of the lever structure with its engaging counterpart on the connector housing.
According to the present invention a connector housing is designed to have a first and a second lever structure mountable on a mounting face of the first connector housing and opposing each other. The first and second lever structures can be operated simultaneously so as to cancel the reaction force perpendicular to the mating direction during mating of the connector. Moreover, the connector housing of the present invention allows to respectively lock the first and second lever structures to the first and second connector housings so as to keep the latter under tension, when the connector is fully mated.
Figure 1 illustrates a connector assembly 1000 including a first connector housing 1010 and a second connector housing 1020 according to an embodiment of the present invention. A first and a second lever assembly 1100 can be rotatably mounted on a side face of a first connector housing 1010 of the connector assembly 1000. The side face 1012 will be referred herein also as the mounting side face. The lever assembly 1100 includes a first lever portion 1120 and a second lever portion 1110. The first lever portion 1120 is adapted to be rotatably mounted, at a bottom end of the mounting side face 1012 of the first connector housing 1010. A top end 1122 of the first lever portion 1120 is adapted to be pivotally mounted to an inner face of the second level portion 1110 facing the first connector housing 1010. The first lever portion 1120 has a front face 1125 and two side faces 1124 perpendicular to the front face 1125 and opposed to each other. The first lever portion 1120 is pivotally mounted to the first connector housing 1010 by inserting at least one pivot 1011 on the mounting side face 1012 of the first connector housing 1010 into a corresponding pivot receiving hole 1123 on each side face 1124 of the second lever portion 1120. The pivot receiving hole 1123 is formed on the side face 1124 in a position toward the bottom end portion 1121 of the first lever portion 1120.
The second lever portion 1110 includes at the bottom end thereof a latch element 1111, such as a hook, that is adapted to be engaged with a corresponding latch portion 1021 on a side face of a second connector housing 1020. In this context, the bottom part of the second lever portion 1110 is the part closer to the second connector housing 1020. The corresponding engaging element 1021 on the second connector housing 1020 may be a hook portion adapted to lock to an opening or to a corresponding hook portion on the bottom end portion of the second lever portion 1110. The first lever portion 1120 is pivotally connected, at a top end portion 1122 to a face of the second lever portion 1110 and is adapted to rotate with respect to the first and second connector housings about the pivot 1011 and with respect to the second lever portion 1110 about a pivotal point on an inner face of the second lever portion 1110.
Figure 2 shows a connector assembly according to a further embodiment of the present invention. The part of the connector assembly 2000 already described with reference to Figure 1 will not be described again. The second connector assembly 2000 includes a first and a second lever structures 2100 adapted to be mounted on a side face of the first connector housing 1010. Mounting of the lever structure 2100 to the first connector housing 1010 is obtained in a similar manner as already described with reference to figure 1. Further, each of the first and second lever structures 2100 includes a first lever portion 2120 and a second lever portion 2110. A bottom end portion 2121 of the first lever portion 2120 includes a toothed head such as a gear element 2122. The gear element 2122 is an example of a synchronization element. The gear element 2122 on the first lever assembly 2100 is adapted to engage a corresponding gear element on the first lever portion of the second lever assembly. The second lever assembly, in this embodiment, is the same as the first lever assembly. By means of the gear element 2122, a rotational movement obtained by applying a force to the first lever structure 2100 is transferred to the second lever structure so that movement of the second lever structure is synchronized with the movement of the first lever structure.
The lever structure 2100 includes on two side faces 2114 of the second lever portion 2110, a curved cam groove 2117 adapted to be engaged with a cam portion 2127 on a side face 2124 of the first lever portion 2120. This provides a constraint that reduces the movement of the first lever portion 2120 with respect to the second lever portion 2110.
The design described with reference to figure 2 allows operation of the first and second lever structures 2100 in a bi-directional lever system in a synchronized manner, so that the two lever structures cannot be operated out of phase. This prevents exerting side loads which may damage the connector housings and the contacts in the connector housings. Moreover, the mating mechanism of the connector assembly 2000 is over-centre due to the synchronization of the first and second lever structures 2100.
The first connector housing 1010 includes a guard element 2200 adapted to be mounted on a side face of the first connector housing on which the first and second lever assembly 2100 are mounted. The guard element 2200 has a substantially flat shape and extends from a bottom end of the first connector housing 1010 to a position substantially in the middle of the mounting side face 1012 of the first connector housing 1010 so as to cover the gear elements 2122 of the first and second lever assembly 2100 and to keep them against the mounting side face 1012.
The guard element 2200 has the function of keeping the gear elements of the first and second lever assembly 2100 aligned and correctly engaged, and to prevent accidental disengagement of said gear elements. The guard element or guard member 2200 can be fixed to the side face 1012 by means of a latch mechanism. The latch mechanism may include a latch element 1013 protruding from the side face 1012 and a corresponding latch aperture 2210 formed in the guard element 2200. This guard element 2200 may be locked pressing same against the mounting side face 1012 so as to lock the latch mechanism.
A side face of the first connector housing 1010 opposing the mounting side face 1012, not shown in the figure, may have the same design of the mounting side face 1012 and may therefore also include pivots for mounting a side face 1124 of the first lever portion 1120 and a safety element 2200 for keeping gear elements 2122 in position as described above.
Figure 3 shows a detail of a mounting side face 1012 of a first connector housing as described in relation with figure 2. From this figure, it is possible to have a closer view of the pivots 1011 that are inserted into the pivot receiving holes 1123 of the first lever portion 2120.
Figure 3 further shows a detail of the engaging mechanism of the second lever portion 2110 with the second connector housing 1020. The engaging mechanism includes a latch element, such as a hook 2111, formed on a bottom portion of the lever portion 2110. The latch element 2111 may be a folded sheet part of a front face 2115 of the second lever portion 2110. The hook 2111 may be engaged with a corresponding hook portion 1021 on the second connector housing 1020.
The guard element 2200 has on the surface facing the mounting side face 1012 a recess shaped so as to tightly encase the gear elements 2122. In this manner, only the rotational movement needed to operate the lever assembly 2100 to move the first connector housing towards or away from the second connector housing 2020 is allowed. Figure 3 shows a section of the guard element 2200 so as to highlight its internal structure and the recess adapted to encase the gear elements 2122.
Figures 4 and 5 show a particular of a mounting side face 1012 on which the gear elements 2122 and the safety element 2200 are mounted. From these figures, it is possible to clearly see the recess portion on an inner face 2220 of the safety element 2200 and how the gear elements 2122 are positioned inside the recess.
Figures 6 and 7 show a particular of the second lever portion 2110 and first lever portion 2120. The first and second lever portions are in this embodiment independent pieces and may be mounted together to form a lever structure 2100. The second lever portion 2110 in figure 6 comprises front face 2115 and two side faces 2114 perpendicular to the front face 2115. The dimensions of the second lever portion 2110 are chosen so that in a closed state the lever structure 2100 at least partially encases the first and/or second connecting housings. A top end portion of the second lever portion 2110 includes a first pivot guide 2116, which may have a hollow cylindrical shape. The pivot guide 2116 is adapted to receive a removable pivot element (not shown) used for pivotally connecting the second lever portion 2110 to the first lever portion 2120. Each of the side faces 2114 of the second lever portion 2110 includes a cam guide 2117 having a curved shape and adapted to receive a corresponding cam portion 2127 formed on a side face 2124 of the first lever portion 2120.
A top end portion of the first lever portion 2120 as depicted in figure 7 comprises two second pivot guides 2126 adapted to be aligned to the first pivot guide 2116 on the second lever portion 2110, and to receive a pivot for rotatably fixing the first and second lever portions. Each of the side faces of the first lever portion includes a cam portion 2127 adapted to be inserted in the cam groove 2117 of the second lever portion 2110. The cam portions 2127 may be formed by cutting and folding a corresponding part of the side face 2124 of the first lever portion 2120. In the paragraph above, the term top end portion indicates the part of the first lever portion 2120 that is to be mounted to the second lever portion 2110.
Figure 8 shows a particular of the lever structure 2100 illustrating engagement of the cam guide 2117 with the cam portion 2127. Since the cam portion 2127 on the first lever portion 2120 is kept inside the cam groove 2117 of the second lever portion 2110, the rotational movement of the second lever portion 2110 with respect to the first lever portion 2120 and to the first and second connector housings is reduced. Such a constraint on the movement of the second lever portion 2110 prevents damaging the lever structure 2100 and the first and second connector housings by positioning the lever structure 2100 at an excessive angle with respect to the connector housings and the first lever portion at an excessive angle with respect to the second lever portion.
Figure 9 shows a detail of an engaging system of the second lever portion 2110 with the corresponding hook portion 1021 of the second connector housing 2020. The hook portion 2111 of the second lever portion 2110 is obtained by inwardly folding a sheet part of the front face 2115 towards the bottom edge of the front face 2115 so as to form a hook 2111 with a roughly flattened cylindrical section. Such a configuration increases the strength of the hook portion 2111 and therefore the reliability of the mating design. In the description above, the term inwardly indicates a direction going from the first lever body 2115 towards the side face of the first and second connector housings. Figure 10 shows a longitudinal section of a detail of the engaging mechanism of the second lever portion 2110 and the second connector housing 2120.
Figures 11 and 12 show a mating sequence of the connector assembly 2000. Figure 11 shows the connector assembly in an open position. By pushing the first and second lever structures 2100 towards the connector housings a pressure is exerted from the hook portion 2111 of the second lever portion 2110 on the corresponding hook element 2021 of the second connector housing 2020 so as to move the first connector housing towards the second connector housing. Similarly, the first lever portion 2120 pushes the first connector housing towards the second connector housing in the mating direction of the connector assembly 2000. The movement of the first lever structure 2100 is synchronized with the movement of the second lever structure. Figure 12 shows a connector assembly 2000 in a fully connected position. The first and second lever structures 2100 partially encase the connector housings 1010 and 1020.
Moreover, a top edge of the first and second lever structures 2100, opposing the edge of the lever structures on which the hook element 2111 and the gear elements 2122 are formed, may be designed so as to be locked on a top surface of the first connector housing so as to keep the first connector housing and the second connector housing under tension. This allows to have a reliable connection even in solutions where the connector is exposed to high vibrations.
Figures 13 and 14 show a connector assembly 3000 according to a further embodiment of the present invention. While in the lever structures 2100 described with reference to figures 2 to 12 the gear elements 2122 are integrally formed with the second lever portion 2120, in the embodiment of figures 13 and 14 the gear elements 3122 are independent parts that can be mounted on pivots on a mounting side of the connector housing, such as the pivots 1011 on which the second lever portion 3120 is mounted, and then fixed to the second lever portion 3120.
More precisely, the connector assembly 3000 includes a first connector housing 1010 and a second connector housing 1020. Each of a first and a second lever structure 3100 comprises a first lever portion 3120 and second lever portion 3110. The structure of the lever assembly 3100 is similar to that as described with reference to the embodiment of figure 1 and will not be described further. A first end side 3121 of the first lever portion 3120 includes a pivot receiving hole 1123. The first lever potion 3120 can be mounted on a mounting side face 1012 of the first connector housing by inserting a pivot 1011 formed on a bottom side of the mounting side face 1012 into the pivot receiving hole 1123. The lever structure 3100 further includes a gear element 3122. The gear element 3122 has a toothed head 3123 having a semi-circular shape and a lobe protruding from an edge opposing the toothed head 3123. The lobe 3124 has an opening so as to form a ring through which the gear element 3122 can be mounted on the pivot 1011. The gear element 3122 can be then fixed to the first lever portion 3120 by a latching mechanism so as to rotate with respect to the first and second connector housing together with the first lever portion as a single body. The toothed head 3123 of the gear element 3122 mounted on the first lever portion 3120 of the first lever structure 3100 is orientated so as to face a corresponding toothed head 3123 of the gear element 3122 mounted on the first lever portion of the second lever structure and to engage therewith.
The second lever portion 3110 is pivotally engageable with the second connector housing 1020 by means of a hook element 3111 to be mounted in a corresponding hook portion 1021 of second connector housing. The hook portion 3111 is formed by folding a free bottom edge of the second lever portion 3110 on itself so as to form a cylindrical engaging element adapted to fit into a corresponding curved recess on a mounting side face of the second connector housing. Alternatively, the hook portion 3111 may be formed as previously described with reference to figures 9 and 10.
By operating the first and second lever structures 3100, for instance by pushing them towards the first and second connector housings, the first connector housing is moved towards the second connector housing. Figure 14 shows a fully connected connector assembly 3000. In this position, the first and second lever structures 3100 are leaned against a side face of the first connector housing perpendicular to the mounting side 1012 and partially encase same. A top edge of the second lever portion 3110 opposing the edge of the second lever portion including the hook 3111 can be formed so as to lock with a corresponding element on a top face of the first connector housing, such as a groove, so that the lever structure 3100 exerts a tension on the first and second connector housing, thereby keeping them firmly connected, as already described with reference with the previous figures.
The gear elements 3122 may be made of plastic material. Clearly, other materials may be considered based on the specific field of application of the connector assembly.
Figures 15 to 17 show a connector assembly 4000 according to a further embodiment of the present invention. The connector assembly 4000 includes a first connector housing 4010 and a second connector housing 4020. A first and a second lever structure 4100, 4200 are mounted on the first connector housing 4010 so as to face two opposing side faces 4013 the first connector housing 4010. Each of the first and second lever structures 4100, 4200 includes a lever body or lever front face 4115 and two side faces 4114 perpendicular to the lever body and opposing to each other. The lever body 4115 may be curved at one end portion so as to form a handle. One top end portion of the side faces 4114 is joined to the curved end portion of the lever body 4115 and a bottom end portion of each side face 4114 opposing the top end portion shows a toothed head 4122, and a pivot receiving hole 4123 adapted to receive a pivot 4011 formed on a bottom portion of the first connecting housing 4010. The first lever structure 4100 is mounted so that the teeth of the gear element are orientated towards the gear element of the opposing second lever structure 4200 and are adapted to engage therewith.
The second connector housing 4020 includes on a side thereof a rack 4040. The teeth of the rack are adapted to be engaged with the teeth of a mating gear element 4124 on the second lever portion 4200. The mating gear element 4124 may be for instance a circular pinion. On one side the circular pinion engages with the teeth on the rack, while on the other side the circular pinion engages the gear element 4122 so as to synchronize the movement of the first lever with the movement of the second lever 4200. Upon pushing the first and second lever 4100 and 4200 towards the first connector housing, the pinion 4222 engages the teeth of the rack formed on a side face of the second connector housing 4020 thereby moving the second connector housing towards the first connector housing until the connector assembly 4000 is fully connected. Two intermediate positions between a fully unmated state and a fully mated state are shown in figures 16 and 17.
Figure 18 schematically illustrates working principle of the present invention according to an embodiment thereof. In the illustrated configuration, the levers 4100 are attached to the first connector housing 4010 trough rotation axles or pivots 4011. The gear element of each of the first lever structure 4100 and second lever structure 4200 engages a corresponding rack 4040 of the second connector housing or header 4020. By using two opposing rack and pinion arrangements and assuming negligible rack and pinion rolling friction, the 0.17F loss due to keyway sliding friction is eliminated because the reaction forces cancel. The remaining loss is the axle friction, which in some practical developments, may be about 7%. The last figure results from the fact that there are two axles, each taking 50% of the load. Therefore the overall loss due to axle friction would be the same as that of a single axle.
The torque required on each lever is halved for a given mating force. This may be important in a design where the levers can be squeezed together with one hand, for instance in the design described with reference to figures 2 and ff. The net effect for a given mating force would be reducing the mating force per lever compared to a single lever of 50% (because each of the lever takes 50% of the load) plus 17% (due to cancelling of the reaction forces as described above), thereby leading to a total reduction of 67% for the mating force required for closing or opening the connector assembly. This approach is ergonomically efficient because the force applied on a single lever structure, such as the first or second lever, for squeezing the lever against the connector housings (for instance if the hand squeezed against the cover) wastes the reaction load on the housing of one half of the force applied on the lever.
Further, the connector would be locked at 4 points: the gear element of the first lever structure (or first gear element) and the corresponding first rack 4040 on one side the gear element of the second lever structure (or second gear element) and the corresponding second rack 4040 on the other side. This prevents rocking during service, which is especially desirable for wide high circuit count designs.
Rocking during service may alternatively or in addition be prevented by providing the top end portion of each lever structure 4100, 4200 with a locking element, such as a top latch (not shown), adapted to be locked to a corresponding counterpart on the top face of the first connector housing 4010, such as a groove or a latch counterpart. In this context a top end portion of the lever structure is the portion opposing the side on which the gear elements are formed. Further, a top face of the first connector housing is the face further from the second connector housing during mating.
Figure 18 is only a schematic drawing and does not show that the gear elements of the first and second lever structures can be engaged with each other, but it has to be understood that such a configuration can be foreseen for the assembly of figure 18. Further, the connector assembly of figure 18 refers to the design described with reference to figures 15 to 17. However, it has to be understood that the principles described above also apply to the other embodiments of the present invention, and in particular to those described with reference to figures 1 to 14. Finally, although figure 18 shows a two rack and gear system, a mating design working with only one rack may also be developed.
Figure 19 is a schematic drawing illustrating an embodiment of the present invention, wherein the first lever portion comprises a gear element that is adapted to engage a corresponding first rack on the header 4020 and the corresponding gear element of the second lever portion, which in turn is adapted to engage a corresponding second rack on the header.
In an alternative embodiment, if the gear element on the first lever portion is synchronously connected by a 1:1 spur gear arrangement to a second gear element adapted to rotate about an axle, then the mechanical efficiency of the twin lever arrangement can be maintained with only one lever, with the addition of the rolling resistance of the synchronising gears. For a given mating load, the force applied to the single lever is twice that applied to twin levers. The lever can be lengthened in compensation.
Figure 20 show in a schematic drawing a detail of a gear element 4122 or 4222 engaged with a corresponding rack 4040. Involute tooth systems with any pressure angle can be theoretically designed for the gear and rack pair. The smaller the angle, the smaller the teeth have to be for a given pitch circle diameter. In most of the practical applications, connectors have levers that only rotate pinions less than 90 degrees, and consequently the rack form usually has one or two teeth. Therefore, unconventional rack forms may be employed.
For example, a rack angle on a first rack tooth may be designed so that the initial rotation of the lever is at a higher lever ratio. This configuration creates a greater mechanical advantage during initial mating. This is particularly beneficial in connector mating because the peak force is generated when contacts are being opened up upon insertion. Similarly, also the radial tooth pitching may be modified.
The example of figure 20 shows a toothed head of pinion as an example of gear element 4222 or 4122, wherein at least two conventional pinion teeth of differing pitch circle diameter are arranged to engage a rack with cooperative conventional tooth forms. This configuration provides a high initial gear ratio to overcome peak mating forces, then a lower ratio to complete mating in the required lever angular rotation.
According to an embodiment of the present invention, the rack may be aligned with the connector mating direction. This concept can be incorporated into single lever or twin lever arrangements, wherein both the first and second levers both engage trough a pinion a corresponding rack 4040 on the header 4020.
Alternatively, in a design including only one engaging rack 4040 adapted to cooperate with a pinion on one of the first or second lever structures, providing the rack 4040 at an angle with respect to the mating direction of the connector assembly would eliminate perpendicular reaction loads on mating. The rack may for instance be angled at 20 deg relative to the mating direction. In addition, the arrangement described above may employ a modified involute pinion form to compensate for the varying distance of the rack to the pinion pivot axis, due to the inclination angle of the rack relative to the mating direction. Further, this design may be incorporated into simple or compound rack and pinion arrangements.
Figure 21 shows a connector assembly 5000 according to a further embodiment of the present invention. The connector assembly 5000 includes a first connector housing 5010 and second connector housing 5020. The connector assembly further comprises a first and a second lever structure 5100, 5200.
Each lever structure 5100, 5200 includes a first lever portion or cover portion 5110, 5210, which also functions as the body of the lever structure 5100, 5200, and a second lever portion 5120, 5220 which may be a clip. In the following only the parts relative to the first lever structure 5100 will be described, but it has to be understood that the same description is also valid for the second lever structure 5200. The clip is pivotally mounted on both sides of the cover portion 5110 into pivotal points. In particular, two opposing free ends of the lever clip 5120 are inserted into corresponding holes on the cover portion 5110, so that the lever clip 5120 can be rotated with respect to the cover portion 5110. The cover portion5110 comprises a front face and two opposing side faces 5104 perpendicular to the front face. The pivotal points of the lever clip 5120 are formed on the side faces 5104.
Further, the cover portion includes, on the two opposing side faces 5104, a first protrusion 5112 and a second protrusion 5111. The first protrusion 5112 and the second protrusion 5111 define a first rest position of the lever clip 5120. In the first rest position, the clip element 5120 is locked between the first and second protrusions. The cover portion further includes a third protrusion 5115 formed by an outwardly protruding edge of the side face 5104 of the cover portion 5110 facing the first connector housing 5010, so that the first protrusion 5112 is positioned between the second and the third protrusions. The first protrusion 5112 and the third protrusion 5115 are adapted to lock the lever clip 5120 in a second predefined rest position with respect to the cover portion 5110. In particular, in the second predefined rest position an upper portion of the clip element 5120 is latched between the first and the third protrusion. A top portion of the lever clip 5120 is in this contest a portion close to the free ends of the lever clip pivotally mounted on the side faces of the cover portion.
The cover portion 5110 has an elongated shape and includes a bottom portion 5116 configured to be pivotally engaged on a mounting side face 5120 of the first connector housing, and a top portion 5117.
The top portion 5117 is shaped so as to tightly enclose a portion proximate to the first connector housing 5010. More specifically, the top portion of the cover portion 5110 extends over the first connector housing 5110, has a cylindrical section and is shaped as to so as to tightly fit and at least partially encase an electrical cable 500 entering the first connector housing.
The bottom portion is shaped so as to at least partially encase the top portion of the first connector housing 5010. Here the top portion of the first connector housing is the part closed to the cable 500 entering the first connector housing 5010. A bottom edge 5114 of the bottom portion 5116 has a semi-circular section and has the function of an engaging member. The engaging member 5114 is adapted to be pressed into an engaging portion 5011 on a mounting face 5012 of the first connector housing 5010. The engaging portion 5011 may comprise a receiving groove having a semi-circular section in which the bottom edge 5114 of the cover portion 5110 can abut and a latch element or fastening latch adapted to hold the cover portion 5110 in position. Since both the bottom edge 5114 and the receiving groove of the engaging member 5011 on the first connector housing have a semi-circular section, the first lever portion 5100 can pivot with respect to the first connector housing.
A first side face of the second connector housing aligned to the mounting side face 5012 of the first connector housing includes a hook 5021. The hook 5021 has the function of an engaging element adapted to engage with an end portion of the clip 5120. A side face opposing the first side face 5012 also includes a hook 5021, having the function a second engaging element 5021, and adapted to engage the clip portion 5120 of a second lever structure 5200. The second lever structure 5200 essentially has the same design of the first lever structure 5100. However, the cover portion of the second lever structure or second cover portion 5210 includes latching elements corresponding to latching elements on the first cover portion5110. The corresponding latching elements on the first and second cover portion form a cooperating clip mechanism for fastening the first and second lever structures 5100 and 5200 about the first and second connector housings.
Although in the embodiment described with reference to figure 21 the engaging portion 5011 includes an engaging groove and a fastening latch for securing the cover portion5110 on the mounting face of the first connector housing 5010, the fastening latch is not essential for carrying out the principles of the invention. The first and second lever structures may indeed be kept in position on the fully connected connector assembly 5000 by the cooperating clip mechanism on the cover portion 5110 of the first and second lever structures and by the tension exerted by the cover portion 5110 and the lever clip 5120 on the first and second connector housings.
Figures 22 to 26 show a closing sequence of the first and the second lever structures 5100 and 5200 on the first and second connector housings 5010 and 5020 so as to enclose part of the first connector housing 5010 and a portion of the cable 500 proximate to the first connector housing 5010. The first and second lever structures 5100, 5200 can be mounted on the first connector housing by pressing the bottom edge 5114 of the first lever portion 5110 into the latching element 5011. Although the latching element 5011 comprises a base portion or receiving groove, formed by a step in the first connector housing 5010 on which the first lever portion abuts, and a latch element to keep the first lever portion 5110 in place, such a configuration is optional and the latch element 5011 may also include only the receiving groove. In this case, the lever structure 5100 will be kept in place once closed, by the tension exerted from first lever portion on the first connector housing 5010 and from the clip portion 5120 on the second connector housing 5020.
Figure 23 shows a connector assembly 5000, wherein the first lever structure 5100 and the second lever structure 5200 are pivotally mounted on the mounting side face 5012 and are positioned in an open position. An open position of the lever structure means in this case that the clip portions 5120 are not engaged with the hook portions 5021 on the second connector housing 5020 and the first cover portion 5110 and the second cover portion 5210 are not locked to each other.
Figure 24 shows an intermediate position, wherein the clip portion 5120 of the first and second lever structures are engaged with the corresponding respective hook 5021 of the second connector housing. In this position, the clip element 5120 is locked in a predefined position with respect to the first lever portion 5110. In particular, the clip element 5120 is locked between the first protrusion 5112 and the second protrusion 5111.
Figure 25 shows a further intermediate locking position of the first and second lever structures. In this position, the cover portion 5110 and the clip element 5120 respectively exert a tension on the first connector housing and on the second connector housing. In this intermediate position, the clip element 5120 is locked in the second predefined rest position with respect to the cover portion 5110. In particular an upper portion of the clip element 5120 is latched between the first protrusion 5112 and the outwardly protruding edge 5115 of the side face of the cover portion 5110.
Fastening of the clip element 5120 in the second rest position is additionally or in alternative guaranteed by the tension on the clip portion 5120 due to the over-travel of the clip portion 5120 with respect to its equilibrium position. When the first and second lever portions 5100 and 5200 are closed on the first and second connector housings 5010 and 5020, the clip portion 5120 is designed to lie in a position, in which it is overstressed and pushed against the protruding edge 5115 by the tension exerted by the pivot points on the respective second lever portion 5510 or 5210 and by the hook portion on the second housing 5021. Said position defines the over-travel of the clip portion 5120, 5220.
Figure 26 shows a situation where the first and second lever structures 5100 and 5200 are fully closed and keep under tension the second connector housing 5020 through the clip elements 5120 and the first connector housing through the pressure exerted from the cover portion 5110 and, in particular from the bottom portion 5114, on the receiving groove of the latch element 5011.
The upper part of the cover portion 5110 encases completely a portion of the cable 500 proximate to the first connector housing and prevents the latter to vibrate or bend. The first and second lever structures 5100, 5200 are locked to each other by means of locking structures formed on the cover portion 5110. In particular, a top edge of the cover portion 5110 includes a fastening protrusion 5118 and a locking hole 5119. The fastening protrusion 5118 on a first side of the cover portion5110 of the first lever structure 5100 is adapted to be locked by means of a corresponding fastening hook 5218 on the cover portion 5210 of the second lever structure 5200. Similarly, the locking hole 5119 is adapted to be locked to a corresponding fastening pivot 5219 on the cover portion5210 of the second lever structure 5200. The fastening protrusion 5118 and the locking hole 5119 are also provided on a side of the cover portion5210 of the second lever structure 5200. In a similar manner, a corresponding fastening hook 5218 and fastening pivot 5219 are provided on the cover portion 5110 in a position corresponding to the fastening protrusion and fastening hole on the cover portion 5210.
Figure 27 shows a top view of a connector structure 5000, where the lever structure are in an open position In this position, the lever clip 5120 is locked in the first rest position between the first protrusion 5111 and the second protrusion 5112. Figure 28 shows an intermediate stage of the closing sequence of the first and second lever structures 5100, 5200. In this position, the clip portion 5120 is locked in the second rest position between the protruding edge, or third protrusion 5115, of the side face 5104 of the cover portion 5110 and the latching protrusion or first protrusion 5112.
in figure 29 the first and second lever structures are locked together. From this figure it is possible to see how the fastening protrusion 5118 is firmly locked to the fastening hook 5218. Although the locking mechanism described with reference to figure 27 to 29 comprises a fastening protrusion and a fastening hole and a respective corresponding fastening hook and fastening pivot, any kind of locking mechanism such as a click-stop mechanism may be used for fastening the first lever structure 5100 to the second lever structure 5200. Alternatively, the first and second lever structures may be fastened by using a cable tie tied around the cover portion 5210. As an example, the cable tie may be provided on the top edge of the cover portion, in a position where the cover portion closes about the cable 500.
Figure 30 shows a side view of a completely locked connector assembly 5000. The clip portion 5120 together with the corresponding cover portion 5110 or 5210 keeps the first connector housing 5010 and the second connector housing 5020 under constant tension so that mating electrical contacts housed in the first and second connector housing remain firmly and reliably mated even in presence of high vibrations. Moreover, the top portion of the first and second lever structures completely encloses the portion of cable 500 close or proximate to the first connector housing so as to reduce vibrations in proximity of the first connector housing. With the term close or proximate it is here intended a portion of the cable entering the first connector housing having a length that allows forming a bend in the cable. Thus, the top portion of the first and second lever structures, prevents by encasing the cable 500, bending of the cable in proximity of the first connector housing, thereby improving the reliability of the connection and increasing the life time of the assembly. Additionally, the lever structure 5000 according to an embodiment of the present invention further serves to relieve the stress exerted on the first and second connector housings and the contacts housed therein. Indeed, the exerted tension or the pulling force will be transferred to the connector assembly directly by the clip portion 5120 and not through the connector coupling.
In a particular embodiment, only the first and second lever structures 5200, 5100 may be provided. Indeed, due to their simple structure, the first and second lever structures can be retrofitted and fastened on already installed connector assemblies so as to improve their reliability and stability.
Although the examples above describe a connector assembly including a first and a second connector housing and lever structures, the principles of the present invention can also be applied to the first and/or second connector housing taken singularly.
The first and second lever assemblies generally have the same shape and structure. However, these may also be different as for the case described in relation with figures 15 to 17 or as in the embodiment of figures 21 to 30. In the embodiments of figures 15 to 17 the first lever structure includes a circular pinion for engaging a corresponding rack on the second connector housing, while the second lever structure merely includes a toothed head for engaging the corresponding circular pinion of the first lever portion. Clearly it is also possible to conceive an embodiment in which each of the first and second lever structures include a circular pinion adapted to engage with a corresponding rack on the second connector housing. Similarly, in the embodiment of figures 21 to 30 the first and second lever portions show mating latch elements so as to form a fastening mechanism.

In summary, the present invention relates to a first connector housing designed to have a first and a second lever structure mountable on a mounting face thereof and opposing each other. The first and second lever structures may be operated simultaneously in order to mate the connector. This has the effect of cancelling the reaction force perpendicular to the mating direction, thereby reducing the losses due to friction during mating. Moreover, the connector housing of the present invention allows to respectively lock the first and second lever structures to the first and second connector housings so as to keep the latter under tension when the connector is fully mated. The cover portion of the first and second lever structures may also be adapted to partially cover an upper portion of the first connector housing and to fully enclose a portion of an electric cable proximate to the first connector housing. This has the effect of reducing vibrations of the cable and avoiding bends in the cable, which may result in ruptures, thereby deteriorating or even interrupting electrical connection.

Reference Numeral	Description
1000, 2000, 3000, 4000, 5000, 300	Connector assembly
1010, 4010, 5010	First connector housing
1012,5012	Mounting side face
1013	Latch element for the guard member
1011, 4011, 5011	Mounting pivot/ engaging element
4013	Opposing side faces of first connector housing
1100, 2100, 3100, 5100	First second lever assembly/structure
1100, 2100, 3100, 4200, 5200	Second lever assembly/structure
311	Lever engaging element
312	Pivot
1120,2120, 3120, 5110, 5210	First lever portion
1110,2110, 3110, 5120	Second lever portion
1122	Top end portion of the second lever portion
1124, 2124	Side face of the first lever portion
2127	Cam portion
2126	Second pivot guides of the first lever portion
1114, 2114, 3114	Side face of the second lever portion
1123,4123	Pivot receiving holes
1121,2121, 3121	Bottom end portion of the second lever portion
2122,3122	Gear element
4122,4222	Toothed head of the lever structure 4100, 4200
4124	Rack-mating gear element
3123	Toothed head of gear element
3124	Lobe of the gear element
4114, 5104	Lever structure side face
1111,2111,3111	Latch hook of the second lever portion
2115, 4115	Lever structure front face
2116	First pivot guide of the second lever portion
2117	Cam guides
5112	First protrusion
5111	Second protrusion
5115	Third protrusion
5116	Bottom portion of the second lever portion 5110
5117	Top portion of the second lever portion 5110
5114	Engaging member of the first lever portion 5120
5118	Fastening protrusion
5119	Locking/fastening hole
5218	Fastening hook
5219	Fastening pivot
1020, 4020, 5020, 301	Second connector housing/ header
1021, 5021	Hook portion of the second connector housing
302,4040	Rack
2200	Guard member
2210	Latch aperture corresponding to the latch element 1013
500	Electric cable

Claims

A first connector housing (1010, 4010, 5010) for accommodating electrical contacts and adapted to be connected to a mating second connector housing (1020,4020,5020), the first connector housing (1010, 4010, 5010) comprising:
a first lever structure (1100, 2100, 3100, 4100, 5100) including a first lever portion (1120, 2120, 3120, 5120) pivotally engageable with a first engaging member (1011, 4011, 5011) on a side face of the first connector housing, and

a second lever structure (1100, 2100, 3100, 4200, 5200) including a first lever portion (1120, 2120, 3120, 5220) pivotally engageable with a second engaging member on a side face of the first connector housing so as to be opposing the first lever structure,

wherein each of the first lever structure (1100, 2100, 3100, 4100, 5100) and the second lever structure (1100, 2100, 3100, 4200, 5200) is further adapted to be respectively engaged to a corresponding first and second engaging element (1021, 5021, 4040) on the mating second connector housing,

wherein at least one of the first and second lever structures is adapted to excite a pressure on at least one of the first connector housing and the second connector housing.
The first connector housing (1010, 4010) according to claim 1, wherein the first lever structure (2100, 3100, 4100) comprises a first synchronization element (2122, 3122, 4122) adapted to engage a corresponding second synchronization (2122, 3122, 4222) element of the second lever structure, the first and second synchronization elements being adapted to synchronize the relative pivotal movement of the first and second lever structures.
The first connector housing (1010, 4010) according to claim 1 or 2, wherein the first and second synchronization elements are a gear members (2122, 3122, 4122, 4222).
The first connector housing (4010) according to any of claims 1 to 3, wherein the gear member (4222) of at least one of the first and second lever structure (2100, 3100, 4100, 4200) is adapted to engage a corresponding toothed element (4040) on a side face of the second connector housing, the toothed element (4040) being one of the first or second engaging element on the second connector housing.
The first connector housing (4010) according to claim 3 or 4, wherein the gear member (4122, 4222) comprises at least two gear teeth of different lengths, so that the lever ratio corresponding to the first tooth is higher than the lever ration corresponding to the second tooth.
The first connector housing (1010, 4010) according to any one of claims 2 to 5, wherein at least one of the first and second lever structure (1100, 2100, 3100, 4100, 5100, 4200, 5200) is adapted to be pivoted simultaneously with the second or first lever structure, respectively so as to move the first connector housing toward the second connector housing.
The first connector housing (5010) according to claim 1, wherein for each of the first and second lever structures the first lever portion is a cover portion (5110, 5210) adapted to at least partially cover an upper portion of the first connector housing (5010) and a portion of an electric cable (500) in proximity of a top surface of the first connector housing, the top surface being a surface through which the cable enters the first connector housing.
The first connector housing (5010) according to claim 1 or 7, wherein in a closed state of the first and second lever structures, the cover portions (5110, 5210) of the first and second lever structures are locked to each other and encase the upper portion of the first connector housing and the portion of the electric cable in proximity of the top surface.
The first connector housing according (5010) to any of claims 1 to 8, wherein each of the first and second lever structures (5100, 5200) further comprises a second lever portion (5120) pivotally movable with respect to the first lever portion (5110, 5210) , said second lever portion being adapted to be respectively engaged with the corresponding first and second engaging element on the mating second connector housing
The first connector housing (5010) according to claim 9, wherein the second lever portion is a clip element (5120) pivotally mounted on the respective cover and adapted to be latched to a hook member on a side face of the second connector housing.
The first connector housing (5010) according to any of claims 1 to 10, wherein in a closed state the first and second lever structures (5100, 5200) are adapted to excite a tension on the first connector housing and on the second connector housing.
A second connector housing (1020, 4020, 5020) for accommodating electrical contacts and adapted to be connected to a mating first connector housing, the second connector housing comprising:
a first engaging element (1021, 5021, 4040) on a first side face of the second connector housing, said first engaging element being adapted to be engaged to a corresponding first lever structure on the mating first connector housing,

wherein the first engaging element (1021, 5021, 4040) is such that the first lever structure is adapted to excite a pressure on the first connector housing and the second connector housing through the first engaging element.
The second connector housing according to claim 12, further including a second engaging element (1021, 5021, 4040) on a side face, said second engaging element being adapted to be engaged to a corresponding second lever structure on the mating first connector housing,
wherein the second engaging element (1021, 5021, 4040) is such that at least one of the first and second lever structures is adapted to excite a pressure on at least one of the first connector housing and the second connector housing..
The second connector housing according to claim 12 or 13, wherein the first engaging element and/or the second engaging element comprises a toothed element (4040) adapted to be engaged with a gear on a first and/or second lever structure.
The second connector housing according to claim 11 or 12, a first tooth of the toothed element (4040) is chosen so that the lever ratio defined by the first tooth is higher than the level ratio defined by a second tooth of the toothed element.
The second connector housing according to any of claims 11 to 13, wherein one of the first and second engaging element is a rack (4040) aligned at an angle relative to the mating direction of the second connector housing with the first connector housing.
A connector system for establishing an electrical connection, the connector system including:
a first connector housing for accommodating electrical contacts according to any one of claims 1 to 9; and

a second connector housing for accommodating electrical contacts according to any one of claims 10 to 14, the second connector housing being adapted to be connected to the first connector housing so as to establish an electrical contact.