Some electronic module sub-assemblies need to be inserted into a chassis and then be connected and fully mated with a chassis-mounted connector. Examples of such sub-assemblies are power supplies, RAID disks, peripheral devices, fan assemblies, and processors, all of which require a power connection of some sort. When these sub-assemblies have a power connection there is a requirement for sufficient surface contact (barrel contact) to insure adequate performance. Sufficient surface contact is only accomplished and assured with a fully mated or almost fully mated connector.
Providing for full connector insertion of power connectors (pre-loading) is of vital importance when preventing power failures as is maintaining the fully loaded connection during service. If a power connector loosens or begins to back out and there is less and less surface contact, the power connection and the connector itself may eventually fail. Consequently, yield (longevity and service life of the connector and thus any product) is compromised by a non-fully inserted power connector.
For purposes of quality and safety, and especially with high voltage, one typically uses an injector tool when inserting a sub-assembly into a chassis, usually then securing the sub-assembly with a lock of some kind and a mounting screw or two.
Previous solutions include securing screws, locking inserter/ejector levers, and simple locking mechanisms (like a door handle).
Securing screws can be used to provide enough pre-load to ensure fully mated connectors. The problem is they are often numerous in number and are subject to stripping or cross threading due to alignment problems. There are also tolerance problems in getting the threads started. The screw stripping, screw binding, and screw damage sometimes leaves metal particles and slivers that can short electronics near the failure. Furthermore, since the screws are not initially attached to the chassis or sub-assembly, they can be easily lost or misplaced. Sometimes when this happens, a sub-assembly is secured with less than the full number of required screws, and the connection is either not as complete as it needs to be initially or is prone to earlier failure.
Inserter/ejector levers themselves are adequate to fully engage a connector pair at time of insertion. The problem is that they generally cannot provide enough pre-loading to overcome extended field shock and vibration, especially in the telecom environment. Furthermore, they generally cannot maintain full engagement during fragility operations such as transportation and shipping because there is no pre-loading spring action.
Simple locking mechanisms do not provide any pre-load, and thus are inadequate for powered sub-assemblies, especially when the service environment includes shocks and vibrations.