Shunted Airbag Connector

1. Field of the Invention

This invention relates to an electrical connector for use with an airbag igniter system.

2. Description of the Prior Art

It is sometimes required to provide an electrical connector for the connection of two electrical conductors, for example electrical leads, with means for the interposition between the conductors of an electrical suppression device, for example a resistor, or a capacitor. Where for example in an airbag igniter system, where the electrical connection is made with the igniter, a suppression device is sometimes placed between adjacent terminals to suppress the signal of the igniter. Typically these igniters include a suppression device which is soldered between adjacent contacts which increases the cost of the manufacturing of the product, as well as the reliability of the connection. Typically such connections also include a shunting feature, which shunts between adjacent contacts when in a disconnected mode, whereby the connection of the two connectors breaks the shunt allowing the connection with the ignitor.

It is an object of the present invention to provide an electrical connection system having the above mentioned features where the suppression device and wires to be connected are all assembable to the connector using automatic tooling.

The objects of the invention were accomplished by providing an electrical connector having a suppression device electrically connected between terminals in a housing, the connector is characterized in that the housing has a receiving section for a suppression device and in that the terminals include an additional wire receiving slot, or leads of the suppression device are terminated in the additional wire receiving slots.

FIG. 1 is a side view of the assembled electrical contact for use in the airbag connector;

FIG. 2 is a top view of the terminal shown in FIG. 1;

FIG. 3 is a side view similar to that of FIG. 1 without the outer spring attached;

FIG. 4 is a cross-sectional view through lines 4--4 of FIG. 1;

FIG. 5 is a cross-sectional view through lines 5--5 of FIG. 1;

FIG. 6 is a cross-sectional view through lines 6--6 of FIG. 1;

FIG. 7 is a view similar to that of FIG. 1, showing the terminal in a right angle configuration;

FIG. 8 is an end view of the terminal shown in FIG. 7;

FIG. 9 is an upper plan view of the ignitor connector and housing cover shown in an unassembled manner;

FIG. 10 is a cross-sectional view through lines 10--10 of FIG. 9;

FIG. 11 is a cross-sectional view of a mating housing connected to the pins of the ignitor;

FIG. 12 is a view similar to that of FIGS. 10 and 11, showing the connector of FIG. 10 in a partially connected configuration with the housing of FIG. 11;

FIG. 13 shows the two connectors in a fully mated condition; and

FIG. 14 shows a diagrammatical view of the manner in which the connector is electrically wired.

With reference first to FIG. 12, an electrical airbag connector includes a housing member 100 carrying terminals 2, and a housing portion 150 which surrounds the igniter pins 142.

With reference now to FIG. 1, the electrical terminal is shown generally at 2 including a front contacting section 4 and a wire terminating section 6. As shown best in FIG. 3, the front mating contact section is shown as a box shaped receptacle at 8 having an overlying outer spring 10 (FIG. 1) in surrounding relationship.

As shown best in FIG. 3, the inner terminal includes a lower base section 12 which runs the substantial length of the terminal having a hinge section at 14 which carries the wire connection section 6. In the preferred embodiment of the invention the wire connecting section 6 is shown as an insulation displacement type slot, although a wire terminating section such as an F-crimp or similar connection could also be incorporated. Two side walls 15 and 16 upstanding from the base portion 12, as best shown in FIG. 5. As also shown in FIG. 5, a top wall portion 18 extends from the side wall portion 16 and is bent at a right angle relative to the side wall portion to form a substantially closed box. Each of the wall portions 12, and 15-18 extend forwardly and are constricted at 20 to form contact sections 22-28 respectively.

A wire receiving slot section is shown at 30 which is profiled to receive a suppression device in the slot 32. This section 30 is profiled by upstanding wall sections 34 and 36 extending upwardly integral with respective wall sections 15 and 16. This section 30 also includes top cover portions 38 and 40, extending from respective extended wall portions 34 and 36 as best shown in FIGS. 2 and 6. Along the front edges 42 and 44 of respective wall portions 34 and 36 are located lead-in openings 48 for the slots 32.

With respect now to FIGS. 1 and 2, the outer spring 10 will be described in greater detail. The outer spring 10 comprises a lower base portion at 52 which lies substantially adjacent to lower base 12 of the inner contact portion and has side wall portions 54 and 56 which lie substantially adjacent to respective side wall portions 15 and 16 of the inner contact. The outer spring member 10 further includes top wall portions 58 and 60 (FIG. 2) adjacent to the front end of the terminal which are folded over to lie substantially adjacent to the top wall portion 18 of the inner contact. These top wall cover portions 58 and 60 include integral tabs 62 and 64 which extend from longitudinal seams 66 and 68, respectively. These tab portions 62 and 64 extend upwardly as shown in FIGS. 1 and 4 and are either welded or soldered together to fix the top wall portions 58 and 60 to hold them in a closed condition.

The outer spring member 10 further includes rear top wall portions 70 and 72 which further include upstanding tab portions at 74 and 76. The top wall sections 78 and 80 which are intermediate the top wall portions 58, 70; 60 and 72 respectively are separated from the side walls and along a rear edge thereby forming two discrete rearwardly facing locking lances, as best shown in FIGS. 2 and 5. As best shown in FIGS. 4 and 5, the tab portions 62,64 and 74,76 define a central polarizing rib where the locking lances 78 and 80 are positioned on opposite sides of the rib. The outer spring is also held to the contact member by way of tab portions 90 and 92 being clinched to the side walls 15 and 16 over an edge 94 formed in an opening 96 (FIG. 3).

As shown in FIGS. 7 and 8, the terminal 2 is rotatable about the web 14, to position the terminal into a right angle configuration.

With respect now to FIG. 9, the airbag connector is shown generally at 100 having a cover 102 where the connector 100 is generally comprised of an insulating housing 104, a plurality of the electrical terminals 2, a suppression device at 106, such as a resistor or capacitor, and electrical cable at 108. As shown best in FIG. 10, as the electrical terminal 2 is bendable about the web 14, the terminal 2 can be positioned in the housing 104 with the front mating portion 4 positioned in a front cavity section 110 of the housing, having a pin receiving opening 112 leading into the contact section 4. The housing 104 also includes a nest at 116 for receiving the suppression device 106. As shown in FIG. 9, the device 106 includes electrical leads 118a, 118b which are electrically connected to the slots 32 on two of the electrical terminals 2. The housing 104 further includes a housing portion 120 for receiving the wire connecting sections 6 of the electrical terminals 2. It should be appreciated that the housing is somewhat T-shaped in a cross section having oppositely directed parallel arm portions 117 and 120, and a perpendicular section 110. As shown in FIGS. 9 and 10, the cover 102 has an upper cover plate at 124 and latching arms such as 126, 128, and retention arms at 130 for maintaining the suppression device in place, having a circular surface 132 for engaging against the cylindrical suppression device 106.

With respect now to FIG. 11, an ignitor for an airbag is shown generally at 140 which includes pin terminals at 142. A mating housing portion is shown at 150 including an outer shroud 152 for receiving the connector housing 104 and includes apertures at 154 for mating with latch elements 157 of latching arms 156 (FIG. 9) on the main housing. The housing 150 includes a cavity at 160 for holding a shunt spring 162 where the shunt spring 162 includes a base portion 164, a contact arm 166 having a cantilever spring beam 168 for contact against the pins 142 when in the unmated condition.

The housing 150 further includes a cavity 170 for receiving the connector 100, and as shown in FIG. 12 the connector 100 begins to mate with the housing portion 150, but where the shunt member 162 is still in engagement with the pin portions 142. It should be noted that a front edge 165 of the housing 100 engages the cantilever spring portion 168 in FIG. 10, and as shown in FIG. 13 has moved the shunt spring away from the pin terminals 142 when in the fully mated condition. When in the fully mated condition, the latch arms 156 carrying latching elements 157 towards the ends, are positioned in the apertures 154 (FIG. 11 maintaining the two in a fully mated condition).

As shown in FIG. 14, the electrical connector 100 includes three terminals 2a, 2b, and 2c where the suppression device 106 has a lead 118a terminated to the slot 32 of terminal 2a. The opposite lead 118b is terminated to the slot 32 of the terminal 2c. The terminal 2a is not terminated to a lead, such as 108b or 108c, whereas the terminal 2c has no mating contact section. Thus the serial signal connection is from pin 142a to contact 4a, through the suppression device 106, to the lead 108c, to the lead 108b, and back to the igniter pin 142b.