Electrical connector assembly for an airbag ignitor

[0001] The present invention relates to electrical connectors for use with vehicle inflatable restraint systems, generally known as airbag systems. More particularly, the present invention relates to an electrical connector assembly for an airbag ignitor, the connector assembly comprising a socket member having a mating aperture, the mating aperture having a mating axis, a top wall portion, an internal side wall portion and a bottom wall portion, the side wall portion having a locking slot, the bottom wall portion having at least one pin contact, each pin contact extending from the bottom wall portion substantially parallel to the mating axis; and a plug member adapted for mating with the socket member by insertion in the mating aperture along the mating axis, the plug member comprising a plug body and a plug nose, this plug nose including a bottom surface having at least one socket contact aperture having a socket contact therein, said socket contact corresponding to a respective pin contact extending from the bottom wall portion of the mating aperture, and a resilient locking device adapted for engaging in the locking slot of the side wall portion of the socket member, the resilient locking device including at least two resilient arms spreading apart from said plug nose towards said plug body, said arms, upon application of a force to separate the plug member from the socket member, locking the plug member in the socket member and preventing separation of the plug member from the socket member.

[0002] A connector system of this type is disclosed, for example, in U.S. Pat. No. 5,876,231. Such a system is known as a non-serviceable connector as the plug member and the socket member cannot be separated when the locking device is engaged in the locking slot.

[0003] Up to now, airbags have been mainly used to protect the driver and the passengers during an accident. Therefore, the airbags and their connectors are installed inside the passenger compartment.

[0004] Now, it appears a need to install an airbag under the hood of a car to protect a pedestrian bumped by the car and projected on the hood. With the current cars, this pedestrian crashes onto the motor, which generates serious injuries. The goal of the airbag is therefore to provide a smooth area to protect the pedestrian from a collision with the motor. However, the environment under the hood is more difficult than the environment of the passenger compartment in terms of moisture, temperature, dust . . . .

[0005] Therefore, there is a need for a rugged connector equipment adapted to such environment with a high level of reliability.

[0006] It is accordingly an object of the invention to provide an electrical connector assembly for an airbag ignitor as defined above, wherein the plug member further includes an annular gasket seal around the plug nose and under the plug body, said seal being adapted to seal the gap between the socket member and the plug member when the plug member is inserted into the socket member aperture.

[0007] Such an electrical connector assembly is particularly adapted to a harsh environment and more particularly protects the electrical connections from moisture. Such a connector assembly is particularly adapted to pass the tests used by the automotive industry to qualify the equipments installed in the motor compartment.

[0015] FIG. 1 shows a perspective and cross-sectional view of an electrical connector assembly 1. The connector assembly 1 comprises a socket member 2 and a plug member 3. The socket member 2 and the plug member 3 are adapted to mate together as shown in FIG. 1.

[0016] The socket member 2, FIG. 2, has a mating aperture 4. The mating aperture 4 has roughly a cylindrical form with a mating axis 5, a top flat wall portion 6, an internal side wall portion 7 and a bottom wall portion 8.

[0017] The side wall portion 7 has an annular locking slot 9. The locking slot 9 includes a top shoulder wall 10 that extends substantially perpendicular to the mating axis 5.

[0018] The bottom wall portion 8 has at least one pin contact 11. Each pin contact 11 extends from the bottom wall portion 8 substantially parallel to the mating axis 5.

[0019] The plug member 3, FIGS. 1, 3 and 4, has a plug body 3a and a plug nose 3b.

[0020] The plug nose 3b includes socket contacts 12 disposed in socket contact apertures 13. The socket contacts 12 are electrically connected to conductors of wiring 14. Each socket contact 12 has a first end to receive a corresponding pin contact 11 and a second end for receiving a conductor of wiring 14. The apertures 13 open onto a bottom surface 15 of the plug nose 3b.

[0021] The plug nose 3b also includes a resilient locking device having three resilient arms 17. Each arm 17 obliquely extends upwardly from a region adjacent the bottom surface 15 of the plug nose 3b and is adapted for engaging the locking slot 9 of the side wall portion 7 of the mating aperture 4. Each arm 17 includes an upper detent portion 19 that has a divergent portion 20 and an abutment portion 21.

[0022] When the plug nose is inserted into the aperture 4, the arms 17 are flexed towards axis 5, then resiliently spread apart in the slot 9.

[0023] Abutment portion 21 extends substantially perpendicular to the mating axis 5 and abuts shoulder portion 10 of locking slot 9, preventing separation of plug member 3 from socket member 2 when a force is applied for separating member 3 from member 2.

[0024] The plug member 3 further includes an annular slot 22, FIGS. 1 and 5, in the top portion of the plug nose 3b. The slot 22 extends between two shoulder portions 23, 24 that extend substantially perpendicular to the mating axis 5.

[0025] The top shoulder portion 23 is preferably formed by an annular bottom wall surface of an annular flange 23a of the plug body 3a, said bottom wall surface having an outer diameter substantially greater than the diameter of the mating aperture 4.

[0026] The slot 22, the bottom of which is substantially parallel to the mating axis 4, maintains an annular gasket seal 25 in position.

[0027] The annular gasket seal 25, FIGS. 5 and 6, has on its internal surface annular ridges 26, which are pressed against the bottom of slot 22, providing an effective seal.

[0028] The external surface of the gasket seal 25 has one or more lips 28, 29.

[0029] In the illustrated preferred embodiment, the gasket seal 25 has a top lip 28 and two lower lips 29.

[0030] The top lip 28 is obliquely directed towards the top wall portion 6 of the socket member 2, and the lower lips 29 extend radially towards the internal side wall portion 7, so that, when the plug member 3 mates with the socket member 2 and is locked in position by the arms 17, the first lip 28 is pressed between the top wall portion 6 of the socket member 2 and the bottom wall surface 23 of the plug member 3 and spreads apart, providing an effective seal.

[0031] The lower lips 29 pressing against the side wall portion 7 provide an additional sealing effect, the seal 25 being pressed in the annular gap between the plug nose 3b and the side wall portion 7 of the socket member 2.