Airbag Igniter Connector Assembly with Diagonal Sliding Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Miniaturization of electrical connector systems in vehicles leads to manageability issues during assembly, especially in cramped spaces, and there is a need for a secure plug connection to prevent incorrect assembly in safety-critical applications.
Innovation Solution
A connector assembly with a connector body comprising two housing parts that can move relative to each other along a housing axis, held together by an elastic element, featuring diagonal sliding surfaces and a collar with complementary sliding surfaces to ensure secure locking only when fully plugged in, along with contact springs and pins for precise contact and locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connector systems are miniaturized to accommodate increased vehicle equipment, then the cross-section and size of connectors are reduced, but the connectors become difficult to handle during assembly and may protrude from mating connectors in cramped installation spaces
Solution Approach 1:
The connector housing is divided into two separable parts: a plug housing and a receptacle housing. This segmentation allows the connector to be assembled in a modular fashion, improving handleability during assembly while maintaining a compact overall size. The two housing parts can be manufactured separately and then joined together, making the assembly process more manageable in cramped spaces.
Solution Approach 2:
The connector incorporates a dynamic locking mechanism with movable housing parts that can shift relative to each other during assembly. The plug housing and receptacle housing are designed to move against the restoring force of an elastic element during the locking process, enabling secure connection while maintaining compact dimensions. This dynamic behavior allows the connector to adapt during assembly, improving ease of operation.
2Volume of moving object
If connector size is reduced through miniaturization, then space is saved in installation areas, but secure locking and prevention of incorrect assembly become more difficult to ensure
Solution Approach 1:
The connector employs asymmetric sliding surfaces with different orientations on the plug housing and receptacle housing. The first sliding surface on the plug housing is oriented at a first angle to the housing axis, while the second sliding surface on the receptacle housing is oriented at a second angle. This asymmetric design ensures that the connector can only be assembled in the correct orientation, preventing incorrect assembly while maintaining compact size.
Solution Approach 2:
The elastic element is pre-loaded to exert a restoring force that automatically engages the locking mechanism when the connector parts are brought together. The sliding surfaces are designed so that relative movement during assembly automatically triggers the locking action before the connector is fully assembled, ensuring secure connection is achieved as part of the normal assembly process without requiring additional steps.
3Reliability
If traditional locking mechanisms are used in miniaturized connectors, then connection security is maintained, but the connector profile increases and is unsuitable for very flat installation spaces
Solution Approach 1:
The locking mechanism utilizes diagonal sliding surfaces that are oriented at angles to the housing axis rather than parallel to it. This dimensional change allows the locking action to occur in a diagonal direction, enabling the connector to achieve secure locking with a reduced profile in the axial direction. The sliding surfaces engage in a staggered manner, allowing compact design while maintaining reliable connection.
Solution Approach 2:
The projection on one housing part is designed to fit into a recess on the other housing part when locked, creating a nested configuration. This nesting arrangement allows the locking features to be contained within the overall connector boundaries, minimizing the connector profile while ensuring secure locking. The elastic element and sliding surfaces are arranged to achieve locking without requiring excessive axial length.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for easy handling during assembly, secure plug connections, and the ability to design very flat connectors suitable for tight spaces, reducing assembly errors and increasing reliability and service life by ensuring correct plugging and secure locking.
Implementation Method 1
an elastic element (90) holding the housing parts together
Implementation Method 2
the sliding surfaces cooperate. A plug-in force is exerted on the plug in the plug-in direction and the first sliding surface slides on the second sliding surface
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Electrical connector arrangement for an airbag igniter, comprising a connector (10) with a connector body (20), a first housing part (40), and a second housing part (50) with a plug-in area (30), wherein the housing part parts (40, 50) are movable relative to each other along a housing axis (A), wherein an elastic element (90) holds the housing parts (40, 50) together, wherein the second housing part has on its surface a projection (51) with a first sliding surface (52) extending diagonally to the housing axis, a mating connector (100) with a plug-in receiving area (110) configured to receive and electrically and mechanically connect the plug-in area of the connector, comprising a collar (101) that partially delimits the plug-in receiving area, wherein the collar has a second sliding surface (152) that is arranged complementary to the first sliding surface when the connectors (10, 100) are aligned on a plug-in axis (X),While the connectors are being connected, the sliding surfaces (52, 152) interact, applying a insertion force (Fs) in the insertion direction (Y) to the connector, causing the first sliding surface (52) to slide on the second sliding surface (152). The second housing part is moved away from the first housing part along the housing axis against a restoring force (Fr) of the elastic element. The second sliding surface terminates at a recess (156) in the collar. In the fully connected state, the projection (51) is in an end plane (E) with the recess, so that the elastic element pulls the projection into the recess and locks the connector body with the mating connector.