Airbag Connector Plug Assembly with Noise Filter Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing plug for electric connectors in airbag systems faces difficulties in simply and surely positioning contacts and noise filters within a housing during assembly, due to the need to maintain a predetermined distance between these components, making the operation cumbersome.
Innovation Solution
A plug design with a housing that includes an insertion space for the noise filter before being covered by a cap, where the cap forms a wall surface to secure the noise filter in place, allowing for simultaneous latching of contacts and fitting of the noise filter onto the electric wire, and ribs are used to prevent rattling and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both contacts and noise filter are positioned in housing at the same time while maintaining predetermined distance, then positioning precision is maintained, but assembly operation becomes difficult
Solution Approach 1:
The assembly process is divided into two independent stages: first positioning the contacts in the housing, then separately positioning the noise filter. This segmentation allows each component to be positioned independently without the operational complexity of simultaneous positioning, while maintaining precision through dedicated positioning structures for each stage.
Solution Approach 2:
The contacts are positioned in the housing first as a preliminary action before the noise filter is installed. This preliminary positioning establishes a reference framework that simplifies the subsequent noise filter installation, allowing the predetermined distance to be maintained through the housing structure rather than through complex simultaneous positioning operations.
2Reliability
If noise filter is fitted onto electric wire before assembly, then noise filtering function is ensured, but positioning and alignment become cumbersome
Solution Approach 1:
The noise filter, once fitted onto the electric wire, utilizes the wire itself as a positioning guide and support structure within the housing. The wire's predetermined routing and the housing's receiving space work together to automatically position the noise filter correctly, eliminating the need for complex external positioning mechanisms and reducing overall device complexity.
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
This design simplifies and secures the assembly process by ensuring the noise filter is fixed in a predetermined position, preventing offset and reducing abnormal noise from rattling, thus facilitating easier integration into airbag system connectors.
Implementation Method 1
a ferrite bead 106 is arranged on the plug 105 while being fitted onto the lengths of electric wire 102... the ferrite bead 106 functions as a noise filter to prevent explosion by mistake in an airbag system
Data Source
AI summary
A plug for electric connectors comprises a housing 34 and a cap 36. The housing 34 comprises an insertion space 71 that allows a noise filter 35 to be fitted onto lengths of electric wire 32 before the housing is covered by the cap 36 after contacts 30 are latched. The cap 36 comprises a wall surface 75 provided in a direction, in which the noise filter 35 comes off. And, the plug for electric connectors is assembled in the order of (1) a step of latching the contacts 30 on a plug portion 31a of the housing 34, (2) a step of fitting the noise filter 35 onto the lengths of electric wire 32 that are connected to the contacts 30 and disposed within the housing 34, and (3) a step of covering the housing 34 with the cap 36 and forming a wall surface 72 in a direction, in which the noise filter 35 comes off.