Safety Plug Connector Cutting Edge Shorting
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Solution Overview
Problem
Modern squib connectors for safety restraint systems in vehicles lack a cost-effective method to reliably monitor the correct coupling of plug connectors with their counterparts, as existing solutions like shorting clips are prone to contamination and high production costs due to gold coating and complex designs.
Innovation Solution
The electrical plug connector features contact blades with sharp cutting edges and a bendable portion that automatically separate upon correct coupling, eliminating the need for additional CPA members and reducing contact area to prevent contamination, thereby enhancing electrical conductivity and monitoring functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shorting clips are used to monitor correct coupling, then coupling monitoring is achieved, but contamination risk increases and manufacturing costs rise due to gold coating requirements
Solution Approach 1:
The invention extracts the monitoring function from the traditional shorting clip design by using separate contact blades that are integrated into the plug connector housing. This separation eliminates the need for gold-coated shorting clips while maintaining reliable electrical contact for monitoring coupling status.
Solution Approach 2:
The patent replaces expensive gold-coated shorting clips with inexpensive, non-coated contact blades made from base materials. These contact blades achieve reliable electrical contact without requiring protective coatings, significantly reducing manufacturing costs while maintaining functionality.
2Reliability
If traditional shorting clips with larger contact area are used, then electrical contact is established, but contamination risk increases
Solution Approach 1:
The invention applies local quality by creating a sharply defined, minimal contact area at the cutting edge of the contact blades. This localized contact point provides sufficient electrical conductivity while minimizing the surface area exposed to contamination, effectively decoupling contact reliability from contamination risk.
3Reliability
If gold coating is applied to shorting clips to prevent contamination, then electrical conductivity is maintained, but manufacturing costs increase
Solution Approach 1:
The patent eliminates the need for expensive gold coating by designing contact blades with sharply defined cutting edges that maintain reliable electrical contact through precise mechanical geometry rather than protective coatings. This approach uses inexpensive base materials without requiring additional coating processes.
4Measurement precision
If complex shorting clip designs are used to ensure reliable coupling monitoring, then monitoring accuracy is improved, but device complexity increases
Solution Approach 1:
The invention extracts the monitoring function from complex shorting clip mechanisms and implements it through simple, integrated contact blades within the plug connector housing. This extraction simplifies the overall device structure while maintaining accurate coupling monitoring through direct electrical contact between corresponding contacts in the plug and socket.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
The present invention relates to an electrical plug connector 1 for a safety restraint system, preferably for an airbag ignition system, wherein the plug connector comprises at least two contact terminals 521, 522 assigned to the plug connector 1 and a shorting clip 530, that is adapted to short-circuit the at least two contact terminals 521, 522 in an uncoupled or incorrectly coupled condition of the plug connector 1 The shorting clip 530 comprises at least two contact blades 533, 534, wherein each contact blade 533,534 is electrically connected with a respective one of the at least two contact terminals 521, 522, and wherein each of the contact blades 533, 534 comprises at least one cutting edge 535, 536, which cutting edges 535, 536 contact each other, such that one edge cuts the other, when the plug connector 1 is in in an uncoupled or incorrectly coupled condition.