Safety Restraint Plug Connector Shorting Clip Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors for safety restraint systems, such as airbag ignition systems, lack reliable and cost-effective means to electronically monitor the correct coupling of plug connectors with their counterparts, and are prone to issues like residual layer deposition and unintended short circuits due to high vibration and operation temperatures.
Innovation Solution
The design incorporates a shorting clip with at least two shorting tongues that are electrically connected to contact terminals, which change states from a short-circuit to an open state upon correct coupling, utilizing a separator means made of plastic to prevent residual layer deposition and ensure reliable electrical monitoring, and includes a CPA member for further assurance of correct coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shorting clip is used to monitor correct coupling, then coupling monitoring is achieved, but residual layer deposition occurs on contact surfaces due to high temperature and vibration
Solution Approach 1:
The contact surfaces are extracted from the separator means structure, creating a spatial separation between the separator and the electrical contact areas. This allows the shorting tongues to contact each other without intermediate separator structures, eliminating residual layer deposition while preserving coupling monitoring functionality through the shorting circuit mechanism.
Solution Approach 2:
The shorting tongues serve as an intermediary element that performs both electrical contact and coupling monitoring functions. By using the shorting tongues themselves as the contact-making elements rather than having them contact the separator means, the patent eliminates the harmful interaction between separator materials and contact surfaces.
2Reliability
If separator means contacts shorting tongues to prevent short circuits, then short circuit prevention is achieved, but contact surfaces become contaminated with residual layers
Solution Approach 1:
The contact surfaces are extracted from the separator means structure, creating a spatial separation between the separator and the electrical contact areas. This allows the shorting tongues to contact each other without intermediate separator structures, eliminating residual layer deposition while preserving coupling monitoring functionality through the shorting circuit mechanism.
3Reliability
If traditional monitoring means are used, then coupling monitoring is possible, but the system becomes complex and costly
Solution Approach 1:
The shorting tongues perform multiple functions: they provide electrical connection during uncoupled states, enable coupling monitoring through their relative movement, and prevent short circuits during coupled states. By integrating these functions into a single element rather than using separate monitoring components, the patent reduces system complexity and cost while maintaining monitoring reliability.
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 solution provides a reliable and cost-effective method for monitoring the correct coupling of plug connectors, maintaining high conductivity and preventing unintended short circuits, even under high vibration and temperature conditions, thus ensuring the safety and efficiency of the safety restraint system.
Implementation Method 1
the at least two shorting tongues (331, 332) contact each other to short circuit the at least two contact terminals (321, 322)
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
The invention relates to an electrical plug connector 2 for a safety restraint system, preferably for an airbag ignition system, comprising at least two contact terminals 521, 522 assigned to the plug connector 2 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 2, wherein the shorting clip 530 comprises at least two shorting tongues 531, 532, wherein each shorting tongue 531, 532 is electrically connected with a respective one of the at least two contact terminals 521, 522 and wherein each shorting tongue 531, 532 comprises further at least one electrical contact surface 535, 536, and at least one of the shorting tongues 531, 532 comprises an actuating member 543, 544, wherein the actuating member 543, 544 is provided with an actuating surface 545, 546 that is adapted to interact with a separator means, wherein the contact surfaces 535, 536 are not arranged within the same plane as the actuating surface(s) 545, 546.