Pyrotechnic Connector Locking Spring Ejection Mechanism
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Solution Overview
Problem
Existing pyrotechnic connectors in safety restraint systems of motor vehicles face challenges in ensuring correct connection and preventing bad connections due to vibrations and shocks, leading to potential deformation of spring-based locking systems and failure to maintain a secure lock.
Innovation Solution
An electrical connector design featuring a main housing with a locking spring and a connector position assurance member that opposes incorrect mating, automatically ejecting the connector if not correctly inserted and maintaining a secure lock when correctly coupled, utilizing a formed wire spring and CPA device to ensure proper alignment and locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring-based locking system is used to maintain connector connection, then the connector can be securely locked, but the spring deforms with each connection/disconnection cycle
Solution Approach 1:
The patent extracts the spring from the repeated connection/disconnection cycle by positioning it only in the retained state housing, rather than requiring it to function during insertion and removal. The spring is engaged only when the connector is properly retained, eliminating deformation from cyclic loading while maintaining secure locking.
Solution Approach 2:
The connector is designed with preliminary positioning features (guide pins, alignment surfaces) that ensure correct engagement before the spring-based locking mechanism activates. This preliminary action prevents misalignment and excessive force on the spring during connection, reducing deformation risk.
2Reliability
If a secondary locking system is added to prevent bad connections, then connection reliability improves, but the device complexity increases
Solution Approach 1:
The patent merges the secondary locking function with the retention mechanism itself. The retention arms and spring system that provide secure locking also serve as the secondary locking mechanism, eliminating the need for separate locking components and reducing overall device complexity while maintaining high connection reliability.
Solution Approach 2:
The spring-based retention system performs multiple functions: it provides secure locking, acts as a secondary locking mechanism, and enables automatic release when misaligned. This multi-functionality reduces the number of separate components needed, simplifying the overall connector structure while improving reliability.
3Productivity
If the connector design is standardized to meet automotive specifications, then manufacturing efficiency improves, but adaptability to different configurations decreases
Solution Approach 1:
The connector is divided into standardized modular components (housing, retention arms, spring assembly, electrical contacts) that can be manufactured separately using standardized processes. This segmentation allows each component to be optimized for mass production while the assembled connector can be configured for different applications, balancing manufacturing efficiency with adaptability.
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 ensures automatic prevention of bad connections and maintains a secure lock by using a formed wire spring and CPA device to prevent incorrect insertion and ensure correct alignment, enhancing the reliability and safety of pyrotechnic connectors in automotive applications.
Implementation Method 1
a locking spring (1221), provided in the main housing (1201) and relaxed in a delivered state of the connector
Implementation Method 2
the spring tension opposes mating as long as the connector and the mating connector are not correctly mated
Data Source
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AI summary
The invention relates to an electrical connector (2200), in particular a pyrotechnic connector, which can be coupled with a conjugate connector (100) in a coupling direction (300), comprising: a main housing (2201); a locking spring (2221) relaxed in a delivery state; a connector position assurance element (2235) movable so as to cause a tension in the spring (2221) opposing coupling until the connector (2200) and the conjugate connector (100) are properly coupled; and at least one main locking element (2217, 2218) which can be deflected during coupling and whose delivery position allows the connector (2200) to be locked to the conjugate connector (100) when they are properly coupled.The connector position assurance element (2235) is further configured to prevent deflection of said at least one main locking element (2217, 2218) in the delivery state.