WO2007131535A1

WO2007131535A1 - Modular connector system

Info

Publication number: WO2007131535A1
Application number: PCT/EP2006/005331
Authority: WO
Inventors: Vincent Regnier; Michael Gunreben; Johannes Hafner
Original assignee: Fci
Priority date: 2006-05-15
Filing date: 2006-05-15
Publication date: 2007-11-22

Abstract

A modular connector system for electronic equipment, in particular for use in an airbag ignition system, is presented, which comprises standardised holding means consisting of at least a holder (10) and a cover (20), and a plurality of different interface means (30). The holding means is adapted to hold an interface means in a predefined position and whereby the different interface means are provided to this purpose with standardised coupling elements (31) corresponding to the holding means. In this way a single standardised holding means may be fitted with different interface means, forming a connector.

Description

MODULAR CONNECTOR SYSTEM

1. Field of the invention

The invention relates to a modular connector system for electronic equipment, in particular for use in an airbag ignition system.

2. Prior Art

Electrical connectors according to the prior art are commonly formed of injection molded plastic parts. Usually each connector casing consists of several parts that have to be assembled.

WO 03/103102 Al shows for example an electrical connector according to the prior art, comprising a plug connector body, which holds and guides the terminals and a further cover part, which holds the plug connector body and the terminals together and which prevents moisture or dust from entering the connector body.

The parts of each connector are specifically designed and shaped according to the individual requirements of each connector situation. Since the connectors and the corresponding counter-part connectors are normally produced and designed by the same manufacturers the number and variations of different connectors can be kept low, since the manufacturers naturally try to keep the variety and thus the complexity as low as possible. However, in certain situations the design and production of connectors and counter-part connectors is independent from each other. This is for example the case in certain areas of automotive airbag development, wherein each airbag manufacturer has different specification for its electronic equipment and thus the corresponding electronic interfaces. Very often the interface equipment, e.g. the electrical connection to control and monitoring units, is realized and provided by different manufacturers, who have to adapt their connectors to the specification and design parameters predetermined by the airbag manu- facturer. Since the manufacturer of the interface equipment cannot freely choose his connector design, and thus keep the variety of different connector versions as low as possible, he has to develop and produce a relatively large number of differ- ent connectors to match the individual specifications and parameters of different airbag manufacturers and airbag designs.

As a result the manufacturer of the interface equipment has to manage a large va- riety of different connector versions and parts, and he has to purchase and maintain a large number of tools needed to produce many different connector versions. Further, since each connector has a different shape it is difficult to assemble the connectors automatically by a single machine. Thus, either several assembling machines have to be provided or a single assembly machine has to be retooled for every connector version. This all leads to higher costs, increased production time and generally a higher complexity of the whole production process with higher error-rates.

It is therefore the object of the present invention to provide a connector respec- tively a connector system, which reduces or minimizes the above described problems and disadvantages.

3. Summary of the invention

According to the invention a modular connector system for electronic equipment, in particular for use in an airbag ignition system is presented, which comprises standardised holding means consisting of at least a holder and a cover, and a plurality of different interface means. The holding means is adapted to hold an interface means in a predefined position and the different interface means are provided to this purpose with standardised coupling elements corresponding to the holding means, hi this way a single standardised holding means may be fitted with one appropriate interface means chosen from the plurality of interface means, to form a connector which is adjusted for a specific interface situation. This modular connector system can also comprise optional devices each in a plurality of different options. By using standardised holding means the number of different parts for a large number of different connector versions can be minimized. Further, since the holding means are standardised and the different interface means are all provided with standardised coupling means it is possible to have a single machine for the assem- bly of different connector versions, whereby the settings need not or only marginally to be changed from one version to the other.

In a preferred embodiment the interface means is provided with a frame part which is standardised and similar to different interface versions. Attached to or integrally formed with the frame part is an individual interface part, which is different for different connector versions. The interface means can thus be fitted to the holder means via the standardised frame part, although the individual interface part, which is actually responsible for the electrical connection with a counter-part connector, may be formed in many different shapes. The frame part thus serves as standardised coupling element.

Preferably, the modular connector system according to the invention further comprises a connector position assurance device (CPA), which is movable between an open position and a closed position. The connector position assurance device can only be moved in the closed position, when the interface means is fully coupled to a corresponding counter-part connector. In this way, a user of the connector system may easily verify whether the connection is fully established or whether connector and corresponding counter-part are only partially plugged into each other. The CPA may be guided on the holding means by e.g. appropriate guide slots and grooves. Alternatively the CPA may be guided on the interface means, or it may be guided by both.

Preferably the CPA is standardised to act together with the holding means and the plurality of interface means. By providing standardised holding means and stan- dardised coupling elements on the plurality of interface means it is advantageously possible to use a standardised CPA with the modular connector system, - A -

thus reducing the number of different parts necessary for different connector versions even further.

Further, the connector position assurance device provides preferably a secondary locking between holding means and interface means, to prevent an accidental release of the interface means from the holding means. This can e.g. be established by locking protrusions on the CPA, which, when the holding means and the interface means are coupled respectively assembled with each other, interlocks the coupled respectively assembled elements.

In a preferred embodiment, the CPA is provided with two resilient locking arms, which locking arms in the open position of the CPA engage the holding means and which locking arms in the closed position of the connector position assurance device further engage the interface means, thus providing an additional locking mechanism between holding means and interface means.

In a still further preferred embodiment, the CPA comprises a short circuit activation / deactivation element. This is particularly preferred for the case of airbag ignition systems, hi e.g. airbag ignition systems the electrical connection between the igniter and the control system is a very sensitive point in the restraining system, since any uncontrolled fluctuations in potential which arise on the igniter's contact pins can result in the airbag being triggered unintentionally. To prevent an uncontrolled ignition of the airbag system, the counter-part connector, i.e. the igniter, in such systems may be provided with a shorting bridge between its contact pins. As long as the shorting bridge short-circuits the contact pins an ignition of the airbag is not possible. The shorting bridge is only released from these contact pins on complete and correct insertion of the interface means. Advantageously this is realized by providing the CPA with a short circuit activation / deactivation element, which releases the shorting bridge only, when the CPA is in the fully closed position, hi this way the CPA not only verifies whether the connection is fully established but it also arms the airbag ignition system, for example. In a preferred embodiment the short circuit activation / deactivation element is in the form of a protruding leg provided on the connector position assurance device, which leg is adapted to release the shorting bridge provided in the counter-part connector, when the CPA is pressed in the fully closed position. In another preferred embodiment the short circuit activation / deactivation element(s) consists of the locking arm(s) of the CPA.

In a further preferred embodiment the CPA is standardised and only the short cir- cuit activation / deactivation element is adapted to different connector versions. As it was explained above, the holding means is standardised, thus the elements or parts of the CPA acting together with the holding means and preferably the interface means can be easily standardised too. However, since the specification of the counter-part connector and thus the specification of any shorting bridges provided in the counter-part connector is individually defined by different manufacturers, it is often advisable to adapt the short circuit activation / deactivation element, like for example a protruding leg or a locking arm provided on the CPA, individually. Since the major part of the CPA is still standardised the same may still be handled by a single assembly machine without the need for any further adjustments of the same. Thus, the inventive modular connector system preferably comprises a plurality of different CPAs, whereby the parts of the CPA acting together with the holding means and preferably the interface means - like for example the coupling and locking elements provided on the CPA - are standardised and the short circuit activation / deactivation elements are different and adjusted according to the spe- cific connector situation.

In a preferred embodiment the wiring of the connector is guided through the holding means and ends in terminals, which are arranged in the interface means. In a most preferred embodiment the holding means is provided with a strain-relief for the terminals and/or for the electrical wiring, to prevent a detachment of the wir- ing from the terminals or a detachment of the terminals themselves, when a pulling force is applied to the wiring.

In a further preferred embodiment, the interface means are provided with primary locking means for connecting with a corresponding counter-part. Preferably the primary locking means are arranged together with the individual interface parts of the interface means. In this way it is possible to adapt the interface means to a number of different counter-part connectors without the need for adapting the holding means. Thus only the interface means have to be adapted and be different for different connector situations and the holding means can be standardised and be the same for a large number of different connector versions.

Still further, in a preferred embodiment the interface means is provided with coding means to ensure that the interface means may only be connected with corre- spondingly coded counter-part connectors. Such a coding may be realized by correspondingly shaped primary locking means on interface means and counter-part connector, as it was described above, however, preferably the coding means are independent from the primary locking means. This allows for a larger variety of different codes, since the form and shape of the coding means can be chosen quite freely.

In another preferred embodiment the electrical contacts in the interface means are arranged scoop-proof to prevent electrical connection in the case of an incorrect mating of interface means and a counter-part connector. This may be realized by providing non-conductive guide passages for the terminals in the interface means. These guide passages surround the terminals in a way that an electrical connection may only be established, when the interface means is correctly plugged with a corresponding counter-part connector. For example, the corresponding terminals on the counter-part connector may be in the form of pins that have to be inserted in the free ends of the non-conductive guide passages to some extend, in order to contact the terminals in the interface means. An accidental connection of the ter- minals in the interface means with some other kind of electrical conductor can thus be ruled out.

In a further preferred embodiment, the interface means is provided with grounding means to connect the interface means to ground.

In another preferred embodiment the connector means and/or the interface means are provided with electromagnetic interference damping devices (EMI). These damping devices may be realized in the form of a coil or a ferrite block. In a par- ticular preferred embodiment these EMI devices are standardised to fit into the standardised holding means.

With the modular connector system of the present invention it is for example possible to serve a large variety of different connector specifications with a minimum of different parts. For example, some manufacturers of counter-part connectors, like e.g. manufacturers of airbag ignition systems, may use different coding elements but the same shorting bridges on their connectors. In this case only the interface means, and preferably only the actual interface part of the interface means, has to be adapted, whereas the CPA with the short circuit activation / deactivation element and the holding means is standardised and always the same. On the other hand, in some situations only the shorting bridge of the counter-part connector may vary, such that the interface means and the holding means may be the same and only the short circuit activation / deactivation elements on the CPA are adapted.

By adapting only those parts on the CPA and the interface means that absolutely have to, like for example the short circuit activation / deactivation element(s) on the CPA or the actual interface part(s) of the interface means, it is possible to mold the different "versions" of interface means and CPAs using a single mold for each, where the particularities are obtained through the change of insert portions in said molds. 4. Description of the preferred embodiments

In the following the invention is described exemplarily with reference to the enclosed figures, in which

Fig. 1 is an exploded view of an assembly of one connector according to the connector system of the present invention;

Fig. 2 is an exploded view of another connector according to the connector system of the present invention;

Fig. 3 is a schematic view of an assembled connector,

Fig. 4 is a schematic view of the backsides of two connector version;

Figs. 5 A to 5C are schematic views of different interface means of the connector system;

Figs. 6A to 6C are schematic views of different interface means of the connector system seen from the backside.

Fig. 1 is an exploded view of the assembly of a connector according to the connector system of the present invention. The connector comprises a holding means consisting of a holder 10 and a cover 20. Arranged between the holder 10 and the cover 20 is an interface means 30 for connection with a corresponding counter- part connector (not shown). The lower part of holder 10 is provided with two opposing guide passages 11 and 12, which run essentially perpendicular to the connector mating axis. The interface means 30 is provided in its upper part with a frame 31, which frame has two opposing guide surfaces 32 and 33. For assembly of holder 10 and interface means 30 the guide surfaces 32 and 33 of frame 31 are pushed into the respective guide passages 11, 12 until a protrusion 34 provided on frame 31 blocks a further movement. In this way the assembly direction of holder and interface means is perpendicular to the mating direction of the connector, thus preventing a loosening of the interface means from the holder, when the assembled connector is pulled out from a corresponding counter-part connector.

In its lower part the interface means 30 is provided with a circular shaped interface part 35 for connecting with a corresponding counter-part connector. Further the interface means is provided with primary locking means in the form of resilient locking arms 36 provided with locking protrusions 37 on their free ends. When the interface means 30 is mated, the locking arms 36 are guided in respec- tive locking apertures provided in the counter-part connector and bend to some extend inwardly towards the circular interface part 35. When fully mated the locking arms 36 are allowed to spring back to their original position and the locking protrusion 37 moves into corresponding locking apertures provided in the counterpart connector, thus locking the connectors.

Provided in the interface means are two terminals 40, which extend to corresponding passages in the interface means. The terminals 40 are provided with electronic interference damping devices (EMI) in the form of a ferrite block 41, which has two through holes 42 to close in on the lower free ends of the terminals. The up- per free ends of the terminals 40 are connected to respective wires 43.

The cover 20 is provided with lower locking apertures 21 and upper locking apertures 22. In assembled condition the lower apertures 21 fixingly receive the protrusions 34 of the interface means 30. The upper locking apertures 22 fixingly receive corresponding locking protrusions 13 provided in the upper half of the holder 10. In this way the cover 20 holds holder and interface means together. Additionally the holder may be provided with a locking aperture 14 provided in the guide passages 11 and 12. The guide surfaces 32 and 33 of the interface means 30 are provided with corresponding locking protrusions 38, which protrusions fit into the locking apertures 14, when interface means 30 and holder 10 are fully mated. The side of the holder 10 directed to the cover 20 is provided with guide slots 15 for accepting the wires 43. hi the upper part of the slots 15 the same are provided with a constriction (can best be seen from Figs. 4A and 4B) which fixingly re- ceives the wires 43 and serves as a strain relief for the wires 43.

The connector according to Fig. 1 is further provided with a connector position assurance device (CPA) 50. The CPA 50 has two resilient locking arms 51 and two rigid locking arms 52. On their free ends the resilient locking arms 51 are provided with locking teeth 53. After holder 10, interface means 30 and cover 20 are assembled the CPA 50 is fitted onto the assembled connector by pushing it in the direction of the mating axis into the holder. The two resilient locking arms 51 fit to the left and the right of a bridge 16 provided in the holder. The locking teeth 53 engage the bridge 16 such that the CPA 50 is hold in a first and "open" posi- tion on the holder. The teeth 53 prevent the CPA 50 from being accidentally detached from the holder. In this "open" position the CPA 50 sticks out from the top of holder 10. When the assembled connector is finally mated, i.e. the interface means is connected to a counter-part connector, the CPA 50 is further pushed downwardly in the mating direction of connector and counter-part connector until locking arms 17 provided on the holder engage respective locking apertures in the inside of CPA 50. In this "closed" position the CPA 50 is flush with the top of the holder 10 and indicates that the connector and counter-connector are fully mated. In this position the rigid locking arms 52 are arranged between the circular interface part 35 and the inner side of locking arms 36 of interface means 30, prevent- ing the locking arms 36 from being bent inwardly. Thus, the interface part 35 cannot be retracted from the corresponding counter-part connector with which it is mated.

Additionally, when the CPA 50 is fully pushed downwardly into holder 10, the resilient locking arms 51 may engage a further bridge (not shown) provided in the interface means 30, similar to the bridge 16 provided in holder 10. Thus CPA 50 can provide an additional locking function between holder 10 and interface means 30.

In the above described connector assembly holder 10, cover 20 and CPA 50 are standardised and can be used for a variety of different connector versions. Only interface means 30 has to be adapted to the specific connector situation and in particular only the lower part of interface means 30, the interface part 35, has to be adapted to different connector versions. The frame 31 of interface means 30 is standardised in order to cooperate with holder 10 and cover 20, irrespective of the interface part 35.

Fig. 2 differs from Fig. 1 in that the EMI device used is in the form of a coil 60, which cooperates with terminals 45 respectively 46. The other parts of the connector are the same as in Fig. 1 and are thus not described in more detail. This is another way to illustrate the modularity according to the invention.

Fig. 3 is a schematic view of an assembled connector example 300. The connector 300 comprises a holder 310, a cover 320, an interface means 330 and a CPA 350. In Fig. 3 the CPA is shown in the "closed" position and it can be seen that CPA 350 is flush with the top side of holder 310. The rigid locking arm 352 of CPA 350 is arranged between the circular locking part 335 of the interface means 330 and the resilient locking arm 336, thus preventing the locking arm 336 from being bent inwardly. As can be seen from the figure, the assembled connector is preferably of the type of a 180° connector, i.e. the wires are aligned with the mating direction of connector and counter-part connector.

Fig. 4 is a schematic view of an exemplary connector seen from the backside with the cover taken off. As can be seen from the figure the holder 410 is provided on its backside with guide slots 415 for the wires 443. Additionally the guide slots 415 are provided with constrictions 416 in the form of ribs which hold the wires 443 and serve as a strain relief for the same. Figs. 5A, 5B and 5C show different versions of interface means 530A, 530B and 530C which are adapted to cooperate with standardised holdings means as for example the holding means of figures 1 and 2 described above. As can be seen from the figures, all interface means 530A, 530B and 530C have standardised frame parts 53 IA, 53 IB and 531C which are similar to the frame part 31 described in connection with Fig. 1. However, the interface means 530A, 530B and 530C have different interface parts 535A, 535B and 535C for connecting with different kinds of counter-part connectors. Thus by using different interface means together with standardised holding means it is possible to build a large number of different connectors with a minimum of different parts. At the same time it is possible to assemble the different connector versions on a single machine, since the holding means and the coupling means provided on the interface means are standardised and can thus be handled with a single set of assembly tools, irrespective of the form and shape of the rest of the interface means.

Figs. 6A 6B and 6C also show different versions of interface means 630A, 630B and 630C with standardised frame parts 63 IA, 63 IB and 631C for connecting with standardised holding means. The interface means have different interface parts 635A, 635B and 635C adapted for different versions of counter-part connectors.

The holdings means, interface means and connector position assurance devices according to the invention and described above are preferably injection molded plastic parts.

Of course, the scope of invention is not limited to a 180° connector and one can easily derive for instance a right angle connector implementing the modularity above described.

Claims

1. Modular connector system for electronic equipment comprising:

- standardised holding means consisting of at least a holder (10) and a cover (20), and

- a plurality of different interface means (30); whereby the holding means is adapted to hold an interface means in a predefined position and whereby the different interface means are provided to this purpose with standardised coupling elements (31) corresponding to the holding means, such that a single standardised holding means may be fitted with different interface means, forming a connector.

2. Modular connector system according to claim 1, wherein the interface means (30) is maintained in the holder (10) with the cover (20).

3. Modular connector system according to claim 1 or 2, wherein the interface means (30) comprises locking protrusions (38) for fitting in locking apertures provided (14) in the holder (10).

4. Modular connector system according to any on of the preceding claims, wherein the cover (20) comprises locking means (21, 22) for cooperating both complementary with locking means (13, 34) provided respectively on the holder (10) and the interface means (30).

5. Modular connector system according any on of the preceding claims, further comprising a connector position assurance device (50), which is movable between an open position and a closed position, whereby the connector position assurance device can only be moved in the closed position, when the interface means (30) is fully coupled to a corresponding counter- part connector.

6. Modular connector system according to claim 5, wherein the connector position assurance device (50) is standardised to act together with the holding means (10, 20) and the plurality of interface means (30).

7. Modular connector system according to claim 5 or 6, wherein the connector position assurance device (50) provides a secondary locking between holding means (10, 20) and interface means (30), to prevent an accidental release of the interface means from the holding means.

8. Modular connector system according to any one of claims 5-7, wherein the connector position assurance device (50) is provided with two resilient locking arms (51), which locking arms in the open position of the connector position assurance device engage the holding means (10, 20) and which locking arms in the closed position of the connector position assurance de- vice engage the interface means (30), thus providing a further locking mechanism between holding means and interface means.

9. Modular connector system according to any one of claims 5-8, wherein the connector position assurance device (50) comprises a short circuit activa- tion / deactivation element.

10. Modular connector system according to claim 9, wherein the short circuit activation / deactivation element is in the form of a protruding leg provided on the connector position assurance device, which leg is adapted to release a shorting bridge provided on the counter-part connector.

11. Modular connector system according to any of claims 5 to 10, wherein the parts of the connector position assurance device (50) acting together with the holding means and the interface means are standardised and the short circuit activation / deactivation element is adapted to different connector versions.