Electrical plug connector for a safety restraint system

Abstract

The present invention relates to an electrical plug connector for a safety restraint system, preferably for an airbag ignition system. The plug connector includes at least two contact terminals assigned to the plug connector and a shorting clip that is configured to short-circuit the at least two contact terminals in an uncoupled or incorrectly coupled condition of the plug connector. The shorting clip includes at least two contact blades. Each contact blade is electrically connected with one of the at least two contact terminals. Each of the contact blades includes at least one cutting edge. The cutting edges contact each other such that one edge cuts the other when the plug connector is in an uncoupled or incorrectly coupled condition.

Claims

1. An electrical plug connector, comprising: at least two contact terminals assigned to the plug connector; and a shorting clip that is configured to short-circuit the at least two contact terminals in an uncoupled or incorrectly coupled condition of the plug connector, wherein the shorting clip has two contact blades, wherein each contact blade is electrically connected with one of the at least two contact terminals, wherein each contact blade has a cutting edge, and wherein the cutting edges contact each other, such that one cutting edge cuts the other when the plug connector is in in an uncoupled or incorrectly coupled condition.

2. The electrical plug connector according to claim 1, wherein at least one of the two contact blades has a bendable portion, wherein the bendable portion is bent to separate contact between the cutting edges of the two contact blades upon correct coupling of the plug connector.

3. The electrical plug connector according to claim 1, further comprising a connector position assurance (CPA) member, wherein the CPA member is insertable into a housing of the plug connector and wherein upon full insertion into the housing of the plug connector the CPA member separates contact between the at least two cutting edges of the two contact blades.

4. The electrical plug connector according to claim 1, wherein contact between the at least two cutting edges of the two contact blades is configured to be separated upon correct coupling to a corresponding counter connector of the plug connector due to a mechanical contact with a separator of the counter connector.

5. The electrical plug connector according to claim 1, wherein the cutting edges of the at least two contact blades do not contact any structure of the plug connector if the plug connector is correctly coupled to a corresponding counter connector.

6. The electrical plug connector according to claim 1, wherein the cutting edges of the at least two contact blades are punched edges having a punching burr.

7. The electrical plug connector according to claim 1, wherein a contact area of a contact between the at least two cutting edges is smaller than 1 mm.sup.2.

8. The electrical plug connector according to claim 1, wherein at least one terminal and at least one contact blade are integrally formed as one part and wherein each contact blade is integrally formed with a respective one of the at least two contact terminals.

9. The electrical plug connector according to claim 1, wherein the two contact blades are not gold plated.

10. The electrical plug connector according to claim 1, wherein the cutting edges of the at least two contact blades are configured to execute a relative cutting movement to each other while establishing electrical contact between the cutting edges.

11. The electrical plug connector according to claim 1, wherein the cutting edges of the at least two contact blades are configured to at least partly remove residual layers deposited on the cutting edges in order to improve electrical contact and wherein the residual layers to be removed may include oxide layers, deposited contaminants, and/or fogged plastic.

12. The electrical plug connector according to claim 1, wherein at least one of the cutting edges have an included angle of less than 90.

13. A method of assembling an electrical connector assembly, comprising the steps of: providing a plug connector including at least two contact terminals assigned to the plug connector and a shorting clip configured to short-circuit the at least two contact terminals in an uncoupled or incorrectly coupled condition of the plug connector, wherein the shorting clip further includes at least two contact blades, wherein each contact blade is electrically connected with a respective one of the at least two contact terminals, and wherein each of the contact blades includes at least one cutting edge, which cutting edges contact each other, such that one edge cuts the other, when the plug connector is in in an uncoupled or incorrectly coupled condition; providing a corresponding counter connector; and mating the plug connector with the corresponding counter connector, wherein contact between the at least two the cutting edges of the contact blades of the plug connector is separated upon correct coupling the plug connector to the corresponding counter connector.

14. The method according to claim 13, further comprising the steps of: providing a connector position assurance (CPA) member; and inserting the CPA member into a housing of the plug connector in order to separate the contact between the at least two cutting edges of the two contact blades upon full insertion of the CPA member into the housing of the plug connector.

15. The method according to claim 13, further comprising the step of separating the contact between the at least two cutting edges of the two contact blades upon correct coupling the plug connector to a corresponding counter connector due to a mechanical contact with a separator of the counter connector.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) The present invention will now be described, by way of example with reference to the accompanying drawings, in which:

(2) FIG. 1 shows a schematic illustration of a plug connector in an exploded view;

(3) FIGS. 2A-D show a schematic illustration of a terminal assembly, including a shorting clip, and

(4) FIGS. 3A-3B show a schematic cut view of an electrical plug connector including a CPA member in an uncoupled and a correctly coupled condition.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1 shows a non-limiting example of an electrical plug connector, hereinafter referred to the plug connector 1 for a safety restraint system, preferably for an airbag ignition system. The plug connector 1 includes a housing, wherein the housing includes at least two parts, a main part 400 and a cover 200. The cover 200 is configured to receive a terminal assembly 500, including at least 2 terminals 521, 522. The two terminals 521, 522 are configured to be connected with corresponding pins of a corresponding counter connector. The terminal assembly 500 further includes a shorting clip 530. The shorting clip 530 is configured to short circuit the at least two contact terminals 521, 522 in an uncoupled or an incorrectly coupled condition of the plug connector. Further, a welding or soldering member 511, 512 is configured to be welded or soldered to a corresponding signal line 601, 602. Other suitable electrically conductive connecting methods are also possible. Further, the plug connector 1 includes a connector position assurance (CPA) member 100 which is insertable into the housing 200, 400 of plug connector 1. The CPA member 100 will upon full insertion into the housing 200, 400 of the plug connector 1 separate the contact between the at least two cutting edges (not shown in FIG. 1) of the shorting clip 530.

(6) FIGS. 2A to 2D show the terminal assembly 500 in greater detail. Thereby FIG. 2A shows the terminal assembly 500 including two terminals 521 and 522, which are configured to be connected to corresponding pins of a counter connector. Further, each of the terminals 521, 522 is assigned to a respective contact blade 533, 534. These contact blades 533, 534 include a bendable portion 531, 532 which bendable portion 531, 532 is bent to separate the contact between the cutting edges 535, 536. The cutting edges 535, 536 are shown in greater detail in FIG. 2C. Still further, each terminal is assigned with a respective welding or soldering member 511, 512. As can be seen, the contact terminal and the corresponding contact blade 533, 534 are integrally formed as one part. Preferably, they are formed from a single metal sheet for example by punching, embossing, and other suitable sheet forming techniques.

(7) FIG. 2B shows the terminal assembly 500 of FIG. 2A from a different view. In particular, the terminal assembly is shown with view on the contact blades 533, 534. Further, FIG. 2C shows a detailed enlarged view of the contact blades 533, 534 of FIG. 2B. As can be best seen in FIG. 2C, each contact blade 533, 534 include at least one cutting edge 535, 536. These cutting edges 535, 536 contact each other such that one edge cuts the other in the contact area 537. The cutting edges are preferably sharp edges and most preferably punching edges, having a punching burr 538. Thus, the contact area 537 can be significantly reduced and the contact pressure is increased under constant contact force. Further, due to the cutting of the cutting edges with one another, residual layers such as oxide layers, fogged plastic layers or contaminant layers or the like can be cut. FIG. 2D shows the terminal assembly 500 in a side view. In particular, the contact blades 533 and 534 of the shorting clip 530 are shown. As can be seen, the cutting edges 535, 536 of the contact blades 533, 534 enclose an angle which is different from 0 and 180, so that one edge cuts the other.

(8) FIG. 3A shows the plug connector 1 in a cut view, wherein the plug connector 1 is in an uncoupled condition. The cover 200 and main part 400 of the housing of the plug connector 1 are engaged with each other. A connector position assurance member (CPA) member 100 is installed within the housing 200, 400. A separator 120 of the CPA member 100 is arranged between the contact blades 533, 534. The cutting edges of the contact blades 533, 534 are in contact with each other in the shown uncoupled condition of the plug connector 1. The contact blades 533, 534 include a bendable portion 531, 532, which bendable portion is bent outwardly if the CPA member 100 is inserted fully into the housing 200, 400 of the plug connector 1. Thereby, the contact between the cutting edges is opened by the separator 120.

(9) This coupled condition can be seen in FIG. 3B. As shown in FIG. 3B, the CPA member 100 is fully inserted into the housing 200, 400 and the plug connector 1 is correctly coupled to a corresponding counter connector 700. By contacting and bending the contact blades 533, 534 by the separator 120 of the CPA member 100, the electrical contact between the cutting edges of the contact blades 533, 534 is opened. Since the CPA member 100 is only insertable if the plug connector 1 is correctly coupled to the corresponding counter connector 700, the shorting clip 530 and in particular the contact between the cutting edges can be used for electrical or electronic monitoring the coupling condition.

(10) While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, primary secondary, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.