Electrical connectors – With circuit component or comprising connector which fully... – Termination circuit
Reexamination Certificate
2000-02-04
2001-04-17
Abrams, Neil (Department: 2839)
Electrical connectors
With circuit component or comprising connector which fully...
Termination circuit
C439S352000, C439S942000
Reexamination Certificate
active
06217388
ABSTRACT:
TECHNICAL FIELD
The present invention relates to matable electrical connection systems, and more specifically, to an electrical connector for use in a supplemental inflatable restraint (SIR) system.
BACKGROUND OF THE INVENTION
It is well known in the art to provide a supplemental inflatable restraint (SIR) system for the protection of vehicle occupants. A typical SIR includes a housing, an airbag normally stored in the housing, and an inflator for discharging gas to inflate the airbag. Typically, the inflator is activated in response to a predetermined amount of vehicle deceleration.
It is known to mount an air bag of a SIR system in an instrument panel, a door panel, as well as within a steering wheel. Air bag inflation in triggered by a device known as an initiator. The initiator is connected to an electrical connector which is operatively coupled to a pair of wires leading from a controller. The space available for an airbag is generally limited, especially for steering wheel mounted air bags. Therefore, it is desirable to minimize the size of any component within a SIR system, including the electrical connector.
U.S. Pat. No. 5,586,902 to Hopf et al, discloses an electrical connector for coupling wires to an initiator. The '902 patent teaches a connector having a pair of 90° terminals coupled to wires leading through a ferrite filter element disposed longitudinally within a connector housing. The geometry of the connector of the '902 patent requires the wires to be inserted through the filter element before being crimped to the 90° terminals. Although the '902 patent discloses a good electrical connector for an SIR system, it has a number of deficiencies. The location of the filter element results in a larger connector that requires more space. Furthermore, the location of the filter element substantially burdens the manufacturing process of the connector.
Therefore, it is desirous to provide an electrical connector for an SIR system having a reduced size. It is further desirous to provide an electrical connector for an SIR system which allows more efficient manufacturing of the connector and its components.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an electrical connector for use in a SIR system having a controller and an initiator comprising a connector housing which has a plug portion with a filter cavity disposed therein. A pair of apertures are disposed within the plug portion of the connector housing which are in communication with the filter cavity. A filter element is disposed within the filter cavity. The filter element has a pair longitudinally disposed receptacles, which when installed in the filter cavity align with the pair of apertures. A pair of terminals, each of which has a barrel portion and a crimp portion, are disposed within the connector housing. The crimp portion is provided to receive a wire leading from the controller. The barrel portions of each terminal is disposed within one of the receptacles within the filter element, whereby the barrel portions are aligned with the pair of apertures so is to receive initiator pin terminals.
A feature of the present invention is that the connector housing has a reduced size as a result of locating the filter element within the plug portion of the connector housing.
Another feature of the present invention is that the barrel portions of the terminals are located within the filter element to reduce the cost of producing an SIR system. By locating the barrel portions of the terminals in receptacles of the filter element, the terminals may be processed on automatic cutters. Furthermore, installation of the filter element into the connector housing may be automated as well.
Another feature of the present invention is the connector housing has a wire shelf portion which has a pair of laterally disposed wire channels for guiding each of a pair of wires to one of the pair of terminals.
Another feature of the present invention is that the connector housing articulates with a retaining cap which has a connector position assurance (CPA) portion and a cover portion connected by a pair of flexible straps.
Another object of the present invention is to provide a method for assembling an electrical connector for use in a SIR system having a controller and an initiator, comprising the steps of providing a connector housing which has a plug portion with a filter cavity. The housing also has a pair of apertures disposed within the plug portion, and in communication with the filter cavity. The filter element has a pair of longitudinally disposed receptacles inserted within the filter cavity, where each of the receptacles are aligned with one of the pair of apertures. A pair of terminals having a barrel portion disposed generally perpendicular to crimp portion is also provided. The crimp portion of the terminal is crimped to a wire. Each of the terminals are inserted in the housing where the barrel portion of each of the pair of terminals is inserted into each of the pair of receptacles within the filter element.
It is another object of the present invention to provide a terminal for an electrical connector, comprising a barrel portion generally perpendicular to a crimp portion, the barrel portion having a contact end and a open end that is adjacent to the crimp portion. The barrel portion is provided to receive a pin terminal, while the crimp portion is provided to receive and secure the terminal to a wire. A generally U-shaped terminal transition area is disposed between the barrel portion and the crimp portion. The terminal transition area has a smaller diameter section, a neck down portion and a formed transition. The neck down portion is disposed between the open end of the barrel portion and the smaller diameter section. The formed transition is disposed between the smaller diameter section and the crimp portion. A position tab is disposed adjacent to the barrel portion for locating the terminal within the electrical connector.
Other objects and features of the present invention will become apparent to those skilled in the art in light of the following detailed description of the preferred embodiment of the present invention, setting forth the best mode of the invention contemplated by the inventors and illustrated by the accompanying sheets of drawings.
REFERENCES:
patent: 5241910 (1993-09-01), Cunnungham et al.
patent: 5314345 (1994-05-01), Chaly et al.
patent: 5514006 (1996-05-01), Getselis et al.
patent: 5586902 (1996-12-01), Hopf et al.
patent: 5853298 (1998-12-01), Pacher
patent: 5876231 (1999-03-01), Pacher
Abrams Neil
Delphi Technologies Inc.
Dinh Phuong
Jones Richard A.
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