SHUNT-LESS SQUIB CONNECTOR BACKGROUND OF THE INVENTION

1. Field of the Invention The invention relates to an electrical connector and, more particularly, to a connection of a cover to a housing of an electrical connector.

2. Brief Description of Prior Developments

U.S. Pat. Publication No. 20140045361 , discloses an airbag connector system comprising a plug connector, and a retainer configured to be inserted into a corresponding holder. The plug connector comprises a connector and a latching arm assigned to the connector housing, whereby the plug connector is configured to be mountable with the retainer. The connector system comprises a deflection portion for causing the latching arm to deflect upon mounting of the plug connector with the retainer. The deflection portion is shaped such that the deflection provides increasing resistance against further movement of the plug connector. The connector system further comprises a release portion configured to enable a release deflection of the latching arm. The release portion is shaped so the release deflection does not provide resistance against further movement of the plug connector. Still further the connector system comprises a latching portion configured to allow the latching arm to lock the plug connector. Referring also to FIGS. 1 and 2, perspective view of a plug connector (100) to be used in connection with an airbag connector system. The plug connector (100) is provided with a connector housing (101 ) which is closed by a lid (104). The connector housing (101 ) is provided with a connection tube (160) with a safety ring (161 ). The plug connector (100) is further provided with two latching arms (102) which are formed integrally with the connection tube (160). Latching sections (130) of the latching arms (102), which are provided with inwardly directed latching projections (131 ) (see also FIG. 2), are cut out of the connection tube (160). The latching arms (102) are connected to the connection tube (160) via flexible portions (connection bridges) (141 ) which are parts of intermediate portions of the latching arms (102). Further, the latching arms (102) are provided with release members (150) which can be pressed inwardly towards the connector housing (101 ) such that the latching arms (102) can be pivoted around pivot members (140), i.e. around said intermediate portions in between the flexible portions (141 ).

The shortcomings of the connector system of the patent include the following: The plug connector (100) latching arms (102) may not achieve retention force (force opposite in direction of insertion force (401 )) in the range of 50N-200N, because utilizing only the latching arms (102) in withstanding the retention force may cause the latching arms (102) to slip out of the retainer prematurely or experience mechanical fractures/deformities, all leading to a poor retention force performance.

The design disclosed in this patent has flaws in maintaining stability during insertion, because the angled surfaces (133) of the inwardly directed latching projections (131 ) rest on the deflection portions (202) of the retainer (200) while the threshold value of the force required in insertion direction (401 ) is to be achieved. It is inherently likely that one angled surface (133) will be deflected outwardly and past deflection portion (202) before the other angled surface (133), resulting in an imbalanced/uneven insertion of the plug connector (100). This scenario presents itself more likely should the plug connector (100) be mated to the retainer (200) with an insertion force (401 ) not centrally applied on the lid (104) or the plug connector (100). The latching arms (102) are connected to the plug connector (100) via the flexible portions (connection bridges) (141 ) which are parts of the intermediate portions of the latching arms (102). These release members (150) can be pressed inwardly towards the connector housing (101 ) such that the latching arms (102) can be pivoted around pivot members (140), i.e., around the intermediate portions in between the flexible portions (141 ). These flexible portions (141 ) may result in high forces required to extract the plug connector (100) from the retainer (200) and may be susceptible to torsional mechanical failure due to the fact that much of it is fused with the connection tube (160), resulting in overly rigid design that allows for little flexibility in translational or rotational movement.

US Patent No. 5616045 discloses a squib connector for an automotive air bag assembly having a squib, the squib having a pair of terminal pins anchored thereto and extending upwardly in a squib connector receiving receptacle, said squib connector comprising: a connector housing having a portion adapted to mate with the receiving receptacle of the squib; a terminal assembly disposed within said connector housing for electrical communication with the terminal pins of the squib; a latching assembly extending from said connector housing moveable from a latched position to a released position, said latching assembly having a latching member thereon adapted to mate with a corresponding latch receiving member on the squib when said latching assembly is in the latched position; a connector position and lock assurance assembly comprising a pivoting member hingedly connected to said connector housing for pivoting about an axis to and from a closed position against said connector housing and having an opening therein located to receive said latching assembly when said pivoting member is in the closed position, thereby ensuring said latching assembly is in the latched position.

SUMMARY OF THE INVENTION In accordance with one aspect of the present invention, a shunt-less squib connector is disclosed. The shunt-less squib connector comprises: a cover housing (10) having a pair of latches (30) fused vertically at the edge thereof, wherein the latches (30) are provided with a flexible bridge (20) being formed as one unit with the latches (30), and a latching extrusion (60) is formed at the end of the latches (30); a female housing (130) having a bridge pockets (20) at a position corresponding to the position of the latches (30) of the cover housing (10) and an upper angled reinforcements (140) and a lower angled reinforcements (150) on a torque protection (170) mounted to the female housing , wherein the bridge pockets (180) allow the latches (30) and the flexible bridges (20) be inserted to the female housing (130) ; and a retainer (200) being used to interact with the latches (30); whereby at a full mate position of the squib connector, the latches prevent the connector from being unmated by way of the upper locks (80) and the lower locks (90) which interact with the retainer (200), and when at the connector is at an initial position, the inertial slopes (400) on the latches (30) interact with the retainer (200) preventing the connector from mating with the retainer (200) until a threshold insertion force has been reached. The combination of the cover housing (10) and female housing (130) shall henceforth be referred to as the connector (100).

Yet another object of the present invention is to provide a shunt-less squib connector, wherein the latches (30) being acted as a pivoting point allow the engagement and disengagement of the connector with the retainer (200). Still another object of the present invention is to provide a shunt-less squib connector, wherein the lower end of the latches (30) is provided with a protruding interference (70) having a reinforcement slope (1 10) at the bottom thereof and an inertial slope (400) on the upper surface thereof.

A further object of the present invention is to provide a shunt-less squib connector, wherein the latches (30) are capable to flex in an up and down direction, enabling movement of the latches to further retain the connector in position if a pull force is being applied on the connector. Yet a further object of the present invention is to provide a shunt-less squib connector, wherein upper locks (80) and lower locks (90) are provided on the latching extrusions (60) at the latches (30).

Still a further object of the present invention is to provide a shunt-less squib connector , wherein the inertial slope (400) interact with the upper angled reinforcements (140) on the female housing (130).

Yet a further object of the present invention is to provide a shut-less squib connector, wherein the reinforcement slopes (1 10) engage with the lower angled reinforcement (150) on the female housing (130). Still a further object of the present invention is to provide a shunt-less squib connector, wherein the terminal end of the cover housing (10) is provided with an assembly latches (120) to secure the cover housing (10) to the female housing (130).

Yet another object of the present invention is to provide a squib connector, wherein a latch overstress protection (50) is formed on the cover housing (10) to prevent the flexible bridge (20) from rotating excessively if the extraction mechanism (40) is being depressed.

Yet a further object of the present invention is to provide a shunt-less squib connector, wherein the upper lock (80) is designed to interact with the retainer (200) initially to withstand accidental disengagement.

Yet still a further object of the present invention is to provide a shunt-less squib connector; wherein a stopper slot (410) is provided at the bottom of the female housing to trap the latches (30) thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:

FIGs. 1 A to 1 C show cross-sectional views of a conventional connector and a retainer inserted into a socket for a prior art;

FIG. 2 shows a cut through a connector system with plug connector partially mounted of the conventional connector for a prior art; FIG. 3 is a perspective view of a cover housing of a shunt-less connector incorporating features of the present invention; FIG. 4 is a cross-sectional view of a cover housing of a shunt-less connector shown in FIG. 3;

FIG. 5 is a perspective view of a protruding interference of the latches of the present invention; FIG. 6 is a perspective view of a female housing of a shunt-less connector incorporating features of the present invention;

FIG. 7 is a cross-sectional view of a female housing of a shunt-less connector as shown in FIG. 6 of the present invention;

FIG. 8 is a schematic view showing the bottom of a female housing in accordance with the present invention;

FIG. 9 is a perspective view of a retainer in accordance with the present invention;

FIGs. 10A to 10C are cross-sectional views showing the insertion of the connector (100) into the retainer (200) in accordance with the present invention.

FIGs 1 1 A to 1 1 C are cross-sectional views showing the retention of cover housing with the female housing in accordance with the present invention.

FIGs 12A to 12C are cross-sectional views showing the extraction of the connector (100) from the retainer (200) in accordance with the present invention;

FIG. 13 is a cross-sectional view showing the insertion stability in accordance with the present invention; FIG. 14 is a perspective view showing the insertion stability of the connector in accordance with the present invention;

FIG. 15 is a schematic view showing the high retention force achieved by the present invention; and

FIG. 16 is a schematic view showing the high retention force in accordance with the present invention.

FIGs. 17 A and 17B are cross-sectional views showing a stopper slot being provided at the bottom of the female housing of a shunt-less squib connector in accordance with the present invention.

FIG. 18 is a schematic view showing a high retention force where the stopper slot prevent the latches from slipping in accordance with the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In accordance with a preferred embodiment of the present invention, the connector (100) comprises a cover housing (10) and a female housing (130). Referring to FIGs. 3 and 4, there are shown perspective views of a cover housing (10) of a shunt-less squib connector (100) incorporating features of the present invention. Although the invention will be described with reference to the exemplary embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.

In the preferred embodiment, the cover housing (10) is having one end being provided with a pair of vertically protruded latches (30) which are formed as one piece with a flexible bridge (20). The flexible bridges (20) together with the latches (30) are flexible and are fused together with the cover housing (10). At the top of the latches (30), an extraction mechanism (40) is provided. The extraction mechanism (40) is functioned by allowing a depression thereon, which in turn, pressing against the side of the latches (30) to cause a disengagement of the lower end thereof from the female housing (130). In accordance with the present invention, the latches (30) with the flexible bridges (20) combine to act as a pivoting point which allows the latches (30) to engage and disengaged easily from a retainer (200), which holds the cover housing (10).

The latches (30) having the flexible bridges (20) are made from flexible materials such as plastic materials, for examples, PS, PE, PBT, PP, etc. and thus the latches (30) have the ability to flex in the direction of up and down to enable movement of the latches (30) to further retain the entire connector (100) in position in case a pulling force is applied onto the connector (100). The flexible bridges (20) have the ability to flex in any translational direction in accordance with the present invention.

At the lower end of the latches (30), there is provided reinforcement slopes (1 10) which is used to engage with lower angled reinforcement (150) on the female housing (130). As shown in FIG. 5 and FIG. 3, a latching extrusion (60) is formed at the end tip of the latches (30). The latching extrusion (60) has an upper lock (80) and a lower lock (90). The locks (80), (90) have the features which interact with the retainer (200) to prevent the connector (100) from disengaging while it is fully mated, unless the extraction mechanism (40) has been depressed. The upper locks (80) and lower locks (90) are configured to interact with the retainer (200) to withstand accidental disengagement. There is an inertial slope (400) provided on the latching extrusion (60) which interacts with the upper angled reinforcement (140) on the female housing (130). The inertial slope (400) also interacts with the retainer (200) to achieve an insertion force that has a GO/NO GO effect (inertial force). On the edge of the cover housing 10 adjacent to the latches (30), a latch overstress protection (50) is provided and is used to prevent the flexible bridges (20) from rotating excessively when the extraction mechanism (40) is being depressed. An assembly latch (120) is formed on the terminal end of the cover housing (10) and is used to secure the cover housing (10) to an assembly lock (190) of the female housing (130).

FIGs. 6-8 show the views of the female housing (130) in accordance with the present invention.

FIG. 6 is a perspective view of the female housing (130) having a bridge pocket (180) at one end and the side thereof. The bridge pockets (180) allow the latches (30) and the flexible bridges (20) to be located in when the cover housing (10) is fully secured to the female housing (130). As shown in FIG. 16., the upper angled reinforcement (140) interacts with the inertial slope (400) of the latches (30), and the lower angled reinforcement (150) interacts with the reinforcement slopes (1 10) to provide mechanical reinforcement against high pull forces that the latches (30) will experience when the connector (100) is accidentally disengaged, as well as prevent the latching extrusions (60) from the slipping away and out of the retainer (200) prematurely.

A plurality of balancing ribs (160) are located along the inner circumference of the female housing (130) interface with the retainer (200), as shown in FIGs 8 and 14. The balancing ribs (160) are served to aid the stability/balance of the connector (100) when the connector (100) is mated into the retainer (200). This is vital to the performance of the GO/NO GO function of the connector (100) that is it allows for a single-feeling high threshold insertion force to be encountered during insertion. This is because both the inertial slopes (400) will interact with the retainer (200) together, and allow activation of the connector (100) together. The torque protections (170) are ribs that flank all the upper angled reinforcements (140) and all the lower angled reinforcements (150) on both sides. The torque protections (170) serve to secure the rotational stability of the connector (100). The assembly locks (190) provided to the female housing (130) at the edge and end terminal of the female housing (130) are served to secure the female housing (130) to the cover housing (10) by way of the assembly latches (120).

FIGs. 9 show perspective views of the retainer (200) together with the ignitor holder (210) in accordance with the present invention. FIGs 10A, 10B and 10C illustrate the insertion of connector (100) in accordance with the present invention. The connector (100) is inserted into the retainer (200) being shown in these figures.

FIG. 10A is a cross-sectional view showing the initial position of the connector (100) in accordance with the present invention. At the initial position, the inertial slopes (400) of the latches (30) interact with the retainer (200), preventing the connector (100) from mating with the retainer (200) until a threshold insertion force applied to the connector (100) has been reached. Once the threshold insertion force has been reached, the connector (100) is activated by way of the interaction of the inertial slopes (400) with the retainer (200), causing the latches (30) to rotate about being pivoted by way of the flexible bridges (20). This causes the connector (100) to be at a mating position, for an instantaneous period of time.

As shown in FIG. 10C, the connector (100) is fully at a mated position. At this position, the connector 100 rests in its final position with the latches (30) rotating back to its rest position with the upper locks (80) and lower locks (90) to retainer (200). FIGs. 1 1 A to 1 1 C illustrate retention of the cover housing (10) in accordance with the present invention. When the connector (100) is at a full mated position, as shown in FIG. 1 1 A, a vertical pull force is exerted. The latches (30) prevent the connector (100) from being unmated by way of the upper locks (80) and the lower locks (90) which interact with the retainer (200) to provide a stopping/locking feature.

As shown in FIG. 15 and FIG. 16, as the pull force is applied in higher magnitude, the latches (30) displace downwards by way of the flexible bridges (20) which allow the inertial slopes (400) and the reinforcement slopes (1 10) built on the latching extrusions (60) of the latches (30) to interact with the upper angled reinforcement (140) and the lower angled reinforcements (150) respectively, allowing the latching extrusions (60) to be squeezed/trapped mechanically in between the retainer (200) and the female housing (130), allowing greater mechanical support in withstanding the pull force.

FIGs. 12A to 12C are cross sectional views to show the extraction of the connector (100) from the retainer (200), in accordance with the present invention. The connector can only be unmated by depressing the extraction mechanism (40) at the latches (30). The extraction mechanism (40) allows the upper locks (80) and the lower locks (90) to be displaced and move clear of the retainer (200), allowing the connector to be pulled out.

In accordance with the preferred embodiment of the present invention, the connector provides excellent insertion stability. In the course of insertion of the connector, the balancing ribs (160) serve to guide the female housing (130) into the retainer (200), aligning the connector to be straight. By the time the inertial slopes (400) on the latching extrusions (60) come into contact with the retainer (200), the connector (100) has been straightened. This will help to ensure the two latching extrusions (60) interact with the retainer (200) at the same timing and with equal compression stresses exerted on them. This will ensure the connector achieving an inertial single-feeling insertion force, preventing any uneven/imbalanced activation of the inertial slopes (400).

As shown in FIG. 5, a protruding interference (70) formed on the latching extension (60) is configured to allow the latches (30) to engage on a bigger surface area of the retainer (200) to enhance retention force of the latching extrusion (60). In the preferred embodiment, as shown in FIG. 15, the flexible bridge (20) is characterized in that it is able to rotate about its pivot easily because the flexible cross-sectional profile thereof. The flexible bridge (20) ensures that the force required to depress the extraction mechanism (40) is controlled and the force is kept to a minimum, and also to ensure that there is minimized torsional or rotational stress experienced by the flexible bridge (20). Accordingly, this will help in reducing a probability of the flexible bridge (20) experiencing a torsional or rotational failure during the insertion and extraction phases of the connector.

In accordance with the present invention, the latches (30) of the cover housing (10) preferably are made from plastics such as PVC, PS, PBT, PP or PE, but it can be made from metals, and can also be made as an extension part of the female housing (130). In other preferred embodiments, one latch (30) may be used to lock the connector to the retainer (200), and the latches (30) is self-adjusting or self-rotating when stationary or when it experiences stresses in any direction.

The upper angled reinforcements (140) and the lower angled reinforcements (150) are made from metal rather than from plastic materials, and may be made as an extension of the cover housing (10). The upper angled reinforcements (140) and lower angled reinforcements (150) have flat surface, and are vertically and horizontally supporting the latches (30) by way of the upper locks (80) and the lower locks (90) in accordance with the present invention. The angled reinforcements (140), (150) have a range of angles from 0 to 30 degrees, and preferably within the range of 1 to 20 degrees and most preferably within 0 to 10 degrees.

As shown in FIGS. 8 and 14, the balancing ribs (160) are boss of any profile, for instance, rectangular, square, triangle, circle, etc. that serve to stabilize the insertion of the connector into the retainer (200). The balancing ribs (160) are provided along inner circumference of the connector tube (260) of the female housing (130). As shown in FIGS. 17A and 17B are cross-sectional views showing a stopper slot (410) being provided at the bottom of the female housing of a shunt-less squib connector in accordance with the present invention. The stopper slot (410) is a feature which can be formed like a notch and is capable to retain the latches. Referring to FIG. 18, there is shown a schematic view illustrating high retention force in accordance with the present invention. The latches (30) are being trapped within the stopper slot (410) and the retainer (200). The trapping of the latches (30) prevents the latches (30) from slipping out but keeps the latches (30) in place if accidental pull is disengaged.

The flexible bridges (20) are designed to allow movement in any translational direction, with a magnitude corresponding to a range of 0 mm to 10 mm, preferably within the range of 0 mm to 7 mm, yet even more preferably with the range of 0 mm to 2 mm, and most preferably within the range of 0 mm to 1 .5mm. The flexible bridges (20) are affixed onto the cover housing (10) and the female housing (130) at any location.

In accordance to the present invention, the retention force/pull force that is required at a specific requirement is corresponding to a retention force within the range of 1 N to 250 N, preferably within the range of 30 N to 230 N, more preferably within the range of 50 N to 220 N, even more preferably within the range of 80 n to 210 N, yet even more preferably within the range of 100N to 200N, and most preferably within the range of 150N to 250N.

In the present disclosure, only a specific embodiment of connectors is disclosed. With the benefit of the present disclosure, it will be appreciated that aspects or features of one embodiment disclosed herein can be used in or combined with aspects and features of other embodiments disclosed herein to produce additional embodiments consistent with the teachings of the present disclosure.

The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.