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 FCI MVL (Motorised Vehicle Division) has delivered another significant breakthrough in the development of more cost effective and reliable connectors for automotive airbags and other safety restraint systems (SRS). Already established as a market leader, the latest innovation from FCI is the ESD squib connector, the first commercially available airbag connector to integrate the grounding element within the connector itself. As a result, volume car manufacturers stand to reap significant improvements in the cost-efficiency of airbag assembly on the production line, and a simplified cabling architecture.
A diverse global market
Across the world, the market for airbags and other safety restraint systems is made up of a number of distinct geographic regions, each with its own characteristics and requirements. North America was the first to see the introduction of the airbag in a mass production car, back in the 1970s. However, it was not until the 1980s that they became widespread. The western European market, in contrast, was relatively slow to adopt the airbag. Despite this, from the 1990s onwards, their use in Europe has grown rapidly. In particular, the increased focus on the safety of vehicle occupants has seen a proliferation in the number of airbags fitted, even to low cost, entry-level models. Typically, these now include multiple passenger, side, curtain and knee bags, to the point that their use is now more prevalent than in North America. For example, up to 24 airbags can now be found in luxury car models in Western Europe.
 From the beginning of the 21st century, major new automotive markets have emerged. The fastest growth in car sales is now occurring in countries such as Brazil, China and India. However, within such developing markets, the priority is still on minimising the purchase price of the vehicle. With safety lower on the agenda, these countries typically lag some ten years behind Europe in the use of airbags.
Throughout a decade of rapid market change, FCI has retained its position as a market leader in the design and manufacture of connectors for airbag and other safety retention systems. In 2008, FCI secured over 30% of the total market, a success that is built on the ability to meet the distinct requirements of a range of different markets. In particular, FCI’s approach is characterised by close partnerships with major automotive manufacturers to deliver new and innovative solutions.
A history of innovation
Over the past ten years, FCI has introduced a series of major developments in airbag connector design. These include the evolution from the original 10 mm to 11 mm diameter connectors and the latest development towards the AK-2 squib interface. Significantly, FCI was the first company to introduce the 11 mm diameter ignitor pocket, allowing better control of the squib mating process and the introduction of various connector codings, as well as the ScoopProof (“Kojiri Safe”) 11 mm AK-2 interface. This ensured that there was no longer a risk of damage to the ignitor pins during mating. Given that assembly of airbag connectors involves blind mating, the ability to guarantee it is plugged correctly and without damage is a priority, eliminating the need for costly QA and rework procedures. Other benefits delivered by the AK-2 include an ergonomic ring geometry that supports excellent mating behaviour and a guidance feature. Furthermore, active elements and coding geometry are located inside this ring geometry, providing an excellent level of protection.
Setting new standards
 The new ESD product from FCI is the result of a partnership with VW/Audi to improve the AK-2 global standard further. In particular, it is designed to overcome the drawbacks of traditional, external grounding of airbag connectors to the car body. For car manufacturers, the current approach adds an extra step to the assembly process and with it additional costs and increased risk of manufacturing errors. Furthermore, there is no traceability of grounding. The new ESD connectors solution (also known as the AK-2+) overcomes these problems, eliminating the potential misfiring caused by electro static discharge with completely integrated grounding. Alongside these benefits, the new connector retains full compatibility with existing standards
(AK, USCAR, ISO 19072-1) as well as FCI’s patented mate assist function, CPA (Connector Position Assurance).
New innovations, new applications
Due to be launched for the first time in a VW model scheduled for serial start early summer 2010, the ESD represents just one of a number of innovations that FCI is currently in the process of bringing to the market. The emerging generation of electric (EV) and hybrid electric (HEV) vehicles requires much higher voltages and operating currents. As a result, measures to tackle EMI are a high priority. In response, FCI is offering the opportunity to improve filtering, through the use of ferrites within the squib, rather than a coil. Ferrites are optimised for frequencies up to 2GHz, compared to typical 100 MHz for the coil.
Despite the proliferation of airbag applications over the past ten years, innovative developments continue to emerge. For example, in 2006 an airbag was offered for the first time as an option on a motorcycle – the Honda Goldwing. Similarly, airbag-equipped suits for motorcyclists, which activate in the event of an accident, are now reaching the market. Furthermore, following considerable focus on the protection of vehicle occupants, attention is turning to pedestrian safety. The potential for airbags to aid this goal is now being explored. Designs that are currently being tested include bags fitted under the vehicle bonnet, which activate in the event of a pedestrian impact. In particular, these should reduce the severity of injuries when a pedestrian is struck either by the bonnet, windscreen or windscreen frame.
 Other OEMs are also pursuing a different safety application – an airbag that deploys under the front of a car when there is a risk of a head-on collision. Effectively this acts as an anchor, rubbing on the road surface to cut the time it takes to bring the car to a standstill. This ‘braking bag’ could be fitted to all new car generations in the medium term and FCI already has available an appropriate solution for such harsh environments. In such applications, the company’s sealed squib family could be utilised ‘off the shelf’.
Developing markets
While European, in particular German, car manufacturers are driving forward new airbag applications; the emerging markets of India, China and Brazil have significantly different requirements. With income levels and car ownership much lower, the emphasis is on producing vehicles that are as cheap as possible to buy and maintain. Given that each airbag also needs a range of associated components, such as controllers and sensors, the implications are clear. And in these markets, cars that do feature airbags will tend to be limited to straightforward driver and possibly front passenger applications. Similarly, seat belts are more likely to feature mechanical rather than pyrotechnic restraint systems. Economic, industry standard connector designs are therefore of much greater significance than the innovative designs being introduced in Europe. Furthermore, the political and economic regulations that apply within these emerging markets often require local production.
In such markets, FCI’s strength lies in its track record of establishing and mass-producing industry standard solutions covering all interface types, combined with the flexibility and capability to assemble locally. Primarily, this adaptability is based on FCI’s Modular Connector Concept, in terms of both the connector design and manufactur-ability. This approach enables the company to meet individual customer requirements quickly and economically, using standard components. An easy change over between all common interfaces and cable types is the key element to improving FCI’s base line manufacturing costs, allowing the company to offer competitive solutions to customers. In addition, it provides a high degree of flexibility to develop alongside each individual customer’s requirements, particularly significant given the rate of growth that is being experienced in countries such as China.
The FCI factory in Kochi, India is geared to produce these ESD squibs for the local market as well.
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