FCI's third-generation airbag squib connector, the ABX-3 (right), is more compact than the company's first- and second-generation models. An integrated fuel flange-connector from FCI features a one-piece design to reduce cost, assembly time, permeation, and part count.

FCI Automotive is using miniaturization, modularization, and other advanced tech-nologies to increase its product range of airbag squib connectors and fuel tank module flanges.

In response to industry requirements, FCI has developed a third-generation safety restraint connector system that has two ferrite sleeves to achieve a broader range of EMI and RFI filtering protection. Called ABX-3, the connectors are significantly smaller than previous-generation models and come in non-serviceable (locking) and serviceable (removable) forms. According to Joel Karczewski, Director of Sales-Safety Restraint Products, they are cost competitive with the previous-generation models but offer enhanced overall performance.

The ABX-3 was developed by FCI's global safety engineering team and was production-launched in April 2000 at the company's Markham, Ontario, facility. The right-angle connector is 13 mm (0.5 in) wide, 18 mm (0.7 in) long, and 5 mm (0.2 in) high with a temperature range of -40 to +100°C (-40 to +212°F) and contact resistance of 10 milliohm. The smaller size of the new model gives OEMs greater design flexibility, particularly with dual-stage, side-impact, and belt-pretensioner applications, according to Karczewski. The first and second generations use a single ferrite block in the connector, considered an industry standard, as opposed to the third generation's dual ferrite sleeves.

FCI continues to work with the U.S. Council for Automotive Research (USCAR) to develop a connector for use in "smart system" applications throughout its global network of engineering resources. FCI offers a broad range of airbag squib connectors produced and engineered locally to meet global industry needs, Karczewski said. FCI produces connectors using ferrites, coils, and capacitors for various OEM applications around the world.

Another technology with which FCI is enjoying considerable market acceptance is mold-in connectors for fuel tank valve flanges. The idea is to eliminate the number of two-part mechanical connections within the volatile environment of a fuel tank and to reduce the evaporative emissions that are associated with multiple through-tank connections. The industry trend toward greater use of plastic fuel tanks, as well as the company's expertise in injection-molding technology, led FCI to develop the plastic valve flange.

According to Scott Wilder, Director of Sales and Marketing - Tier Accounts, FCI is the leader in this new technology.

Jean L. Broge

AEI October 2000