ISO 19072-2:2019

Road vehicles - Connection interface for pyrotechnic devices, two-way and three-way connections - Part 2: Test methods and general performance requirements

This document specifies the performance criteria and requirements of a three-way connection interface, including ground connection, linking the pyrotechnic device and harness connector built into a road vehicle. Performance criteria and requirements are defined for a sealed variant of the pyrotechnic device/initiator harness connector assembly (see Annex A). Performance criteria and requirements are defined for a two-way (without ground) variant of the pyrotechnic device/initiator harness connector assembly (see Annex B). Performance criteria and requirements are defined for a variant without a retainer of the pyrotechnic device/initiator harness connector assembly is defined (see Annex C).

Véhicules routiers — Interface de raccordement pour dispositifs pyrotechniques, deux voies et trois voies — Partie 2: Méthodes d'essai et exigences des performances générales

General Information

• Status: Published
• Publication Date: 10-Dec-2019
• ICS: 43.040.10 - Electrical and electronic equipment
• Technical Committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
• Drafting Committee: ISO/TC 22/SC 32/WG 6 - On-board electrical connections
• Current Stage: 9092 - International Standard to be revised
• Start Date: 08-Sep-2025
• Completion Date: 13-Dec-2025

Relations

• Revises: ISO 19072-2:2013 - Road vehicles - Connection interface for pyrotechnic devices, two-way and three-way connections - Part 2: Test methods and general performance requirements
• Effective Date: 26-Aug-2017

Overview

ISO 19072-2:2019 defines test methods and general performance requirements for connector interfaces between road-vehicle pyrotechnic devices (e.g., initiators for airbags, pretensioners) and their harness connectors. The standard covers both three-way (including ground) and two-way (without ground) connection variants, plus a variant without a retainer. It specifies the mechanical, electrical and environmental tests needed to verify connector performance and safety in automotive applications.

Key topics and technical requirements

This part of the ISO 19072 series focuses on measurable performance criteria and test methods, including:

• Connector variants and annexes: sealed three-way assemblies (Annex A), two-way assemblies (Annex B), and assemblies without retainers (Annex C).
• Functional tests: visual examination, mating and unmating operations (maximum connecting/disconnecting force < 40 N), correct polarization and coding.
• Mechanical tests: tensile and compressive loading, torque tests, mechanical strength of retainers and squib holders, and resistance to forces for straight and right-angle connectors.
• Electrical tests: contact resistance (millivolt drop), insulation resistance, withstand voltage, short‑circuit resistance and behavior when opening/closing a short circuit.
• Environmental and durability tests: combination of temperature/humidity/vibration, thermal ageing, rapid temperature change (thermal shock), chemical fluid exposure.
• Test sequencing and classification: test sequences are defined to simulate realistic service conditions; temperature class references follow ISO 8092-2 (temperature class 2 unless otherwise specified).

These requirements are intended to ensure reliable electrical and mechanical connections for life‑safety pyrotechnic components in vehicles.

Practical applications and users

ISO 19072-2 is intended for organizations involved in design, manufacture and verification of vehicle safety connectors:

• Automotive OEMs specifying connector interfaces for airbags and pretensioners.
• Connector and cable harness manufacturers developing pyrotechnic-device interfaces.
• Safety-system suppliers producing initiators, squib holders and retainers.
• Test laboratories and certification bodies conducting standardized mechanical, electrical and environmental tests.
• Systems engineers and quality managers ensuring compliance with vehicle safety requirements.

Using ISO 19072-2 helps harmonize connector designs across suppliers, reduce integration risks, and provide consistent test methods for safety-critical pyrotechnic interfaces.

Related standards

• ISO 19072 series (other parts covering interface definitions)
• ISO 8092-2 (connections for on‑board wiring harnesses - definitions and test methods)
• ISO 20653 (vehicle degrees of protection - IP code)

Keywords: ISO 19072-2, pyrotechnic device connectors, airbag connector test methods, initiator harness connector, vehicle safety connectors, contact resistance, insulation resistance, connector mechanical strength.

Standards Content (Sample)

INTERNATIONAL ISO
STANDARD 19072-2
Third edition
2019-12
Road vehicles — Connection interface
for pyrotechnic devices, two-way and
three-way connections —
Part 2:
Test methods and general
performance requirements
Véhicules routiers — Interface de raccordement pour dispositifs
pyrotechniques, deux voies et trois voies —
Partie 2: Méthodes d'essai et exigences des performances générales
Reference number
©
ISO 2019
© ISO 2019
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.iso.org
Published in Switzerland
ii © ISO 2019 – All rights reserved

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Functional characteristics of mated connectors . 2
4.1 General . 2
4.2 Visual examination . 2
4.3 Mating and unmating . 2
4.4 Resistance to tensile and compressive force between the connector and squib
holder equipped with initiator and retainer . 3
4.4.1 Test . 3
4.4.2 Requirements . 4
4.5 Mechanical strength of the retainer in the squib holder . 5
4.5.1 Test . 5
4.5.2 Requirements . 5
4.6 Combination of temperature/humidity/vibration . 6
4.6.1 Test . 6
4.6.2 Requirements . 8
4.7 Coding . 9
4.7.1 Test . 9
4.7.2 Requirements . 9
4.8 Polarisation . 9
4.8.1 Test . 9
4.8.2 Requirements . 9
4.9 Contact resistance (voltage drop), millivolt test . 9
4.9.1 Test . 9
4.9.2 Requirements .11
4.10 Insulation resistance .11
4.11 Withstand voltage .11
4.12 Thermal ageing .11
4.13 Opening and closing of the short-circuit .11
4.14 Short-circuit resistance .12
4.14.1 Test .12
4.14.2 Requirements .13
4.15 Rapid change of temperature (thermal shock) .13
4.16 Chemical fluids .13
5 Test sequences .13
Annex A (normative) Sealed variant of the pyrotechnic device/initiator harness connector
assembly .15
Annex B (normative) Two-way (without ground) variant of the pyrotechnic device/initiator
harness connector assembly .17
Annex C (normative) Variant without retainer of the pyrotechnic device/initiator harness
connector assembly .19
Bibliography .20
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso .org/
iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 32,
Electrical and electronic components and general system aspects.
This third edition cancels and replaces the second edition (ISO 19072-2:2013), which has been
technically revised.
The main changes compared to the previous edition are as follows:
— 4.4.2.1 Table 1, force and torque requirements for straight connectors;
— 4.4.2.2 Table 2, force and torque requirements for right angle connectors;
— 4.9.1.2 Figure 8 including key, signal contact resistance;
— 4.9.2.1 Table 5, maximum signal contact resistance;
— 4.9.2.2 Table 6, maximum contact resistance between ground and squib holder.
A list of all parts in the ISO 19072 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
iv © ISO 2019 – All rights reserved

Introduction
Road vehicles integrate an increasing number of pyrotechnic devices contributing to occupant safety in
vehicles (for example, frontal and side air bags, safety belt pretensioner, etc.).
To build the complete system providing the function requires a supply of various components from
several different equipment makers. Vehicle manufacturers need to define a common specification
to ensure that connectors designed and produced by the various equipment makers meet the same
performance criteria and requirements.
In the current design of this vehicle equipment, three areas of connection have been identified:
— between the pyrotechnic device (e.g. initiator) and the harness connector;
— between the tab holder and the clip holder of the harness connector;
— between the harness connector and the electronic control module.
The connection between the pyrotechnic device and the harness connector is the only connection that
can be standardized and forms the subject of this document. Due to the location of the safety device in
the vehicle, the connector design could be a right angle or straight.
A sealed variant of the pyrotechnic device/initiator harness connector assembly is defined in Annex A.
INTERNATIONAL STANDARD ISO 19072-2:2019(E)
Road vehicles — Connection interface for pyrotechnic
devices, two-way and three-way connections —
Part 2:
Test methods and general performance requirements
1 Scope
This document specifies the performance criteria and requirements of a three-way connection
interface, including ground connection, linking the pyrotechnic device and harness connector built into
a road vehicle.
Performance criteria and requirements are defined for a sealed variant of the pyrotechnic device/
initiator harness connector assembly (see Annex A).
Performance criteria and requirements are defined for a two-way (without ground) variant of the
pyrotechnic device/initiator harness connector assembly (see Annex B).
Performance criteria and requirements are defined for a variant without a retainer of the pyrotechnic
device/initiator harness connector assembly is defined (see Annex C).
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 8092-2, Road vehicles — Connections for on-board electrical wiring harnesses — Part 2: Definitions,
test methods and general performance requirements
ISO 20653, Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against
foreign objects, water and access
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
3.1
connector
assembly used to connect several conductors together or a single conductor to an appliance
Note 1 to entry: A male (female) connector is a housing (3.2) containing male (female) contacts and accessory
items. A male connector may be permanently fixed to a wiring harness or to an appliance [an electronic control
unit (ECU) for example]. A female connector is generally permanently fixed to a wiring harness.
[SOURCE: ISO 19072-1:2019, 3.1]
3.2
housing
connector (3.1) without its contacts
[SOURCE: ISO 19072-1:2019, 3.2]
3.3
retainer
ring holding an optional shorting clip (shunt) and providing coding and electrical insulation, generally
made of plastic
Note 1 to entry: The shorting clip (shunt) may be omitted by decision between manufacturer and supplier.
[SOURCE: ISO 19072-1:2019, 3.5]
3.4
short-circuited initiator
inert initiator (3.6) with two male contacts internally short-circuited with a shunt, used for testing
3.5
squib holder
part of the pyrotechnic device, holding the initiator (3.6) and the retainer (3.3)
3.6
initiator
part of the pyrotechnical device with two male contacts
4 Functional characteristics of mated connectors
4.1 General
Mated connectors shall meet the requirements specified in 4.2 to 4.16.
Unless other specifications are given, the temperature class to be taken into account for these tests (see
ISO 8092-2) is class 2.
4.2 Visual examination
The test and corresponding requirements shall comply with ISO 8092-2.
4.3 Mating and unmating
The test shall be carried out in compliance with ISO 8092-2 by measuring the force applied on the
connector.
The connector shall not be locked during the mating and unmating process unless otherwise specified.
The mating/unmating sequence shall comply with the one described in Table 7.
The maximum connecting and disconnecting force measured on the connector shall be less than 40 N.
NOTE The movements of the mating sequence (Table 7) can be carried out simultaneously with the same force.
2 © ISO 2019 – All rights reserved

4.4 Resistance to tensile and compressive force between the connector and squib
holder equipped with initiator and retainer
4.4.1 Test
4.4.1.1 General
The connector shall be locked for testing.
This test is a destructive test carried out on an assembly comprising a squib holder, an initiator with
male contacts, and a retainer.
4.4.1.2 Straight connectors
The test is carried out on a new sample, applying the forces in the directions shown in Figure 1 on the
straight connector without its cable.
Key
F tensile force
F tensile and compressive forces
F tensile and compressive forces
M torque
Figure 1 — Direction of forces applied on straight connectors
4.4.1.3 Right-angle connectors
The test is carried out on a new sample, applying the forces F and F on the connector body where the
4 6
cable exits the connector in the directions shown in Figure 2.
Apply the force F in the central axis of the connector as shown in Figure 2.
...