CN113841301A

CN113841301A - Method for improving electrical clearance and creepage distance in high voltage connector assembly using male or female Terminal Position Assurance (TPA) device

Info

Publication number: CN113841301A
Application number: CN202080001615.XA
Authority: CN
Inventors: D·德马拉托斯; F·A·霍卢布
Original assignee: JST Corp
Current assignee: JST Corp
Priority date: 2020-04-23
Filing date: 2020-04-25
Publication date: 2021-12-24
Anticipated expiration: 2040-04-25
Also published as: CN113841301B; JP2022545756A

Abstract

A method of improving electrical clearance and creepage distance in a male or female high voltage connector assembly using a male Terminal Position Assurance (TPA) device. The high voltage connector assembly is adapted for use with a high voltage electrical terminal. The method comprises the following steps: such that the electrical gap and creepage or electrical path extends from the at least one high voltage electrical terminal to the electrically conductive male housing body and/or between the at least one high voltage electrical terminal to the other terminal using a male or female TPA device. The TPA device is inserted into the high voltage connector assembly with an electrical gap and creepage or electrical path extending from the high voltage electrical terminal to the male housing body of the high voltage connector assembly at least along a surface of the TPA device, or from the high voltage electrical terminal to another high voltage electrical terminal using a male or female TPA device.

Description

Method for improving electrical clearance and creepage distance in high voltage connector assembly using male or female Terminal Position Assurance (TPA) device

Cross Reference to Related Applications

This patent application claims priority from U.S. provisional patent application No.62/810,179 and U.S. provisional patent application No.63/014,576, filed on 25/2/2019, the entire contents of which are incorporated herein by reference in their entirety.

Technical Field

Because high voltage connector assemblies are required to withstand very high voltages and Terminal Position Assurance (TPA) devices are used in the connector assemblies, there is a need to improve conventional shielded automotive connectors or housings for use with high voltage electrical terminals; accordingly, it is desirable to improve or increase the electrical clearance and creepage distance of the electrical path from at least one high voltage electrical terminal to another high voltage electrical terminal, a possible associated short circuit current of the component/circuit, and further to improve or increase the electrical clearance and creepage distance from at least one high voltage electrical terminal to the electrically conductive housing, the electrical component/circuit, or the conventional metal stamping shields for shielding, when operating or using the connector assembly.

Disclosure of Invention

The present invention is directed to methods of improving the electrical clearance and creepage distance of an electrical path in a high voltage connector assembly using a male or female Terminal Position Assurance (TPA) device and a housing. The electrical path may be included in or related to the short circuit current. The high voltage connector assembly of the present invention is particularly suitable for use with high voltage electrical terminals (larger terminals). The female TPA device of the present invention includes a forwardly extending member, while the female housing includes a front portion (in which the terminals are received) and a rear portion. The male TPA device of the present invention includes wing members having intermediate members that extend substantially downward from the wing members and into their male inner housings, respectively, during use and operation. The male TPA device of the present invention also includes a lower member that is received between the high voltage electrical terminals when the male TPA device is received in the housing during use and operation. According to the above-described features of the invention, the "creepage distance" (the shortest distance measured along a surface from any given circuit in a connector to any other circuit (typically adjacent)) and the "electrical clearance" (defined as the shortest electrical path measured, for example, from any exposed conductive element in a given circuit of a connector to any other conductive element in a different circuit in the same connector) are advantageously improved, thereby altering or influencing the electrical path involved in or related to the short circuit current when the connector assembly is operated or used.

Drawings

Fig. 1 is a front perspective view of a female Terminal Position Assurance (TPA) device of the present invention for a female high voltage connector assembly.

Fig. 2 is a side elevational view of the parent TPA device of the present invention.

Fig. 3 is a top elevational view of the parent TPA device of the invention.

Fig. 4 is a front elevational view of a female TPA device of the invention.

Fig. 5 is a perspective view of the female TPA device of the invention that is assembled or mounted in the female housing in a pre-lock position and further shows the electrical gap or creepage distance of the electrical path on the female housing from one high voltage electrical terminal to another high voltage electrical terminal.

Fig. 6 is a perspective view of the female TPA device of the invention assembled or mounted in the female housing in a fully locked position and further showing the electrical gap or creepage distance of the electrical path on the female housing from the high voltage electrical terminal to the other high voltage electrical terminal.

Fig. 7 is a cross-sectional view taken along section line 7-7 in fig. 5 showing the corresponding high voltage electrical terminal, the corresponding forward downwardly extending member of the corresponding forward extending member of the female TPA device in the pre-lock position inside the female housing, and further showing the electrical gap or creepage distance of the electrical path extending from the high voltage electrical terminal as indicated by the vertical arrow.

Fig. 8 is a cross-sectional view taken along section line 8-8 in fig. 6 showing the corresponding high voltage electrical terminal, the corresponding forward downwardly extending member of the corresponding forward extending member of the female TPA device in a fully locked position inside the female housing, and further showing an electrical gap or creepage distance of the electrical path extending from the high voltage electrical terminal as indicated by the vertical arrow.

Fig. 9 shows the electrical gap or creepage distance of the electrical path extending from the high voltage electrical terminal as shown in phantom and further extending through the female housing into the other high voltage electrical terminal and further extending into the other high voltage electrical terminal as shown in phantom.

Fig. 10 shows a front elevational view of the female housing showing the electrical gap or creepage distance of the electrical path extending from one high voltage electrical terminal as shown in phantom and further extending through the female housing into the other high voltage electrical terminal and further into the other high voltage electrical terminal as shown in phantom.

Fig. 11 is a front perspective view of a male Terminal Position Assurance (TPA) device of the present invention for use with a male high voltage connector assembly.

Fig. 12 is a front elevational view of a male TPA device of the invention.

Fig. 13A is a perspective view of a male TPA device of the invention that is fitted or installed in a male inner housing in a pre-locked position.

Fig. 13B is a perspective view of the male TPA device of the invention assembled or installed in the male inner housing in a fully locked position.

Fig. 14 is a cross-sectional view of a high voltage connector assembly with a high voltage electrical terminal inserted therein to enable the male TPA device of the invention to be received in the TPA window, as shown by the square portions separated by the dashed lines.

Fig. 15 is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein, capable of receiving a male TPA device of the invention in a TPA window, and further showing an electrical gap of an electrical path extending from the high voltage electrical terminal to a male housing body as indicated by the vertical arrow.

Fig. 16 is a cross-sectional view of a high voltage connector assembly with a high voltage electrical terminal inserted therein and a male TPA device of the present invention positioned in the TPA window, the male TPA device being in a fully locked position.

Fig. 17 is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein, the male TPA device of the invention positioned in the TPA window, and showing the electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 18 is a perspective view of the male inner housing of the present invention with a high voltage electrical terminal therein.

Fig. 19A is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a pre-lock position.

Fig. 19B is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a fully locked position.

Fig. 20A is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a pre-lock position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 20B is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a fully locked position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 21A is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a pre-lock position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 21B is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a fully locked position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 22A is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a pre-lock position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 22B is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a fully locked position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 23A is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a pre-lock position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Fig. 23B is a cross-sectional view of a portion of a high voltage connector assembly with a high voltage electrical terminal inserted therein with the male TPA device of the invention in a fully locked position and showing an electrical gap or creepage distance of the electrical path substantially along the surface of the male TPA device of the invention.

Detailed Description

Fig. 1 shows a front perspective view of a female Terminal Position Assurance (TPA) device, generally designated by reference numeral 1. The female TPA device 1 includes a middle member 3 and a rounded corner member 5. The central member 3 extends from an upper portion 7 to a lower portion 9 of the fillet member 5. The fillet member 5 has forwardly extending

members

10, 12 extending therefrom on opposite sides thereof.

An upper rearwardly extending member 13 and a lower rearwardly extending member 15 are shown in figure 2. At the front end of each

forward extending member

10, 12 is a corresponding forward downwardly extending

member

20, 22. Each

forward extending member

10, 12 also has a corresponding

upper side member

25, 27; and each

upper member

25, 27 has a corresponding ramp-

like front end

29, 30.

A top elevational view of the female TPA device 1 is shown in fig. 3, showing the forwardly extending

members

10, 12, the corresponding

upper side members

25, 27 extending from the forwardly extending

members

10, 12, respectively, and the respective

ramped front ends

29, 30 of the forwardly extending

members

10, 12. Also shown are upper 13 and lower 15 rearward extension members. The upper rearwardly extending member 13 has an upper barb member 35 extending from the upper rearwardly extending member 13 and the lower rearwardly extending member 15 has a lower barb member 37 extending from the lower rearwardly extending member 15. As shown in fig. 4, the

openings

40, 42 pass through both sides of the female TPA device 1 with the middle member 3 therebetween.

Fig. 5 shows the female TPA device in a pre-lock position while inserted into the female housing 50, mounted on the female housing 50. The female housing 50 has a front 53 and a rear 55. Fig. 6 shows the female TPA device 1 in a fully locked position while inserted into the female housing 50, mounted on the female housing 50.

The present invention is directed to a method of improving electrical clearance and creepage distance using a female TPA device 1. The invention is also particularly applicable to high voltage electrical terminals 60 (larger terminals). As further shown in fig. 5 and 6, there is an electrical gap or creepage distance for the electrical path 110 on the female housing 50 near the female TPA device 1, the electrical path 110 extending across from the exposed high voltage electrical terminal 60 along the upper surface of the front portion 53 of the female housing 50 and towards the other exposed high voltage electrical terminal 60 inside the front portion 53.

In accordance with the above-described features of the present invention, as shown in fig. 5 and 6, as described above, the "creepage distance" (the shortest electrical path measured along the surface from any given electrical circuit (here, one of the high voltage electrical terminals 60) running in one direction or extending along the surface (here, the surface of the forwardly extending

members

10, 12 of the female TPA device 1 and the upper surface of the front portion 53 of the female housing 50) to any (usually adjacent) other electrical circuit (here, the other high voltage electrical terminal 60)) and the "electrical clearance" (the shortest electrical path measured from any exposed conductive element (here, the high voltage electrical terminal 60) in a given electrical circuit of the connector to any other conductive element (here, the other high voltage electrical terminal 60) in a different electrical circuit in the same connector) are advantageously improved, thereby altering or affecting the electrical path involved in or associated with the short circuit current when the connector assembly is operated or used. Further, as shown by the dotted line L in fig. 10, in another embodiment of the present invention, the exposed portion of one of the high voltage electric terminals 60 and the position of the forward extending member 10 are above, and can be operated on the other side end portion on the front portion 53, whereby the electric gap or creepage distance of the electric path 110 can be further increased.

As shown in fig. 7, the protrusion member 62 extends from the lower portion of the female housing 50. The projecting member 62 includes a ramp-like leading end 65. The leading portion 68 of the terminal 60 has a notch 70 such that when the terminal 60 is fully inserted into the female housing 50, the notch 70 readily passes the ramped leading end 65 of the projecting member 62. When the terminal 60 is fully inserted into the female housing 50, the projecting member 62 of the female housing 50 is caught in the notch 70 of the leading end 68 of the terminal 60, thereby locking (first locking) the terminal 60 inside the female housing 50.

Fig. 7 further shows a cross-sectional view taken along line 7-7 in fig. 5 with the female TPA device 1 in the pre-lock position. As described above, when the projecting member 62 inside the female housing 50 is caught or enters the notch 70 of the leading end 68 of the terminal 60, the terminal 60 is locked (first locking). Therefore, the terminal 60 cannot be pulled out from the female housing 50; at this time, the upper recesses 80 of the terminals 60 can receive or accommodate therein the corresponding one of the front downwardly extending

members

20, 22. That is, unless the terminal 60 is in the first lock inside the female housing 50 and the upper side recess 80 of the terminal 60 is able to receive or accommodate therein the corresponding one of the front downwardly extending

members

20, 22, the front downwardly extending

members

20, 22 cannot provide the necessary second lock to the terminal 60 inside the female housing 50. In other words, if the terminal 60 is not first locked inside the female housing 50, the female TPA device 1 is prevented from being pushed further downward by the upper portion 85 of the leading end 68 of the terminal 60. Therefore, if the upper portion 85 of the leading end 68 of the terminal 60 blocks the female TPA device 1 (more specifically, blocks the front downward extending

members

20, 22 of the female TPA device 1), the female TPA device 1 can detect that it cannot be pushed further downward, and thus cannot provide the second lock to the terminal 60 inside the female housing 50 (i.e., the female TPA device 1 cannot be pushed further downward to the full lock position).

Fig. 8 shows the female TPA device 1 in a fully locked position inside the female housing 50. Here, the upper side recesses 80 of the terminals 60 become capable of accommodating therein the front downward extending

members

20, 22 of the corresponding one of the female TPA devices 1; therefore, when inserted into the upper side notch 80 of the corresponding one of the terminals 60, the front downward extending

members

20, 22 of the female TPA device 1 block the terminals 60 from being pulled out of the inner housing 50, respectively, and thus the second locking of the terminals 60 inside the female housing 50 can be provided.

As further shown in each of the pre-locked female TPA device 1 in fig. 7 and the fully locked female TPA device 1 in fig. 8, due to the orientation of the female TPA device 1 on or towards the female housing 50, showing the creepage distance or electrical clearance (see arrows) of the electrical pathways 110, extend substantially vertically from the high voltage electrical terminals 60, further extend along or between the corresponding one of the front downward extending members 20, 22 (of the respective

forward extending members

10, 12 of the female TPA device 1), and extend along a vertical and/or substantially sloped or angled portion of the front portion 53 of the female housing 50. The front downwardly extending

members

20, 22 are each directed substantially rearward of a portion of the corresponding high voltage electrical terminal 60.

The female TPA device 1 is shown in a pre-lock position in the female housing 50, for example, in fig. 9 and 10. In fig. 9 and 10 it is shown that the forwardly extending

members

10, 12 of the female TPA device 1 are located above and partially inserted into the front 53 of the female housing 50. In fig. 9 and 10, the creepage distance or electrical gap (see dashed lines) of the electrical paths 110 is shown extending substantially vertically from one of the high voltage electrical terminals 60, further partially exiting or exiting between along one of the front downwardly extending members 20 (of the respective forwardly extending member 10 of the parent TPA device 1), and exiting along a vertical and/or substantially sloped or angled portion of the front portion 53 of the parent housing 50, further running in one direction or extending and traversing along the upper surface of the front portion 53 of the parent housing 50, and further extending substantially vertically into the other one of the high voltage electrical terminals 60, extending along or extending between one of the front downwardly extending members 22 (of the respective forwardly extending member 12 of the parent TPA device 1), and extending along a vertical or substantially sloped or angled portion of the front portion 53 of the parent housing 50 (see fig. 6), the above process is reversed between the terminals 60 and is further present in the fully locked orientation of the female TPA device 1 and the female housing 50 (see fig. 6, 8).

Fig. 11 shows a front perspective view of a male Terminal Position Assurance (TPA) device of the present invention, generally designated by reference numeral 201. Male TPA device 201 comprises an upper member 203 and a lower member 205. The upper member 203 is substantially wing-shaped having

side portions

210, 214. The lower member 205 includes a flexible arm member 218 at its front.

As shown in fig. 12, the flexible arm member 218 includes at least a projecting member or node member 220. Although two projecting members or node members 220 are shown in fig. 12, this is not a limitation. As shown in fig. 11, the upper front portion 211 of the flexible arm member 218 is in an inclined state. Also, as shown in FIG. 11, the lower front portion 212 of the flexible arm member 218 is in a tilted state.

Further shown in fig. 12 are

end members

224, 226 that extend substantially downward from the wing-

like side members

210, 214, respectively. The

intermediate members

228, 229 also extend substantially downward from the wing-

like side members

210, 214, respectively. Each

intermediate member

228, 229 has a

corresponding nub

231, 233, respectively, extending from the

intermediate member

228, 229.

The male TPA device 1 of the present invention is shown in a pre-lock position in fig. 13A and a full lock position in fig. 13B, the male TPA device 201 is inserted through the opening 208 (the opening 208 penetrates an upper portion of the male inner housing 230 of the high-voltage connector assembly (indicated generally by reference numeral 200 in fig. 14 and 16)) and is fitted or mounted in the male inner housing 230 in the lower opening 400 (see fig. 18, 21A, 21B). Fig. 13A and 13B also show fitting recesses 232, 234, 236 on the outer surface of the male inner housing 230 for enabling the male TPA device 201 to be mounted or inserted into a male outer housing 260 of the high-voltage connector assembly 200 (see fig. 14 to 17).

Fig. 14 is a cross-sectional view of the high-pressure connector assembly with the male inner housing 230 with the male TPA device 201 in a pre-lock position or orientation. Fig. 14 further shows the male TPA device 201 in the male inner housing 230 and the male outer housing 260. The high voltage connector assembly 200 has high voltage electrical terminals 265 inserted therein that are capable of receiving the male TPA device 201 of the present invention in TPA windows 272, as shown by the square portions separated by the dashed lines.

Fig. 15 is a cross-sectional view of a portion of the high voltage connector assembly 200 into which the high voltage electrical terminals 265 are inserted to be able to receive the male TPA device 201 of the present invention in the TPA windows 272 and shows the electrical clearance of the electrical path 210, as indicated by the vertical arrows in fig. 15, at least from the high voltage electrical terminals 265 through the openings 208 (the openings 208 pass through the upper portion of the male inner housing 230) to the male inner housing 230 of the high voltage connector assembly 200 and to the male outer housing 260.

The present invention is directed to a method of improving electrical clearance and creepage distance in a high voltage connector assembly 200 using a male TPA device 201. The high voltage connector assembly 200 is particularly suited for high voltage electrical terminals 265 (larger terminals). The male TPA device 201 of the present invention includes wing-shaped

side members

210, 214 with

intermediate members

228, 229, the

intermediate members

228, 229 extending substantially downward from the wing-shaped

side members

210, 214, respectively. Each

intermediate member

228, 229 has a

corresponding nub

231, 233, respectively, extending from the

intermediate member

228, 229.

In accordance with the above-described features of the present invention, there is advantageously improved "creepage distance" (the shortest path measured along the surface from the electrical circuit (here the high voltage electrical terminals 265) running in one direction or extending along the surface (here the surface of the male TPA device 201 and the male inner housing 230) to any (typically adjacent) other electrical circuit (here the electrically conductive male outer housing 260 or a conventional stamped metal housing (not shown)) and "electrical clearance" (the shortest electrical path measured from any exposed electrically conductive element (here the high voltage electrical terminals 265) in a given electrical circuit of the connector to any other electrically conductive element (here the male outer housing 260 or a conventional stamped metal housing (not shown)) in a different electrical circuit in the same connector), thereby altering or affecting the electrical path involved in or associated with the short circuit current when the connector assembly is operated or used.

More specifically, fig. 16 is a cross-sectional view of the high voltage connector assembly 200 of the present invention with the high voltage electrical terminals 265 inserted into the male inner housing 230 and the male TPA device 201 of the present invention inserted therein in a fully locked position or orientation. The corresponding wing-

like side members

210, 214 are received in the openings 208 (see also fig. 13B), and their

intermediate members

228, 229 are received in the TPA windows 272. As shown in fig. 16, the intermediate member 228 is located substantially just behind a portion of the high voltage electrical terminal 265.

Fig. 17 is a cross-sectional view of a portion of a high voltage connector assembly 200 into which the high voltage electrical terminals 265 and the male TPA device 201 of the present invention are inserted. The

intermediate members

228, 229 are located in the TPA windows 272 and substantially just behind a portion of the high voltage electrical terminal 265 where the electrical clearance and/or creepage distance of the electrical path 210 is shown, which runs at least from the high voltage electrical terminal 265 to the male housing body 260 substantially along the outer surface of the male TPA device 201 of the present invention. As shown in fig. 17, the electrical gap and/or creepage distance of the electrical path 210 extends, for example, at least from the high voltage electrical terminal 265 along or between the surface of at least one of the

intermediate members

228, 229 and the surface of the male inner housing 230, further along or between the surface of at least one of the corresponding wing-

like side members

210, 214 and the surface of the male inner housing 230, still further along the opening 208 (the opening 208 passes through and is substantially straight through the upper portion of the male inner housing 230) to just the male outer housing 260 of the high voltage connector assembly 200.

In fig. 18 is further shown a male inner housing 230 having a first passage 501 and a second passage 502, respectively. The first and

second channels

501, 502 may receive the

intermediate members

228, 229 of the male TPA device 201 therein, respectively. The first channel 501 and the second channel 502 are each provided with an opening portion that exits and extends to the middle channel 400, respectively. The first mid-recess 601 and the second mid-recess 602 define an open portion and a lower portion of the first channel 501 and the second channel 502, where the first channel 501 and the second channel 502 each enter and extend into the mid-channel 400, respectively. The upper portions of the first channel 501 and the second channel 502 are defined by the opening 208. As will be discussed later, the lower surfaces of

intermediate members

228, 229 additionally further define the upper portions of first and

second passages

501, 502, respectively, when male TPA device 201 is in the pre-lock position in male inner housing 230 (see fig. 19A, 19B).

The male inner housing 230 with the terminals 265 contained therein is further shown in fig. 18. The male inner housing 230 in operation has the electrical clearance and/or creepage distance of the electrical path 310 when the male TPA device 201 is not present or required to be inserted or received therein: which extends from one of the high voltage electrical terminals 265 into the corresponding first 501 and second 502 channel, respectively, substantially right through the top of the first 601 and second 602 recesses, and substantially directly through the middle channel 400 of the male inner housing 230, respectively, further towards and into the other high voltage electrical terminal 265, as shown by electrical path 310.

As will be discussed below, with the TPA of the present invention, the "creepage distance" (the shortest path measured along the surface from the circuit (here, the high voltage electrical terminals 265) running in one direction or extending along the surface (here, the lower portion 205 of the male TPA device 201 and the surface of the male inner housing 230) to any (typically adjacent) other circuit (here, another high voltage electrical terminal 265)) and the "electrical clearance" (the shortest electrical path measured from any exposed conductive element (here, the high voltage electrical terminals 265) in a given circuit of the connector to any other conductive element (here, another high voltage electrical terminal 265) in a different circuit in the same connector) are advantageously improved, thereby changing or affecting the electrical path involved in or associated with the short circuit current when the connector assembly is operated or used.

Fig. 19A is a cross-sectional view of the male TPA device 200, clearly showing that the terminals 265 are received inside the male inner housing 30 in a pre-lock position. The lower member 205 of the male TPA device 200 is received in a portion of the central passage 400 of the male inner housing 230 (see fig. 20A, 21A, and 22A). When male TPA device 201 is in the pre-lock position, lower member 205 is inserted into a portion of central passage 400 and received therein. A portion of the elongated slot 225 of the lower member 205 is exposed in the opening 208 of the male inner housing 230 and is located substantially above the first and

second channels

501, 502. Further, the pre-lock orientation thus aligns the first and

second channels

501, 502 of the male inner housing 230 below a corresponding one of the intermediate members 228, 229 (with a corresponding one of the nodules 231, 233) of the male TPA device 1. Thus, the first and

second channels

501, 502 may receive and insert a corresponding one of the intermediate members 228, 229 (see fig. 22B). Further, in the pre-locked position of the male TPA device 1, the

intermediate members

228, 229 are located in a portion of the opening 208 and, above it, further define respective upper portions of the first and

second channels

501, 502.

In fig. 19B the male TPA device 201 is shown in a fully locked position. As has been explained before, here pushing the male TPA device 201 further down from the pre-lock position to the fully locked position, the corresponding

intermediate members

228, 229 of the male TPA device 201 are fully inserted or received in the corresponding slots 270 of the first and

second channels

501, 502 and the corresponding terminals 265 (see also fig. 22A). Therefore, the male TPA device 1 is located at the full locking position in the male inner housing 230, and the terminal 265 cannot be taken out of the male inner housing 230 (i.e., the male TPA device 1 functions as a second locking of the terminal 65 in the male inner housing 30). Here, the male TPA device 1 is at the full locking position, and the lower member 205 is further inserted and received in the middle passage 400 of the male inner housing 230 than when the male TPA device 1 is at the pre-locking position. Thus, as shown in fig. 21B, when the TPA is fully locked, the elongated slot 225 of the lower member 205 is positioned further down, substantially in the central channel 400 (see fig. 22B). When the male TPA device 1 is in the fully locked position, the upper portion of the elongated slot 225 and a smaller portion thereof are above and flush with the first channel 501 and the second channel 502, thereby accommodating electrical clearance and/or creepage distance of the electrical path 310, as discussed further below (see fig. 21B, 22B).

As shown in more detail in fig. 21A and 21B, when the male TPA device 201 is active and located in the male inner housing 230, the lower member 205 acts as a kind of "wall" or "barrier" in the male inner housing 230 and is located substantially between the high voltage electrical terminals 265 (see also fig. 22A, 22B). In effect, the lower member 205 adds a surface substantially further in the length direction of the male inner housing in the central passage 400 of the male inner housing 230, the electrical pathway 310 running substantially as previously described in the male inner housing 230 (see fig. 18, 19A, 19B). Thus, the lower member 205 thus increases the creepage and clearance distances of the electrical pathways 310 (see also fig. 22A, 22B). In contrast, as described above, the electrical path 310 has a smaller electrical gap from one high voltage electrical terminal 265 to another high voltage electrical terminal 265 (see, e.g., fig. 18, 22A, 22B) than if the male TPA device 201 were housed in the pre-lock orientation or the fully lock orientation, if the inventive male inner housing 230 were validated without the lower member 205 and male TPA device 201 therein. Further, the wing-

like side members

210, 214 advantageously prevent the electrical path 310 between the high voltage electrical terminals 265 from traveling through or across the top of the male TPA device 201 (see fig. 13A, 13B). The surface distance between the high voltage electrical terminals 265 of the inner and outer surfaces of the wing-

like side members

210, 214 is greater than the creepage or clearance surface provided along the lower member 205 and the male inner housing 230. Thus, the electrical clearance and creepage distance of the electrical path 310 extending along the male TPA device 201 is towards the vicinity of the lower member 205 (see also fig. 23A, 23B).

As further shown in fig. 22A, the electrical gap and/or creepage distance of the electrical path 310 extends substantially from one of the high voltage electrical terminals 265 to the other high voltage electrical terminal 265. As shown in fig. 20A, an electrical path emanates from one of the high voltage electrical terminals 265 into a portion of one of the first and

second channels

501, 502, respectively. The electrical gap and/or creepage distance of the electrical path 310 further extends in the first and

second vias

501 and 502, respectively, and exits into the middle via 400 (see fig. 21A). As shown in fig. 21A, the electrical pathway 310 exits from the first and

second vias

501 and 502, respectively, passes along a corresponding side surface of one of the first and

second notches

601 and 602, and may pass along a corresponding portion of a top surface of one of the first and

second notches

601 and 602, respectively (see fig. 20A). As shown in detail in fig. 21A, the electrical gap and/or creepage distance of the electrical pathway 310 further extends along and between a surface of one side of the lower member 205 and an inner surface of the central passage 400. Further, as shown in fig. 21A and 22A, the electrical clearance and/or creepage distance of the electrical path 310 enters and passes through a portion of the elongated slot 225 at one end of the male TPA device 201. Further, at an end opposite the elongated slot 225, an electrical gap and/or a creepage distance of the electrical pathways 310 extends through between an opposite end of the lower member 205 of the male TPA device 200 and a surface of the central passage 400 of the male inner housing 230. The electrical gap and/or creepage distance of the electrical path 310 further passes therebetween along the surface of one side of the lower member 205 and the inner surface of the middle passage 400 (see fig. 22A). The electrical path 310 then passes from the central passage 400 into one of the opposing first and

second passages

501 and 502, respectively (see fig. 23A). As shown in detail in fig. 23A, the electrical pathway 310 enters one of the opposing first and

second channels

501, 502, respectively, passes substantially along a corresponding side surface of one of the opposing first and

second notches

601, 602, and may pass along a top portion of one of the opposing first and

second notches

601, 602, respectively. Once the electrical path 310 further enters one of the opposing first and

second channels

501, 502, respectively, the electrical path 310 eventually leads directly to and into the other high voltage electrical terminal 265 (see fig. 22A, 23A). The order described above, which also has electrical paths 310 between terminals 265, may be reversed.

Fig. 19B and 20B show cross-sectional views of the male TPA device 201 in the male inner housing 230 in a fully locked position or orientation. Further, the lower member 205 of the male TPA device 200 is further received in a portion of the central channel 400 of the male inner housing 230 than in the aforementioned pre-lock position. Further, as previously described, the

intermediate members

228, 229 are located at their corresponding portions of the first and

second channels

501, 502, respectively. Here, as previously described, the wing-

like side members

210, 214 are located substantially in the opening 208. Here, as shown in detail in fig. 20B, in the fully locked position, the electrical gap and/or creepage distance from the electrical path 310 of one of the high voltage electrical terminals 265 substantially extends from the one of the high voltage electrical terminals 265 and into a portion of one of the first channel 501 and the second channel 502, respectively (see fig. 22B). In the fully locked position or orientation, the electrical pathway 310 further extends toward and/or along a side surface of one of the

intermediate members

228, 229, and further extends on a lower surface of the intermediate member 228, 229 (see fig. 21B). Also in fig. 20B, the electrical gap and/or creepage distance of the electrical path 310 further passes through and/or exits the first and

second vias

501 and 502, respectively, towards the middle via 400 (see also fig. 22B). Here, the male TPA device 201 is in a fully locked position with the

intermediate members

228, 229 substantially located in the first and

second channels

501, 502, respectively, and into the first and second recesses 601, 602 (see fig. 22B). This orientation thus creates substantially less clearance between the side surfaces of

intermediate members

228, 229 and the side surfaces of first recess 601 and second recess 602, respectively, as compared to the pre-locking orientation of male TPA device 201 (see fig. 20B, 23B). As shown in fig. 20B and 23B, the

intermediate members

228, 229 substantially contact the top surfaces of the

recesses

601, 602, therebetween at a portion of the top surfaces of the

recesses

601, 602. The substantially smaller clearance formed thereby directs electrical clearance and creepage distance further along and toward lower member 205, in a position substantially intersecting or aligned with the side surfaces of first notch 601 and second notch 602, and over a lesser or smaller portion of the corresponding top surfaces of first notch 601 and second notch 602, as compared to the pre-lock orientation. Accordingly, the electrical pathway 310 continues to travel extending through and/or out of one of the first and

second channels

501, 502, respectively, and substantially between and along the smaller portion of the corresponding side and top surfaces of one of its first and

second notches

601, 602 and the side surface of one of the intermediate members 228, 229 (see fig. 22B, 23B). Further, the electrical gap and/or creepage distance of the electrical path 310 further extends along and travels between the surface of one side of the lower member 205 and the inner surface of the middle passage 400 (see fig. 21B, 22B). As shown in fig. 22B, the electrical clearance and/or creepage distance of the electrical path 310 enters at one end of the male TPA device 201 and passes through a portion of the elongated slot 225. Further, at the end opposite the elongated slot 225, the electrical gap and/or creepage distance of the electrical pathways 310 extend through between the opposite end of the lower member 205 of the male TPA device 201 and the surface of the central passage 400 of the male inner housing 230. The electrical gap and/or creepage distance of the electrical path 310 further passes therebetween along the surface of one side of the lower member 205 and the inner surface of the middle passage 400 (see fig. 22B). As can be seen in fig. 23B, the electrical gap and/or creepage distance of the electrical path 310 further passes from the middle passage 400 into the first passage 501 and the second passage 502, respectively. The electrical vias 310 enter one of the opposing first and

second channels

501, 502, respectively, substantially between and along the corresponding side surface and a portion of the top surface of the respective one of the opposing first and

second recesses

601, 602 and the side surface of the respective one of the opposing intermediate members 228, 229 (see fig. 22B, 23B). Further, once the electrical path 310 further enters one of the opposing first and

second channels

501, 502, respectively, the electrical path 310 eventually leads directly to and into the other high voltage electrical terminal 265 (see fig. 22B, 23B). The order described above, which also has electrical paths 310 between terminals 265, may be reversed.

The present invention is not limited to the above embodiments; various modifications in design, structural arrangement, and the like may be used without departing from the scope or equivalents of the present invention.

The claims (modification according to treaty clause 19)

1. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a male terminal position assurance device, characterized by the steps of:

inserting at least one terminal inside a male inner housing of the high voltage connector assembly;

locking the terminal inside the male inner housing of the high voltage connector assembly;

providing the high-voltage connector assembly with a male outer housing with the male inner housing received therein;

causing an electrical gap or electrical path to extend from the at least one terminal to the male housing body; and

inserting the male terminal position assurance device through the opening of the male inner housing,

wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male housing body comprises: the step of extending the electrical gap or electrical path from the at least one terminal to the male housing body along a surface of the terminal position assurance device.

2. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, wherein the step is such that the electrical clearance or electrical path extends substantially vertically from the at least one terminal to the male housing body.

3. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further characterized by the steps of: locking the male terminal position assurance device into the male inner housing.

4. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further characterized by the steps of: inserting the male terminal position assurance device through the opening of the male inner housing and locking the male terminal position assurance device into the male inner housing, wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male outer housing comprises: the step of extending said electrical gap or electrical path from said at least one terminal to said male housing body along a surface of at least one substantially wing-shaped side member of said terminal position assurance device.

5. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further characterized by the steps of: inserting the male terminal position assurance device through the opening of the male inner housing and locking the male terminal position assurance device into the male inner housing, wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male outer housing comprises the steps of: extending said electrical gap or electrical path from said at least one terminal to said male housing body along a surface of at least one intermediate member of said at least one substantially wing-shaped side member of said terminal position assurance device and further along said at least one substantially wing-shaped side member of said terminal position assurance device.

6. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a female terminal position assurance device in a female housing of the high voltage connector assembly, characterized by the steps of:

inserting at least one high voltage electrical terminal inside the female housing of the high voltage connector assembly;

locking the high voltage electrical terminal inside the female housing of the high voltage connector assembly;

inserting the female terminal position assurance device into the female housing; and

such that an electrical gap or creepage distance of the electrical path extends from said at least one said high voltage electrical terminal to the other of said high voltage electrical terminals,

characterized in that said step of causing an electrical gap or creepage distance of an electrical path to extend from said at least one said high voltage electrical terminal to another one of said high voltage electrical terminals comprises the steps of: such that the electrical path extends substantially vertically from the at least one high voltage electrical terminal through a first top of a front portion of the female housing and a second top of the front portion of the female housing, and further extends substantially vertically to the other one of the high voltage electrical terminals.

7. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of extending an electrical clearance or creepage distance of an electrical path from the at least one of the high voltage electrical terminals to the other of the high voltage electrical terminals comprises the step of: such that the electrical path extends substantially vertically from the at least one high voltage electrical terminal through the top of the female housing and further substantially vertically to the other one of the high voltage electrical terminals.

8. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of inserting the female terminal position assurance device into the female housing comprises: a step of locking the female terminal position assurance device to the female housing in a pre-lock position.

9. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of inserting the female terminal position assurance device into the female housing comprises: a step of locking the female terminal position assurance device to the female housing in a full locking position.

10. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 2, wherein the female terminal position assurance device comprises extension members extending downward from forward extension members, respectively, and the female housing comprises a front portion.

11. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a male terminal position assurance device in a male housing of the high voltage connector assembly, characterized by the steps of:

inserting at least one high voltage electrical terminal inside the male housing of the high voltage connector assembly;

locking the high voltage electrical terminal inside the male housing of the high voltage connector assembly;

inserting the male terminal position assurance device into the male housing;

characterized in that said step of causing an electrical gap or creepage distance of an electrical path to extend from said at least one said high voltage electrical terminal to another one of said high voltage electrical terminals comprises the steps of: such that the electrical path extends from the at least one high voltage electrical terminal substantially through the lower member of the male terminal position assurance device and further substantially to the other one of the high voltage electrical terminals.

12. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of causing an electrical clearance or creepage distance of an electrical path to extend from the at least one of the high voltage electrical terminals to the other of the high voltage electrical terminals comprises the step of: such that the electrical path extends from the at least one high voltage electrical terminal substantially through the lower member of the male terminal position assurance device and further substantially to the other one of the high voltage electrical terminals.

13. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of inserting the male terminal position assurance device into the male housing comprises: a step of locking the female terminal position assurance device to the male housing in a pre-lock position.

14. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of inserting the male terminal position assurance device into the male housing comprises: a step of locking the male terminal position assurance device to the male housing in a full locking position.

15. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 2, wherein the male terminal position assurance device comprises substantially wing-shaped side members extending therefrom, respectively.

Claims

1. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a male terminal position assurance device, comprising the steps of:

such that an electrical gap or electrical path extends from the at least one terminal to the male housing body.

3. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further comprising the steps of: inserting the male terminal position assurance device through the opening of the male inner housing and locking the male terminal position assurance device into the male inner housing, wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male outer housing comprises: the step of extending the electrical gap or electrical path from the at least one terminal to the male housing body along a surface of the terminal position assurance device.

4. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further comprising the steps of: inserting the male terminal position assurance device through the opening of the male inner housing and locking the male terminal position assurance device into the male inner housing, wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male outer housing comprises: the step of extending said electrical gap or electrical path from said at least one terminal to said male housing body along a surface of at least one substantially wing-shaped side member of said terminal position assurance device.

5. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the male terminal position assurance device of claim 1, further comprising the steps of: inserting the male terminal position assurance device through the opening of the male inner housing and locking the male terminal position assurance device into the male inner housing, wherein the step of extending an electrical gap or electrical pathway from the at least one terminal to the male outer housing comprises the steps of: extending said electrical gap or electrical path from said at least one terminal to said male housing body along a surface of at least one intermediate member of said at least one substantially wing-shaped side member of said terminal position assurance device and further along said at least one substantially wing-shaped side member of said terminal position assurance device.

6. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a female terminal position assurance device in a female housing of the high voltage connector assembly, comprising the steps of:

such that an electrical gap or creepage distance of the electrical path extends from the at least one of the high voltage electrical terminals to the other of the high voltage electrical terminals.

7. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of causing an electrical clearance or creepage distance of an electrical path to extend from the at least one high voltage electrical terminal to the other of the high voltage electrical terminals comprises the step of: such that the electrical path extends substantially vertically from the at least one high voltage electrical terminal through the top of the female housing and further substantially vertically to the other one of the high voltage electrical terminals.

8. The method of improving electrical clearance and creepage distances in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of inserting the female terminal position assurance device into the female housing comprises: a step of locking the female terminal position assurance device to the female housing in a pre-lock position.

9. The method of improving electrical clearance and creepage distances in a high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 1, wherein the step of inserting the female terminal position assurance device into the female housing comprises: a step of locking the female terminal position assurance device to the female housing in a full locking position.

11. A method of improving electrical clearance and creepage distance in a high voltage connector assembly using a male terminal position assurance device in a male housing of the high voltage connector assembly, comprising the steps of:

inserting the male terminal position assurance device into the male housing;

12. The method of improving electrical clearance and creepage distance in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of causing an electrical clearance or creepage distance of an electrical path to extend from the at least one high voltage electrical terminal to the other of the high voltage electrical terminals comprises the step of: such that the electrical path extends from the at least one high voltage electrical terminal substantially through the lower member of the male terminal position assurance device and further substantially to the other one of the high voltage electrical terminals.

13. The method of improving electrical clearance and creepage distances in the high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of inserting the male terminal position assurance device into the male housing comprises: a step of locking the female terminal position assurance device to the male housing in a pre-lock position.

14. The method of improving electrical clearance and creepage distances in the high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 1, wherein the step of inserting the male terminal position assurance device into the male housing comprises: a step of locking the male terminal position assurance device to the male housing in a full locking position.

15. The method of improving electrical clearance and creepage distances in a high voltage connector assembly using the male terminal position assurance device in the male housing of the high voltage connector assembly of claim 2, wherein the male terminal position assurance device comprises substantially wing-shaped side members extending therefrom, respectively.