CN113841301B

CN113841301B - Method for improving electrical clearance and creepage distance in high voltage connector assemblies using male or female Terminal Position Assurance (TPA) devices

Info

Publication number: CN113841301B
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: 2024-03-08
Anticipated expiration: 2040-04-25
Also published as: CN113841301A; JP2022545756A

Abstract

Methods 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 high voltage electrical terminals. The method comprises the following steps: such that the electrical gap and creepage distance or path extends from at least one high voltage electrical terminal to the conductive male housing and/or between at least one high voltage electrical terminal to another terminal using a male or female TPA device. The TPA device is inserted into the high voltage connector assembly with electrical gaps and creepage distances or paths extending from the high voltage electrical terminals to the male housing of the high voltage connector assembly at least along a surface of the TPA device or from the high voltage electrical terminals 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 assemblies using male or female Terminal Position Assurance (TPA) devices

Cross Reference to Related Applications

The present patent application claims priority from U.S. provisional patent application Ser. No.62/810,179 and U.S. provisional patent application Ser. No.63/014,576, filed on 25.2.2019, the entire contents of which are incorporated herein by reference.

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 terminals; accordingly, when operating or using the connector assembly, it is desirable to improve or increase the electrical clearance and creepage distance of the electrical path of the possible associated short circuit current from at least one high voltage electrical terminal to another high voltage electrical terminal, component/circuit, and further to improve or increase the electrical clearance and creepage distance from at least one high voltage electrical terminal to a conductive housing, electrical component/circuit, or conventional metal stamping protection for protection.

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 Terminal Position Assurance (TPA) device or a female Terminal Position Assurance (TPA) device and a housing. The electrical path may be included in or associated with the short circuit current. The high voltage connector assembly of the present invention is particularly suited 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 a wing member having an intermediate member that extends substantially downward from the wing member and into the male housing thereof, respectively, during use and operation. The male TPA device of the present invention further 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 present invention, the "creepage distance" (shortest distance measured along a surface from any given circuit to any (typically adjacent) other circuit in a connector) and the "electrical clearance" (defined as, for example, the shortest electrical path measured 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 changing or affecting the electrical path that the short circuit current includes or is associated with 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 a female TPA device of the present invention.

Fig. 3 is a top elevation view of a female TPA device of the present invention.

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

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

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

Fig. 7 is a cross-sectional view taken along section line 7-7 in fig. 5 showing the corresponding high voltage electrical terminals with the corresponding forward downward extending members of the corresponding forward extending members of the female TPA device in a pre-lock position inside the female housing, and further showing the electrical clearance or creepage distance of the electrical paths extending from the high voltage electrical terminals as indicated by the vertical arrows.

Fig. 8 is a cross-sectional view taken along section line 8-8 in fig. 6 showing the corresponding high voltage electrical terminals with the corresponding forward downward extending members of the corresponding forward extending members of the female TPA device in a fully locked position inside the female housing, and further showing the electrical clearance or creepage distance of the electrical paths extending from the high voltage electrical terminals as indicated by the vertical arrows.

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

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

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

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

Fig. 13A is a perspective view of a male TPA device of the present invention assembled or mounted in a pre-locked position in a male inner housing.

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

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

Fig. 15 is a cross-sectional view of a portion of a high voltage connector assembly into which a high voltage electrical terminal is inserted to enable the male TPA device of the present invention to be received in a TPA window, and further illustrates the electrical clearance of an electrical path extending from the high voltage electrical terminal to the male housing 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 with the male TPA device of the present invention positioned in a TPA window with the male TPA device 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 and a male TPA device of the present invention positioned in a TPA window and showing an electrical clearance or creepage distance of an electrical path substantially along a surface of the male TPA device of the present invention.

Fig. 18 is a perspective view of the male inner housing of the present invention with high voltage electrical terminals 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 present 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 present 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 and a male TPA device of the present invention in a pre-locked position and showing an electrical clearance or creepage distance of an electrical path substantially along a surface of the male TPA device of the present 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 and the male TPA device of the present invention in a fully locked position and showing an electrical clearance or creepage distance of the electrical path substantially along the surface of the male TPA device of the present 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 and a male TPA device of the present invention in a pre-locked position and showing an electrical clearance or creepage distance of an electrical path substantially along a surface of the male TPA device of the present 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 and the male TPA device of the present invention in a fully locked position and showing an electrical clearance or creepage distance of the electrical path substantially along the surface of the male TPA device of the present 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 and a male TPA device of the present invention in a pre-locked position and showing an electrical clearance or creepage distance of an electrical path substantially along a surface of the male TPA device of the present 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 and the male TPA device of the present invention in a fully locked position and showing an electrical clearance or creepage distance of the electrical path substantially along the surface of the male TPA device of the present 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 and a male TPA device of the present invention in a pre-locked position and showing an electrical clearance or creepage distance of an electrical path substantially along a surface of the male TPA device of the present 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 and the male TPA device of the present invention in a fully locked position and showing an electrical clearance or creepage distance of the electrical path substantially along the surface of the male TPA device of the present 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 member 5. The middle member 3 extends from the upper portion 7 to the lower portion 9 of the rounded member 5. The rounded member 5 has forward extending members 10, 12 extending therefrom on opposite sides thereof.

In fig. 2, an upper rearwardly extending member 13 and a lower rearwardly extending member 15 are shown. 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.

In fig. 3, a top elevation view of the female TPA device 1 is shown 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 an upper rearwardly extending member 13 and a lower rearwardly extending member 15. The upper rear extension member 13 has an upper barb-like member 35 extending from the upper rear extension member 13 and the lower rear extension member 15 has a lower barb-like member 37 extending from the lower rear extension member 15. As shown in fig. 4, openings 40, 42 extend through both sides of the female TPA device 1 with the central member 3 therebetween.

Fig. 5 shows the female TPA device in a pre-locked position while inserted into female housing 50, mounted on female housing 50. The female housing 50 has a front 53 and a rear 55. Fig. 6 shows female TPA device 1 in a fully locked position while inserted into female housing 50, mounted on 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 present 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 of electrical path 110 on female housing 50 near female TPA device 1, with electrical path 110 extending from exposed high voltage electrical terminal 60 across the upper surface of front portion 53 of female housing 50 and toward the other exposed high voltage electrical terminal 60 inside front portion 53.

In accordance with the above-described features of the present invention, as illustrated in fig. 5 and 6, the "creepage distance" (the shortest electrical path measured along a surface from any given circuit (here one of the high voltage terminals 60) to any (typically adjacent) other circuit (here another high voltage terminal 60) running in one direction or along a 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) and the "electrical gap" (the shortest electrical path measured from any exposed conductive element (here another high voltage terminal 60) in a given circuit of the connector to any other conductive element (here another high voltage terminal 60) in a different circuit in the same connector) are advantageously improved, thereby altering or affecting the electrical path that the short circuit current includes or is associated with when the connector assembly is operated or used. Further, as shown by a broken line L in fig. 10, in another embodiment of the present invention, the exposed portion of one of the high-voltage 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 protruding member 62 extends from the lower portion of the female housing 50. The protruding member 62 includes a ramp-like leading end 65. The leading edge portion 68 of the terminal 60 then has a notch 70 such that the notch 70 readily passes the ramp-like leading end portion 65 of the projecting member 62 when the terminal 60 is fully inserted into the female housing 50. When the terminal 60 is fully inserted into the female housing 50, the protruding member 62 of the female housing 50 snaps into the recess 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 illustrates a cross-sectional view taken along line 7-7 in fig. 5 with the female TPA device 1 in a pre-lock position. As described above, when the protruding member 62 inside the female housing 50 is caught or entered into the recess 70 of the leading end portion 68 of the terminal 60, the terminal 60 is locked (first lock). Therefore, the terminal 60 cannot be pulled out from the female housing 50; at this time, the upper recess 80 of the terminal 60 is capable of receiving or accommodating therein a corresponding one of the front downward extending members 20, 22. That is, unless the terminal 60 is in the first lock inside the female housing 50, and the upper recess 80 of the terminal 60 is able to receive or accommodate therein a corresponding one of the front downward extending members 20, 22, the front downward extending members 20, 22 are unable to provide the necessary second lock for the terminal 60 inside the female housing 50. In other words, if terminal 60 is not first locked inside female housing 50, female TPA device 1 is prevented from being pushed further downward by upper portion 85 of leading end 68 of terminal 60. Thus, if the upper portion 85 of the leading end 68 of terminal 60 blocks the female TPA device 1 (and more specifically, blocks the forward downwardly extending members 20, 22 of the female TPA device 1), then the female TPA device 1 can detect that it cannot be pushed further downward and thus cannot provide a secondary lock to the terminal 60 inside the female housing 50 (i.e., the female TPA device 1 cannot be pushed further downward to the fully locked position).

Fig. 8 shows female TPA device 1 in a fully locked position inside female housing 50. Here, the upper side recess 80 of the terminal 60 becomes capable of receiving the front downward extension members 20, 22 of a corresponding one of the female TPA devices 1 therein; accordingly, when inserted into the upper recess 80 of a corresponding one of the terminals 60, the front downward extending members 20, 22 of the female TPA device 1 respectively block the terminal 60 from being pulled out of the inner housing 50, and thus can provide a second locking of the terminal 60 inside the female housing 50.

As further shown in each of pre-locked female TPA device 1 in fig. 7 and fully locked female TPA device 1 in fig. 8, as female TPA device 1 is oriented on or toward female housing 50, a creepage distance or an electrical clearance (see arrows) of electrical path 110 is shown extending substantially vertically from high voltage electrical terminals 60, further along or between corresponding one of forward downward extending members 20, 22 (of respective forward extending members 10, 12 of female TPA device 1), and along a vertical and/or substantially inclined or angled portion of front 53 of female housing 50. The front downward extending members 20, 22 are directed substantially rearward of a portion of the corresponding high voltage electrical terminals 60, respectively.

Female TPA device 1 is shown in a pre-locked position in female housing 50, for example in fig. 9 and 10. In fig. 9 and 10, the forwardly extending members 10, 12 of the female TPA device 1 are shown above and partially inserted into the front 53 of the female housing 50. In fig. 9 and 10, a creepage distance or clearance (see dashed lines) of the electrical pathway 110 is shown extending substantially vertically from one of the high voltage electrical terminals 60, further partially along or between one of the forward downwardly extending members 20 (of the respective forward extending member 10 of the female TPA device 1), and along a vertical and/or substantially angled or angled portion of the front 53 of the female housing 50, further traveling in one direction or extending and traversing along an upper surface of the front 53 of the female housing 50, and further extending substantially vertically into the other of the high voltage electrical terminals 60, extending along or between one of the forward downwardly extending members 22 (of the respective forward extending member 12 of the female TPA device 1), and extending along a vertical or substantially angled or angled portion of the front 53 of the female housing 50 (see fig. 6), and vice versa in reverse between the terminals 60, 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. The male TPA device 201 includes an upper member 203 and a lower member 205. The upper member 203 is substantially wing-shaped with sides 210, 214. The lower member 205 includes a flexible arm member 218 at a front portion thereof.

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

The end members 224, 226 are further shown in fig. 12 as extending generally downwardly from the wing-like side members 210, 214, respectively. Intermediate members 228, 229 also extend substantially downwardly 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-locked position in fig. 13A, in a fully locked position in fig. 13B, with the male TPA device 201 inserted through opening 208 (the opening 208 passing through the 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 fitted or installed in the male inner housing 230 in the lower opening 400 (see fig. 18, 21A, 21B). Fig. 13A and 13B also show mating grooves 232, 234, 236 on the outer surface of the male inner housing 230 for enabling the male TPA device 201 to be installed or inserted into the male outer housing 260 of the high voltage connector assembly 200 (see fig. 14-17).

Fig. 14 is a cross-sectional view of a high voltage connector assembly having a male inner housing 230 with a male TPA device 201 in a pre-lock position or orientation. Fig. 14 further shows male TPA device 201 in male inner housing 230 and male outer housing 260. High voltage connector assembly 200 has high voltage electrical terminals 265 inserted therein to enable receipt of male TPA device 201 of the present invention in TPA window 272 as shown by the square sections separated by the dashed lines.

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

The present invention is directed to a method of improving electrical clearance and creepage distance in high voltage connector assembly 200 using a male TPA device 201. The high voltage connector assembly 200 is particularly suited for use with high voltage electrical terminals 265 (larger terminals). The disclosed TPA device 201 includes wing-like side members 210, 214 with intermediate members 228, 229, the intermediate members 228, 229 extending 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.

According to the above-described features of the present invention, the "creepage distance" (the shortest electrical path measured along a surface from an electrical circuit (here, high voltage electrical terminal 265) to travel in one direction or along a surface (here, the surfaces of male TPA device 201 and male inner housing 230) to any (typically adjacent) other electrical circuit (here, electrically conductive male housing 260 or a conventional stamped metal housing (not shown)) and the "electrical clearance" (the shortest electrical path measured from any exposed conductive element (here, high voltage electrical terminal 265) in a given electrical circuit of a connector to any other conductive element (here, male housing 260 or a conventional stamped metal housing (not shown)) in a different electrical circuit in the same connector) are advantageously improved, thereby altering or affecting the electrical path included 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 a high voltage connector assembly 200 of the present invention with high voltage electrical terminals 265 inserted into a male inner housing 230 into which a male TPA device 201 of the present invention is inserted in a fully locked position or orientation. The corresponding wing-like side members 210, 214 are received in the opening 208 (see also fig. 13B), and the intermediate members 228, 229 thereof are received in the TPA windows 272. As shown in fig. 16, the intermediate member 228 is located substantially immediately 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 with a high voltage electrical terminal 265 and a male TPA device 201 of the present invention inserted therein. The intermediate members 228, 229 are located in the TPA window 272 and substantially just behind a portion of the high voltage electrical terminals 265, wherein the electrical gap and/or creepage distance of the electrical paths 210 is shown, which travels at least from the high voltage electrical terminals 265 to the male housing 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 a surface of at least one of the intermediate members 228, 229 and a surface of the male inner housing 230, further along or between a surface of at least one of the corresponding wing-like side members 210, 214 and a surface of the male inner housing 230, and still further along the opening 208 (the opening 208 passing through and substantially straight through an upper portion of the male inner housing 230) just to the male outer housing 260 of the high voltage connector assembly 200.

The male inner housing 230 is further shown in fig. 18 with a first channel 501 and a second channel 502, respectively. First channel 501 and second channel 502 may receive intermediate members 228, 229, respectively, of male TPA device 201 therein. 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 and second middle recesses 601 and 602 define open portions and lower portions of the first and second channels 501 and 502, where the first and second channels 501 and 502 each enter and extend into the middle channel 400, respectively. An upper portion of each of the first channel 501 and the second channel 502 is defined by the opening 208. As will be discussed later, the lower surfaces of the intermediate members 228, 229 additionally further define upper portions of the first and second channels 501, 502, respectively, when the male TPA device 201 is in a pre-lock position in the male inner housing 230 (see fig. 19A, 19B).

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

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

Fig. 19A is a cross-sectional view of male TPA device 200 clearly showing terminal 265 housed inside male housing 30 in a pre-locked 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 the male TPA device 201 is in the pre-lock position, the lower member 205 is inserted into a portion of the 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 channel 501 and the second channel 502. Further, the pre-lock orientation thus aligns the first channel 501 and the second channel 502 of the male inner housing 230 under a corresponding one of the intermediate members 228, 229 (with a corresponding one of the nubs 231, 233) of the male TPA device 1. Thus, the first channel 501 and the second channel 502 can accommodate 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 defining respective upper portions of the first and second channels 501, 502.

In fig. 19B, male TPA device 201 is shown in a fully locked position. As shown, the foregoing has described that where the male TPA device 201 is pushed further downward 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). Accordingly, male TPA device 1 is in the fully locked position in male inner housing 230 and terminal 265 cannot be removed from male inner housing 230 (i.e., male TPA device 1 acts as a second lock of terminal 65 in male inner housing 30). Here, the male TPA device 1 is in the fully locked 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 in the pre-locked position. Thus, as shown in fig. 21B, when the TPA is in the fully locked position, the elongate slot 225 of the lower member 205 is positioned further down, substantially in the central passage 400 (see fig. 22B). When male TPA device 1 is in the fully locked position, an upper portion of elongate slot 225 and a smaller portion thereof are positioned above and flush with first channel 501 and second channel 502 to accommodate an electrical clearance and/or creepage distance of electrical path 310, as will be discussed further below (see fig. 21B, 22B).

As shown in more detail in fig. 21A and 21B, when the male TPA device 201 is in effect and positioned in the male inner housing 230, the lower member 205 acts as a "wall" or "stop" in the male inner housing 230 and is positioned substantially between the high voltage electrical terminals 265 (see also fig. 22A, 22B). In effect, the lower member 205 adds substantially further surface to the length of the male inner housing in the central passage 400 of the male inner housing 230, and the electrical pathway 310 extends substantially as previously described in the male inner housing 230 (see fig. 18, 19A, 19B). Accordingly, the lower member 205 thus increases the creepage distance and clearance of the electrical path 310 (see also fig. 22A, 22B). In contrast, as described above, electrical pathway 310 has a smaller electrical clearance from one high voltage electrical terminal 265 to another high voltage electrical terminal 265 than if the lower member 205 of the present invention and male TPA device 201 were not present in an active male inner housing 230 when the male TPA device 201 is received in either the pre-lock orientation or the fully locked orientation (see, e.g., fig. 18, 22A, 22B). Further, wing-like side members 210, 214 advantageously prevent electrical pathway 310 between high voltage electrical terminals 265 from traveling through or across the top of 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 distance or electrical clearance surfaces provided along the lower member 205 and the male housing 230. Accordingly, the electrical clearance and creepage distance of electrical path 310, which extends along male TPA device 201, is directed toward the vicinity of lower member 205 (see also fig. 23A, 23B).

As further shown in fig. 22A, the electrical gap and/or creepage distance of electrical path 310 extends substantially from one of 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 terminals 265 into a portion of one of the first channel 501 and the second channel 502, respectively. The electrical gap and/or creepage distance of the electrical path 310 further extends in the first channel 501 and the second channel 502, respectively, and exits into the middle channel 400 (see fig. 21A). As shown in fig. 21A, the electrical pathway 310 exits from the first and second channels 501 and 502, respectively, passes along a corresponding side surface of one of the first and second recesses 601 and 602, and may travel along a corresponding portion of a top surface of one of the first and second recesses 601 and 602, respectively (see fig. 20A). As shown in detail in fig. 21A, the electrical gap and/or creepage distance of electrical path 310 further extends along the surface of one side of lower member 205 and the inner surface of middle channel 400 therebetween. Further, as shown in fig. 21A and 22A, the electrical clearance and/or creepage distance of electrical path 310 enters and passes through a portion of elongate slot 225 at one end of male TPA device 201. Further, at the end opposite elongated slot 225, an electrical gap and/or creepage distance of electrical path 310 extends through between the opposite end of lower member 205 of male TPA device 200 and the surface of middle passage 400 of 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 channel 400 (see fig. 22A). The electrical pathway 310 then enters one of the opposing first 501 and second 502 channels (see fig. 23A) from the central channel 400, respectively. 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 recesses 601, 602, and may pass along a top portion of one of the opposing first and second recesses 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 with the electrical path 310 between terminals 265 may also be reversed.

Fig. 19B and 20B show cross-sectional views of male TPA device 201 in a fully locked position or orientation in male housing 230. Further, the lower member 205 of the male TPA device 200 is further received in a portion of the central passage 400 of the male inner housing 230 than in the pre-lock position previously described. Further, as previously described, the intermediate members 228, 229 are located in their respective portions of the first channel 501 and the second channel 502. Here, as previously described, the wing-like side members 210, 214 are located substantially within the opening 208. Here, shown in detail in fig. 20B, in the fully locked position, the electrical gap and/or creepage distance of the electrical path 310 from one of the high voltage terminals 265 extends substantially from one of the high voltage 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 extends further 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 channels 501, 502, respectively, toward the middle channel 400 (see also fig. 22B). Here, the male TPA device 201 is in full lock, 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 forms a substantially smaller void between the side surfaces of the intermediate members 228, 229 and the side surfaces of the first and second recesses 601, 602, respectively, as compared to the pre-locked orientation of the 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 void formed thereby directs the electrical gap and creepage distance further along and toward the lower member 205 than in the pre-lock orientation, is located at a position that substantially intersects or aligns with the side surfaces of the first recess 601 and the second recess 602, and is at a smaller or smaller portion of the corresponding top surfaces of the first recess 601 and the second recess 602. Accordingly, the electrical pathway 310 continues to travel extending through and/or away from 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 recesses 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 the surface of one side of the lower member 205 and the inner surface of the middle channel 400 therebetween (see fig. 21B, 22B). As shown in fig. 22B, the electrical clearance and/or creepage distance of electrical path 310 enters and passes through a portion of elongate slot 225 at one end of male TPA device 201. Further, at the end opposite elongated slot 225, an electrical gap and/or creepage distance of electrical path 310 extends through between the opposite end of lower member 205 of male TPA device 201 and the surface of middle passage 400 of 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 channel 400 (see fig. 22B). As can be seen in fig. 23B, the electrical gap and/or creepage distance of the electrical path 310 passes further from the middle channel 400 into the first channel 501 and the second channel 502, respectively. The electrical pathway 310 enters into and along one of the opposing first and second channels 501, 502, respectively, substantially between and along a portion of the corresponding side surfaces of the respective one of the opposing first and second recesses 601, 602 and the side surfaces of the respective one of the opposing intermediate members 228, 229 (see fig. 22B, 23B). Further, once the electrical pathway 310 further enters one of the opposing first and second channels 501, 502, respectively, the electrical pathway 310 eventually leads directly to and into the other high voltage electrical terminal 265 (see fig. 22B, 23B). The order described above with the electrical path 310 between terminals 265 may also be reversed.

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

Claims

1. A method for 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 terminals 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;

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

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

characterized in that said step of extending an electrical gap or path from said at least one terminal to said male housing comprises: and extending the electrical gap or path from the at least one terminal to the male housing 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 path extends substantially vertically from the at least one terminal to the male housing.

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 an 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 path from the at least one terminal to the male outer housing comprises: and extending the electrical gap or path from the at least one terminal along a surface of at least one substantially wing-shaped side member of the terminal position assurance device to the male housing.

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 an 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 path from the at least one terminal to the male outer housing comprises the steps of: the electrical gap or path is extended from the at least one terminal along a surface of at least one intermediate member of at least one substantially wing-shaped side member of the terminal position assurance device and further along the at least one substantially wing-shaped side member of the terminal position assurance device to the male housing.

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 the at least one of the high voltage electrical terminals to the other one of the high voltage electrical terminals,

characterized in that said step of extending an electrical gap or creepage distance of an electrical path from said at least one of said high voltage electrical terminals to another one of said high voltage electrical terminals comprises the steps of: such that the electrical pathway 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 of the high voltage electrical terminals.

7. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 6, wherein the step of extending an electrical clearance or creepage distance of an electrical path from the at least one high voltage electrical terminal to another one of the high voltage electrical terminals includes the steps of: such that the electrical pathway 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 of the high voltage electrical terminals.

8. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 6, wherein the step of inserting the female terminal position assurance device into the female housing includes: and 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 the high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 6, wherein the step of inserting the female terminal position assurance device into the female housing includes: and a step of locking the female terminal position assurance device to the female housing in a fully locked position.

10. The method of improving electrical clearance and creepage distance in the high voltage connector assembly using the female terminal position assurance device in the female housing of the high voltage connector assembly of claim 6, wherein the female terminal position assurance device includes extension members that extend downward from forward extension members, respectively, and the female housing includes 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 extending an electrical gap or creepage distance of an electrical path from said at least one of said high voltage electrical terminals to another one of said high voltage electrical terminals comprises the steps of: such that the electrical pathway 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 of the high voltage electrical terminals.

12. The method of improving electrical clearance and creepage distance 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 11, wherein the step of extending an electrical clearance or creepage distance of an electrical path from the at least one high voltage electrical terminal to another one of the high voltage electrical terminals includes the steps of: such that the electrical pathway 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 of the high voltage electrical terminals.

13. The method of improving electrical clearance and creepage distance 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 11, wherein the step of inserting the male terminal position assurance device into the male housing includes: and a step of locking the male terminal position assurance device to the male housing in a pre-lock position.

14. The method of improving electrical clearance and creepage distance 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 11, wherein the step of inserting the male terminal position assurance device into the male housing includes: and a step of locking the male terminal position assurance device to the male housing in a fully locked position.

15. The method of improving electrical clearance and creepage distance 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 11, wherein the male terminal position assurance device includes substantially wing-shaped side members that each extend therefrom.