Power connector

Abstract

The invention relates to a power connector. A power connector includes a housing extending between a mating end and a wire end. The mating end is configured to mate with a mating power connector. The housing includes a terminal channel. The housing includes a chamber at the wire end. The power connector includes a terminal received in the terminal channel. The terminal includes a mating end configured to mate to a mating terminal of a mating power connector. The terminal includes a termination end terminated to the power line. A power cord extends from a wire end of the housing. The power connector includes a TPA device received in the chamber. The TPA device includes a terminal blocking element located rearward of the terminal for blocking the terminal in the terminal channel and ensuring a position of the terminal in the terminal channel. The TPA device includes a sealing element for sealing the chamber of the housing.

Description

Technical Field

[0001] The subject matter herein relates generally to power connectors. Background Art

[0002] Conventional power connectors are used in various applications. For example, power connectors can be used in appliances, vehicles, computers, network devices, industrial applications or other applications. In some applications, the power connector is arranged in a sealed environment, such as surrounded by potting materials or insulating foam to fix the power connector in a machine or device (such as an appliance). For example, the insulating material can form a thermal shell around a portion of the appliance. In applications where the surrounding material is applied to a position around the power connector, problems may arise regarding the entry of material into the housing of the power connector, which may result in connection problems of the power connector in terms of field failure and / or rework costs. For example, if the power connector is not sealed to the environment, the material may enter the internal space of the power connector through an opening or interface between various components of the power connector. For example, some power connectors may include a terminal position assurance (TPA) device at the rear of the power connector. The material may enter the housing of the power connector at the interface between the TPA device and the housing or at the interface between the TPA device and the power cord.

[0003] There remains a need for a robust power connector that can be sealed to prevent material or debris from entering the interior portion of the power connector. Summary of the invention

[0004] In one embodiment, a power connector is provided, and the power connector includes a housing extending between a mating end and a line end. The mating end is configured to mate with a mating power connector. The housing includes a terminal channel. The housing includes a chamber at the line end. The power connector includes a terminal received in the terminal channel. The terminal includes a mating end configured to mate to a mating terminal of a mating power connector. The terminal includes a terminating end terminated to a power line. The power line extends from the line end of the housing. The power connector includes a terminal position assurance (TPA) device received in the chamber. The TPA device includes a terminal blocking element, which is located behind the terminal for blocking the terminal in the terminal channel and ensuring the position of the terminal in the terminal channel. The TPA device includes a sealing element for sealing the chamber of the housing.

[0005] In another embodiment, a power connector is provided, and the power connector includes a housing extending between a mating end and a wire end. The mating end is configured to mate with a mating power connector. The housing includes a terminal channel. The housing includes a chamber at the wire end. The power connector includes a terminal received in the terminal channel. The terminal includes a mating end configured to mate with a mating terminal of a mating power connector. The terminal includes a terminating end terminated to a power cord. The power cord extends from the wire end of the housing. The power connector includes a terminal position assurance (TPA) device received in the chamber. The TPA device includes a terminal blocking element located behind the terminal for blocking the terminal in the terminal channel and ensuring the position of the terminal in the terminal channel. The TPA device includes a sealing element for sealing the chamber of the housing. The TPA device includes a wire seal configured to seal between the TPA device and the power cord.

[0006] In another embodiment, a power connector is provided, and the power connector includes a housing extending between a mating end and a wire end. The mating end is configured to mate with a mating power connector. The housing includes a terminal channel. The housing includes a chamber at the wire end. The power connector includes a terminal received in the terminal channel. The terminal includes a mating end configured to mate with a mating terminal of a mating power connector. The terminal includes a termination end terminated to a power cord. The power cord extends from the wire end of the housing. The power connector includes a terminal position assurance (TPA) device received in the chamber. The TPA device includes a TPA base, which includes a wire channel configured to receive a power cord. The TPA base includes a sealing element for sealing the chamber of the housing. The TPA device includes a terminal blocking element, which is located behind the terminal for blocking the terminal in the terminal channel and ensuring the position of the terminal in the terminal channel. The TPA device includes a cover connected to the TPA base to close the wire channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 A power connector according to an exemplary embodiment is illustrated.

[0008] Figure 2 is a cross-sectional view of a power connector according to an exemplary embodiment.

[0009] Figure 3 is a cross-sectional view of a power connector according to an exemplary embodiment.

[0010] Figure 4 is a rear perspective view of a TPA device according to an exemplary embodiment.

[0011] Figure 5 is a front perspective view of a portion of a TPA apparatus according to an exemplary embodiment.

[0012] Figure 6is an exploded rear perspective view of a TPA apparatus according to an exemplary embodiment.

[0013] Figure 7 is a partially assembled rear perspective view of a TPA apparatus according to an exemplary embodiment.

[0014] Figure 8 is a rear perspective view of a power connector according to an exemplary embodiment showing a TPA device ready to be loaded into a housing.

[0015] Fig. 9 is a bottom perspective view of a TPA apparatus according to an exemplary embodiment.

[0016] Fig.10 is a top perspective view of a TPA apparatus according to an exemplary embodiment.

[0017] Fig.11 is a rear perspective view of a power connector according to an exemplary embodiment.

[0018] Fig.12 According to an exemplary embodiment Fig.11 An exploded view of the power connector is shown in FIG.

[0019] Fig.13 According to an exemplary embodiment, Fig.11 and Fig.12 A front perspective view of the TPA device of the power connector is shown in FIG.

[0020] Fig.14 According to an exemplary embodiment, Fig.11 and Fig.12 A rear perspective view of the TPA device showing the power connector. DETAILED DESCRIPTION

[0021] Figure 1 A power connector 100 is shown according to an exemplary embodiment. The power connector 100 is configured to be electrically connected to a mating power connector 10. The power connector 100 may be used in various applications such as appliances, automobiles, industries, networks, computers, or other applications. For example, in an exemplary embodiment, the power connector 100 may be used in an appliance such as a refrigerator to power one or more components of the refrigerator, such as a light or an ice maker of the refrigerator. In alternative embodiments, the power connector 100 may be used in other types of devices.

[0022] In an exemplary embodiment, the power connector 100 can be integrated into a device (appliance). For example, the power connector 100 can be integrated into the insulating foam of a refrigerator to fix the power connector 100 within the appliance. The insulating foam can be formed in a position around the power connector 100 to encapsulate a portion of the power connector 100 within the appliance. In various embodiments, after the power connector 100 is mated with the mating power connector 10, the insulating foam can be formed around the power connector 100. In an exemplary embodiment, the power connector 100 is sealed to prevent materials such as insulating foam from entering the internal portion of the power connector 100 to damage the terminals of the power connector 100. As such, the power connector 100 provides a robust electrical connection that can be used in specific applications (such as in an appliance).

[0023] The power connector 100 includes a housing 110 that holds one or more terminals 150 that terminate to the ends of a power cord 152. The power connector 100 includes a terminal position assurance (TPA) device 200 that is used to improve the quality and reliability of the power connector 100 by preventing terminal back-out and ensuring proper positioning of the terminals in the housing 110. In an exemplary embodiment, the TPA device 200 provides a sealed interface with the housing 110 and / or the power cord 152 to prevent the ingress of material into the housing 110, such as the ingress of insulating foam during application of the foam around the power connector 100.

[0024] The mating power connector 10 includes a housing 12 that holds one or more terminals 50 ( Figure 2 ), the terminal 50 is terminated to the end of the corresponding power line 52. In the exemplary embodiment, the terminal 50 is a socket contact having a receptacle for receiving a terminal of the power connector 100. However, in alternative embodiments, the terminal 50 may include other types of contacts, such as pin contacts, tab contacts, beam contacts, blade contacts, etc. The mating power connector 10 may include a TPA device 60. In the exemplary embodiment, the housing 12 includes a latch feature 14, such as a deflectable latch, which is configured to be latchably coupled to the power connector 100. In the exemplary embodiment, the mating power connector 10 includes a connector seal 20, which is configured to provide a sealed interface between the mating power connector 10 and the power connector 100.

[0025] Figure 2 is a cross-sectional view of a power connector 100 according to an exemplary embodiment. Figure 3 is a cross-sectional view of a power connector 100 according to an exemplary embodiment. Figure 2 and Figure 3 The terminal 150 and the power line 152 arranged in the housing 110 of the power connector 100 are shown. Figure 2 and Figure 3The TPA device 200 is shown disposed in the housing 110 of the power connector 100 .

[0026] The housing 110 holds the terminals 150 for mating with the power connector 10 ( Figure 1 ) are matched. In an exemplary embodiment, the housing 110 is made of a dielectric material (such as a plastic material). The housing 110 may be a molded structure. In various embodiments, the housing 110 is a single-piece housing. However, in alternative embodiments, the housing 110 may be a multi-piece housing.

[0027] The housing 110 extends between a mating end 112 and a wire end 114. The mating end 112 is configured to mate with the mating power connector 10. The power cord 150 extends from the wire end 114. In the illustrated embodiment, the wire end 114 is opposite to the mating end 112. However, in alternative embodiments, other orientations are possible. For example, the housing 110 may be a right-angle housing having a wire end 114 perpendicular to the mating end 112. The housing 110 extends between a front portion 116 and a rear portion 118. In the illustrated embodiment, the mating end 112 is disposed at the front portion 116, and the wire end 114 is disposed at the rear portion 118. The housing 110 includes a top portion 120 and a bottom portion 122. The housing 110 includes side portions 124, 126 extending between the top portion 120 and the bottom portion 122. In the illustrated embodiment, the housing 110 is a parallelepiped (e.g., substantially rectangular). In alternative embodiments, other shapes are possible.

[0028] In an exemplary embodiment, the housing 110 includes a latching feature 128 that is configured to latchably couple to the mating power connector 10. In the illustrated embodiment, the latching feature 128 is disposed at the top 120. In alternative embodiments, other locations are possible. The latching feature 128 may include one or more latching surfaces that are configured to interface with the latching feature 14 of the mating power connector 10. In alternative embodiments, other types of securing features may be used, such as fasteners, clips, etc.

[0029] The housing 110 includes a terminal passage 130 that receives a corresponding terminal 150. In the illustrated embodiment, the housing 110 includes three terminal passages 130 that receive the corresponding terminal 150. In an alternative embodiment, more or less terminal passages 130 may be provided. The terminal passages 130 are separated from each other by a separation wall 132. In an exemplary embodiment, the housing 110 includes a primary latch 134 in the corresponding terminal passage 130. The primary latch 134 is used to fix the terminal 150 in the terminal passage 130. In an exemplary embodiment, the primary latch 134 is a deflectable latch that is configured to latch behind the latch surface of the corresponding terminal 150. In the illustrated embodiment, the primary latch 134 is positioned along the top side of the terminal 150. In an alternative embodiment, other positions are possible. In an exemplary embodiment, each terminal passage 130 includes a front portion 136 and a rear portion 138. The rear portion 138 receives a power line 152 in addition to receiving the terminal 150. The rear portion 138 can be oversized relative to the front portion 136 to receive both the power cord 152 and the terminal 150. In the illustrated embodiment, the primary latch 134 is located in the front portion 136. The housing 110 can include an angled wall transitioning between the front portion 136 and the rear portion 138 to guide the terminal 150 into the front portion 136 when the terminal 150 is loaded into the terminal channel 130.

[0030] The TPA device 200 is used as an auxiliary fixing feature to retain the terminal 150 in the terminal channel 130 (such as in the event that the primary latch 134 is broken or fails). Optionally, a portion of the TPA device 200 may extend into the rear portion 138 of the terminal channel 130 to interface with the terminal 150. In an exemplary embodiment, the TPA device 200 ensures that the terminals 150 are fully loaded into the terminal channel 130 and properly interact with the primary latch 134. For example, if one or more of the terminals 150 are improperly loaded into the housing 110, the TPA device 200 may not be able to be fully loaded into the housing 110 to provide a visual indication to the installer that the terminal 150 is improperly loaded into the housing 110. In other various embodiments, the TPA device 200 is operable to push the terminal 150 forward in the terminal channel 130 to a fully loaded position in which the primary latch 134 can be latchably coupled to the terminal 150.

[0031] In an exemplary embodiment, the housing 110 includes a chamber 140 that receives the TPA device 200. In the illustrated embodiment, the chamber 140 is disposed at the rear 118 of the housing 110. The chamber 140 is open to the terminal passage 130. The terminal 150 can be loaded into the corresponding terminal passage 130 through the chamber 140. The chamber 140 is an enlarged area that is sized and shaped to receive the TPA device 200. In an exemplary embodiment, the TPA device 200 can be sealingly connected to the housing 110 in the chamber 140. For example, the TPA device 200 can engage or dock with an inner surface 142 of the housing 110 that defines the chamber 140. The TPA device 200 can prevent material, such as insulating foam, from entering the interior of the housing 110 between the TPA device 200 and the inner surface 142. For example, the TPA device 200 can engage the inner surface 142 through an interference fit, thereby preventing or eliminating any space between the TPA device 200 and the inner surface 142 for material to enter.

[0032] In an exemplary embodiment, each terminal 150 includes a mating end 154 and a terminating end 156. The mating end 154 is configured to mate with the terminal 50 of the mating power connector 10. In various embodiments, the mating end 154 may include a tab contact configured to be inserted into a socket of the terminal 50. In alternative embodiments, other types of contacts may be used, such as a pin, a socket, a blade, a spring beam, or another type of contact. The terminating end 156 is configured to terminate to the power cord 152. In an exemplary embodiment, the terminating end 156 includes a crimp barrel 158, which is configured to be crimped to the end of the power cord 152, such as crimped to the center conductor and jacket of the power cord 152. In alternative embodiments, other types of termination features may be used, such as insulation displacement contacts, welding pads, soldering portions, or another type of termination features.

[0033] In an exemplary embodiment, the terminal 150 includes a latching element 160. The primary latch 134 is configured to interface with the latching element 160 to secure the terminal 150 in the terminal passage 130. The latching element 160 may be a wall or surface configured to be engaged by the primary latch 134. In an exemplary embodiment, the terminal 150 includes a stabilizing feature 162. The stabilizing feature 162 is configured to interface with the TPA device 200 to block the terminal 150 or prevent the terminal 150 from being pulled out of the terminal passage 130. The stabilizing feature 162 may be located at the rear of the terminal 150. The stabilizing feature 162 may be defined by a wall or tab at the rear of the terminal 150. The stabilizing feature 162 may be defined by the crimp barrel 158.

[0034] Figure 4 is a rear perspective view of a TPA device 200 according to an exemplary embodiment. Figure 5 is a front perspective view of a portion of a TPA apparatus 200 according to an exemplary embodiment. Figure 6is an exploded rear perspective view of a TPA apparatus 200 according to an exemplary embodiment. Figure 7 is a partially assembled rear perspective view of a TPA device 200 according to an exemplary embodiment.

[0035] The TPA device 200 includes a body 202 configured to receive the power cord 152 and to mate with the terminal 150 to retain the terminal 150 in the housing 110 ( Figure 2 and Figure 3 ). In an exemplary embodiment, the body 202 is made of a dielectric material, such as a plastic material. The body 202 may be a molded component. In an exemplary embodiment, the TPA device 200 includes a wire sealing portion 204 configured to seal to the power cord 152 and a housing sealing portion 206 configured to seal to the housing 110. In an exemplary embodiment, the TPA device 200 includes a wire seal 250 at the wire sealing portion 204. The wire seal 250 is separate and discrete from the body 202. The wire seal 250 may be held by the body 202 to interface with the power cord 152. The wire seal 250 may be made of a different material from the body 202.

[0036] The TPA device 200 includes a TPA base 210 and a cover 230. The cover 230 is configured to be coupled to the TPA base 210 to cover one or more openings in the TPA base 210 and prevent material from entering through the TPA device 200. The TPA device 200 includes a terminal blocking element 240 configured to block the terminal 150 and provide position assurance of the terminal 150 in the housing 110.

[0037] The TPA base 210 includes a wire channel 212 therethrough, the wire channel 212 being configured to receive a corresponding power cord 152. In an exemplary embodiment, the TPA base 210 includes a slot 214 that is open to the wire channel 212. The power cord 152 can be loaded into the wire channel 212 through the slot 214. The TPA base 210 extends between a front portion 216 and a rear portion 218. The TPA base 210 includes a top portion 220 and a bottom portion 222. The TPA base 210 includes opposite sides 224, 226 extending between the top portion 220 and the bottom portion 222. The TPA base 210 is sized and shaped to fit in the chamber 140 of the housing 110. In an exemplary embodiment, the TPA base 210 may be generally rectangular. Optionally, the TPA base 210 may include curved corners where the sides 224, 226 intersect the top portion 220 and / or the bottom portion 222. In alternative embodiments, TPA base 210 may have other shapes.

[0038] The wire channel 212 passes through the TPA base 210 between the rear portion 218 and the front portion 216. In the illustrated embodiment, the slot 214 is provided at the bottom 222. However, in alternative embodiments, the slot 214 may be located at the top 220. In other alternative embodiments, the TPA base 210 may not be provided with the slot 214. Instead, the power cord 152 may be loaded into the wire channel 212 through the rear portion 218.

[0039] In an exemplary embodiment, the terminal blocking element 240 extends from the front 216 of the TPA base 210. The terminal blocking element 240 extends to a distal end 242. The distal end 242 is configured to abut with the terminal 150 to block the terminal 150 in the terminal channel 130 of the housing 110. In the illustrated embodiment, the TPA device 200 includes a pair of terminal blocking elements 240, which are located on the sides of each of the wire channels 212. A gap 244 is provided between the terminal blocking elements 240. The gap 244 is configured to receive a portion of the separation wall 132 of the housing 110. The terminal blocking elements 240 have openings between the terminal blocking elements 240 at the top and bottom. However, in alternative embodiments, the terminal blocking elements 240 may additionally or alternatively extend in front of the TPA base 210 along the top and / or bottom of the power cord 152. For example, in various embodiments, the terminal blocking element 240 may extend completely around the power line 152 circumferentially to form a cylindrical shield around the power line 152, rather than having flanking terminal blocking elements 240, such as Figure 4-7 As shown in .

[0040] In an exemplary embodiment, the TPA device 200 includes one or more latches 246 for securing the TPA device 200 to the housing 110. In the illustrated embodiment, the latches 246 are disposed at the sides 224, 226 of the TPA base 210. The latches 246 extend in front of the TPA base 210. The latches 246 may be deflectable. In an exemplary embodiment, the latches 246 are configured to release from the housing 110 to allow the TPA device 200 to be removed from the housing 110. In alternative embodiments, other types of securing features (such as fasteners, clips, etc.) may be used to secure the TPA device 200 to the housing 110.

[0041] In an exemplary embodiment, the cover 230 is configured to be coupled to the rear portion 218 of the TPA base 210. The cover 230 can cover a portion of the wire channel 212. In an exemplary embodiment, the cover 230 is attached to the TPA base 210 by a hinge 232. For example, the cover 230 can be integral with the TPA base 210, such as being co-molded with the TPA base 210 during a co-molding process. However, in alternative embodiments, the cover 230 can be a separate and discrete component from the TPA base 210 that is configured to be coupled to the TPA base 210, such as after the wire seal 250 and / or the power cord 152 are received in the TPA base 210.

[0042] The cover 230 includes an end wall 234 configured to cover a rear end of the TPA base 210. In various embodiments, the cover 230 may include a sealing rib 235 at a front portion of the end wall 234. The sealing rib 235 is configured to interface with the wire seal 250. For example, when the cover 230 is coupled to the TPA base 210, the sealing rib 235 may be pressed inwardly against the wire seal 250. The sealing rib 235 may retain the wire seal 250 in the TPA base 210. When the cover 230 is closed, the sealing rib 235 may compress the wire seal 250.

[0043] The cover 230 includes an opening 236 aligned with the wire channel 212. The opening 236 is configured to receive the corresponding power wire 152. Optionally, the opening 236 can be open at the bottom of the cover 230 to allow the cover 230 to be installed on the TPA base 210 (e.g., rotating the cover 230 to a closed position).

[0044] In an exemplary embodiment, the cover 230 includes a latch feature 238 configured to secure the cover 230 to the TPA base 210. The latch feature 238 can be a deflectable latch configured to latchably couple to a corresponding latch feature 228 on the TPA base 210. The latch feature 238 is used to close the cover 230 on the back side of the TPA 200 to secure the wire seal 250 in the TPA 200. In alternative embodiments, other types of securing features can be used.

[0045] In an exemplary embodiment, the TPA base 210 includes a sealing recess 252 at the rear portion 218. The wire seal 250 is configured to be received in the sealing recess 252. The cover 230 is used to retain the wire seal 250 in the sealing recess 252. In an exemplary embodiment, the TPA base 210 includes a groove at the bottom 222, the groove opening to the sealing recess 252. The groove 254 can be aligned with the slot 214. The groove 254 is configured to receive a portion of the wire seal 250.

[0046] The wire seal 250 provides a seal between the power cord 152 and the TPA base 210. The wire seal 250 is used to seal the wire channel 212. In an exemplary embodiment, the wire seal 250 is made of a foam material. In an alternative embodiment, the wire seal 250 may be made of other materials (such as a rubber material). In various embodiments, the wire seal 250 can create an airtight seal with the power cord 152. For example, the wire seal 250 can create a moisture-proof seal to prevent moisture from entering the wire channel 212 and the housing 110. In an alternative embodiment, the wire seal 250 can be used to create a physical barrier to prevent materials such as insulating foam from entering the wire channel 212 in the housing 110. For example, the wire seal 250 can fill the space between the power cord 152 and the TPA base 210 to ensure that the material cannot flow or creep into the interior of the TPA device 200 and the housing 110. Optionally, the wire seal 250 may be compressible and / or flexible to fit within the space around the power wire 152 and the TPA base 210 .

[0047] The wire seal 250 extends between a front portion 256 and a rear portion 258. The front portion 256 may be planar and the rear portion 258 may be planar. The rear portion 258 may be parallel to the front portion 256. In an exemplary embodiment, the wire seal 250 includes an opening 260 configured to receive a corresponding power cord 152. The opening 260 is configured to align with the wire channel 212. In the illustrated embodiment, the opening 260 is cylindrical and sized to receive the power cord 152. Optionally, the opening 260 may have a diameter that is slightly smaller than the diameter of the power cord 152 to ensure that the wire seal 250 seals against the power cord 152 when the power cord 152 is received in the opening 260. For example, the wire seal 250 may be compressed or stretched around the opening 260 to receive the power cord 152 to ensure that the wire seal 250 is in sealing engagement with the power cord 152.

[0048] In an exemplary embodiment, the wire seal 250 includes a slit 262 extending from the opening 260 and an outer periphery (such as at the bottom) of the wire seal 250. The slit 262 allows the power cord 152 to pass through the slit 262 into the opening 260 during assembly. In an exemplary embodiment, the wire seal 250 includes a flange 264 on opposite sides of the slit 262. The flange 264 is configured to be received in the groove 254. The flange 264 engages the TPA base 210 to keep the slit 262 closed, such as to prevent the entry of insulating foam material through the slit 262 once the TPA device 200 is assembled.

[0049] In an exemplary embodiment, the housing seal portion 206 of the TPA device 200 is configured to dock with the housing 110 to create a barrier between the housing 110 and the TPA device 200 to prevent material from entering the housing 110. In an exemplary embodiment, the housing seal portion 206 is disposed on the exterior of the TPA base 210. The housing seal portion 206 may be located at the top 220 and / or the bottom 222 and / or the first side 224 and / or the second side 226. In an exemplary embodiment, the housing seal portion 206 includes at least one interference rib 280 configured to engage the housing 110. The interference rib 280 is stepped outward from an adjacent portion of the TPA base 210. In an exemplary embodiment, the interference rib 280 engages the housing 110 by an interference fit. Optionally, the interference rib 280 may be compressible. For example, the interference rib 280 may be configured to elastically deform or plastically deform when the interference rib 280 engages the housing 110. Alternatively, the interference rib 280 may be a compression rib configured to be compressed when the TPA device 200 is inserted into the chamber 140 of the housing 110 .

[0050] In an exemplary embodiment, the top 220 includes at least one interference rib 280, and / or the bottom 222 includes at least one interference rib 280, and / or the first side 224 includes at least one interference rib 280, and / or the second side 226 includes at least one interference rib 280. In an exemplary embodiment, the interference rib 280 extends completely circumferentially around the exterior of the TPA base 210. For example, the interference rib 280 is continuous around the periphery of the TPA base 210 to form a circumferential band 282. The circumferential band 282 is configured to interface with the housing 110 at the top, bottom, and both sides of the chamber 140. In alternative embodiments, the interference rib 280 may be discontinuous. For example, a plurality of interference ribs 280 may be provided, such as parallel ribs extending longitudinally along the TPA base 210. The interference ribs 280 may be angled and overlapped so that a straight path extends along the exterior of the TPA base 210. The interference ribs 280 may have a sawtooth pattern around the TPA base 210, thereby defining a plurality of interference areas between the TPA base 210 and the housing 110 to substantially close any gaps or access areas to seal the TPA base 210 to the housing 110, such as to prevent insulating foam from entering the interior of the housing 110. The interference ribs 280 may be a plurality of bands or ribs extending around the TPA base 210 and axially spaced apart from each other (e.g., offset forward and backward relative to each other).

[0051] In an exemplary embodiment, the TPA base 210 includes a rear block 284 at the rear 218 of the TPA base 210. The rear block 284 is a portion of the TPA base 210 that is configured to remain outside of the housing 110, such as behind the housing 110, while the portion of the TPA base 210 in front of the rear block 284 is configured to be inserted into the chamber 140 of the housing 110. The interference rib 280 is located in front of the rear block 284, such as immediately in front of the rear block 284. The rear block 284 can be wider and / or taller than the interference rib 280. For example, the TPA base 210 can be stepped inwardly at the interference rib 280 compared to the rear block 284. In an exemplary embodiment, the TPA base 210 is stepped inwardly in front of the interference rib 280. For example, the TPA base 210 is narrower and / or shorter in front of the interference rib 280, wherein the front portion of the TPA base 210 can be inserted into the chamber 140 without engaging the housing 110, while the interference rib 280 is configured to engage the housing 110 when the interference rib 280 is inserted into the housing 110.

[0052] Figure 8 1 is a rear perspective view of the power connector 100 showing the TPA device 200 ready to be loaded into the housing 110. During assembly, the terminals 150 and the power cord 152 may be loaded into the terminal passages 130 of the housing 110. For example, the terminals 150 and the power cord 152 may be loaded into the housing 110 from the rear through the rear portion 118. The TPA device 200 is configured to be coupled to the power cord 152 and the housing 110 after the terminals 150 are loaded into the housing 110. For example, the assembled TPA device 200 may be pressed onto the power cord 152 in a downward mating direction, and then the TPA device 200 may be slid forward into the housing 110 in a forward loading direction.

[0053] The slot 214 at the bottom of the TPA base 210 provides access to the wire channel 212 and allows the TPA device 200 to be loaded onto the power cord 152 in a downward mating orientation. In addition, the opening 236 is open at the bottom of the cover 230 to receive the power cord 152 when the TPA device 200 is loaded onto the power cord 152. The slit 262 and the wire seal 250 allow the power cord 152 to pass through the wire seal 250 into the opening 260.

[0054] During assembly, the TPA device 200 can be slid along the power cord 152 in a forward loading direction to couple with the housing 110. The TPA base 210 is configured to be inserted into the chamber 140 at the rear 118 of the housing 110. For example, the housing seal portion 206 is configured to be inserted into the chamber 140 to seal the TPA device 200 to the housing 110. In an exemplary embodiment, the interference rib 280 is configured to engage the inner surface 142 of the housing 110 to seal the TPA device 200 to the housing 110. The terminal blocking element 240 is received in the corresponding terminal channel 130 behind the terminal 150 to block the terminal 150 in the terminal channel 130 and prevent the terminal 150 from being pulled out of the housing 110. The latch 246 is used to secure the TPA device 200 to the housing 110. For example, the latch 246 interfaces with the corresponding latch 146 at the side 124, 126 of the housing 110.

[0055] Fig. 9 is a bottom perspective view of a TPA apparatus 200 according to an exemplary embodiment. Fig.10 is a top perspective view of a TPA apparatus 200 according to an exemplary embodiment. Fig. 9 Wire seal 250 is shown ready to be loaded into TPA base 210. Fig.10 Wire seal 250 is shown located in TPA base 210 . Fig. 9 and Fig.10 The illustration does not include any covers (e.g. Figure 4 2. The wire seal 250 forms a wire sealing portion 204 of the TPA device 200. For example, the wire seal 250 forms a barrier that prevents material, such as insulating foam, from entering the wire channel 212 of the TPA base 210. The wire seal 250 prevents material from flowing or creeping into the interior of the TPA base 210.

[0056] The TPA base 210 includes a sealing recess 252 at the rear portion 218. The sealing recess 252 is formed by a track or channel 266 along the side of the sealing recess 252. The channel 266 receives the wire seal 250 and is used to position the wire seal 250 relative to the TPA base 210. During assembly, the wire seal 250 is loaded into the sealing recess 252 through the bottom 222. The wire seal 250 can be retained in the sealing recess 252 using an adhesive, epoxy, or other fixing feature, and optionally, a cover (not shown) can be fixed to the bottom 222 after the wire seal 250 is loaded into the sealing recess 252.

[0057] Fig.11 is a rear perspective view of the power connector 100 according to an exemplary embodiment. Fig.12 yes Fig.11 An exploded view of the power connector 100 is shown in FIG. Fig.11 and Fig.12 The power connector 100 shown in FIG. 1 is not provided with any wire seals (such as Figure 4 Wire seal 250 shown in FIG. Fig.11 and Fig.12 The shapes of the TPA base 210 and the cover 230 of the power connector 100 shown in FIG. 2 are different to provide the wire sealing portion 204 and the housing sealing portion 206 at the rear of the power connector 100 .

[0058] Fig.13 According to an exemplary embodiment, Fig.11 and Fig.12 2 is a front perspective view of the TPA device 200 of the power connector 100 shown in FIG. Fig.14 According to an exemplary embodiment, Fig.11 and Fig.12 1 is a rear perspective view of the TPA device 200 of the power connector 100 shown in FIG.

[0059] The TPA device 200 includes a TPA base 210 and a cover 230. The cover 230 is configured to be coupled to the TPA base 210 to cover one or more openings in the TPA base 210 and prevent material from entering through the TPA device 200. The TPA device 200 includes a terminal blocking element 240 configured to block the terminal 150 and provide position assurance of the terminal 150 in the housing 110.

[0060] The TPA base 210 includes a wire channel 212 therethrough, the wire channel 212 being configured to receive a corresponding power cord 152. In an exemplary embodiment, the TPA base 210 includes a slot 214 at the top 220, the slot 214 opening to the wire channel 212. The power cord 152 can be loaded into the wire channel 212 through the slot 214. The TPA base 210 extends between a front 216, a rear 218, a top 220, a bottom 222, and sides 224, 226. The wire channel 212 passes through the TPA base 210 between the rear 218 and the front 216. In an exemplary embodiment, the terminal blocking element 240 extends from the front 216 of the TPA base 210 to a distal end 242. A latch 246 is disposed at the sides 224, 226 of the TPA base 210.

[0061] In an exemplary embodiment, the cover 230 is configured to be coupled to the rear portion 218 of the TPA base 210. For example, the cover 230 can be received in the recess 219 at the rear portion 218. The cover 230 can cover a portion of the wire channel 212. In the illustrated embodiment, the cover 230 is separate and discrete from the TPA base 210. For example, the cover 230 can be molded separately and configured to be coupled to the TPA base 210 using a latch or other securing feature.

[0062] The cover 230 includes an end wall 234 configured to be received in the recess 219 to cover the rear end of the TPA base 210. The end wall 234 includes an opening 236 configured to align with the wire channel 212. The opening 236 is configured to receive a corresponding power cord 152. Optionally, the opening 236 may be open at the bottom of the cover 230 to allow the cover 230 to be mounted on the power cord 152.

[0063] In an exemplary embodiment, the cover 230 includes a plug 270 extending forward from the end wall 234. The plug 270 is configured to be inserted into the TPA base 210, such as into the slot 214, to cover a portion of the power cord 152. The plug 270 can extend along the top side of the TPA base 210 to cover the top portion of the power cord 152. In an exemplary embodiment, the plug 270 forms a portion of the wire channel 212. For example, the plug 270 fills the slot 214 to close the open portion of the wire channel 212. Optionally, the inner surface 272 of the plug 270 can be curved to follow the curvature of the power cord 152. The plug 270 is separated by a gap 274. The wall 276 of the TPA base 210 is received in the gap 274. The wall 276 can fill the gap 274. For example, when the cover 230 is coupled to the TPA base 210, the cover 230 and the TPA base 210 form a nested structure surrounding the power cord 152.

[0064] In an exemplary embodiment, the housing seal portion 206 of the TPA device 200 is configured to interface with the housing 110 to create a barrier between the housing 110 and the TPA device 200 to prevent material from entering the housing 110. In an exemplary embodiment, the housing seal portion 206 is defined by the combined nested structure of the TPA base 210 and the cover 230. The housing seal portion 206 is disposed on the exterior of the plug 270 of the TPA base 210 and the cover 230. The housing seal portion 206 may be located at the top 220 and / or the bottom 222 and / or the first side 224 and / or the second side 226. In an exemplary embodiment, the plug 270 of the cover 230 forms a section of the housing seal portion 206 at the top 220. For example, the plug 270 includes an interference rib 286 that cooperates with the interference rib 280 of the TPA base 210 to form the housing seal portion 206. In an exemplary embodiment, the interference rib(s) 280, 286 extend completely circumferentially around the exterior of the TPA base 210. For example, the interference ribs 280, 286 form a continuous sealing portion or band around the perimeter of the TPA device 200. The circumferential band 282 is configured to interface with the housing 110 at the top, bottom, and both sides of the chamber 140.

[0065] In an exemplary embodiment, the TPA base 210 includes a rear block 284 at the rear 218 of the TPA base 210. The cover 230 may form part of the rear block 284, such as at the top of the TPA device 200. The interference ribs 280, 286 are located in front of the rear block 284, such as immediately in front of the rear block 284.

[0066] Return to Fig.11 and Fig.12 During assembly, the terminals 150 and the power cord 152 may be loaded into the terminal passage 130 of the housing 110. For example, the terminals 150 and the power cord 152 may be loaded into the housing 110 from the rear through the rear portion 118. The TPA device 200 is configured to be coupled to the power cord 152 and the housing 110 after the terminals 150 are loaded into the housing 110. For example, the TPA base 210 may be loaded onto the power cord 152 in an upward mating direction, and then the TPA base 210 may be slid forward into the housing 110 in a forward loading direction. After the TPA base 210 is loaded into the housing 110, the cover 230 may be coupled to the TPA base 210.

[0067] The slot 214 at the top of the TPA base 210 provides access to the wire channel 212 and allows the TPA device 200 to be loaded onto the power cord 152 in an upward mating orientation. The wire channel 212 can be sized to accommodate the power cord 152. For example, the wire channel 212 can have a radius of curvature similar to the radius of curvature of the jacket of the power cord 152 so that the power cord 152 is tightly held in the wire channel 212. In an exemplary embodiment, the power cord 152 is held in the wire channel 212 without a gap or space between the power cord 152 and the TPA base 210. The cover 230 is configured to be coupled to the power cord 152 and the TPA base 210 from above and / or from the rear. The opening 236 is open at the bottom of the cover 230 to receive the power cord 152 when the TPA device 200 is loaded onto the power cord 152. During assembly, the plug 270 of the cover 230 is aligned with the slot 214. The plug 270 can be loaded into the slot 214 from above and / or from behind. For example, the cover 230 can be initially lowered onto the power cord 152 and then slid in a forward loading direction to load the plug 270 into the slot 214. When assembled, the end wall 234 is received in the recess 219 at the rear 218 of the TPA base 210. The opening 236 is sized to accommodate the power cord 152. For example, the opening 236 can have a radius of curvature similar to the radius of curvature of the jacket of the power cord 152 so that the power cord 152 is tightly retained in the opening 236. The cover 230 and the TPA base 210 define the wire sealing portion 204. The cover 230 and the TPA base 210 prevent material (such as insulating foam) from entering the interior of the TPA device 200 along the power cord 152.

[0068] During assembly, the TPA base 210 and the cover 230 fill the rear portion of the chamber 140 as they slide forward into the housing 110. The housing seal portion 206 is configured to be inserted into the chamber 140 to seal the TPA device 200 to the housing 110. In an exemplary embodiment, the interference ribs 280, 286 are configured to engage the inner surface 142 of the housing 110 to seal the TPA device 200 to the housing 110. The terminal blocking element 240 is received in the corresponding terminal channel 130 behind the terminal 150 to block the terminal 150 in the terminal channel 130 and prevent the terminal 150 from being pulled out of the housing 110. The latch 246 is used to secure the TPA device 200 to the housing 110. For example, the latch 246 interfaces with the corresponding latch 146 at the side 124, 126 of the housing 110.

[0069] It will be understood that the above description is intended to be illustrative rather than restrictive. For example, the embodiments described above (and / or aspects thereof) may be used in combination with each other. In addition, without departing from the scope of the present invention, many modifications may be made to adapt specific situations or materials to the teachings of the present invention. The dimensions, material types, orientations of various components, and the number and position of various components described herein are intended to define the parameters of certain embodiments, and are by no means restrictive, but are merely exemplary embodiments. Upon reviewing the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the present invention should be determined with reference to the attached claims together with the full scope of equivalents granted by such claims. In the attached claims, the terms "including" and "wherein" are used as the plain English equivalents of the corresponding terms "including" and "wherein". In addition, in the following claims, the terms "first", "second", and "third", etc. are used only as marks, and are not intended to impose numerical requirements on their objects. Furthermore, the following claim limitations are not written in a means-plus-function format and are not intended to be interpreted under 35 U.S.C. § 112(f) unless and until such claim limitations expressly use the phrase "means for..." followed by a recitation of the function without additional structure.

Claims

1. A power connector, comprising: a housing extending between a mating end and a wire end, the mating end being configured to mate with a mating power connector, the housing including terminal passages, the housing including a cavity at the wire end; a terminal received in the terminal passage, the terminal including a mating end configured to mate to a mating terminal of the mating power connector, the terminal including a terminating end terminated to a power cord extending from the cord end of the housing; as well as A terminal position assurance (TPA) device is received in the cavity, the TPA device including a terminal blocking element, the terminal blocking element being located behind the terminal for blocking the terminal in the terminal channel and ensuring the position of the terminal in the terminal channel, the TPA device including a sealing element for sealing the cavity of the shell.

2. The power connector according to claim 1, wherein: The sealing element engages the housing in the chamber to seal the TPA device to the housing.

3. The power connector according to claim 1, wherein: The sealing element includes an interference rib that engages the housing with an interference fit.

4. The power connector according to claim 1, wherein: The sealing element includes a circumferential band surrounding an exterior of the TPA device to engage an interior surface of the housing to seal the TPA device to the housing.

5. The power connector according to claim 1, wherein: The TPA device includes a wire channel for receiving the power wire, and the TPA device is sealed to the power wire passing through the wire channel.

6. The power connector according to claim 1, wherein: The TPA device further includes a wire seal sealed to the power wire.

7. The power connector according to claim 1, wherein: The TPA device includes a TPA base having a wire channel, the TPA base including a sealing recess, the TPA device including a wire seal received in the sealing recess, the wire seal sealing between the power wires in the TPA base.

8. The power connector according to claim 1, wherein: The TPA device includes a TPA base having a wire channel for receiving the power cord and a cover for closing the wire channel.

9. The power connector according to claim 8, wherein: The cover is hingedly coupled to the TPA base.

10. The power connector according to claim 8, wherein: The cover may be latchably coupled to the TPA base.

11. The power connector according to claim 8, wherein: The TPA base includes a slot at the top of the TPA base that opens to the wire channel, the wire is loaded into the wire channel through the slot, and the cover includes a plug that is inserted into the slot to close the slot.

12. The power connector according to claim 1, wherein: The terminal channel is one of a plurality of terminal channels, the terminal is one of a plurality of terminals received in a corresponding terminal channel, and the terminal blocking element is one of a plurality of terminal blocking elements received in the corresponding terminal channel to block the corresponding terminal and secure the position of the corresponding terminal.

13. The power connector according to claim 12, wherein: The sealing element of the TPA device provides a seal around all of the terminals within the cavity of the housing.

14. The power connector according to claim 12, wherein: The cable is one of a plurality of cables terminated to corresponding terminals, and the TPA device includes a wire seal sealed between the TPA device and the plurality of cables.

15. The power connector according to claim 1, wherein: The TPA device includes a latch latchably coupled to the housing.

16. A power connector, comprising: a housing extending between a mating end and a wire end, the mating end being configured to mate with a mating power connector, the housing including terminal passages, the housing including a cavity at the wire end; a terminal received in the terminal passage, the terminal including a mating end configured to mate to a mating terminal of the mating power connector, the terminal including a terminating end terminated to a power cord extending from the cord end of the housing; as well as A terminal position assurance (TPA) device is received in the cavity, the TPA device including a terminal blocking element, the terminal blocking element is located behind the terminal to block the terminal in the terminal channel and ensure the position of the terminal in the terminal channel, the TPA device includes a sealing element for sealing the cavity of the shell, and the TPA device includes a wire seal configured to seal between the TPA device and the power line.

17. The power connector according to claim 16, wherein: The sealing element engages the housing in the chamber to seal the TPA device to the housing.

18. The power connector according to claim 16, wherein: The TPA device includes a TPA base having a wire channel, the TPA base including a sealing recess, the wire seal being received in the sealing recess, the wire seal sealing between the power wires in the TPA base.

19. The power connector according to claim 16, wherein: The TPA device includes a TPA base having a wire channel for receiving the power cord and a cover for closing the wire channel.

20. A power connector, comprising: a housing extending between a mating end and a wire end, the mating end being configured to mate with a mating power connector, the housing including terminal passages, the housing including a cavity at the wire end; a terminal received in the terminal passage, the terminal including a mating end configured to mate to a mating terminal of the mating power connector, the terminal including a terminating end terminated to a power cord extending from the cord end of the housing; as well as A terminal position assurance (TPA) device is received in the chamber, the TPA device comprising a TPA base, the TPA base comprising a wire channel configured to receive the power cord, the TPA base comprising a sealing element for sealing the chamber of the shell, the TPA device comprising a terminal blocking element, the terminal blocking element being located behind the terminal for blocking the terminal in the terminal channel and ensuring the position of the terminal in the terminal channel, the TPA device comprising a cover connected to the TPA base to close the wire channel.

21. The power connector according to claim 20, wherein: The sealing element engages the housing in the chamber to seal the TPA device to the housing.

22. The power connector according to claim 20, wherein: The TPA base includes a sealing recess, and the TPA device includes a wire seal received in the sealing recess, the wire seal sealing between the power wires in the TPA base.

23. The power connector according to claim 20, wherein: The TPA base includes a slot at the top of the TPA base that opens to the wire channel, the wire is loaded into the wire channel through the slot, and the cover includes a plug that is inserted into the slot to close the slot.

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