Method for improving spatial and creepage paths in a high voltage connector assembly using male or female terminal position assurance (TPA) devices

Abstract

A method for improving space and creepage 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 high-voltage electrical terminals. The method includes using a male or female TPA device to provide a space and creepage or electrical path extending from at least the high-voltage electrical terminal to a conductive outer male housing and / or between other terminals. Inserting the TPA device into the high-voltage connector assembly results in a space and creepage or electrical path extending along at least a surface of the TPA device from the high-voltage electrical terminal to the outer male housing of the high-voltage connector assembly, or from the high-voltage electrical terminal to another high-voltage electrical terminal during use of the male and / or female TPA device.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 810,179, filed Feb. 25, 2019, and U.S. Provisional Patent Application No. 63 / 014,576, and the entire disclosure of which is incorporated herein by reference.

Background Art

[0002] There is a desire to improve conventional shielded automotive connectors or housings for use with high - voltage terminals due to the high voltages that high - voltage connector assemblies need to satisfy and terminal position assurance (TPA) devices within the connector assembly. Thereby, it is desirable to improve or increase the space and creepage of the electrical path, at least from one high - voltage electrical terminal to another high - voltage electrical terminal, element / circuit, during operation or use of the connector assembly. Further, it is desirable to improve or increase the space and creepage from at least a high - voltage electrical terminal to a conductive outer housing, to an electrical element / circuit, or to a conventional stamped metal shield for shielding.

Summary of the Invention

[0003] The present invention is directed to a method of improving the spatial and creepage paths of electrical paths in a high voltage connector assembly using male or female terminal position assurance (TPA) devices and housings. The electrical paths may include, or be related to, short circuit currents. The high voltage connector assembly of the present invention has a high suitability for high voltage electrical terminals which are larger terminals. The female TPA device in the present invention includes a forward extension member, and the female housing includes a front portion where the terminals are located and a rear portion. The male TPA device in the present invention includes a wing-shaped member substantially extending downwardly from a wing-shaped member having an intermediate member that enters the inner male housing during use or operation. The male TPA device in the present invention also includes a lower member located between the high voltage electrical terminals when the male TPA device is located within the housing during use or operation. By the above features of the present invention, "creepage" (the dimension of the shortest path along the surface from any given circuit within the connector to any other (usually adjacent) circuit), and "clearance" (defined, for example, as the dimension of the shortest electrical path from any exposed conductive element in any given circuit of the connector to any other conductive element in a different circuit within the same connector) are advantageously increased, thereby modifying or affecting the electrical paths including the associated short circuit currents, or the electrical paths of the associated short circuit currents, when the connector assembly is in operation or use. BRIEF DESCRIPTION OF THE DRAWINGS

[0004]

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DETAILED DESCRIPTION OF THE INVENTION

[0005] Figure 1 shows a front perspective view of a female terminal position assurance (TPA) device generally referenced by reference numeral 1. The female TPA device 1 includes a central member 3 and a round member 5. The central member 3 extends from an upper portion 7 to a lower portion 9 of the round member 5. The round member 5 has, on both of its sides, front extending members 10, 12 extending from the round member.

[0006] Figure 2 shows an upper rear extending member 13 and a lower rear extending member 15. At the front end of each of the front extending members 10, 12, there are corresponding front lower extending members 20, 22. Also, each of the front extending members 10, 12 has a corresponding upper member 25, 27, and each of the upper members 25, 27 has a corresponding lamp-shaped front end 29, 30.

[0007] Figure 3 shows a top view of the female TPA device 1, showing the front extending members 10, 12, the corresponding upper members 25, 27 extending from the front extending members 10, 12 respectively, and the lamp-shaped front ends 29, 30 of each of the upper members 25, 2. Also shown are the upper rear extending member 13 and the lower rear extending member 15. The upper rear extending member 13 has an upper return-shaped member 35 extending from the upper rear extending member 13, and the lower rear extending member 15 has a lower return-shaped member 37. As shown in Figure 4, the openings 40, 42 have the central member 3 in between and pass through both sides of the female TPA device 1.

[0008] Figure 5 shows the female TPA device in a pre-lock position while inserted and attached to the female housing 50. The female housing 50 has a front portion 53 and a rear portion 55. Figure 6 shows the female TPA device 1 in a full-lock position while inserted and attached to the female housing 50.

[0009] The present invention is directed to a method for improving the space and creepage using the female TPA device 1. The present invention is also highly suitable for high-voltage electrical terminals 60 which are large terminals. Each of FIGS. 5 and 6 further shows a space or creepage for the electrical path 110 that extends transversely along the upper surface of the front portion 53 of the female housing 50 from the exposed high-voltage electrical terminal 60 and extends towards another exposed high-voltage electrical terminal 60 inside the front portion 53.

[0010] As described above and as shown in FIGS. 5 and 6, due to the above features of the present invention, the "creepage" (from any given circuit, herein from one of the high-voltage electrical terminals 60, in a certain direction or along the surface, herein along the surfaces of the front extension members 10, 12 of the female TPA device 1 and along the upper surface of the front portion 53 of the female housing 50, to any other (usually adjacent) circuit, herein to another high-voltage electrical terminal 60, the dimension of the shortest electrical path along the surface), and the "clearance" (from any exposed conductive element in a given circuit of the connector, herein from the high-voltage electrical terminal 60, to any other conductive element in a different circuit in the same connector, herein to another high-voltage electrical terminal 60, the dimension of the shortest electrical path) are advantageously increased, thereby modifying or affecting the electrical path including the associated short-circuit current or the electrical path of the associated short-circuit current when the connector assembly is in operation or use. Further, as seen in the dashed line L of FIG. 10, the space or creepage for the electrical path 110 may be further increased to be operable on the opposite end of the front portion 53 by the location of the exposure of one of the high-voltage electrical terminals 60 and another embodiment of the present invention having the upper front extension member 10.

[0011] As shown in FIG. 7, the protruding member 62 extends from the lower part of the female housing 50. The protruding member 62 includes a lamp-shaped tip 65. And since the tip 68 of the terminal 60 has a notch 70, when the terminal 60 is fully inserted into the female housing 50, the notch 70 easily advances beyond the lamp-shaped tip 65 of the protruding member 62. When the terminal 60 is fully inserted into the female housing 50, the protruding member 62 of the female housing 50 snaps into the notch 70 of the tip 68 of the terminal 60, thereby engaging the terminal 60 inside the female housing 50 (primary lock).

[0012] FIG. 7 further shows a cross-sectional view along line 7-7 of FIG. 5 where the female TPA device 1 is in the pre-lock position. As described above, when the protruding member 62 inside the female housing 50 snaps into or enters the notch 70 of the tip 68 of the terminal 60, the terminal 60 is locked (primary lock). As a result, the terminal 60 cannot be pulled out from the female housing 50, and in such a case, the upper notch 80 of the terminal 60 becomes available to receive or accommodate a corresponding one of the front lower extension members 20, 22 therein. That is, unless the terminal 60 is in a primary locked state inside the female housing 50 and the upper notch 80 of the terminal 60 is available to receive or accommodate a corresponding one of the front lower extension members 20, 22 therein, the front lower extension members 20, 22 cannot provide the necessary secondary lock to the terminal 60 inside the female housing 50. In other words, if the terminal 60 is not in a primary locked state inside the female housing 50, the female TPA device 1 is prevented from being pushed further downward by the upper part 85 of the tip 68 of the terminal 60. As a result, when the upper part 85 of the tip 68 of the terminal 60 obstructs the advancement of the female TPA device 1 (more specifically, the advancement of the front lower extension members 20, 22 of the female TPA device 1), the female TPA device 1 cannot be pushed further downward, so it is possible to detect that the female TPA device 1 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 full-lock position).

[0013] FIG. 8 shows the female TPA device 1 in the fully locked position inside the female housing 50. At this time, the upper notch 80 of the terminal 60 becomes available to receive therein a corresponding one of the front lower extension members 20, 22 of the female TPA device 1, such that when each one of the upper notches 80 of the terminal 60 is inserted therein, the front lower extension members 20, 22 of the female TPA device 1 respectively prevent the terminal 60 from being pulled out from the inner housing 50, and thus, a secondary lock can be provided to the terminal 60 inside the female housing 50.

[0014] As further shown for each of the pre-locked female TPA device 1 of FIG. 7 and the fully locked female TPA device 1 of FIG. 8, a creepage or space (see arrow) for the electrical path 110 is shown when the female TPA device 1 is disposed on or within the female housing 50, and the electrical path 110 extends substantially vertically from the high voltage electrical terminal 60 and further along a corresponding one of the front lower extension members 20, 22 (of each of the front extension members 10, 12 of the female TPA device 1) or extends between the front lower extension members 20, 22 and extends along one or more vertical and / or substantially inclined or angled portions of the front portion 53 of the female housing 50. The front lower extension members 20, 22 are respectively substantially immediately behind a part of the corresponding high voltage electrical terminal 60.

[0015] For example, as shown in FIGS. 9 and 10, the female TPA device 1 is in the pre-lock position within the female housing 50. FIGS. 9 and 10 show the front extension members 10, 12 of the female TPA device 1 partially inserted above the front portion 53 of the female housing 50. FIGS. 9 and 10 show the surface or space (see dashed lines) of the electrical path 110, which extends substantially vertically from one of the high-voltage electrical terminals 60, and further partially along one of the front lower extension members 20 (of each of the front extension members 10 of the female TPA device 1) or proceeds between the front lower extension members 20, exits along one or more vertical and / or substantially inclined or angled portions of the front portion 53 of the female housing 50, and further proceeds in the direction of or across the upper surface of the front portion 53 of the female housing 50, and further along one of the front lower extension members 22 (of each of the front extension members 12 of the female TPA device 1) or proceeds between the front lower extension members 22, and extends substantially vertically into another one of the high-voltage electrical terminals 60 along one or more vertical and / or substantially inclined or angled portions of the front portion 53 of the female housing 50 (see FIG. 6). The above also has the reverse order between the terminals 60, and the above further exists in the full-lock arrangement of the female TPA device 1 using the female housing 50 (see FIGS. 6 and 8).

[0016] FIG. 11 shows a front perspective view of a male terminal position assurance (TPA) device, generally referenced by reference numeral 201, of the present invention. The male TPA device 201 includes an upper member 203 and a lower member 205. The upper member 203 has a generally wing shape with sides 210, 214. The lower member 205 includes a flexible arm member 218 at its front portion.

[0017] As shown in FIG. 12, the flexible arm member 218 includes at least a protruding member or a projecting member 220. The number of the protruding member or the projecting member 220 shown in FIG. 12 is two, but is not limited thereto. The upper front portion 211 of the flexible arm member 218 is inclined as shown in FIG. 11. Also, the lower front portion 212 of the flexible arm member 218 is inclined as shown in FIG. 11.

[0018] Further, FIG. 12 shows end members 224 and 226 extending substantially downward from the wing-shaped side members 210 and 214, respectively. Also, intermediate members 228 and 229 extend substantially downward from the wing-shaped side members 210 and 214, respectively. Each of the intermediate members 228 and 229 has corresponding protrusions 231 and 233 extending downward therefrom.

[0019] The male TPA device 1 of the present invention is in the pre-lock position in FIG. 13A and in the full-lock position in FIG. 13B. The male TPA device 201 is inserted through an opening 208 penetrating the upper part of the inner male housing 230 of the high-voltage connector assembly (generally referred to by reference numeral 200 in FIGS. 14 and 16) and is fitted or attached to the inner male housing 230 within the lower opening 400 (see FIGS. 18, 21A, 21B). Also, FIGS. 13A and 13B show fitting grooves 232, 234, 236 on the outer surface of the inner male housing 230 to enable the male TPA device 201 to be attached or inserted into the outer male housing 260 of the high-voltage connector assembly 200 (see FIGS. 14 to 17).

[0020] FIG. 14 is a cross-sectional view of a high-voltage connector assembly having an inner male housing 230 with a male TPA device 201 in a pre-lock position or arrangement. FIG. 14 further shows the inner male housing 230 and the male TPA device 201 within the outer male housing 260. The high-voltage connector assembly 200 has a high-voltage electrical terminal 265 capable of receiving the male TPA device 201 of the present invention inside a TPA window 272, which is shown as a square portion inserted therein and separated by a dashed line.

[0021] FIG. 15 is a partial cross-sectional view of a high-voltage connector assembly 200 capable of receiving the male TPA device 201 of the present invention inside the TPA window 272 with a high-voltage electrical terminal 265 inserted therein. Through an opening 208 penetrating the upper part of the inner male housing 230, there is shown a space for an electrical path 210 from at least the high-voltage electrical terminal 265 to the upper part of the inner male housing 230 of the high-voltage connector assembly 200, and also, as shown by the vertical arrow in FIG. 15, up to the outer male housing 260.

[0022] The present invention is directed to a method of improving the space and creepage in a high-voltage connector assembly 200 using a male TPA device 201. The high-voltage connector assembly 200 is highly suitable for a high-voltage electrical terminal 265 which is a large terminal. The male TPA device 201 in the present invention includes wing-shaped side members 210, 214 and intermediate members 228, 229 respectively extending substantially downward from the wing-shaped side members 210, 214. Each of the intermediate members 228, 229 has corresponding protrusions 231, 233 extending downward therefrom respectively.

[0023] Due to the above features of the present invention, the "creepage" (the dimension of the shortest electrical path along the surface from one circuit, herein from the high-voltage electrical terminal 265, in a certain direction or along the surface, herein along the surfaces of the male TPA device 201 and the inner male housing 230, to any (usually adjacent) circuit, herein to the conductive outer male housing 260 or a conventional press metal shield (not shown)), and the "clearance" (the dimension of the shortest electrical path from any exposed conductive element in a given circuit of the connector, herein from the high-voltage electrical terminal 265, to any other conductive element in a different circuit in the same connector, herein to another high-voltage electrical terminal 60, to the outer male housing 260 or a conventional press metal shield (not shown)) are advantageously increased, thereby modifying or affecting the electrical path including the related short-circuit current or the electrical path of the related short-circuit current when the connector assembly is in operation or in use.

[0024] More specifically, FIG. 16 is a cross-sectional view of a high-voltage connector assembly 200 of the present invention having a high-voltage electrical terminal 265 inserted into an inner male housing 230 and a male TPA device 201 of the present invention inserted therein in a fully locked position or arrangement. Corresponding wing-shaped side members 210, 214 are located within the opening 208 (see also FIG. 13B), and intermediate members 228, 229 are located within the TPA window 272. As shown in FIG. 16, intermediate member 228 is located substantially immediately after a portion of high-voltage electrical terminal 265.

[0025] FIG. 17 is a partial cross-sectional view of a high-voltage connector assembly 200 having a high-voltage electrical terminal 265 and a male TPA device 201 of the present invention inserted therein. Intermediate members 228, 229 are within the TPA window 272 and are located substantially immediately after a portion of high-voltage electrical terminal 265, and the space and / or surface of an electrical path 210 that proceeds from at least the high-voltage electrical terminal 265, substantially along the outer surface of the male TPA device 201 of the present invention, to the outer male housing 260 is shown in the figure. As shown in FIG. 17, the space and / or surface for the electrical path 210 is, for example, from at least the high-voltage electrical terminal 265, along at least one surface of intermediate members 228, 229, or through the space between the surfaces, and along the surface of the inner male housing 230, or through the space between its surfaces, and further, along at least one surface of the corresponding wing-shaped side members 210, 214, or through the space between the wing-shaped side members 210, 214, and along the surface of the inner male housing 230, or through the space between the inner male housings 230, and further, through the upper portion of the inner male housing 230 and extends substantially linearly along an opening 208 that leads directly to the outer male housing 260 of the high-voltage connector assembly 200.

[0026] Further, FIG. 18 shows an inner male housing 230 having a first channel 501 and a second channel 502, respectively. The first channel 501 and the second channel 502 can each accommodate one of the intermediate members 228, 229 of the male TPA device 201 therein. The first channel 501 and the second channel 502 are each provided with an opening that extends out of the central channel 400. The first central notch 601 and the second central notch 602 define the lower portions of the opening and the first channel 501 and the second channel 502, and each of the first channel 501 and the second channel 502 enters and extends into the central channel 400, respectively. The upper portion of each of the first channel 501 and the second channel 502 is defined by the opening 208. As will be described later, when the male TPA device 201 is positioned in the pre-lock position in the inner male housing 230, the lower surfaces of the intermediate members 228, 229 additionally further define the upper portions of the first channel 501 and the second channel 502, respectively (see FIGS. 19A and 19B).

[0027] Further, FIG. 18 shows an inner male housing 230 having a terminal 265 therein. In the absence or lack of a male TPA device 201 inserted into or positioned in the male housing 230, the inner male housing 230 has a space and / or a creepage path for an electrical path 310 extending from one of the high voltage terminals 265 during operation, and the electrical path 310 extends into the corresponding first channel 501 and second channel 502, respectively, substantially directly across the upper portions of the first notch 601 and the second notch 602, respectively, substantially directly across the central channel 400 of the inner male housing 230, and further extends into it towards another high voltage terminal 265 as shown in the electrical path 310.

[0028] As described below, the TPA of the present invention advantageously increases the "creepage" (the dimension of the shortest electrical path from one circuit, in this specification from the high voltage electrical terminal 265, in a certain direction or along the surface, in this specification along the lower part 205 of the male TPA device 201 and the surface of the inner male housing 230, to any (usually adjacent) other circuit, in this specification to another high voltage electrical terminal 265) and the "clearance" (the dimension of the shortest electrical path from any exposed conductive element in a given circuit of the connector, in this specification from the high voltage electrical terminal 265, to any other conductive element in a different circuit in the same connector, in this specification to the high voltage electrical terminal 265), thereby modifying or affecting the electrical path including the associated short - circuit current or the electrical path of the associated short - circuit current during operation or use of the connector assembly.

[0029] FIG. 19A is a cross-sectional view of the male TPA device 200 clearly showing the terminal 265 located inside the inner male housing 30 at the pre-lock position. The lower member 205 of the male TPA device 200 is located in a part of the central channel 400 of the inner male housing 230 (see FIGS. 20A, 21A, and 22A). When the male TPA device 201 is in the pre-lock position, the lower member 205 is inserted and located in a part of the central channel 400. A part of the long slot 225 of the lower member 205 is within the opening 208 of the inner male housing 230 and is substantially exposed above the first channel 501 and the second channel 502. Further, as a result of the pre-lock arrangement, the first channel 501 and the second channel 502 of the inner male housing 230 are aligned below the corresponding one of the intermediate members 228, 229 of the male TPA device 1 (which has the corresponding one of the protrusions 231, 233). Thereby, the first channel 501 and the second channel 502 can accommodate and receive the corresponding one of the intermediate members 228, 229 therein (see FIG. 22B). Further, at the pre-lock position of the male TPA device 1, the intermediate members 228, 229 are located inside a part of the opening 208 and further, above, respectively define the corresponding upper parts of the first channel 501 and the second channel 502.

[0030] FIG. 19B shows the male TPA device 201 in the full-lock position. As shown and described above, here, the male TPA device 201 is further pressed downward from the pre-lock position to the full-lock position, and the corresponding intermediate members 228, 229 of the male TPA device 201 are fully inserted or received into the first channel 501 and the second channel 502, and the corresponding slots 270 of the corresponding terminals 265 (see also FIG. 22A). As a result, when the male TPA device 1 is in the full-lock position inside the inner male housing 230, the terminal 265 cannot be removed from the inner male housing 230 (i.e., the male TPA device 1 functions as a secondary lock for the terminal 65 inside the inner male housing 30). At this time, when the male TPA device 1 is in the full-lock position, the lower member 205 is inserted further inside the central channel 400 of the inner male housing 230 and is located further inside compared to the male TPA device 1 in the pre-lock position. Therefore, as shown in FIG. 21B, when the TPA is in full-lock, the elongated slot 225 of the lower member 205 thus descends further and is substantially located in the central channel 400 (see FIG. 22B). When the male TPA device 1 is in the full-lock position, the upper part of the elongated slot 225 and its smaller part are at the same height above the first channel 501 and the second channel 502, thereby receiving the spatial path and / or the creeping path of the electrical path 310 as further described below (see FIGS. 21B, 22B).

[0031] In FIGS. 21A and 21B, as can be seen in more detail, when the male TPA device 201 is in operation and inside the inner male housing 230, the lower member 205 functions as a kind of "wall" or "obstacle" inside the inner male housing 230 and is substantially between the high-voltage electrical terminals 265 (see also FIGS. 22A and 22B). During operation, the lower member 205 further substantially adds a surface in the longitudinal direction of the inner male housing inside the central channel 400 of the inner male housing 230 where the electrical path 310 is substantially directed peripherally (see FIGS. 18, 19A, and 19B). As a result, the lower member 205 increases the creepage surface, and as a result, increases the space of the electrical path 310 (see also FIGS. 22A and 22B). By comparison, as described above, when the inner male housing 230 is in operation without the lower member 205 and the male TPA device 201 of the present invention, the electrical path 310 has a smaller space from one high-voltage electrical terminal 265 to another high-voltage electrical terminal 265 than when the male TPA device 201 is positioned in a pre-lock or full-lock arrangement (for example, see FIGS. 18, 22A, and 22B). More advantageously, the wing-shaped side members 210, 214 prevent the electrical path 310 from traveling above or across the upper part of the male TPA device 201 between the high-voltage electrical terminals 265 (see FIGS. 13A and 13B). The inner and outer surfaces of the wing-shaped side members 210, 214 have a surface distance between the high-voltage electrical terminals 265 that is greater than the creepage surface or the space surface provided by the surface along the lower member 205 and provided on the inner male housing 230. Thereby, the space and the creepage surface of the electrical path 310 extending along the male TPA device 201 are directed around the lower member 205 (see also FIGS. 23A and 23B).

[0032] As further shown in FIG. 22A, the space and / or creepage of the electrical path 310 from one of the high voltage terminals 265 extends substantially to another one of the high voltage terminals 265. As in FIG. 20A, the electrical path exits from one of the high voltage electrical terminals 265 into a portion of one of the first channel 501 and the second channel 502, respectively. Further, the space and / or creepage of the electrical path 310 faces or extends within the first channel 501 and the second channel 502 and exits into the central channel 400 (see FIG. 21A). As in FIG. 21A, the electrical path 310 exits from the first channel 501 and the second channel 502, respectively, so as to proceed along the corresponding side surfaces of one of the first notch 601 and the second notch 602, and can also proceed along the corresponding portions of the upper surfaces of one of the first notch 601 and the second notch 602 (see FIG. 20A). As shown in detail in FIG. 21A, the space and / or creepage of the electrical path 310 is further directed along between the side surface of the lower member 205 and the inner surface of the central channel 400. Further, as in FIGS. 21A and 22A, the space and / or creepage of the electrical path 310 enters and proceeds through a portion of the elongated slot 225 at one end of the male TPA device 201. Further, at the opposite end of the elongated slot 225, the space and / or creepage of the electrical path 310 proceeds along between the opposite end of the lower member 205 of the male TPA device 200 and the surface of the central channel 400 of the inner male housing 230. The space and / or creepage of the electrical path 310 further proceeds along between the opposite surface of the side of the lower member 205 and the inner surface of the central channel 400 (see FIG. 22A). Thereafter, the electrical path 310 enters into one of the opposite sides of the first channel 501 and the second channel 502 from the central channel 400, respectively (see FIG. 23A). As can be seen in detail in FIG. 23A, the electrical path 310 enters into one of the opposite sides of the first channel 501 and the second channel 502, respectively, and proceeds substantially along the corresponding side surfaces of one of the opposite sides of the first notch 601 and the second notch 602, and can pass through along the upper portion of one of the opposite sides of the first notch 601 and the second notch 602.When the electrical path 310 enters one on each opposite side of the first channel 501 and the second channel 502, the electrical path 310 will ultimately proceed directly towards another one of the high voltage electrical terminals 265 and enter another one of the high voltage electrical terminals 265 (see FIGS. 22A and 23A). The above also has the order of the electrical paths 310 that are opposite between the terminals 265.

[0033] As shown in FIGS. 19B and 20B, it is a cross-sectional view of the male TPA device 201 located within the inner male housing 230 and in its full-lock position or arrangement. Further, the lower member 205 of the male TPA device 200 is located further inside a part of the central channel 400 of the inner male housing 230 than the pre-lock position, as described above. Further, the intermediate members 228, 229 are located inside the respective corresponding parts of the first channel 501 and the second channel 502, as described above. At this time, the wing-shaped side members 210, 214 are substantially within the opening 208 and located inside the opening 208, as described above. At this time, as shown in detail in FIG. 20B, in the full-lock position, the space and / or surface along the electrical path 310 from one of the high-voltage terminals 265 extends substantially from one of the high-voltage electrical terminals 265 into a part of one of the first channel 501 and the second channel 502 (see FIG. 22B). In the full-lock position or arrangement, the electrical path 310 goes up and / or extends thereon, goes along and / or extends along one side surface of one of the intermediate members 228, 229, and further goes towards and / or extends towards the lower surface of the intermediate members 228, 229 (see FIG. 21B). As also shown in FIG. 20B, the space and / or surface along the electrical path 310 goes towards the central channel 400, passes through and / or exits the first channel 501 and the second channel 502 (see also FIG. 22B). At this time, in the full-lock state of the male TPA device 201, the intermediate members 228, 229 are substantially located in the first channel 501 and the second channel 502 respectively and located in the first notch 601 and the second notch 602 (see FIG. 22B). Therefore, this arrangement forms a considerably smaller gap respectively between the side surfaces of the intermediate members 228, 229 and the side surfaces of the first notch 601 and the second notch 602 as compared with the pre-lock arrangement of the male TPA device 201 (see FIGS. 20B, 23B). As seen in FIGS. 20B and 23B, the intermediate members 228, 229 contact the upper surfaces of the notches 601, 602 and substantially contact each other at a part of the upper surfaces of the notches 601, 602.As a result, the substantially small gaps formed are substantially in contact with and / or aligned at the sides of the first notch 601 and the second notch 602, and at locations where, compared to the pre-lock arrangement, there is less or a smaller portion of the corresponding upper surfaces of the first notch 601 and the second notch 602. Further, the space and the creepage path are directed along and towards the lower member 205 along the lower member 205. Accordingly, the electrical path 310 passes through and / or exits one of the first channel 501 and the second channel 502, and substantially continues along and between the corresponding side surface and each of the small portions of the upper surface of one of the first notch 601 and the second notch 602, and one of the side surfaces of the intermediate members 228, 229 and / or exits (see FIGS. 22B and 23B). Further, the space and / or the creepage path of the electrical path 310 further proceeds along between the side surface of the lower member 205 and the inner surface of the central channel 400 (see FIGS. 21B and 22B). As shown in FIG. 22B, the space and / or the creepage path for the electrical path 310 enters and proceeds through a part of the elongated slot 225 at one end of the male TPA device 201. Further, at the opposite end of the elongated slot 225, the space and / or the creepage path for the electrical path 310 proceeds along between the opposite end of the lower member 205 of the male TPA device 200 and the surface of the central channel 400 of the inner male housing 230. The space and / or the creepage path of the electrical path 310 further proceeds along between the opposite side surface of the lower member 205 and the inner surface of the central channel 400 (see FIG. 22B). As seen in FIG. 23B, the space and / or the creepage path of the electrical path 310 further enters and proceeds along from the central channel 400 into one of the opposite sides of the first channel 501 and the second channel 502 respectively. The electrical path 310 substantially enters into one of the opposite sides of the first channel 501 and the second channel 502 respectively along between the corresponding side surface and a part of the upper surface of one of the opposite sides of each of the first notch 601 and the second notch 602, and one of the side surfaces of the opposite sides of each of the intermediate members 228, 229 (see FIGS. 22B and 23B).Furthermore, when the electrical path 310 further enters into one of the opposite sides of each of the first channel 501 and the second channel 502, the electrical path 310 finally proceeds directly towards another high voltage electrical terminal 265 and enters into the another high voltage electrical terminal 265 (see FIGS. 22B and 23B). The above also has the order of the opposite electrical paths 310 between the terminals 265.

[0034] The present invention is not limited to the above embodiments, and various modifications such as design, structure and position may be used without departing from the scope of the present invention or equivalents.

Claims

1. A method for improving the space and surface path in a high-voltage connector assembly using a male terminal position assurance (TPA) device, comprising: inserting at least one terminal into the inner male housing of the high-voltage connector assembly; locking the terminal inside the inner male housing of the high-voltage connector assembly; providing an outer male housing for the high-voltage connector assembly, with the inner male housing being accommodated inside the outer male housing; extending the space for the electrical path from the at least one terminal to the outer male housing; and inserting the male terminal position assurance (TPA) device through the opening of the inner male housing, the male terminal position assurance (TPA) device having an upper member and a lower member, the lower member having a flexible arm member at the front, the upper member having at least a first wing-shaped side portion, and a first intermediate member extending downward from the first wing-shaped side portion; characterized by; the step of extending the space for the electrical path includes extending the space for the electrical path directly from at least the terminal, along the surface of the first intermediate member of the male terminal position assurance (TPA) device, along the surface of the first wing-shaped side portion, along the surface of the inner male housing, along the opening of the inner male housing, to the outer male housing; characterized method.

2. The step of extending the space for the electrical path is characterized by extending the space substantially vertically from at least the terminal to the outer male housing. A method for improving the space and surface path in a high-voltage connector assembly using a male terminal position assurance (TPA) device according to Claim 1, characterized by.

3. The method for improving the space and surface path in a high-voltage connector assembly using a male terminal position assurance (TPA) device according to Claim 1, further characterized by locking the male terminal position assurance (TPA) device inside the inner male housing. A method for improving the space and surface path in a high-voltage connector assembly using a male terminal position assurance (TPA) device according to Claim 1, further characterized by.

4. Further characterized by the step of inserting the male terminal position assurance (TPA) device through the opening of the inner male housing and locking the male terminal position assurance (TPA) device inside the inner male housing. The step of extending the space for the electrical path includes extending the space for the electrical path from at least the terminal along the surface of at least the first wing-like side portion of the male terminal position assurance (TPA) device to the outer male housing. A method for improving the space and creepage path in a high voltage connector assembly using a male terminal position assurance (TPA) device according to claim 1.

5. Further characterized by inserting the male terminal position assurance (TPA) device through the opening of the inner male housing and locking the male terminal position assurance (TPA) device within the inner male housing. The step of extending the space for the electrical path includes extending the space for the electrical path from at least the terminal along the surface of at least the first intermediate member of the first wing-like side portion of the male terminal position assurance (TPA) device, and further along at least the first wing-like side portion of the male terminal position assurance (TPA) device to the outer male housing. A method for improving the space and creepage path in a high voltage connector assembly using a male terminal position assurance (TPA) device according to claim 1.

6. A method for improving the space and creepage path in a high voltage connector assembly using a female terminal position assurance (TPA) device in the female housing of the high voltage connector assembly, comprising: Inserting at least one high voltage electrical terminal into the interior of the female housing of the high voltage connector assembly; Locking the high voltage electrical terminal within the interior of the female housing of the high voltage connector assembly; Inserting the female terminal position assurance (TPA) device into the female housing, the female terminal position assurance (TPA) device having a central member and a circular member, the central member extending from the upper portion to the lower portion of the circular member, a first front extending member and a second front extending member extending from the circular member, the circular member having an upper rear extending member and a lower rear extending member, the first front extending member having a first front lower extending member, the second front extending member having a second front lower extending member, the front extending members having an upper member, the upper member having a lamp-shaped front end, and an upper return-shaped member extending from the upper rear extending member. extending a space or a surface for an electrical path from said at least one high-voltage electrical terminal to another one of said high-voltage electrical terminals characterized by said step of extending said space or said surface for said electrical path comprises the step of extending said electrical path substantially vertically from at least said high-voltage electrical terminal, partially emerging along said first front extension member, crossing a first upper part of a front portion of said female housing and a second upper part of said front portion of said female housing, and further extending substantially vertically to another one of said high-voltage electrical terminals characterized method **Claim 7** said step of extending said space or said surface for said electrical path comprises the step of extending said electrical path substantially vertically from at least said high-voltage electrical terminal, crossing an upper part of said female housing, and further extending substantially vertically to another one of said high-voltage electrical terminals A method for improving the space and surface path in a high-voltage connector assembly using a female terminal position assurance (TPA) device in a female housing of a high-voltage connector assembly according to claim 6, characterized by **Claim 8** said step of inserting said female terminal position assurance (TPA) device into said female housing comprises the step of locking said female terminal position assurance (TPA) device to said female housing in a pre-lock position A method for improving the space and surface path in a high-voltage connector assembly using a female terminal position assurance (TPA) device in a female housing of a high-voltage connector assembly according to claim 6, characterized by **Claim 9** said step of inserting said female terminal position assurance (TPA) device into said female housing comprises the step of locking said female terminal position assurance (TPA) device to said female housing in a full-lock position A method for improving the space and surface path in a high-voltage connector assembly using a female terminal position assurance (TPA) device in a female housing of a high-voltage connector assembly according to claim 6, characterized by **Claim 10** said female terminal position assurance (TPA) device includes extension members extending downwardly respectively from a front extension member, and said female housing includes a front portion A method for improving the spatial and creepage paths in a high-voltage connector assembly, characterized by using a female terminal position assurance (TPA) device in the female housing of the high-voltage connector assembly according to claim 7.

11. A method for improving the spatial and creepage paths in a high-voltage connector assembly, using a male terminal position assurance (TPA) device in the male housing of the high-voltage connector assembly, comprising: inserting at least one high-voltage electrical terminal into the interior of 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 (TPA) device into the male housing, the male terminal position assurance (TPA) device having an upper member and a lower member, the lower member having a flexible arm member at the front, the upper member having at least a first wing-shaped side portion, and a first intermediate member extending downward from the first wing-shaped side portion; extending a space or creepage path for an electrical path from the at least one high-voltage electrical terminal to another one of the high-voltage electrical terminals; characterized by; the step of extending the space or creepage path for the electrical path includes extending the electrical path substantially from at least the high-voltage electrical terminal along the surface of the first intermediate member, along the surface of the first wing-shaped side portion, along the surface of the inner male housing, along the opening, to the outer male housing, and further substantially to another one of the high-voltage electrical terminals; a method characterized by.

12. The step of extending the space or creepage path for the electrical path includes extending the electrical path substantially from at least the high-voltage electrical terminal across the lower member of the male terminal position assurance (TPA) device and further substantially to another one of the high-voltage electrical terminals; A method for improving the spatial and creepage paths in a high-voltage connector assembly, using a male terminal position assurance (TPA) device in the male housing of the high-voltage connector assembly according to claim 11, characterized by.

13. The step of inserting the male terminal position assurance (TPA) device into the male housing includes locking the male terminal position assurance (TPA) device to the male housing at a pre-lock position. A method for improving the space and creepage path in a high-voltage connector assembly, using a male terminal position assurance (TPA) device in the male housing of the high-voltage connector assembly as claimed in claim 11, characterized by the above.

14. The step of inserting the male terminal position assurance (TPA) device into the male housing includes locking the male terminal position assurance (TPA) device to the male housing at a full-lock position. A method for improving the space and creepage path in a high-voltage connector assembly, using a male terminal position assurance (TPA) device in the male housing of the high-voltage connector assembly as claimed in claim 11, characterized by the above.

15. The male terminal position assurance (TPA) device includes second wing-like side portions extending therefrom respectively. A method for improving the space and creepage path in a high-voltage connector assembly, using a male terminal position assurance (TPA) device in the male housing of the high-voltage connector assembly as claimed in claim 12, characterized by the above.

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