High voltage connector assembly having improved female and male housings with female terminal position assurance (TPA) devices, and an improved method for improving clearance and creepage distances in a high voltage connector assembly

Abstract

A high voltage connector assembly having improved female and male housings with a female terminal position assurance (TPA) device and a method for improving the clearance and creepage of electrical paths in the high voltage connector assembly are provided. The female housing includes a mid-top having an opening for receiving a front downward extension member of a forward extension member of the female TPA device, respectively, to finally lock the high voltage electrical terminal within the female housing and to position the female TPA device in a fully locked position within the female housing. When fully assembled, the clearance and creepage of electrical paths in the high voltage connector assembly extend in a generally vertical direction from the high voltage electrical terminal, along a separating wall of the male housing, and in a generally horizontal direction across the mid-top of the female housing toward the rear of the female housing to the adjacent high voltage electrical terminal. Also, when in the full-locked position, the TPA device is assembled in a manner that allows the terminal to be substantially completely enclosed in all directions by continuous insulating material, or, except for the lower extension member, is entirely outside the female housing such that no part of the TPA device is required to enter the cavity that receives the terminal while at rest in the pre-locked position.

Description

[Background technology]

[0001] Due to the high voltages that high voltage connector assemblies must meet and the design of conventional shielded automotive connectors, it is desirable to improve or increase at least the clearance and creepage distances from one high voltage electrical terminal to another high voltage electrical terminal, electrical element / circuit. Summary of the Invention

[0002] The present invention relates to a connector assembly having improved female and male housings with a female terminal position assurance (TPA) device, as well as an improved method for improving clearance and creepage distances in the high-voltage connector assembly of the present invention. The high-voltage connector assembly of the present invention is well suited for larger terminals, i.e., high-voltage electrical terminals. The female TPA device of the present invention includes an improved female housing having a front and a rear, the front having an upper portion with an opening for allowing only the front lower extension member of the female TPA device to enter therein. The improved male housing includes an inner separator wall disposed between the front forward extension members of the TPA device during operation. With the above-described structural arrangement of the present invention, "creepage" (a measurement 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 a measurement of the shortest electrical path from an exposed conductive element in a given circuit of the connector to any other conductive element in a different circuit in the same connector) are advantageously increased. [Brief explanation of the drawings]

[0003] [Figure 1] FIG. 1 is a front perspective view of a female terminal position assurance (TPA) device for use in the improved female high voltage connector assembly of the present invention. [Figure 2] FIG. 1 is a side view of a female TPA device for use in the improved female high voltage connector assembly of the present invention. [Figure 3]FIG. 1 is a top view of a female TPA device for use in the improved female high voltage connector assembly of the present invention. [Figure 4] FIG. 1 is a front view of a female TPA device for use in the improved female high voltage connector assembly of the present invention. [Figure 5] FIG. 1 is a perspective view of the improved female housing of the present invention with a female TPA device mounted or installed therein in a pre-locked position. [Figure 6] FIG. 1 is a perspective view of the improved female housing of the present invention with a female TPA device mounted or installed therein in a fully locked position. [Figure 7] FIG. 7 is a cross-sectional view taken along section line 7-7 of FIG. 5 showing the corresponding high voltage terminal with the corresponding forward downward extension member of the corresponding forward extension member of the female TPA device in a pre-locked position in the improved female housing of the present invention, further illustrating the clearance or creepage distance for the electrical path extending from the high voltage electrical terminal, as indicated by the vertical arrows. [Figure 8] FIG. 8 is a cross-sectional view taken along section line 8-8 of FIG. 6 showing the corresponding high voltage terminal with the corresponding forward downward extension member of the corresponding forward extension member of the female TPA device in the fully locked position in the improved female housing of the present invention, further illustrating the clearance or creepage distance for the electrical path extending from the high voltage electrical terminal, as indicated by the vertical arrows. [Figure 9] 1 illustrates the clearance or creepage distance for an electrical path extending from a high voltage electrical terminal as indicated by the vertical arrow passing through a corresponding opening in the upper middle portion of the improved female housing in the pre-lock position, where the forward downward extension member of the corresponding forward extension member partially penetrates or is about to penetrate a corresponding opening in the upper middle portion of the improved female housing of the present invention. [Figure 10]1 illustrates the clearance or creepage distance for an electrical path extending from a high voltage electrical terminal as indicated by a vertical arrow passing through a corresponding opening in the upper middle portion of the improved female housing in a fully locked position, where the forward downward extension member of the corresponding forward extension member fully enters the corresponding opening in the upper middle portion of the improved female housing of the present invention. [Figure 11A] Illustrated is a female housing and an improved male housing of the present invention for receiving a TPA device therein, and further illustrates a separation wall within the male housing for separating the upper member of the forward extension member located at the front of the TPA device when the improved male housing accommodates the TPA device and the improved female housing therein. [Figure 11B] 1 illustrates the TPA device and improved female housing of the present invention assembled together, further illustrating an arrow indicating the direction in which a separation wall in the male housing moves to be positioned between the forward extension members at the front of the TPA device, and further illustrating the increased spatial distance between adjacent electrical terminals housed within the improved female housing of the present invention. [Figure 12] FIG. 1 is a top view of the TPA device and improved female housing of the present invention assembled together, further illustrating the generally horizontal portion of the increased spatial distance for the electrical path, shown in dashed lines, between adjacent electrical terminals housed within the improved male housing of the present invention. [Figure 13A] FIG. 1 is a top view of a fully assembled TPA device and improved female housing of the present invention inserted into the improved male housing of the present invention. [Figure 13B] FIG. 1 is a top view of the improved male housing of the present invention with the fully assembled TPA device and improved female housing housed therein, further illustrating the generally horizontal portion of the increased clearance distance for the electrical path, shown in dashed lines, between adjacent terminals housed within the improved male housing of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0004] 1 illustrates a front perspective view of a female terminal positioning (TPA) device, generally designated by reference numeral 1. Female TPA device 1 includes a central member 3 and a rounded member 5. Central member 3 extends from an upper portion 7 to a lower portion 9 of rounded member 5. Rounded member 5 has forward extending members 10, 12 extending therefrom on opposite sides thereof.

[0005] 2 illustrates upper rearward extension member 13 and lower rearward extension member 15. At the forward end of each of forward extension members 10, 12 is a corresponding forward lower extension member 20, 22. Each of forward extension members 10, 12 also has a corresponding upper member 25, 27, each of which has a corresponding ramped forward end 29, 30.

[0006] Figure 3 shows a top view of the female TPA device 1, illustrating the anterior extension members 10, 12 and the corresponding upper members 25, 27 extending therefrom, and their ramped front ends 29, 30, respectively. Also shown are the upper posterior extension member 13 and the lower posterior extension member 15. The upper posterior extension member 13 has an upper jaw member 35 extending therefrom, while the lower posterior extension member 15 has a lower jaw member 37 extending therefrom. Openings 40, 42, sandwiching the central member 3, pass through either side of the female TPA device 1, as shown in Figure 4.

[0007] Figure 5 illustrates female TPA device 1 in a pre-lock position inserted into and installed in improved female housing 50. Improved female housing 50 has a front portion 53 and a rear portion 55. Figure 6 illustrates female TPA device 1 in a full-lock position inserted into and installed in improved female housing 50.

[0008] As will be explained in more detail below, the present invention includes an improved female housing 50, and in Figure 7, the TPA device 1 is shown in a pre-lock position, where the improved female housing 50 allows only the front lower extension members 20, 22 of the front extension members 10, 12, respectively, of the TPA device 1 to enter the improved female housing 50. As also shown in Figure 7 (cross section along line 7-7 in Figure 5), the thickness of the front top portion 61 of the improved female housing 50 is greater than the middle top portion 59 of the improved female housing 50.

[0009] 8 (cross-section taken along line 8-8 of FIG. 6), TPA device 1 is in the fully locked position, in which improved female housing 50 allows only front lower extension members 20, 22 of front extension members 10, 12 of TPA device 1 to enter openings 57, 58, respectively, in middle-upper portion 59 of improved female housing 50. Due to the above structural arrangement, the present invention is also well suited for larger terminals, such as high-voltage electrical terminal 60.

[0010] 7 and 8, respectively, the clearance or creepage distance for electrical paths 170, 175 (see arrows) from each exposed high-voltage electrical terminal 60 extends generally vertically through openings 57, 58, respectively, in the mid-top 59 of the improved female housing 50. Due to the above features of the present invention, as discussed above and shown in FIGS. 7 and 8, the "creepage distance" (a measurement of the shortest electrical path along a surface from any given circuit to any other (usually adjacent) circuit, here a measurement of the shortest electrical path to another high-voltage electrical terminal 60) and the "clearance distance" (a measurement of the shortest electrical path from any exposed conductive element in a given circuit of the connector to any other conductive element in a different circuit in the same connector, here a measurement of the shortest electrical path from a high-voltage electrical terminal 60 to another high-voltage electrical terminal 60) are advantageously increased, as will be explained in more detail below.

[0011] 7, a protruding member 62 extends from the bottom of the improved female housing 50. The protruding member 62 includes a ramp-shaped leading end 65. A leading portion 68 of the terminal 60, in turn, has a notch 70 that easily passes over the ramp-shaped leading end 65 of the protruding member 62 when the terminal 60 is fully inserted into the improved female housing 50. When the terminal 60 is fully inserted into the improved female housing 50, the protruding member 62 of the improved female housing 50 snaps into the notch 70 in the leading end portion 68 of the terminal 60, thereby locking the terminal 60 inside the improved female housing 50 (primary lock).

[0012] 7, the female TPA device 1 is in a pre-lock position. As described above, the terminal 60 is locked (primary lock) when the protruding member 62 in the improved female housing 50 snaps or enters the notch 70 in the leading end portion 68 of the terminal 60. As a result, the terminal 60 cannot be withdrawn from the improved female housing 50, and 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 that passes into and through the openings 57, 58, respectively, at the top of the mid-top portion 59 of the improved female housing 50. That is, unless terminal 60 is in the primary lock position within improved female housing 50 and upper notch 80 of terminal 60 is available to receive or accommodate a corresponding one of front lower extension members 20, 22 therein, front lower extension members 20, 22 cannot enter through openings 57, 58 and provide the necessary secondary lock to terminal 60 within improved female housing 50. In other words, when terminal 60 is not in the primary lock within improved female housing 50, female TPA device 1 is prevented from being pushed further downward by upper portion 85 of leading portion 68 of terminal 60. As a result, if the upper portion 85 of the leading portion 68 of the terminals 60 blocks the female TPA device 1 (more specifically, blocks the front downward extension members 20, 22 of the female TPA device 1), the female TPA device 1 can detect that the terminals 60 are not in their proper or correctly installed position or location, i.e., the female TPA device 1 cannot be pushed further downward and therefore cannot provide a secondary lock to the terminals 60 within the improved female housing 50 (i.e., the female TPA device 1 cannot be pushed further downward to the full lock position).

[0013] 8 illustrates the improved female TPA device 1 in a fully locked position inside the improved female housing 50. The shape of the front lower extension members 20, 22 generally resembles the edges or rims of the openings 57, 58 and are sized to fit within the openings 57, 58, respectively, which aids in the alignment and reception of the front lower extension members 20, 22 within the openings 57, 58. Here, the upper notch 80 of the primarily locked terminal 60 becomes available to receive therein a corresponding one of the front downward extension members 20, 22 of the forward extension members 10, 12, respectively, of the improved female TPA device 1, and thus, when inserted into each one of the upper notches 80 of the terminal 60, the front downward extension members 20, 22 of the forward extension members 10, 12, respectively, of the improved female TPA device 1 prevent the primarily locked terminal 60 from being pulled away from the protruding member 62 and removed from the improved female housing 50, and therefore the TPA device 1 can provide a secondary lock to the terminal 60 within the improved female housing 50.

[0014] 7 (female TPA device 1 in pre-lock position) and 8 (female TPA device 1 in full-lock position), respectively, there are shown creepage or clearance distances (see arrows) for vertical portions 170, 175 of the electrical pathway extending generally vertically from high voltage electrical terminal 60 through openings 57, 58 in upper middle portion 59 of improved female housing 50 when female TPA device 1 is oriented on or within improved female housing 50. Note also that herein, front downward extension members 20, 22 are each substantially immediately behind a portion of corresponding high voltage electrical terminal 60 to provide secondary locking for high voltage electrical terminal 60 within improved female housing 50.

[0015] As further shown in FIGS. 7 and 8, the female TPA device 1 is operated (or moved relative to the female housing 50) in a direction perpendicular to the direction in which the high voltage terminal 60 is inserted into the female housing 50.

[0016] Additionally, female TPA device 1 of the present invention has such a geometric shape or structural arrangement (as described above) that female TPA device 1 is entirely outside female housing 50, with the exception of only lower extension members 20, 22, such that no portion of female TPA device 1 is required to pass through or enter cavity 200 containing high-voltage electrical terminals 60 while female TPA device 1 is assembled to female housing 50 or while resting in the pre-lock state or position (see FIGS. 5, 7, and 9). As described above, only lower extension members 20, 22 enter distal cavity 200 through openings 57, 58, never through openings 67, 68, and only when female TPA device 1 is in the full-lock state or position. The above structural arrangement allows each of the high voltage electrical terminals 60 to be completely enclosed in all directions by four walls (i.e., the top, bottom, and both sides of the continuous insulating material (i.e., the female housing 50 formed of, for example, resin)), except for a small discontinuity required for the openings 57, 58 to pass through for the lower extension members 20, 22 when the TPA device 1 is in the fully locked position or state.

[0017] Additionally, female TPA device 1 is locked and unlocked from the front of the connector assembly (i.e., the mating end of the connector assembly). This allows TPA device 1 to be used in fully shielded connector assemblies that would otherwise prevent the use of TPA devices that operate at the rear of the connector assembly (i.e., the end wires of the connector assembly) due to the shielding required at the rear of the connector and the shielding required to contact (electrically ground) the shield to the wires.

[0018] As illustrated in Figure 9, the female TPA device 1 is in a pre-lock position within the improved female housing 50, while as illustrated in Figure 10, the female TPA device is in a full-lock position within the improved female housing 50. Figure 9 shows the lower extension members 20, 22 of the forward extension members 10, 12 of the female TPA device 1 above or partially inserted into the openings 57, 58 that pass through the middle-top portion 59 of the improved female housing 50. Figures 9 and 10 also show the creepage or clearance distance (see arrows) for the vertical portions 170, 175 of the electrical pathway that extend generally vertically from the high voltage electrical terminal 60 through the openings 57, 58 in the upper middle portion 59 of the improved female housing 50.

[0019] FIG. 11A illustrates an improved male housing 130 having openings 150, 153 for receiving the front portion 53 of the female housing 50 therein. As further illustrated in FIG. 11A , the openings 150, 153 are separated by a separation wall 160 of the male housing 130. The separation wall 160 separates adjacent high-voltage electrical terminals 60 housed within the female housing 50, as will be further described below. When the female housing 50 and the male housing 130 are assembled together, the front portion 53 of the divided female housing 50 is divided or separated by the separation wall 160, which is positioned as shown in FIG. 11B . With the separation wall 160 in place, the front lower extension members 20, 22 of the forward extension members 10, 12, which house the high-voltage electrical terminals 60 therein, are likewise divided or separated by the separation wall 160, as shown in FIG. 11B . 11B, vertical portions 170, 175 of the electrical pathway extend from high voltage electrical terminal 60 out of openings 57, 58 (as indicated by dashed lines at 180, 185), and the electrical pathway with the creepage distance extends along upper middle portion 59 and then toward rear 55 of female housing 50, crossing along or around separator wall 160. As separator wall 160 extends near the front of rounded member 5 of female TPA device 1, the generally horizontal portions 180, 185 of the creepage distance for the electrical pathway extend further across the periphery of separator wall 160, crossing substantially in front of and along (as indicated by dashed line at 190) a portion of rounded member 5 of female TPA device 1. With the vertical portions 170, 175 and horizontal portions 180, 185, 190 of the creepage distance for the electrical path extending as shown in Figures 11B and 12, the clearance distance of the electrical path between the terminals 60 of the present invention is increased and therefore significantly improved.

[0020] 12 is a top view of the assembled female TPA device 1 and female housing 50, further illustrating the creepage distance of the generally horizontal portions 180, 185, 190 of the electrical path shown as dashed lines, illustrating the clearance around the separation wall 160 and between adjacent electrical terminals 60 housed within the female housing 50. The clearance is increased because the electrical path must traverse back along the top of the upper intermediate portion 59 and separation wall 160, which together introduce more surface area between the openings 57, 58 and exposed portions of the terminals 60 that further directs the creepage path in a route that increases the clearance between the terminals 60 (i.e., a longer distance is provided or introduced for creepage, which is the shortest electrical path along a surface, or for clearance that flows directly through air, i.e., without an insulating barrier).

[0021] Figure 13A is a top view of TPA device 1 and female housing 50 inserted and fully assembled into male housing 130. Male housing 130 has separation wall 160 therein (see Figure 11A). Figure 13B is a top view of male housing 130 with fully locked TPA device 1 and female housing 50 housed therein, further illustrating the creepage distances of generally horizontal portions 180, 185, 190 and the resulting clearance distance for the increased electrical path between adjacent terminals 60 housed within female housing 50, represented by the same dashed line.

[0022] 11A and 11B, the creepage distance of the electrical pathway includes generally horizontal portions 180, 185, 190, further illustrated in FIGS. 12, 13A, and 13B, which allow the electrical pathway to traverse a portion of the side of separation wall 160 disposed between front portions 53 of split female housings 50 that each house adjacent high voltage electrical terminals 60 therein. As described above, separation wall 160 increases the route of the electrical pathway within the high voltage connector assembly from one adjacent high voltage electrical terminal 60 to the other, increasing the creepage distance of the electrical pathway, and with this increase, the clearance distance between exposed portions of electrical terminals 60 within the high voltage connector assembly of the present invention is significantly improved for high voltage applications and uses.

[0023] The present invention is not limited to the above-described embodiments, and various modifications in design, structural arrangement, etc. may be used without departing from the scope or equivalent of the present invention.

Claims

1. 1. A high voltage connector assembly comprising: a female terminal position assurance (TPA) device having a front and a rear portion, the front portion including a plurality of forward extending members with a front downward extending member; a female housing having a front top, a middle top, and a rear, said female housing substantially enclosing at least a high voltage electrical terminal therein, said middle top including an opening through which said front downward extension member of said female TPA device passes for receipt therein; a male housing having a separation wall separating a front portion of the female housing having openings for receiving each of the plurality of forwardly extending members of the TPA device; is characterized by a male housing, wherein when the TPA device is in a fully locked position, only the front downward extension member of the TPA device is received within an internal cavity of the female housing containing the high voltage electrical terminal; A high voltage connector assembly characterized by:

2. The separating wall of the male housing further separates a plurality of high voltage electrical terminals contained within the female housing.

2. The high voltage connector assembly of claim 1, wherein:

3. The female housing pre-locks the high voltage electrical terminal therein.

3. The high voltage connector assembly of claim 2, wherein:

4. The front downward extension member of the female TPA device finally locks the high voltage electrical terminal within the female housing.

4. The high voltage connector assembly of claim 3, wherein:

5. The female TPA device is in a pre-lock position.

4. The high voltage connector assembly of claim 3, wherein:

6. The female TPA device is in the fully locked position.

5. The high voltage connector assembly of claim 4, wherein:

7. The high voltage electrical terminal is completely enclosed in substantially all directions by the female housing when the TPA device is in the fully locked position.

2. The high voltage connector assembly of claim 1, wherein:

8. The female housing is made of resin.

8. The high voltage connector assembly of claim 7, characterized by:

9. 1. A method for assembling a high voltage connector assembly, comprising: inserting a plurality of high voltage electrical terminals into the female housing; locking the plurality of high voltage electrical terminals respectively within the female housing; inserting a plurality of front lower extension members of a female TPA device into openings passing through the upper middle portion of the female housing; separating adjacent high voltage electrical terminals from the plurality of high voltage electrical terminals locked within the female housing; is characterized by the separating step is performed by a separating wall in a male housing, the male housing receiving the female housing therein; The method, wherein only the plurality of front downward extension members of the TPA device are received within an interior cavity of the female housing containing the plurality of high voltage electrical terminals when the TPA device is in a fully locked position.

10. The step of inserting the plurality of front lower extension members of the female TPA device finally locks the plurality of high voltage electrical terminals within the female housing.

10. The method for assembling a high voltage connector assembly of claim 9, characterized by:

11. The step of inserting each of the plurality of front lower extension members of the front extension member of the female TPA device places the female TPA device in a final locked position within the female housing.

10. The method for assembling a high voltage connector assembly of claim 9, characterized by:

12. The high voltage electrical terminal is completely enclosed in substantially all directions by the female housing when the TPA device is in the fully locked position.

10. The method for assembling a high voltage connector assembly of claim 9, characterized by:

13. The female housing is made of resin.

13. The method for assembling a high voltage connector assembly of claim 12, characterized by:

14. 1. A method for improving clearance and creepage distances within a high voltage connector assembly using female terminal position assurance (TPA) devices in female and male housings of said high voltage connector assembly, comprising: inserting a plurality of high voltage electrical terminals into the female housing respectively; inserting a plurality of front lower extension members of a female TPA device into openings formed by the upper middle portion of the female housing; separating adjacent high voltage electrical terminals from the plurality of high voltage electrical terminals, the separating step being performed by a separating wall of a male housing, the male housing containing the female housing; providing clearance or creepage distance for electrical paths extending from the plurality of high voltage electrical terminals along and around the separating wall of the male housing, toward the rear of the female housing, across the middle-top of the female housing, and across the female TPA device substantially in front of the female TPA device to adjacent plurality of high voltage electrical terminals; is characterized by The method wherein when the TPA device is in a fully locked position, only the front downward extension member of the TPA device is received within an interior cavity of the female housing containing the high voltage electrical terminals.

15. Providing the clearance or creepage distance for the electrical pathways includes extending the electrical pathways generally vertically from the plurality of high voltage electrical terminals through respective openings passing through the middle-top of the female housing, the openings receiving the plurality of front downward extension members of the forward extension member of the female TPA device when the female TPA device is in a fully locked position.

15. The method for improving clearance and creepage distances within a high voltage connector assembly according to claim 14, characterized by using a female TPA device in the female and male housings of said high voltage connector assembly.

16. The step of inserting the plurality of front lower extension members of the female TPA device into the openings in the middle upper portion of the female housing includes locking the female TPA device in a full lock position within the female housing.

15. The method for improving clearance and creepage distances within a high voltage connector assembly according to claim 14, characterized by using a female TPA device in the female and male housings of said high voltage connector assembly.

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