Low profile high voltage connector and method for assemblying thereof

A method for assembling a low profile high voltage connector having a male housing with a plurality of pins inserted therein, a female housing with a plurality of electrical wires or cables inserted therein, a terminal position assurance (TPA) device insertable into said female housing for locking said plurality of wires or cables inside said female housing, and a connector position assurance (CPA) device insertable into said female housing for locking said male housing and said female housing together, each of said TPA device and said CPA device being insertable into said female housing at one of a pre-lock position and a full-lock position, said method comprising the steps of:

• inserting wire core portions of said plurality of electrical wires or cables into said female housing;
• inserting said TPA device into said female housing at a pre-lock position, said wire core portions of said plurality of electrical wires or cables blocking said TPA device from further entering said female housing;
• further inserting said wire core portions of said plurality of electrical wires or cables into said female housing, a tang member of each of said wire core portions being accommodated inside a cavity inside said female housing;
• substantially aligning a space within said wire core portion with an aperture passing through an intermediate terminal housing of said female housing;
• allowing a member extending from said TPA device to pass through said aperture of said intermediate terminal housing of said female housing and said space within said wire core portion of said electrical wire or cable;
• further inserting said TPA device into said female housing at a full-lock position within said female housing, wherein said step of further inserting said TPA device into said female housing at said full-lock position comprises a step of blocking each of said wire core portions of said plurality of electrical wires or cables from being removed or dislodged away from said female housing.

A method for improving clearance and creepage in a low profile high voltage connector, comprising the steps of:

• inserting at least an electrical wire or cable into a female housing of said low profile high voltage connector, said female housing having a plurality of alley portions therein;
• locking said electrical wire or cable inside said female housing of said low profile high voltage connector;
• inserting a terminal position assurance (TPA) device through at least an opening of said female housing, and further inserting said TPA device into said female housing at a full-lock position within said female housing, said TPA device having a substantially elongated member extending therealong, wherein said step of further inserting said TPA device into said female housing at said full-lock position comprises a step of blocking each of said wire core portions of said plurality of electrical wires or cables from being removed or dislodged away from said female housing, said TPA device having a plurality of wall members extending therefrom, and each of said plurality of wall members of said TPA device being accommodated within a corresponding one of said plurality of alley portions of said female housing;
• providing said low profile high voltage connector with a male housing, said male housing accommodating therein said female housing;
• and
• allowing a clearance or electrical path to extend from said at least electrical wire or cable to said female housing, wherein said step of allowing said clearance or electrical path comprises a step of extending said clearance or electrical path from at least said electrical wire or cable along a surface of at least one of said plurality of wall members of said TPA device to said female housing having at least one of said alley portions which accommodates therein said at least one of said wall members, said clearance or electrical path further extending along said substantially elongated member of said TPA device, thereby extending the clearance or electrical path between electrical wires or cables inserted within said female housing and further preventing said electrical path from traveling or traversing the top portion of said TPA device.

A low profile high voltage connector, comprising:

• a male housing having a plurality of pins inserted therein, said male housing further having a lock member;
• a female housing having a plurality of electrical wires or cables inserted therein, said female housing having a first ramp member and a second ramp member therein, said first ramp member being located at a first portion of said female housing, while said second ramp member being located at a second portion of said female housing;
• a terminal position assurance (TPA) device insertable into said female housing for locking said plurality of wires or cables inside said female housing, said TPA device insertable into said female housing at one of a pre-lock position and a full-lock position;
• and
• a connector position assurance (CPA) device insertable into said female housing for locking said male housing and said female housing together, said CPA device insertable into said female housing at one of a pre-lock position and a full-lock position, wherein said CPA device comprises a centrally located flexible member,
• wherein said CPA device comprises a lock member at an end thereof,
• wherein said CPA device further comprises a head member, and a front member connected to side members, said front member being at an opposite side of said head member,
• wherein said front member of said CPA device travels along said first ramp member of said female housing when said CPA device is positioned in a pre-lock position,
• wherein when said CPA device is positioned in a full-lock position, said male housing and said female housing become fully mated, and said second ramp member of said female housing blocks said lock member of said male housing thereby said female housing is unable to be dislodged or removed from said male housing, and
• wherein said ramp member resting between said lock member of said male housing and said lock member of said CPA device.