[0001] The present application relates to an electrical connector and more particularly to an electrical connector having a terminal position assurance device (TPA).

[0002] It is known in various industries to have electrical connectors in the form of plugs and headers to provide electrical connection in such systems as automotive systems, for example, for engine electronics, engine control management systems and the like. It is also known to have "anti-sco oping" devices such as posts or ribs (see U.S. Patent 6,409,525) which prevent electrical connection of mating connectors at an angle other than along a common longitudinal axis. Typical anti-scooping ribs are inserted adjacent the terminal cavity. Cunent connectors may also use a terminal assurance member (TPA) to assure that the terminal is properly positioned in the cavity. For connectors having a front loaded TPA, the TPA is inserted adjacent the terminal cavity. Many current electrical connectors have a space adjacent to the terminal cavities to accommodate the TPA. Additionally, many cunent connectors may have more than one row of terminal cavities. Consequently, in connectors using a front loaded TPA, space is needed for both the TPA and the anti-scooping rib. The problem is that in some current connectors having closely spaced terminal cavities, the space is not available for both the typical TPA and anti-scooping rib.

[0003] The solution is provided by the electrical connector as described herein. The electrical connector comprises a housing having a plurality of terminal receiving

passageways positioned in at least one row, the passageways including a locking latch. An overstress protection rib positioned adjacent each latch. A channel extends through- the housing and adjacent to the at least one row of terminal receiving passageways. The electrical connector includes a terminal position assurance member (TPA) having a blade. The blade includes a plate and a rear edge. The blade is positioned within the channel so that the terminal position assurance member has a pre-locked position with the rear edge positioned forward of the latch allowing the latch to resile into the channel, and a fully locked position where the rear edge is positioned underneath the latch.

[0004] The invention will now be described by way of example with reference to the accompanying drawings in which. [0005] Fig. 1 shows an underside perspective view of the plug assembly of the present disclosure;

[0006] Fig. 2 shows an exploded of the plug assembly of Fig. 1;

[0007] Fig- 3 shows a front perspective view of the plug housing;

[0008] Fig. 4 shows a front end view of the plug housing of Fig. 3;

[0009] Fig. 5 shows a cross-sectional view through lines 5-5 of Fig. 4;

[0010] Fig. 6 shows a front view of the TP A;

[0011] Fig. 7 shows a front perspective view of the TPA of Fig. 6;

[0012] Fig. 8 shows a rear perspective view of the TPA of Figs. 6 and 7;

[0013] Fig. 9 shows a rear view of the TPA of Fig. 8;

[0014] Fig. 10 shows an enlarged view of the portion denoted in Fig. 6;

[0015] Fig. 11 shows an enlarged view of the portion denoted in Fig. 8;

[0016] Fig. 12 shows a cross-sectional view showing the cooperation of the TPA and plug housing in a pre-locked position; and

[0017] Fig. 13 shows the cross-sectional view of Fig. 12 with the TPA in the fully locked position.

[0018] With reference to Figs. 1 and 2, an exemplary embodiment of the electrical connector assembly of the present disclosure is shown generally at 2 including a plug housing 4 preferably molded from an electrically insulating material such as a plastic material, a tenninal position assurance member (TPA) 6, and a mating assist member 8 in the form of a lever. As shown, connector assembly 2 includes an opening 10 formed therethrough for receiving a laterally extending anti-scooping rib as described herein. In the exemplary embodiment, the connector assembly 2 includes a plurality of terminal receiving passageways shown generally at 14 for signal contacts and one or more terminal receiving passageways such as 16 for power contacts, In the exemplary embodiment, the terminal receiving passageways 14 are positioned in at least one row. The connector assembly 2 further includes peripheral seal 20, rear wire seal 22 and rear housing portion 24.

[0019] With reference now to Figs. 3-5, the plug housing 4 will be described in greater detail. As shown, plug housing 4 includes a shroud portion 30 which encircles housing upper and lower platforms 32 and 34 which provides support for terminal receiving passageways 14 as described above. The upper platform 32 includes a row of upper and a row of middle terminal receiving passageways 14. The lower platform 34 includes a row of lower terminal receiving passageways 14. Shroud portion 30 defines upper and lower planar wall portions 36 and 38 which define support for mating assist member 8 (Fig 2).

[0020] With reference now to Fig. 5, plug housing 4 also includes a front face 40, rear face 42, an inner wall 44 and a central wall 48 which separates terminal receiving

passageways 14. As shown best in Figs. 3 and 5, a laterally extending channel 50 is adjacent to at least one row of terminal receiving passageways and is defined by housing upper and lower platforms 32 and 34 which provide access for an anti-scooping rib as further described herein. As shown, upper terminal receiving passageway 14 includes a locking latch 54 and the middle terminal receiving passageway includes a locking latch 58. As shown in Fig. 5, when a terminal is inserted into or removed from the terminal receiving passageway 14, the locking latch 54 may resile upwardly until it hits inner surface 60 of an overstress protection rib. Likewise, when a terminal is inserted into or removed from the middle terminal receiving passageway 14 the locking latch 58 may resile downwardly until it contacts an inner surface 62 of overstress protection rib 64. As shown, rib 64 extends from surface 70 of the lower housing platform 34 and is aligned with locking latch 58. As best shown in Fig. 12, an overstress protection rib 64 is positioned adjacent to each terminal receiving passageway 17. As shown in Figs 5, 12 and 13, each terminal receiving passageway 14 also includes a partial or side wall 80 extending from the front face 40 and defining the side of the terminal receiving passageway 14. The side wall 80 has an upper edge 82 and a lower edge at 84. Each locking latch 54, 58 further include a forwardly facing lock surface 90, a forwardly extending tongue 92 and a ramp surface 94.

[0021] With reference now to Figs. 6-11, the TPA 6 will be described in greater detail. The TPA 6 includes a front face 100 and an outer shroud wall 102 which is receivable within shroud 30 (Fig. 3) of plug housing 4. The front face 100 includes apertures 110 configured to receive the terminal receiving passageways 14 in the upper platform 32 and openings 112 configured to receive terminal receiving passageways 14 in the lower platform 34. Front face 100 further includes a laterally extending opening 116 which aligns with laterally extending channel 50 (Fig. 3) as described herein. The TPA 6 includes a TPA plate or blade 120 (Fig. 11). The TPA blade 120 is defined by a generally flat plate 122 and a raised rear edge 124. The plate 122 defines a lower boundary of opening 116. The distance from the front face 100 to the rear edge 124 generally defines the depth of the opening 116. As shown in Fig. 11, the raised rear edge 124 of the TPA blade 120 is raised or vertically offset from the surface of the blade plate 122. The raised rear edge 124 includes raised blocks defining a plurality of slots 130. Extending from the opposite side of the TPA plate 122 are a plurality of projections 140 defining a plurality of grooves 132 between the projections 140. As shown best in Fig. 12, when the blade 120 is positioned within the channel 50 the plurality of slots 130 are aligned with ribs 64 (Fig. 5) and the plurality of grooves 132 are aligned with each partial wall 80 (Fig. 5) as described herein. As shown in Figs. 10 and 11, the slots 130 are staggered related to the grooves 132.

[0022] With reference now to Figs. 12 and 13, the operation of the TPA 6 and the plug housing 4 will be described in greater detail. With reference first to Fig. 12, TPA 6 is shown in a pre-locked position where rear edge 124 is positioned forward of ribs 64 and latch 58, A terminal may now be inserted into cavity 14 in a direction from right to left as shown in Fig. 12. The terminal biases latch 58 downwardly into the channel 50 by way of engagement of the terminal against surface 94. If the terminal is fully inserted, an edge of the terminal will engage locking surface 90 and the latch 58 will return to a position similar to that shown in Fig. 12. If the terminal is not fully inserted, the body of the terminal will continue to deflect latch 58 downwardly and any attempt to move TPA 6 to the right as viewed in Fig. 12, will cause projection 140 to engage the tongue 92 (or lock surface 90) preventing the full assembly of TPA 6.

[0023] When the terminal is fully positioned in terminal receiving passageway 14, the

TPA 120 is moved further into engagement with the housing 6 which causes each of the slots 130 of the rear edge 124 to overlap a corresponding rib 64. As the rear edge 124 is positioned within the ribs 64, projections 140 are positioned underneath latch 58 as shown in Fig. 13. The positioning of the projections 140 under the latch ensures the terminal is fully mated in the housing 6 and prevents the deflection of the latch 58. [0024] The proper function of the TPA requires the proper vertical positioning of the projections 140 to have proper engagement of the projections 140. As described above, the plate 122 of the TPA blade 120 is vertically offset from the projections. The offset allows the proper vertical positioning of the projections 140 as related to the latch 58. At the same time, since the vertical location of the blade plate 122 would interfere with the overstress protection ribs, slots 130 provide recesses to allow the TPA to be fully inserted into the channel 50.

[0025] As shown in Fig. 13, the opening 116 is defined by plate 122 and lower edge

84 of passageway side walls 80. Due to the offset, the blade plate 122 is positioned at the lower side of the channel allowing space for the opening 116. As assembled as shown in Fig. 13, connector assembly 2 may now be interconnected to a corresponding header having an anti-scoop rib. The anti-scoop rib would be profiled to be received in opening 116.

[0026] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.