Patent Description:
Electrical connectors typically include electrical terminals that are held within an insulative housing. The electrical terminals have to be properly positioned or seated within the housing to successfully mate to a corresponding electrical contact of a mating connector. If one or more of the terminals are not properly positioned, the connector may form a faulty connection when mated to a mating connector. It may be costly and/or difficult fix a faulty connection due to poor accessibility of the terminals within the connector, and a common remedy is to discard the entire connector,.

Another concern with electrical connectors is retention of the terminals within the housing when in use. For example, some terminals can be exposed to significant forces towards a back or mounting end of the housing. The forces may be exerted on the terminals by mating contacts that push the terminals during the mating process, by tension on the cables attached to the terminals caused by human operators pulling the cables, or the like. Known terminals, such as those disclosed in <CIT>, may be retained within a respective cavity of the housing via small complementary retention features, such as latches, on the terminal and the housing. However, the retention features may not be sufficiently robust to withstand the forces exerted on the terminals, causing the retention features to fail and allowing the terminals to be pulled out of position.

The problem to be solved is to provide an electrical connector having an attachable device or member that robustly secures the terminals in the cavities of the housing and ensures that the terminals are properly positioned in the housing prior to mating the connector to a complementary mating connector.

This problem is solved by an electrical connector as recited in claim <NUM>, that includes a housing, multiple blade terminals, and a terminal position assurance (TPA) device. The housing has a mating end and a mounting end, and defines multiple cavities. The blade terminals are held by the housing within the cavities. The blade terminals have two edge sides between two broad sides and a rib projecting from at least one of the two edge sides. The TPA device is coupled to the housing at the mounting end and is movable relative to the housing between an unlock position and a lock position. The TPA device has a base plate that defines multiple terminal openings therethrough. The base plate includes ledges that jut out into the terminal openings. The ledges extend behind and align with the ribs of the corresponding blade terminals when the TPA device is in the lock position to retain the blade terminals within the housing by abutting against back shoulders of the ribs.

The invention will now be described by way of example with reference to the accompanying drawings:.

<FIG> is a perspective view of an electrical connector <NUM> in accordance with an embodiment. <FIG> is an exploded perspective view of the electrical connector <NUM> according to an embodiment. The electrical connector <NUM> includes a housing <NUM>, a terminal position assurance (TPA) device <NUM>, and multiple blade terminals <NUM>. The blade terminals <NUM> are held within corresponding cavities <NUM> of the housing <NUM>. The blade terminals <NUM> protrude from the housing <NUM> at a mounting end <NUM> of the housing <NUM>.

In the illustrated embodiment, the housing <NUM> has a mating end <NUM> opposite the mounting end <NUM>. The mating end <NUM> defines a mating interface for engaging a mating connector (not shown) during a mating operation. The mating end <NUM> of the housing <NUM> may define a socket <NUM> (shown in <FIG>) that receives a portion of the mating connector therein during the mating operation. The cavities <NUM> are open at the mounting end <NUM> and extend towards the mating end <NUM>. For example, the terminals <NUM> may be loaded into the cavities <NUM> through the mounting end <NUM>. The cavities <NUM> are fluidly connected (e.g., open) to the mating end <NUM>. The cavities <NUM> may extend fully to the mating end <NUM> or may be open to the mating end <NUM> via the socket <NUM>. Each blade terminal <NUM> is loaded into a different one of the cavities <NUM>. The blade terminals <NUM> within the housing <NUM> are configured for electrically connecting to corresponding mating contacts of the mating connector to establish conductive pathways across the mating interface. In an embodiment, the cavities <NUM> are oriented parallel to one another and parallel to a cavity axis <NUM>.

In <FIG>, the housing <NUM> has an in-line or straight shape that extends linearly from the mounting end <NUM> to the mating end <NUM>. The housing <NUM> may be elongated parallel to the cavity axis <NUM>, such that the cavity axis <NUM> extends through both the mounting end <NUM> and the mating end <NUM>. In an alternative embodiment, the housing <NUM> may have a right angle shape or another shape that is no in-line.

The electrical connector <NUM> optionally is a header connector that is configured to be mounted directly to a structure, such as a chassis, a case of a device, a wall, of the like. The electrical connector <NUM> is configured to mate with a mating connector, which may be a plug connector terminated one or more cables. The housing <NUM> in the illustrated embodiment includes a main body (portion) <NUM> and a mounting flange <NUM> connected to the main body <NUM>. The mounting flange <NUM> is configured to be mechanically fastened to a panel or wall (not shown) of a structure to mount the connector <NUM> through an opening in the panel. The cavities <NUM> are defined by and extend through the main body <NUM>. The mounting flange <NUM> projects outward (e.g., radially) from the main body <NUM><NUM>. The mounting flange <NUM> is disposed at or proximate to the mounting end <NUM> of the housing <NUM>.

The mounting flange <NUM> has a first side <NUM> that faces the panel (not shown) to which the connector <NUM> is mounted, and an opposite, second side <NUM> that faces towards the mating end <NUM>. The first side <NUM> is also referred to herein as a panel-facing side <NUM>. The mounting flange <NUM> optionally defines openings <NUM> therethrough for receiving fasteners (not shown), such as bolts and/or screws. The openings <NUM> may also hold compression limiters <NUM> or other bearings that extend between the fasteners and the flange <NUM> to protect the material of the flange <NUM>.

Optionally, the electrical connector <NUM> may be a sealed connector that is configured to form a seal against the panel. The mounting flange <NUM> may include a compression seal <NUM> that is mounted to the panel-facing side <NUM> of the mounting flange <NUM>. The compression seal <NUM> may include a rubber or rubber-like material that compresses when sandwiched between the panel-facing side <NUM> of the flange <NUM> and the panel to prevent debris and contaminants from passing through the interface the panel and the connector <NUM>. The compression seal <NUM> in the illustrated embodiment is a hollow band that surrounds a perimeter of both the TPA device <NUM> and the main body <NUM>, as shown in <FIG>. Optionally, the compression seal <NUM> surrounds the perimeter of the TPA device <NUM> and the main body <NUM> without engaging either component. The compression seal <NUM> may be a gasket, an O-ring, or the like.

As shown in <FIG>, the TPA device <NUM> couples to the housing <NUM> at the mounting end <NUM>. As described in more detail herein, the TPA device <NUM> is movable relative to the housing <NUM> between an unlock position and a lock position. For example, during assembly, the TPA device <NUM> may be disposed in the unlock position, which represents a "pre-lock" configuration of the connector <NUM> that occurs during assembly of the electrical connector <NUM>. Once the terminals <NUM> are loaded within the cavities <NUM>, an operator may actuate the TPA device <NUM> to the lock position. In the lock position, the TPA device <NUM> supports retention of the terminals <NUM> in the housing <NUM>. For example, the TPA device <NUM> may back up the terminals <NUM>, which locks the terminals <NUM> in the cavities <NUM> by blocking the terminals <NUM> from retreating through the mounting end <NUM> of the housing <NUM>. The TPA device <NUM> may provide a secondary means of retaining the terminals <NUM> in the housing <NUM>, or, alternatively, may provide the primary and/or sole means of retaining the terminals <NUM> in the housing <NUM>. As described in more detail herein, the TPA device <NUM> is configured to increase the permissible amount of force that can be exerted on the terminals <NUM> before the terminals <NUM> are forced out of fixed positions within the housing <NUM>. For example, the use of TPA device <NUM> may enable each of the terminals <NUM> to meet and exceed requirements according to designated standards, such as being able to withstand forces up to <NUM> N or the like.

The TPA device <NUM> also provides terminal position assurance to indicate if any of the terminals <NUM> are not properly positioned within the housing <NUM>. For example, if one or more of the terminals <NUM> are not fully loaded within the corresponding cavity <NUM>, the connector <NUM> is designed such that the TPA device <NUM> is obstructed from attaining the lock position. The mechanical obstruction experienced when attempting to move the TPA device <NUM> to the lock position provides a tactile, audible, and/or visual indication that one or more of the components of the connector <NUM> are mispositioned, misshaped, and/or defective. For example, the obstruction may indicate that at least one of the blade terminals <NUM> is not fully loaded within the housing <NUM> to the designated position. The TPA device <NUM> may be at least partially composed of a dielectric material, such as one or more plastics, and optionally may be strengthened by fibers of glass and/or carbon. Alternatively, the TPA device <NUM> may include one or more metals. The TPA device <NUM> may be formed by a molding process.

In one or more embodiments described herein, the TPA device <NUM> is configured to load onto the mounting end <NUM> of the housing <NUM> in a loading direction <NUM> that is parallel to the cavity axis <NUM>. The TPA device <NUM> is configured to load to the unlock position to achieve the pre-lock configuration. Furthermore, the TPA device <NUM> is configured to be actuated between the unlock and lock positions along an actuation axis <NUM> (shown in <FIG>) that is transverse to the loading direction <NUM> and the cavity axis <NUM>. In the illustrated embodiment, the actuation axis <NUM> is perpendicular to the cavity axis <NUM>. Thus, the TPA device <NUM> may load onto the housing <NUM> parallel to the cavity axis <NUM> and may move perpendicular to the cavity axis <NUM> between the unlock and lock positions.

In one example application, the electrical connector <NUM> may be installed within an electric vehicle, such as a fully electric vehicle, a plug-in hybrid vehicle, or the like. The electrical connector <NUM> may represent part of, or may connect to, a charger inlet harness that is used to convey electric power for charging a battery of the electric vehicle. For example, the electrical connector <NUM> may be mounted to a panel of a battery pack, and the blade terminals <NUM> of the connector <NUM> may electrically connect and mechanically engage electrical bus bars or other current-carrying components of the battery pack. The electrical connector <NUM> is not limited to use in electric vehicles, and may be used in various other applications, such as in appliances, industrial machinery, and the like.

As shown in <FIG>, the blade terminals <NUM> have a mating segment <NUM>, a termination segment <NUM>, and a transition segment <NUM> between the mating segment <NUM> and the termination segment <NUM>. The mating segments <NUM> may be linear and extend through the cavities <NUM> of the housing <NUM>. The termination segments <NUM> are configured for electrically connecting and mechanically securing to corresponding electrical components, such as circuit boards, bus bars, cables, or the like. In the illustrated embodiment, the termination segments <NUM> include contact plates <NUM> that are configured to be mechanically secured via fasteners <NUM> in direct engagement with electrical bus bars (not shown), circuit boards, or the like. The transition segments <NUM> have contoured trajectories that optionally resemble S-shaped curves. As shown in <FIG>, the transition segments <NUM> and the termination segments <NUM> may be located outside of the housing <NUM> when the blade terminals <NUM> are fully loaded into the cavities <NUM>.

The mating segments <NUM> of the blade terminals <NUM> have two edge sides <NUM> and two broad sides <NUM>. The edge sides <NUM> extend between the broad sides <NUM>. For example, in the illustrated orientation shown in <FIG>, the edge sides <NUM> represent top and bottom sides of the terminals <NUM>, and the broad sides <NUM> represent left and right sides of the terminals <NUM>. As used herein, relative or spatial terms such as "top," "bottom," "left," "right," "upper," and "lower" are only used to identify and distinguish the referenced elements in the illustrated orientations and do not necessarily require particular positions or orientations in the surrounding environment of the electrical connector <NUM>. The edge sides <NUM> are narrower than the broad sides <NUM>.

Each of the blade terminals <NUM> has a rib <NUM> projecting from at least one of the two edge sides <NUM>. Due to the rib <NUM> projecting from the edge side <NUM>, the broad sides <NUM> of the blade terminals <NUM> are wider in the location of the rib <NUM> than along lengths of the blade terminals <NUM> bordering the rib <NUM>. The rib <NUM> steps out from the blade terminal <NUM>, such that the rib <NUM> has a back shoulder <NUM> that faces towards the termination segment <NUM>. The back shoulder <NUM> of the rib <NUM> may be oriented perpendicular to the edge side <NUM>.

In the illustrated embodiment, each of the blade terminals <NUM> has two ribs <NUM> projecting from different corresponding edge sides <NUM>. For example, in the illustrated orientation, the two ribs <NUM> include an upper rib 154A projecting from a first edge side 150A and a lower rib 154B projecting from a second edge side 150B. The upper and lower ribs 154A, 154B of each terminal <NUM> are disposed at the same location along the length of the mating segment <NUM>. The blade terminals <NUM> in an embodiment are stamped and formed of one or more metals, but may be molded in an alternative embodiment.

The blade terminals <NUM> may be high voltage power terminals that are configured to convey DC electric power at high voltages. For example, the blade terminals <NUM> may be configured to convey DC power at voltages up to (or exceeding) <NUM> volts (V). In a non-limiting example, the blade terminals <NUM> may be designed to convey voltages in excess of <NUM> V, and optionally up to <NUM> V. The blade terminals <NUM> in a non-limiting example application may represent components of a DC fast charge line for charging electric vehicles.

The TPA device <NUM> has a base plate <NUM> that defines multiple terminal openings <NUM> therethrough. Each of the terminal openings <NUM> is configured to receive a different one of the blade terminals <NUM> therein, The base plate <NUM> defines two terminal openings <NUM> in the illustrated embodiment to accommodate the two blade terminals <NUM>. When the TPA device <NUM> is coupled to the housing <NUM>, the base plate <NUM> is positioned at the mounting end <NUM> of the housing <NUM>, and the terminal openings <NUM> align with the cavities <NUM> of the housing <NUM>. As the blade terminals <NUM> are loaded into the connector <NUM> during assembly, the blade terminals <NUM> pass through the terminal openings <NUM> before entering the cavities <NUM> of the housing <NUM>. The TPA device <NUM> also includes mounting latches <NUM> and other features that protrude from the base plate <NUM> into corresponding recesses and apertures in the housing <NUM> for coupling the TPA device <NUM> to the housing <NUM>. The mounting latches <NUM> and other features that protrude from the base plate <NUM> do not extend into the cavities <NUM>.

<FIG> is a top down cross-sectional view of the electrical connector <NUM> according to an embodiment. The electrical connector <NUM> is in the assembled state. The cross-section line extends through one rib <NUM> on each of the two blade terminals <NUM>. The blade terminals <NUM> are both fully loaded in the corresponding cavities <NUM> of the housing <NUM>. The TPA device <NUM> is coupled to the housing <NUM> at the mounting end <NUM> and is in the lock position relative to the housing <NUM>. The base plate <NUM> of the TPA device <NUM> may be planar and relatively thin, such that the TPA device <NUM> is relatively compact.

The TPA device <NUM> in the lock position provides a locking mechanism to retain the blade terminals <NUM> in the fully loaded positions within the housing <NUM>. In the lock position, portions of the TPA device <NUM> along the base plate <NUM> extend behind and align with the ribs <NUM> of the blade terminals <NUM>. In the illustrated embodiment, the portions of the TPA device <NUM> that extend behind the ribs <NUM> are ledges <NUM> that jut out into the terminal openings <NUM> of the base plate <NUM>. The ledges <NUM> extend into the retreat paths of the terminals <NUM>, such that the ledges <NUM> extend into the spaces behind the ribs <NUM> of the terminals <NUM> without extending into the cavities <NUM> of the housing <NUM>.

During installation and/or use of the connector <NUM>, forces may be exerted on the blade terminals <NUM> in a rearward direction <NUM> that would urge the terminals <NUM> to back out of the cavities <NUM> through the mounting end <NUM>. The forces may be due to a mating connector pushing the blade terminals <NUM> rearward or tension applied on the blade terminals <NUM> due to relative movement between the connector <NUM> and the electrical components to which the termination segments <NUM> (<FIG>) of the blade terminals <NUM> are mounted. The TPA device <NUM> is designed to withstand such forces to retain the terminals <NUM> in position because the back shoulders <NUM> of the ribs <NUM> abut against the ledges <NUM>. The contact between the ribs <NUM> and the ledges <NUM> transfers forces to the TPA device <NUM>, which may be robustly mounted to the housing <NUM>.

In the illustrated embodiment, the TPA device <NUM> provides secondary retention of the blade terminals <NUM> within the cavities <NUM>. For example, the housing <NUM> includes deflectable locking latches <NUM> within the cavities <NUM>. The blade terminals <NUM> have locking protrusions <NUM> (shown also in <FIG>) disposed along one of the broad sides <NUM> (<FIG>). When the blade terminals <NUM> attain the fully loaded positions, the locking protrusions <NUM> engage and catch on the corresponding locking latches <NUM> to provide primary retention of the blade terminals <NUM> within the cavities <NUM>. The primary retention may be insufficient to withstand certain amounts of force, such as a designated amount of force that is set by a connector regulation or standard. The TPA device <NUM> may provide secondary retention to supplement the locking latches <NUM> of the housing <NUM> in the task of retaining the blade terminals <NUM> in the cavities <NUM>. For example, the TPA device <NUM> may increase the amount of force on the terminals <NUM> that the connector <NUM> can withstand to levels that exceed applicable regulations and/or standards. In a non-limiting example, the connector <NUM> with the TPA device <NUM> may be able to withstand forces up to or exceeding <NUM> N on each blade terminal <NUM> without the blade terminals <NUM> moving out of position within the housing <NUM>.

In an embodiment, when the TPA device <NUM> is in the unlock position, as shown in <FIG>, the ledges <NUM> do not extend into the retreat paths of the ribs <NUM>. Therefore, the blade terminals <NUM> can be loaded into the cavities <NUM> of the housing <NUM> and unloaded out of the cavities <NUM> when the TPA device <NUM> is in the unlock position.

<FIG> show different views of the TPA device <NUM> of the electrical connector <NUM> according to an embodiment. For example, <FIG> is a perspective view of the TPA device <NUM> showing an outer side <NUM> of the base plate <NUM>. <FIG> is a perspective view of the TPA device <NUM> showing an inner side <NUM> of the base plate <NUM>. <FIG> is a plan view of the TPA device <NUM> showing the inner side <NUM> of the base plate <NUM>. The inner side <NUM> is opposite the outer side <NUM>. As shown in <FIG>, when the TPA device <NUM> is coupled to the housing <NUM>, the inner side <NUM> of the base plate <NUM> faces (and may engage) the housing <NUM>, and the outer side <NUM> faces away from the housing <NUM>.

As shown in <FIG>, the TPA device <NUM> may have cable routing fingers <NUM> that project from the outer side <NUM> of the base plate <NUM>. The cable routing fingers <NUM> are designed to engage and control the positioning of one or more cables <NUM> (shown in <FIG>) of the connector <NUM> that extend through the TPA device <NUM>. The cables <NUM> may convey data and/or control signals, such as for a high voltage interlock circuit. The TPA device <NUM> defines a central recess <NUM> through which the cables <NUM> may be routed. The central recess <NUM> is disposed between the two terminal openings <NUM>.

As shown in <FIG>, the TPA device <NUM> includes several mounting latches <NUM> that project from the inner side <NUM>. The mounting latches <NUM> have respective hook tips <NUM> that engage the housing <NUM>. In the illustrated embodiment, the TPA device <NUM> has five mounting latches <NUM> that are spaced apart along the base plate <NUM>. The mounting latches <NUM> are spaced apart to provide the TPA device <NUM> with a wide coupling stance on the housing <NUM> for stability. The TPA device <NUM> also includes alignment posts <NUM> that project from the inner side <NUM> of the base plate <NUM>. The alignment posts <NUM> and the mounting latches <NUM> extend into the housing <NUM> beyond the mounting end <NUM> when the TPA device <NUM> is coupled to the housing <NUM>. The alignment posts <NUM> may guide the TPA device <NUM> into a designated proper orientation and position relative to the housing <NUM>, and may also serve as keying members to block attempted coupling of the TPA device <NUM> in a non-designated orientation or position. For example, one alignment post 322A between two mounting latches <NUM> has a keying feature <NUM> that projects from the alignment post 322A towards an opposite alignment post 322B. The alignment post 322B lacks a keying feature such that the alignment posts 322A, 322B have different shapes. The housing <NUM> is designed to accommodate the alignment posts 322A, 322B in only a single orientation of the TPA device <NUM> to ensure proper coupling.

As shown in <FIG> and <FIG>, the TPA device <NUM> has a position-retaining latch <NUM> that extends from an alignment post 322C and is elongated transverse to the mounting latches <NUM>. The position-retaining latch <NUM>, as described in more detail herein, is configured to prohibit premature actuation of the TPA device <NUM> from the unlock position to the lock position. Once the TPA device <NUM> is moved to the lock position, the position-retaining latch <NUM> is configured to retain the TPA device <NUM> in the lock position by prohibiting unintended actuation of the TPA device <NUM> towards the unlock position.

The plan view in <FIG> shows the two terminal openings <NUM> defined in the base plate <NUM>. The base plate <NUM> has at least one ledge <NUM> that juts out into each of the terminal openings <NUM>. In the illustrated embodiment, two ledges <NUM>, including a first ledge 202A and a second ledge 202B, jut out into each of the terminal openings <NUM>, but a single ledge <NUM> may jut into each terminal opening <NUM> in an alternative embodiment. The ledges <NUM> are located at corners of the terminal openings <NUM>. Due to the presence of the ledges <NUM>, the terminal openings <NUM> have irregular cross-sectional shapes. For example, the cross-sectional shape of each terminal opening <NUM> has a short region <NUM> and a long region <NUM>. The long region <NUM> has a greater length than the short region <NUM> along a longitudinal axis <NUM> of the connector <NUM>. The short region <NUM> is defined between the two ledges <NUM>. The long region <NUM> is spaced apart from the ledges <NUM>. The blade terminals <NUM> (<FIG>) extend through the long regions <NUM> when the TPA device <NUM> is in the unlock position. Movement of the TPA device <NUM> to the lock position causes the blade terminals <NUM> to be received into the short regions <NUM>, allowing the ledges <NUM> to extend behind and align with the ribs <NUM> (<FIG>) of the terminals <NUM>,.

<FIG> is a perspective view showing the mounting end <NUM> of the housing <NUM> of the electrical connector <NUM> according to an embodiment. The housing <NUM> defines two cavities <NUM> for receiving the blade terminals <NUM> (<FIG>). The housing <NUM> in the illustrated embodiment also includes cable apertures <NUM> located between the two cavities <NUM>. The cable apertures <NUM> accommodate the cables <NUM> (shown in <FIG>). The housing <NUM> defines multiple latch-receiving slots <NUM> that are configured to accommodate the mounting latches <NUM> (<FIG>) of the TPA device <NUM>. The latch-receiving slots <NUM> are elongated parallel to the actuation axis <NUM> for distances greater than the widths of the mounting latches <NUM> to provide clearance for the mounting latches <NUM> to translate along the actuation axis <NUM> while disposed within the slots <NUM>. The housing <NUM> also includes a catch feature <NUM> that projects transverse to the actuation axis <NUM>. The catch feature <NUM> is designed to engage the position-retaining latch <NUM> (shown in <FIG> and <FIG>) of the TPA device <NUM>. The housing <NUM> also includes at least one keying feature <NUM> that makes the mounting end <NUM> of the housing <NUM> asymmetrical relative to the longitudinal axis <NUM> of the connector <NUM>. The keying feature(s) <NUM> interact with the alignment posts <NUM> of the TPA device <NUM> and ensure that the TPA device <NUM> is coupled to the housing <NUM> in the predetermined, designated position and orientation.

<FIG> illustrate an assembly process of the electrical connector <NUM> according to an embodiment, including the coupling and actuation of the TPA device <NUM> relative to the housing <NUM>. For example, <FIG> is a cross-sectional perspective view of the TPA device <NUM> coupled to the housing <NUM>. The cross-section line extends through two of the mounting latches <NUM> and one alignment post <NUM> of the TPA device <NUM>. As the TPA device <NUM> is loaded in the loading direction <NUM>, the mounting latches <NUM> and alignment posts <NUM> penetrate the mounting end <NUM> of the housing <NUM>. The mounting latches <NUM> are received in the latch-receiving slots <NUM> of the housing <NUM>. The hook tips <NUM> of the mounting latches <NUM> catch on corresponding catch features of the housing <NUM> within the slots <NUM> to couple the TPA device <NUM> to the housing <NUM>. In the illustrated embodiment, the housing <NUM> has elongated shelves <NUM> within the slots <NUM> that define the catch features. The hook tips <NUM> are able to slide along the shelves <NUM> with the translational movement of the TPA device <NUM> between the lock and unlock positions.

<FIG> shows the mounting end <NUM> of the electrical connector <NUM> without the blade terminals <NUM> loaded into the housing <NUM> according to an embodiment. The TPA device <NUM> is configured to load onto the housing <NUM> in the unlock position to achieve the pre-lock configuration. In the unlock position, the long regions <NUM> of the terminal openings <NUM> align with the cavities <NUM> of the housing <NUM>. The illustrated embodiment shows two cables <NUM> that are routed through the cable apertures <NUM> of the housing <NUM>. The cables <NUM> optionally may be components of a high voltage interlock circuit or system. The cables <NUM> project through the central recess <NUM> of the base plate <NUM> of the TPA device <NUM> and are routed in opposite directions from each other via the cable routing fingers <NUM> on the base plate <NUM>. In the illustrated example, the cables <NUM> are routed using the cable routing fingers <NUM> before loading the blade terminals <NUM> (<FIG>) in to the cavities <NUM>, but the blade terminals <NUM> may be loaded into the cavities <NUM> prior to routing the cables <NUM> in an alternative embodiment.

<FIG> is a top-down cross-sectional view of the electrical connector <NUM> according to an embodiment. The cross-section line is taken through the blade terminals <NUM> but not through the ribs <NUM> (<FIG>) thereof, so the ribs <NUM> are not visible in <FIG>. The cables <NUM> are omitted in <FIG> for descriptive purposes. During assembly of the connector <NUM>, the blade terminals <NUM> are loaded into the corresponding cavities <NUM> in the housing <NUM> through the corresponding terminal openings <NUM> in the TPA device <NUM>. The TPA device <NUM> is in the unlock position while the blade terminals <NUM> are loaded. The blade terminals <NUM> attain the fully loaded positions within the cavities <NUM> upon the protrusions <NUM> of the terminals <NUM> engaging and catching on the locking latches <NUM> of the housing <NUM>.

<FIG> is a cross-sectional view of the mounting end <NUM> of the electrical connector <NUM> with the TPA device <NUM> in the unlock position according to an embodiment. <FIG> is a cross-sectional view of the mounting end <NUM> of the electrical connector <NUM> with the TPA device <NUM> in the lock position according to an embodiment. The cross-section lines in <FIG> only extend through the blade terminals <NUM> and the cables <NUM>.

The position-retaining latch <NUM> has a hook feature <NUM> with a ramp surface <NUM> and a catch surface <NUM>. When the TPA device <NUM> is in the unlock position, as shown in <FIG>, the ramp surface <NUM> engages the catch feature <NUM> of the housing <NUM>. The engagement between the ramp surface <NUM> and the catch feature <NUM> prohibits unintentional premature actuation of the TPA device <NUM> to the lock position, but can be overcome by sufficient force in a loading direction <NUM> along the actuation axis <NUM>. When the TPA device <NUM> is moved along the actuation axis <NUM> relative to the housing <NUM> to the lock position, as shown in <FIG>, the catch surface <NUM> of the hook feature <NUM> engages the catch feature <NUM> of the housing <NUM>. The position-retaining latch <NUM> may lock the TPA device <NUM> in the lock position. The engagement between the catch surface <NUM> and the catch feature <NUM> prohibits unintended actuation of the TPA device <NUM> towards the unlock position. To intentionally release the TPA device <NUM> from the lock position, an operator may manually force the TPA device <NUM> in a direction opposite the loading direction <NUM>. Based on the orientations of the surfaces, more force is required to overcome the engagement between the catch surface <NUM> and the catch feature <NUM> shown in <FIG> (to unlock the TPA device <NUM>) than the force required to overcome the engagement between the ramp surface <NUM> and the catch feature <NUM> (to lock the TPA device <NUM>).

When the TPA device <NUM> is in the unlock position as shown in <FIG>, the ledges <NUM> do not extend behind the ribs <NUM>. For example, the long regions <NUM> of the terminal openings <NUM> align with the terminals <NUM> in the cavities <NUM> (shown in <FIG>). The TPA device <NUM> translates in the locking direction <NUM> along the actuation axis <NUM> from the unlock position to the lock position. The movement in the locking direction <NUM> may be perpendicular to the movement of the TPA device <NUM> in the loading direction <NUM> along the cavity axis <NUM> (<FIG> and <FIG>) to couple the TPA device <NUM> to the housing <NUM>.

In the lock position shown in <FIG>, the short regions <NUM> of the terminal openings <NUM> align with the blade terminals <NUM> in the cavities <NUM>. The ledges <NUM> back up the ribs <NUM>, such that the ledges <NUM> extend behind and align with the back shoulders <NUM> of the ribs <NUM>. As a result, the ledges <NUM> obstruct the view of the back shoulders <NUM> of the ribs <NUM> in <FIG>. The first ledge 202A in each terminal opening <NUM> backs up the upper rib 154A of each corresponding blade terminal <NUM>, and the second ledge 202B backs up the lower rib 154B. As described with reference to <FIG>, the ledges <NUM> are configured to abut the back shoulders <NUM> of the ribs <NUM> to prevent the blade terminals <NUM> from being pushed or pulled out of the cavities <NUM>.

Claim 1:
An electrical connector (<NUM>) comprising:
a housing (<NUM>) having a mating end (<NUM>) and a mounting end (<NUM>), and defining multiple cavities (<NUM>) oriented parallel to a cavity axis (<NUM>);
multiple blade terminals (<NUM>) held by the housing (<NUM>) within the cavities (<NUM>), the blade terminals (<NUM>) having two edge sides (<NUM>) between two broad sides (<NUM>) and a rib (<NUM>) projecting from at least one of the two edge sides (<NUM>); and
a terminal position assurance device (<NUM>) coupled to the housing (<NUM>) at the mounting end and configured to linearly move relative to the housing (<NUM>) between an unlock position and a lock position along an actuation axis (<NUM>) that is perpendicular to the cavity axis (<NUM>), the terminal position assurance device (<NUM>) having a base plate (<NUM>) that defines multiple terminal openings (<NUM>) therethrough, wherein the base plate (<NUM>) includes ledges (<NUM>) that jut out into the terminal openings (<NUM>), wherein the ledges (<NUM>) extend behind and align with the ribs (<NUM>) of the corresponding blade terminals (<NUM>) when the terminal position assurance device (<NUM>) is in the lock position to retain the blade terminals (<NUM>) within the housing (<NUM>) by abutting against back shoulders (<NUM>) of the ribs (<NUM>);
characterized in that:
the base plate (<NUM>) of the terminal position assurance device (<NUM>) has an inner side (<NUM>) that faces the housing (<NUM>) and an outer side (<NUM>) opposite the inner side (<NUM>) facing away from the housing (<NUM>) and an alignment post (322C) projecting from the inner side (<NUM>) of the base plate (<NUM>) of the terminal position assurance device (<NUM>) into the housing (<NUM>), the alignment post (322C) comprising a position-retaining latch (<NUM>) projecting therefrom, the latch (<NUM>) being elongated parallel to the actuation axis (<NUM>), the position-retaining latch (<NUM>) having a hook feature (<NUM>) that secures to a complementary catch feature (<NUM>) of the housing (<NUM>) when the terminal position assurance device (<NUM>) is in the lock position to restrict movement of the terminal position assurance (<NUM>) device towards the unlock position.