Charging inlet with thermal sensor

Abstract

A charging inlet (110) includes a power terminal (204), a retainer member (602), and a thermal sensor (312). The power terminal is configured to releasably engage a mating contact of an external power source (104). The retainer member is adjacent to the power terminal and has an electrically insulating material. The retainer member defines at least a portion of a fully enclosed recess (606). The thermal sensor is disposed in the recess for monitoring the temperature of the power terminal.

Description

Technical Field

[0001] The subject matter herein relates to a charging system having an electrical connector for establishing a conductive path for supplying electrical current from a power source to a battery. Background Art

[0002] Electric vehicles, including all-electric and plug-in hybrid vehicles, have a charging system for charging a battery that provides the current used to propel the vehicle. The charging system includes a charging inlet on the vehicle that is releasably coupled to a mating connector that is connected to an external power source. Because the vehicle is fixed during the charging operation, it is desirable to reduce the duration of the charging operation to reduce the amount of time the vehicle is fixed. The charging duration can be reduced by increasing the rate at which power (e.g., current) is transferred. At high currents, components of the vehicle's charging system, such as the charging inlet, may heat up due to electrical contact resistance. If left unchecked, the heat may damage components of the charging system, such as melting the components, and potentially cause a fire.

[0003] To prevent heat-related damage, some known charging systems have sensors for monitoring the temperature in or around the charging inlet. If the measured temperature exceeds a threshold, the charging system automatically reduces the power transfer rate and / or takes other measures to maintain the temperature at a safe level that is unlikely to cause damage. However, temperature sensors in known charging systems may be inaccurate and / or have delayed response times. For example, in order to provide electrical isolation for the sensing circuit from the high currents transmitted through the power contacts, the temperature sensor may be positioned relatively far away from the power contacts and / or placed behind a wall or other structure. However, the separation distance and intermediate structures can result in significant temperature differences between the power contacts and the temperature sensor, thereby reducing accuracy and slowing the response time of the sensor. Due to the low accuracy and slow response time, known charging systems have limited control over charging operations.

[0004] The problem to be solved is to provide a charging inlet with a thermal sensor that can monitor the temperature of the power contacts during charging operations more accurately and quickly than known charging systems, thereby allowing greater power transfer rates during charging operations to reduce charging duration without concern for heat-related damage. Summary of the invention

[0005] In one or more embodiments of the present disclosure, this problem is solved by a charging inlet including a power terminal, a retainer member, and a thermal sensor. The power terminal is configured to releasably engage a mating contact of an external power source. The retainer member is adjacent to the power terminal and has an electrically insulating material. The retainer member defines at least a portion of a fully enclosed recess. The thermal sensor is disposed in the recess for monitoring the temperature of the power terminal.

[0006] In one or more embodiments, a charging inlet is provided, which includes first and second power terminals, a retainer member, and first and second thermal sensors. The first and second power terminals are spaced apart from each other and are configured to releasably engage corresponding mating contacts of an external power source. The retainer member extends between the first and second power terminals and has an electrically insulating material. The retainer member defines a first recess located near the first power terminal and at least a portion of a second recess spaced apart from the first recess and located near the second power terminal. The first and second recesses are completely enclosed. The first thermal sensor is disposed in the first recess for monitoring the temperature of the first power terminal. The second thermal sensor is disposed in the second recess for monitoring the temperature of the second power terminal.

[0007] In one or more embodiments, a charging inlet is provided, which includes a power terminal, a secondary lock, a tray, and a thermal sensor. The power terminal is configured to releasably engage a mating contact of an external power source. The power terminal includes a flange. The secondary lock has an electrically insulating material. The secondary lock overlaps and supports the flange of the power terminal to secure the power terminal in a fixed position within the charging inlet. The secondary lock has a slot extending inward from an opening along an outer surface of the secondary lock. The slot defines at least a portion of a fully enclosed recess. The tray is loaded into the slot of the secondary lock. The thermal sensor is mounted on the tray and disposed in the recess for monitoring the temperature of the power terminal. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will now be described by way of example with reference to the accompanying drawings:

[0009] Figure 1 A charging system according to an embodiment is shown including an electric vehicle parked next to a charging station.

[0010] Figure 2 is a top view of a charging inlet according to an embodiment.

[0011] Figure 3 is a bottom perspective view of a portion of a charging inlet according to an embodiment.

[0012] Figure 4 is an isometric perspective view of a power terminal of a charging inlet according to an embodiment.

[0013] Figure 5 is a side perspective view of a portion of a charging inlet according to an embodiment.

[0014] Figure 6 is a side view of a portion of a charging inlet including a sub-lock and a power terminal according to a first embodiment.

[0015] Figure 7 is based on Figure 6 Cross-sectional view of a portion of a charging inlet of the illustrated embodiment.

[0016] Figure 8 is a side sectional view of a portion of a charging inlet including a sub-lock and a power terminal according to a second embodiment.

[0017] Fig. 9 is based on Figure 8 A top cross-sectional view of a portion of a charging inlet of the illustrated embodiment.

[0018] Fig.10 is a cross-sectional view of a portion of a charging inlet according to a third embodiment. DETAILED DESCRIPTION

[0019] Figure 1 A charging system 100 according to an embodiment is shown, including an electric vehicle 102 parked next to a charging station 104. The electric vehicle 102 includes an onboard battery pack 106 electrically connected to an onboard charging inlet 110. Figure 1 Battery pack 106 is shown in dashed lines in FIG. 1 . Vehicle 102 may be an all-electric vehicle without an internal combustion engine, a plug-in hybrid vehicle including battery pack 106 and an internal combustion engine, and the like. Battery pack 106 supplies power (e.g., current) for powering a traction motor (not shown) of vehicle 102 to provide traction to the powertrain and wheels 116. The traction propels vehicle 102 along a route. Optionally, when traction is not needed, such as when traveling downhill, the traction motor may selectively be used as a generator to generate electrical energy using regenerative braking to charge battery pack 106. Battery pack 106 may represent an array of batteries and / or battery cells. Although in Figure 1 Although the electric vehicle 102 is shown as a passenger car, the embodiments of the charging inlet 110 described herein are not limited to use with passenger cars, but may be installed on other types of vehicles, such as buses, trucks, rail vehicles, ships, etc.

[0020] The charging inlet 110 is configured to connect to a mating connector of an external power source to charge the battery pack 106. In the illustrated embodiment, the charging station 104 represents the external power source and the plug connector 112 represents the mating connector. When the vehicle 102 is not near the charging station 104, other external power sources that can be used to connect to the charging inlet 110 to charge the battery pack 106 include a household electrical outlet, an external generator, etc. The mating plug connector 112 is coupled to the charging station 104 via a power cable 114.

[0021] In the illustrated embodiment, the charging inlet 110 is mounted to a side 118 of the vehicle 102. The charging inlet 110 has a mating interface that is releasably coupled directly to a mating plug connector 112 to establish an electrical connection for conducting current from the charging station 104 to the battery pack 106. The charging inlet 110 may have a locking device (not shown) that releasably secures the mating connector 112 in a mated position with the charging inlet 110 to prevent the mating plug connector 112 from being prematurely disconnected from the charging inlet 110.

[0022] Figure 2 1 is a top view of the charging inlet 110 according to an embodiment. The charging inlet 110 includes a housing 202 and a power terminal 204 held by the housing 202. The housing 202 has a mating side 206 that is coupled to the mating connector 112 ( Figure 1 For example, the mating side 206 has an interface that is complementary to the interface of the mating connector 112. The housing 202 may include a connector for mounting the charging inlet 110 to the vehicle 102 ( Figure 1 The housing 202 may include a mounting flange 208 (shown). For example, the mounting flange 208 may define a hole 210 that receives a fastener therethrough to secure the charging inlet 110 to a panel of the vehicle 102, such as a body panel or a chassis wall. The housing 202 extends from the mating side 206 to a rear side 212 opposite the mating side 206. The housing 202 defines a channel 214 extending from the rear side 212 to the mating side 206. As used herein, relative or spatial terms such as "front," "rear," "back," "top," "bottom," "inside," and "outside" are used only to identify and distinguish reference elements shown in the drawings in the illustrated orientation, and do not necessarily require a specific position or orientation relative to gravity and / or the surrounding environment of the charging inlet 110.

[0023] In the illustrated embodiment, the charging inlet 110 has two power terminals 204, namely a first power terminal 204A and a second power terminal 204B, but in other embodiments there may be a different number of power terminals 204. The power terminals 204 extend into different corresponding channels 214 of the housing 202. Portions of the power terminals 204 protrude beyond the rear side 212 of the housing 202 outside the channels 214. Each power terminal 204 is mechanically fixed to a different corresponding power cable 216 to electrically connect the corresponding power terminal 204 to the corresponding power cable 216. The power cable 216 extends from the power terminal 204 toward the battery pack 106 ( Figure 1 The power terminal 204 is connected to the housing 202 and is configured to transmit current to charge the battery pack 106. The power terminal 204 engages one or more conductors 218 of the power cable 216 at the interface. The interface can be located outside the housing 202, such as Figure 2 In an embodiment, the charging inlet 110 includes a cover 220 ( Figure 3As shown in FIG. 2 , when the cover 220 is assembled to the housing 202 , the cover 220 covers and surrounds the exposed interface.

[0024] Figure 3 2 is a bottom perspective view of a portion of the charging inlet 110 according to an embodiment. The perspective view shows the rear side 212 of the housing 202. The cover 220 is mounted to the housing 202 to surround the cavity 324 of the charging inlet 110. The cavity 324 is defined by the housing 202 and the cover 220. The cover 220 is Figure 3 324 for descriptive purposes to show the power terminals 204 located within the cavity 324. The power cable 216 may extend through one or more exit openings (not shown) in the cover 220 to exit the cavity 324.

[0025] The power terminals 204 are configured to deliver high power electrical energy (e.g., high voltage, high current, etc.). The power terminals 204 may be direct current (DC) fast charging terminals for delivering direct current at high current rates up to or exceeding 1000A. In addition to the two power terminals 204, the charging inlet 110 may also include other power terminals retained within the housing 202. For example, although not shown in Figure 3 , but charging inlet 110 may include power terminals that deliver alternating current (AC) at a reduced power level relative to the power level delivered by power terminals 204 .

[0026] The two power terminals 204A, 204B are spaced apart from each other. In the illustrated embodiment, the charging inlet 110 includes a secondary lock 326. The secondary lock 326 is a discrete component that is releasably mounted to the housing 202. The secondary lock 326 engages the power terminal 204 to secure the power terminal 204 in a fixed position relative to the housing 202. The secondary lock 326 has an electrically insulating material, such as a thermoplastic, etc. A portion of the secondary lock 326 may extend between the first and second power terminals 204A, 204B, which provides some electrical insulation to prevent arcing and / or interference.

[0027] Figure 4 FIG. 2 is an isometric perspective view of one of the power terminals 204 of the charging inlet 110 according to an embodiment. The power terminal 204 shown may represent Figure 2 and 3 Any one of the first and second power terminals 204A, 204B is shown. The power terminal 204 has a head 302 and a shaft 304 protruding from the head 302. The shaft 304 extends from the head 302 to a mating end 402 of the power terminal 204.

[0028] The head 302 terminates (e.g., mechanically and electrically connects to) one or more conductors 218 of a corresponding power cable 216. The head 302 may have a termination region 306 that is planar and joins the one or more conductors 218 by chemical bonding, such as welding, soldering, etc. In a non-limiting example, the conductors 218 of the power cable 216 are ultrasonically welded to the termination region 306 to non-removably mechanically couple and electrically connect the power cable 216 to the power terminal 204. The termination region 306 may be disposed along a rear side 308 of the corresponding head 302 facing away from the shaft 304. In the illustrated embodiment, the head 302 includes an elongated tab 310 that protrudes outwardly from the location where the head 302 is connected to the shaft 304. The termination region 306 is located along the tab 310.

[0029] The shaft 304 defines a pin-shaped contact 404 that engages a mating connector 112 (eg, Figure 1 In alternative embodiments, the shaft 304 may have other types of contacts at the mating end 402, such as blades, spring beams, sockets, etc. Due to the various features of the shaft 304 and the housing 202 ( Figure 3 The shaft 304 may optionally have a varying diameter along its length, such as within the spacing tolerances shown in the drawings. For example, the shaft 304 in the illustrated embodiment has a radially outwardly extending flange 406 having a larger diameter than the portion of the shaft 304 on either side of the flange 406.

[0030] The power terminal 204 is made of one or more metals. In the illustrated embodiment, the head 302 of the power terminal 204 is a separate component from the shaft 304. The shaft 304 is received in the opening 408 in the head 302 to mechanically couple the two components together. The shaft 304 can be threadedly connected to a screw in the opening 408, or connected via an interference fit, adhesive, welding or other chemical bonding methods. In an alternative embodiment, the power terminal 204 can be a one-piece, integral structure so that the shaft 304 is integrated with the head 302 without the need for a joining operation to couple the two components.

[0031] Figure 5 2 is a side perspective view of a portion of the charging inlet 110 according to an embodiment. When the power terminal 204 is loaded into the housing 202, the shaft 304 of the power terminal 204 extends into the corresponding channel 214 of the housing 202, and the head 302 is exposed to the outside of the rear side 212 of the housing 202. The secondary lock 326 is mounted on the housing 202. The secondary lock 326 surrounds and engages the shaft 304 of the power terminal 204 to secure the power terminal 204 in the channel 214.

[0032] Figure 6is a side view of a portion of the charging inlet 110 including the secondary lock 326 and the power terminal 204 according to the first embodiment. The charging inlet 110 includes at least one thermal sensor 312 that measures and monitors the temperature within the charging inlet 110. In the illustrated embodiment, the charging inlet 110 includes two thermal sensors 312. The thermal sensor 312 is configured to be mounted to a retainer member 602, which secures the thermal sensor 312 in a fixed position relative to the retainer member 602. The retainer member 602 is proximate to the power terminal 204 and holds the thermal sensor 312 near the power terminal 204 without directly engaging the power terminal 204. The retainer member 602 has an electrically insulating material to allow the thermal sensor 312 to be electrically insulated from the power source transmitted along the power terminal 204 for the battery pack 106 ( Figure 1 606A and 606B. The first recess 606A is adjacent to the first power terminal 204A, and the second recess 606B is adjacent to the second power terminal 204B.

[0033] In the illustrated embodiment, the retainer member 602 is a secondary lock 326. The secondary lock 326 defines all or a portion of the pockets 606. The thermal sensors 312 are mounted to the secondary lock 326 in different corresponding pockets 606. For example, the first thermal sensor 312A of the two thermal sensors 312 is mounted in the first pocket 606A. Because only the first thermal sensor 312A is mounted to the secondary lock 326, Figure 6 The charging inlet 110 is shown in a partially assembled state or condition. The second thermal sensor 312B is ready to be installed to the secondary lock 326 by loading it into the second recess 606B.

[0034] When the charging inlet 110 is fully assembled and operational, the thermal sensor 312 can be communicatively connected to a control device (not shown) that is used to adjust the current rate transmitted along the power terminal 204 during the charging operation to reduce the risk of damage related to overheating. For example, during the charging operation, the power terminal 204 generates heat due to electrical resistance. The thermal sensor 312 measures the temperature and generates temperature data, which is transmitted to the control device as an electrical signal.

[0035] The control device may include one or more processors that analyze temperature data received from the thermal sensor to monitor the temperature within the charging inlet 110. If the temperature data indicates that the temperature within the charging inlet 110 exceeds a first specified threshold, the control device may be programmed to automatically reduce (e.g., slow down) the power transfer rate during the charging operation to reduce the heat generated and allow the heat within the charging inlet 110 to dissipate. Conversely, if it is determined that the temperature is below a second specified threshold (which is at a lower temperature than the first threshold), the control device may be programmed to automatically increase the power transfer rate during the charging operation. The increased power transfer rate advantageously reduces the battery pack 106 ( Figure 1 ) to charge, thereby allowing the vehicle 102 ( Figure 1 In order to provide improved control of the charging operation to achieve fast charging times with low risk of overheating, the thermal sensor 312 described herein provides more accurate temperature measurements and / or faster response times (e.g., reduced delays) compared to temperature sensors in known charging inlets.

[0036] The first thermal sensor 312A is disposed proximate to the first power terminal 204A. Once mounted to the secondary lock 326, the second thermal sensor 312B is disposed proximate to the second power terminal 204B. As a result, the temperature measured by the first thermal sensor 312A may reflect the temperature of the first power terminal 204A, while the temperature measured by the second thermal sensor 312B may reflect the temperature of the second power terminal 204B.

[0037] The first and second thermal sensors 312A, 312B may have the same size and components as each other. The thermal sensor 312 includes a substrate 320 and a sensing element 322 mounted on the substrate 320. The sensing element 322 may be configured to measure the temperature of the surrounding environment of the sensing element 322 based on the resistance of the sensing element 322. The sensing element 322 may be or include a thermistor, a thermocouple, a resistance temperature detector (RTD), etc. Optionally, at least a portion of the sensing element 322 may be formed directly onto the substrate 320 by screen printing. Although in Figure 6 Each thermal sensor 312A, 312B has only one sensing element 322 , but the thermal sensor 312 may alternatively include a plurality of sensing elements 322 spaced apart from each other on the respective substrate 320 .

[0038] The substrate 320 may have material properties that enable the substrate 320 to provide electrical insulation between the corresponding sensing element 322 and the adjacent power terminal 204. The substrate 320 may be in the form of a film, a panel, a block, or a sheet. The material of the substrate 320 may have heat-resistant properties, such as polyimide, aluminum nitride, silicon, a composite material including fiberglass and epoxy resin, etc. In a non-limiting example embodiment, the substrate 320 includes an aluminum nitride material, which has a relatively high dielectric strength.

[0039] Optionally, the thermal sensor 312 includes an epoxy layer 604 covering the sensing element 322. The epoxy layer 604 can be or include an epoxy material that is electrically insulating and thermally conductive. The epoxy layer 604 can be applied to the substrate 320 after the sensing element 322 is formed or attached to the substrate 320. The epoxy layer 604 surrounds and encapsulates the sensing element 322 to protect the sensing element 322 from debris and other contaminants. In an alternative embodiment, the thermal sensor 312 does not include the epoxy layer 604, and the sensing element 322 is exposed to air in the surrounding environment on the substrate 320.

[0040] The thermal sensor 312 may be electrically connected to the control device via wires 318. The wires 318 may be insulated to separate the electrical signal from the power supply terminal 204 for controlling the battery pack 106 ( Figure 1 The electrical isolation is performed to prevent interference caused by high electrical power (as shown) charging. The wire 318 is electrically terminated to the substrate 320 by welding, through-hole mounting, discrete connectors, etc. The wire 318 is electrically connected to the sensing element 322 via a conductive element 410 on the substrate 320, such as a trace. The conductive element 410 may be exposed along the surface of the substrate 320 or recessed relative to the surface and encapsulated in the material of the substrate 320. The conductive element 410 transmits an electrical signal representing temperature data from the sensing element 322 to the wire 318 for remote communication with a control device.

[0041] In an alternative embodiment, instead of wire 318, thermal sensor 312 may include passive or active communication circuitry for wirelessly transmitting temperature data to a control device. For example, the communication circuitry may receive an activation signal to communicate (e.g., transmit or broadcast) from the control device, and may utilize energy from the activation signal to obtain an updated temperature measurement and generate a wireless response signal to the control device including the updated temperature measurement. The communication circuitry may be on substrate 320 and may be connected to sensing element 322 via conductive element 410.

[0042] In the illustrated embodiment, the secondary lock 326 representing the retainer member 602 defines two slots 608, which are spaced apart by a middle section 610 of the secondary lock 326. Each of the two slots 608 protrudes from a corresponding opening 612 into the secondary lock 326 along a peripheral surface 614 of the secondary lock 326. The thermal sensor 312 is disposed in the slot 608. The thermal sensor 312 can be loaded into the slot 608 through the opening 612 during assembly. The substrate 320 of each thermal sensor 312 can be attached to the inner wall of the corresponding slot 608 to secure the thermal sensor 312 in place. For example, the substrate 320 can be secured in the slot 608 using adhesives, fasteners, interference fits, latches, etc.

[0043] The inner wall of the slot 608 defines at least a portion of the pocket 606. When the charging inlet 110 is in a fully assembled condition or state, the pocket 606 can be completely enclosed to isolate the air (or other material) within the pocket 606 from the air within the charging inlet 110 outside of the pocket 606, as described in more detail herein.

[0044] Figure 7 is based on Figure 6 A cross-sectional view of a portion of the charging inlet 110 of the illustrated embodiment. The cross-section is taken along a line extending through the first power terminal 204A and the axis 304 of the secondary lock 326. The charging inlet 110 is shown in an assembled condition or state. The first thermal sensor 312A is mounted in the first recess 606A adjacent to the first power terminal 204A. Although Figure 7 Only one thermal sensor 312A and one recess 606A are shown in FIG, but another thermal sensor 312B and another recess 606B may be similar. For example, the thermal sensors 312A, 312B and recesses 606A, 606B may mirror each other across the entire middle section 610 of the secondary lock 326.

[0045] The first recess 606A is partially defined by a slot 608 in the secondary lock 326. The recess 606A is completely enclosed, which prevents convective heat transfer into and out of the recess 606A. The recess 606A is close to the power terminal 204A, and the air (or other material) within the recess 606A can be heated to an equilibrium temperature faster than the air within the charging inlet 110 outside of the recess 606. For example, the air within the recess 606A can be heated faster than the cavity 324 ( Figure 3 6A). Alternatively, the cavity 606A may be filled with a material other than air to allow for improved thermal conductivity (relative to filling the cavity 606A with air). For example, the material within the cavity 606A may be an injectable sealant having a relatively high thermal conductivity (e.g., greater than 1 Watt per meter Kelvin (W / mK)). Alternatively, the cavity 606A may be filled with a gas other than air.

[0046] like Figure 7 As shown, the secondary lock 326 has an inner edge 710 that extends around at least a portion of the circumference of the shaft 304. The inner edge 710 overlaps and supports the flange 406 of the power terminal 204A to secure the power terminal 204A in a fixed position within the charging inlet 110.

[0047] The thermal sensor 312A within the cavity 606A is separated from the power terminal 204A by a partition wall 702. The partition wall 702 can be a portion of the secondary lock 326, such as a section of the inner edge 710. The partition wall 702 can allow heat transfer from the power terminal 204A to the cavity 606A by radiation and / or conduction. The partition wall 702 represents a portion of the perimeter of the cavity 606A. Figure 7 The remainder of the recess 606A is shown to be defined by the inner wall 704 of the secondary lock 326 (which defines the boundaries of the slot 608) and the back wall 706 covering the opening 612 of the slot 608. The recess 606A according to one or more embodiments is completely enclosed, thereby inhibiting the flow of fluid into and out of the recess 606A.

[0048] In the illustrated embodiment, the back wall 706 is defined by a sealant 708. The sealant 708 may be formed or applied after the thermal sensor 312A is loaded into the slot 608. The sealant 708 covers the opening 612 to surround the cavity 606A. The sealant 708 blocks air and other gases from flowing through the opening 612 to prevent convective heat transfer into and out of the cavity 606A. The sealant 708 may be an epoxy resin or the like.

[0049] The thermal sensor 312 of the charging inlet 110 can provide more accurate temperature measurements and / or faster response times (e.g., less lag or delay) than known charging inlet temperature sensing systems. For example, the air (or other material) within the enclosed recess 606 is heated by conduction and radiation heating from the power terminal 204. The sensing element 322 of the thermal sensor 312 monitors the temperature of the power terminal 204 by measuring the temperature of the air (or other material) within the corresponding recess 606. The air within the recess 606 can heat faster than the air within the charging inlet 110 outside the recess 606. Therefore, by measuring the temperature of a relatively small isolated volume of air in the recess 606 that is quickly heated in response to heating from the power terminal 204, the thermal sensor 312 can provide a fast response time to temperature increases. In addition, the insulation provided by the partition wall 702 can allow the thermal sensor 312 to be positioned closer to the power terminal 204 than the thermal sensors of the known charging inlet and / or have a reduced thermal gradient between the power terminal 204 and the thermal sensor 312, thereby enabling more accurate temperature measurements compared to known temperature sensors.

[0050] Alternatively, sensing element 322 of thermal sensor 312A may be off-center relative to substrate 320. For example, sensing element 322 may be positioned along a portion of substrate 320 closer to power terminal 204A than if sensing element 322 were centrally positioned to reduce the distance between sensing element 322 and power terminal 204A.

[0051] Wires 318 extend from thermal sensor 312A to the exterior of pocket 606A for transmitting electrical signals representing temperature data from thermal sensor 312A for analysis (e.g., by a control device). Wires 318 may penetrate sealant 708. Sealant 708 may surround and enclose the portion of wires 318 that penetrates sealant 708.

[0052] Figure 8 is a side cross-sectional view of a portion of the charging inlet 110 including the secondary lock 326 and the power terminal 204 according to the second embodiment. Figure 6 and 7 The illustrated embodiment differs in that the thermal sensor 312 is mounted on a corresponding tray 802. The tray 802 extends into the recess 606 and defines a portion of the recess 606. For example, in Figure 8 Two trays 802 are shown, each tray 802 being disposed within a different one of the slots 608 of the secondary lock 326 representing the retainer member 602. The trays 802 define a portion of the pocket 606. Figure 8 The section line in extends through a portion of the secondary lock 326 and the two trays 802 .

[0053] Fig. 9 is based on Figure 8 A top cross-sectional view of a portion of the charging inlet 110 of the illustrated embodiment. Fig. 9 The cross-sectional line in FIG. 8 extends through the shaft 304 of the two power terminals 204A, 204B, the secondary lock 326 and the tray 802. The following description also refers to Figure 8 and 9 .

[0054] In the illustrated embodiment, each tray 802 has a bottom wall or panel 804. The thermal sensor 312 is mounted to the tray 802 such that the substrate 320 of the thermal sensor 312 engages and is secured to the bottom wall 804. Figure 8 As shown, the tray 802 may also have a top wall 806 extending above the corresponding thermal sensor 312. Alternatively, the base plate 320 may be secured to the top wall 806 instead of the bottom wall 804. The top wall 806 is optional, and in another embodiment, the tray 802 may be devoid of a top wall.

[0055] The tray 802 has one or more walls extending from a bottom wall 804 to a top wall 806. For example, Fig. 9As shown, each tray 802 has a side wall 808, which represents the partition wall 702 that separates the thermal sensor 312 from the corresponding power terminal 204. For example, the slot 608 of the secondary lock 326 can optionally be open to the power terminal 204. The side wall 808 of the tray 802 separates the corresponding thermal sensor 312 from the power terminal 204. In the embodiment shown, each tray 802 also includes a rear wall 810 that covers the opening 612 of the slot 608 to close the cavity 606. The tray 802 optionally includes an additional side wall 812 for structural support and / or sealing the cavity 606.

[0056] The tray 802 may include electrically insulating and thermally conductive materials such as glass, ceramic, composite materials (eg, glass epoxy), etc. As non-limiting examples, the tray 802 may include aluminum nitride, boron nitride, silicon carbide, beryllium oxide, etc.

[0057] The tray 802 enables the thermal sensor 312 to be assembled at a location remote from the secondary lock 326 and subsequently coupled to the secondary lock 326 in the form of a package. For example, after the thermal sensor 312 is secured to the tray 802, each tray 802 can be inserted into a corresponding slot 608 through the opening 612. The tray 802 can optionally be latched into place within the slot 608 to couple the tray 802 to the secondary lock 326. For example, the secondary lock 326 can include a deflectable latch finger 814 that engages and snaps onto the tray 802 once the tray 802 extends beyond the latch finger 814 to releasably secure the tray 802 (and the thermal sensor 312) within the slot 608. Fig. 9 The latch fingers 814 in the tray engage the rear wall 810 of the tray 802.

[0058] Similar to Figure 6 and 7 In the illustrated embodiment, when the charging inlet 110 is fully assembled, the recess 606 surrounding the thermal sensor 312 can be completely enclosed. For example, after the tray 802 is fully loaded into the slot 608, the wall of the tray 802 and the inner wall 704 of the secondary lock 326 can seal the recess 606. The rear wall 810 can be sized to seal against the inner wall 704 of the secondary lock 326 to prevent air from flowing through the opening 612 of the slot 608. Optionally, a sealant can be applied at the seam and interface between the tray 802 and the secondary lock 326 to seal the opening 612.

[0059] Figure 8 and 9 The thermal sensor 312 shown does not have Figure 6 and 7The wires of the wires 318 shown are because the thermal sensor 312 has wireless communication circuitry configured to wirelessly transmit electrical signals representing temperature data to a control device for analysis. Alternatively, if the thermal sensor 312 does have wires, the wires can extend through one or more openings in the rear wall 810 of the tray 802.

[0060] like Fig. 9 As shown, the first and second thermal sensors 312A, 312B are disposed between the first and second power terminals 204A, 204B. The thermal sensor 312 may be located in the space between the two power terminals 204 because the space may absorb heat from the two power terminals 204 during charging operations. The space between the power terminals 204 may experience some of the highest temperatures (if not the highest temperature) of the charging inlet 110.

[0061] Fig.10 is a cross-sectional view of a portion of the charging inlet 110 according to the third embodiment. The cross-sectional line extends through the power terminals 204A, 204B, the secondary lock 326, the housing 202, and the cover 220. In the illustrated embodiment, the retainer member 602 that holds the one or more thermal sensors 312 is an attachment 902 of the cover 220. The attachment 902 protrudes from an inner surface 904 of the cover 220 that faces the power terminals 204. When the cover 220 is coupled to the housing 202, the attachment 902 extends between the first and second power terminals 204A, 204B, as shown in FIG. Fig.10 As shown, the accessory 902 defines a recess 606 in which the thermal sensor 312 is disposed. The recess 606 and the thermal sensor 312 are disposed between the two power terminals 204A, 204B. As described above with reference to other embodiments, the thermal sensor 312 includes a sensing element 322 on a substrate 320. The recess 606 may be completely enclosed to allow the air within the recess 606 to heat faster than the air within the cavity 324 of the charging inlet 110 outside the recess 606 during charging operations, thereby producing more accurate temperature measurements and faster response times than known charging inlet temperature sensors. Although only one recess 606 and one thermal sensor 312 are shown in the illustrated embodiment, in another embodiment, the accessory 902 may define more than one recess 606 to hold multiple thermal sensors 312.

[0062] In the embodiments presented herein, the retainer member 602 that holds the thermal sensor 312 and defines at least a portion of the pocket 606 is described as an attachment 902 to the secondary lock 326 or the cover 220. However, in alternative embodiments, the retainer member 602 may be a separate component from the cover 220 and the secondary lock 326. For example, the retainer member 602 may be a separate plastic component that is coupled to the power terminal 204 between the secondary lock 326 and the cover 220.

Claims

1. A charging inlet (110), comprising: a power terminal (204) configured to releasably engage a mating contact of an external power source (104); a retainer member (602) proximate the power terminals, the retainer member having an electrically insulating material, the retainer member defining at least a portion of a fully enclosed recess (606); and a thermal sensor (312) disposed in the recess for monitoring the temperature of the power terminal; The recess (606) protrudes from an opening (612) into the holder member (602) along a peripheral surface (614) of the holder member, and a sealant (708) covers the opening to close the recess.

2. The charging inlet (110) according to claim 1, wherein: The cavity (606) is sealed to isolate air within the cavity from air within a charging inlet located outside the cavity to prevent convective heat transfer from the cavity.

3. The charging inlet (110) according to claim 1, wherein: The thermal sensor (312) includes a substrate (320) and a sensing element (322) mounted on the substrate, the substrate including an aluminum nitride material.

4. The charging inlet (110) according to claim 1, wherein: The thermal sensor (312) in the recess (606) is separated from the power terminal (204) by a partition wall (702) that defines a section of the recess.

5. The charging inlet (110) according to claim 1, wherein: The retainer member (602) is a secondary latch (326) that overlaps and supports a flange (406) of the power terminal (204) to secure the power terminal in a fixed position within the charging inlet.

6. The charging inlet (110) according to claim 1, wherein: The power terminal (204) is a first power terminal (204A), and the charging inlet includes a second power terminal (204B) adjacent to the first power terminal, wherein the thermal sensor (312) within the recess (606) is located between the first and second power terminals.

7. The charging inlet (110) according to claim 1, wherein: The thermal sensor (312) is mechanically and electrically connected to at least one wire (318) extending from the thermal sensor to the exterior of the cavity (606) for conductively conveying an electrical signal representative of temperature data from the thermal sensor for analysis.

8. A charging inlet (110), comprising: a power terminal (204) configured to releasably engage a mating contact of an external power source (104); a retainer member (602) proximate the power terminals, the retainer member having an electrically insulating material, the retainer member defining at least a portion of a fully enclosed recess (606); and a thermal sensor (312) disposed in the recess for monitoring the temperature of the power terminal; a tray (802) having the thermal sensor (312) mounted thereon, the tray extending into the recess (606) of the holder member (602); wherein the pocket (606) protrudes from an opening (612) into the holder member (602) along a peripheral surface (614) of the holder member, wherein the tray (802) has a rear wall (810) covering the opening to close the pocket.

9. The charging inlet (110) according to claim 8, wherein: The cavity (606) is sealed to isolate air within the cavity from air within a charging inlet located outside the cavity to prevent convective heat transfer from the cavity.

10. The charging inlet (110) according to claim 8, wherein: The thermal sensor (312) includes a substrate (320) and a sensing element (322) mounted on the substrate, the substrate including an aluminum nitride material.

11. The charging inlet (110) according to claim 8, wherein: The thermal sensor (312) in the recess (606) is separated from the power terminal (204) by a partition wall (702) that defines a section of the recess.

12. The charging inlet (110) according to claim 8, wherein: The retainer member (602) is a secondary latch (326) that overlaps and supports a flange (406) of the power terminal (204) to secure the power terminal in a fixed position within the charging inlet.

13. The charging inlet (110) according to claim 8, wherein: The power terminal (204) is a first power terminal (204A), and the charging inlet includes a second power terminal (204B) adjacent to the first power terminal, wherein the thermal sensor (312) within the recess (606) is located between the first and second power terminals.

14. The charging inlet (110) according to claim 8, wherein: The thermal sensor (312) is mechanically and electrically connected to at least one wire (318) extending from the thermal sensor to the exterior of the cavity (606) for conductively conveying an electrical signal representative of temperature data from the thermal sensor for analysis.

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