High-power electrical connector with cooling feature

Abstract

An electrical connector assembly (100) includes: a connector housing (112); a planar busbar (124) having a rectangular cross-section defining two opposing major surfaces and four minor surfaces; a cooling plate (130) sized, shaped, and arranged to be in thermal contact with a first major surface of the planar busbar (124); and an L-shaped busbar (118) partially disposed within the connector housing (112) and having a first end (120) and a second end (122), the first end being connected to an electrical terminal (116) and the second end being attached to and in thermal contact with the second major surface of the planar busbar (124). The cooling plate (130) is configured to reduce the temperature of the planar busbar (124) and the attached L-shaped busbar (118). A method (200) of assembling the electrical connector (100) is also provided.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 187,588, filed May 12, 2021, and U.S. Provisional Patent Application No. 63 / 195,223, filed June 1, 2021, the entire disclosures of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to an electric connector assembly, in particular to a high-power electric connector assembly with cooling characteristics. Background Art

[0004] High-power electrical connector assemblies, such as those used in electric vehicles, may need to conduct 90 kilowatts or more of electricity. The contact resistance between the electrical components in the electrical connector assembly results in power loss, which is converted into heat energy within the connector assembly. This heat energy can cause the temperature within the electrical connector assembly to rise, and if the thermal limit is exceeded, it may damage the electrical connector assembly and / or surrounding components due to overheating. To prevent damage from overheating, the conductive components of the electrical connector assembly (including the cable) are increased in size to carry the additional current, thereby "derating" the connector to compensate for the resistive heating.

[0005] The subject matter discussed in the Background section should not be considered prior art simply because it is mentioned in the Background section. Similarly, problems mentioned in the Background section or related to the subject matter in the Background section should not be considered to have been previously discovered in the prior art. The subject matter in the Background section merely represents different approaches and may themselves be inventions. Summary of the Invention

[0006] According to one embodiment, an electrical connector assembly is provided. The electrical connector assembly includes: a connector housing; a planar busbar having a rectangular cross-section, the rectangular cross-section defining two opposing primary surfaces and four secondary surfaces; a cooling plate sized, shaped, and arranged to be in thermal contact with a first primary surface of the planar busbar; and an L-shaped busbar partially disposed within the connector housing and having a first end and a second end, the first end being connected to an electrical terminal and the second end being attached to and in thermal contact with the second primary surface of the planar busbar. The cooling plate is configured to reduce the temperature of the planar busbar and the attached L-shaped busbar.

[0007] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the electrical connector assembly further comprises an electrically insulating and thermally conductive pad disposed between the second major surface of the planar busbar and the cooling plate.

[0008] In an exemplary embodiment of the electrical connector assembly having one or more features of any of the preceding paragraphs, the L-shaped busbar is attached to the planar busbar by a threaded fastener having a head with an outer surface flush with or offset from the second major surface.

[0009] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraphs, the electrical connector assembly further comprises a pair of planar busbars, a pair of L-shaped busbars, and a pair of electrical terminals. Each planar busbar in the pair of planar busbars is connected to one L-shaped busbar in the pair of L-shaped busbars and one electrical terminal in the pair of electrical terminals.

[0010] In an exemplary embodiment of the electrical connector assembly having one or more features of any of the preceding paragraphs, the electrical connector assembly further comprises a cooling plate holder formed of an insulating material and disposed between the cooling plate and the connector housing.

[0011] In an exemplary embodiment of the electrical connector assembly having one or more features of any of the preceding paragraphs, the cooling plate holder and the cooling plate are separated from the connector housing by a plurality of brackets.

[0012] In an example embodiment of the electrical connector assembly having one or more features of any of the preceding paragraphs, the cooling plate holder defines a snap feature configured to secure the cooling plate holder to the cooling plate.

[0013] In an exemplary embodiment having one or more features of the electrical connector assembly of any of the preceding paragraphs, the cooling plate holder and the cooling plate define an alignment feature configured to align the cooling plate holder with the cooling plate.

[0014] In an exemplary embodiment of the electrical connector assembly having one or more features of any of the preceding paragraphs, the cooling plate includes a coolant channel configured to allow liquid coolant to flow into the inlet port of the cooling plate and out of the outlet port of the cooling plate through the coolant channel.

[0015] In an exemplary embodiment of an electrical connector assembly having one or more features of any of the preceding paragraphs, the cooling plate further comprises a first portion and a second portion, the first portion defining an inlet port and an outlet port, the second portion having an outer surface in thermal contact with the first major surface of the planar busbar.

[0016] According to another embodiment of the present invention, a method for assembling an electrical connector is provided. The above method includes the steps of providing an electrical connector, wherein the above electrical connector has a connector housing, a cooling plate, a planar busbar having a rectangular cross-section and defining two opposing main surfaces and four secondary surfaces, and an L-shaped busbar partially configured in the connector housing. The first end of the L-shaped busbar is connected to an electrical terminal configured in the connector housing. The above method also includes the steps of: placing the first main surface of the planar busbar in thermal contact with the cooling plate; attaching the second end of the L-shaped busbar to the second main surface of the above-mentioned planar busbar so that the second end is in close contact with the second main surface; and fixing the cooling plate to the connector housing. The cooling plate is configured to reduce the temperature of the above-mentioned planar busbar and the attached above-mentioned L-shaped busbar.

[0017] In an exemplary embodiment having one or more of the features of the method of the preceding paragraph, the method further comprises the step of disposing a pad between the second main surface of the planar busbar and the cooling plate, the pad being thermally conductive and electrically insulating.

[0018] In an exemplary embodiment having one or more features of the method of any of the preceding paragraphs, the method further comprises the step of attaching the L-shaped busbar to the planar busbar by a threaded fastener, wherein the head of the threaded fastener has an outer surface that is flush with or offset from the second major surface.

[0019] In an exemplary embodiment having one or more features of the method of any of the preceding paragraphs, the method further comprises the step of disposing a cooling plate retainer formed of an insulating material between the cooling plate and the connector housing.

[0020] In an exemplary embodiment having one or more features of the method of any of the preceding paragraphs, the method further comprises the step of separating the cooling plate holder and the cooling plate from the connector housing using a plurality of brackets.

[0021] In an exemplary embodiment having one or more features of the method of any of the preceding paragraphs, the cooling plate includes coolant channels configured to allow liquid coolant to flow into the cooling plate via the inlet port, through the coolant channels, and out of the cooling plate via the outlet port.

[0022] According to another embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes: a connector housing; a planar busbar having a rectangular cross-section, the rectangular cross-section defining two opposing major surfaces and four minor surfaces; an L-shaped busbar partially disposed within the connector housing and having a first end and a second end, the first end being connected to an electrical terminal and the second end being attached to and in thermal contact with the second major surface of the planar busbar; and a device for reducing the temperature of the planar busbar and the L-shaped busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0024] Figure 1 is a perspective assembly diagram of an electrical connector assembly according to one embodiment;

[0025] Figure 2 According to one embodiment Figure 1 an exploded side view of an electrical connector assembly;

[0026] Figure 3 According to one embodiment Figure 1 a cross-sectional side view of an electrical connector assembly;

[0027] Figure 4 According to one embodiment Figure 1 Thermal imaging view of an electrical connector assembly and a corresponding mating connector; and

[0028] Figure 5 According to one embodiment Figure 1 Flowchart of a method for assembling an electrical connector assembly. DETAILED DESCRIPTION

[0029] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other cases, well-known methods, processes, components, circuits, and networks have not been described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0030] Figures 1 to 3A non-limiting example of one embodiment of an electrical connector assembly is shown, hereinafter referred to as connector 100. Connector 100 is a header connector designed to be mounted on a flat surface, such as a panel of a battery pack or the bulkhead of an electric vehicle. Connector 100 includes an electrically insulating connector housing 112 that defines a shroud 114 that partially encloses a pair of electrical terminals 116. In this example, electrical terminals 116 are female terminals configured to receive corresponding male terminals. The electrical terminals are connected to a pair of L-shaped busbars 118 partially disposed within connector housing 112. As used herein, "L-shaped" refers to a busbar having a first planar end 120 arranged generally perpendicular to a second planar end 122. In the example shown, electrical terminals 116 are connected to first ends 20 of L-shaped busbars 118. Connector 100 also includes a pair of planar busbars 124, each having a rectangular cross-section defining two opposing major surfaces 126, 128 and four minor surfaces. As used herein, a primary surface is distinguished from a secondary surface due to the larger surface area of ​​the primary surface. The connector 100 also includes a planar busbar 124 and an attached L-shaped busbar 118 for reducing the temperature of the connector 100, the device comprising a cooling plate 130 sized, shaped, and arranged to be in thermal contact with a first major surface 126 of each planar busbar 124. The second end 122 of the L-shaped busbar 118 is attached to and in thermal contact with a second major surface 128 of the planar busbar 124.

[0031] In an alternative embodiment, the first end of the L-shaped busbar may form a male terminal that is received within a corresponding female terminal in a mating connector housing.

[0032] The L-shaped busbars 118 are secured to the housing 118 by threaded fasteners 132 such as countersunk cap screws and rotating or self-locking nuts, e.g. Nuts, through which cap screws pass) are attached to the planar busbars 124. Figure 3 As shown, when the cap screw is fully tightened, the head of the cap screw has an outer surface that is flush with or clear of the second major surface 128. This maximizes the interface surface area between the L-shaped generatrix 118 and the planar generatrix 124, which would be limited to the surface area of ​​the screw head if it protruded from the second major surface 128 when the cap screw is fully tightened.

[0033] The connector assembly further includes a cooling plate retainer (hereinafter referred to as retainer 134), which is formed of an insulating material such as polyamide (nylon) or polybutylene terephthalate (PBT) and is disposed between the cooling plate 130 and the connector housing 112. The retainer 134 and the cooling plate 130 are separated from the connector housing 112 by a plurality of brackets 136. The retainer 134 defines a snap feature 138 configured to secure the retainer 134 to the cooling plate 130. The retainer 134 and the cooling plate 130 define an alignment feature 140 configured to align the retainer 134 with the cooling plate 130. The retainer 134 also defines a fin 42 that protrudes between the pair of L-shaped bus bars 118 to maintain the spacing therebetween and to electrically insulate the L-shaped bus bars 118 from each other. The retainer 134 also includes an insert or compression limiter to prevent over-torquing of the threaded fasteners 132 used to secure the retainer 134 and the cooling plate 130 to the bracket 136 .

[0034] The cooling plate 130 includes a bottom portion 44 having a liquid inlet port 146 and a liquid outlet port 148, which can be interconnected with the vehicle's cooling system, such as a liquid cooling system for cooling the vehicle's battery pack and / or the vehicle's power electronics. The vehicle's cooling system includes a pump that flows liquid coolant through the cooling plate. In an alternative embodiment, the liquid inlet port and the liquid outlet port can be interconnected with a cooling system dedicated to cooling the connector. The bottom portion can advantageously be formed from a polymer material, which can reduce weight and provide better electrical isolation compared to a metal bottom portion.

[0035] The cooling plate 130 also includes a top portion 150 that defines a coolant channel 152 having a plurality of cooling fins 154 through which liquid coolant flows from the liquid inlet port 146 to the liquid outlet port 148. The top portion 150 can advantageously be formed of a metal material to optimize heat transfer between the cooling fins 154 and the liquid coolant. The top portion 150 protrudes through an opening 156 in the retainer 134. The retainer 134 also defines a plurality of reinforcing ribs 160 that extend from the opening 156 to the outer edge of the retainer 134.

[0036] An electrically insulating and thermally conductive pad 158 is disposed between the second major surface 128 of the planar busbar 124 and the top portion 150 of the cooling plate 130. The pad 158 may be formed from a layer of dielectric thermal interface material (such as THERM-A-GAPTMGEL 30, available from Parker Chomerics of Woburn, Massachusetts) in direct contact with the planar busbar and an additional layer of dielectric material (such as ISOEDGET MPR 4305, available from Henkel Corporation of Warren, Michigan) in direct contact with the cooling plate. The dielectric thermal interface material layer and the additional layer of dielectric material provide stable electrical isolation between the planar busbar and the metallic top portion.

[0037] The results of thermal modeling of the cooling performance of the connector 100 are shown in FIG. Figure 4 shown.

[0038] While the illustrated embodiment of connector 100 is configured to conduct liquid coolants, other embodiments of connectors configured to conduct gaseous coolants are contemplated. In yet another embodiment of the connector, the cooling plate may include external cooling fins and rely on passive cooling rather than active coolant flow.

[0039] Figure 5 A flow chart of a method 200 for assembling the connector 100 described above is shown. The method 200 comprises the following steps:

[0040] Step 202, providing an electrical connector; Step 202 includes providing an electrical connector 100, the electrical connector 100 having a connector housing 112, a cooling plate 130, a planar bus bar 124 having a rectangular cross-section and defining two opposing major surfaces 126, 28 and four minor surfaces, and an L-shaped bus bar 118 partially disposed within the connector housing 112. A first end 120 of the L-shaped bus bar 118 is connected to an electrical terminal 16 disposed within the connector housing 112;

[0041] Step 204, disposing a pad between the planar busbar and the cooling plate; Step 204 is an optional step, comprising disposing a pad 158 between the second main surface 128 of the planar busbar 124 and the cooling plate 130. The pad 158 is thermally conductive and electrically insulating;

[0042] Step 206 , placing the planar busbar in thermal contact with the cooling plate; Step 206 includes placing the first major surface 126 of the planar busbar 124 in thermal contact with the cooling plate 130 ;

[0043] Step 208 , connecting the second end of the L-shaped busbar to the planar busbar; Step 208 includes attaching the second end 122 of the L-shaped busbar 118 to the second major surface 128 of the planar busbar 124 such that the second end 122 is in close contact with the second major surface 128 ;

[0044] Step 210, attaching the L-shaped busbar to the planar busbar using a threaded fastener; Step 210 is an optional step and includes attaching the L-shaped busbar 118 to the planar busbar 124 using a threaded fastener 132, such as a countersunk cap screw and a rotating or self-locking nut. The head of the threaded fastener 132 has an outer surface that is flush with or offset from the second main surface 128;

[0045] Step 212, disposing a cooling plate retainer between the cooling plate and the connector housing; Step 212 is an optional step, comprising disposing a cooling plate retainer 134 formed of an insulating material between the cooling plate 130 and the connector housing 112;

[0046] Step 214, separating the cooling plate holder and the cooling plate from the connector housing; this step 214 is an optional step and includes separating the cooling plate holder 134 and the cooling plate 130 from the connector housing 112 using the plurality of brackets 136; and

[0047] Step 216, securing the cooling plate to the connector housing; Step 216 includes securing the cooling plate 130 to the connector housing 112. The cooling plate 130 is configured to reduce the temperature of the planar busbar 124 and the attached L-shaped busbar 118. The cooling plate 130 includes coolant channels 152 configured to allow liquid coolant to flow into the cooling plate 130 via the inlet port 146, pass through the coolant channels 152, and exit the cooling plate 130 via the outlet port 148.

[0048] Thus, a connector 100 and a method for assembling the connector 100 are provided. The connector 100 described above provides advantages for thermally managing the temperature of the connector 100 and associated components, such as cables. By reducing the temperature of the connector 100, the connector derating is no longer necessary, allowing for the use of smaller connector components, thereby reducing material costs and reducing the weight and size of the connector 100. Furthermore, since the cable attached to the connector no longer requires a heat sink, the cable gauge may also be reduced, further reducing material costs and reducing the weight and size of the cable.

[0049] While the present invention has been described with reference to preferred embodiments thereof, the present invention is not intended to be limited thereto, but rather is limited only by the scope set forth in the claims below. For example, the embodiments described above (and / or various aspects thereof) may be used in combination with one another. Furthermore, various modifications may be made to adapt circumstances or materials to the teachings of the present invention without departing from its broad scope. The sizes, types, orientations of the various components, and the number and position of the various components described herein are intended to define parameters of a particular embodiment and are not intended to be limiting, but rather are merely prototype embodiments.

[0050] After reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art. Therefore, the scope of the present invention is limited only by the appended claims and the full range of equivalents encompassed by these claims.

[0051] As used herein, “one or more” includes functions performed by one element, functions performed by more than one element, such as in a distributed fashion, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0052] It should also be understood that although the terms "first," "second," and the like are used herein to describe various elements in some cases, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact. Both the first contact and the second contact are contacts, but they are not the same contact.

[0053] The terms used in the description of the various embodiments herein are for the purpose of describing the embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and covers all possible combinations of one or more associated listed items. It should also be understood that the term "comprising" used in this article specifically refers to the presence of the stated features, wholes, steps, operations, elements and / or parts, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or combinations thereof.

[0054] As used herein, the term “if” is alternatively construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if “[the stated condition or event] is detected” is alternatively construed to mean “upon deciding” or “in response to deciding” or “upon detecting [the condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

[0055] In addition, although terms of regulation or orientation may be used herein, these elements should not be limited by these terms. Unless otherwise specified, all terms of regulation or orientation are used to distinguish one element from another and do not imply any order of operation, direction or orientation unless otherwise specified.

Claims

1. An electrical connector assembly (100), comprising: Connector housing (112); a planar busbar (124) having a rectangular cross-section defining two opposing major surfaces and four minor surfaces; a cooling plate (130) sized, shaped, and arranged to be in thermally conductive contact with the first major surface of the planar busbar (124); an L-shaped busbar (118) partially disposed within the connector housing (112) and having a first end (120) connected to an electrical terminal (116) and a second end (122), the first end being attached to and in thermal contact with the second major surface of the planar busbar (124), wherein the cooling plate (130) is configured to reduce the temperature of the planar busbar (124) and the attached L-shaped busbar (118); as well as A cooling plate holder (134) is formed of an insulating material and is arranged between the cooling plate (130) and the connector housing (112). The cooling plate holder (134) and the cooling plate (130) are separated from the connector housing (112) by a plurality of brackets (136).

2. The electrical connector assembly (100) according to claim 1, characterized in that Also included is an electrically insulating and thermally conductive pad (158) disposed between the second major surface of the planar busbar (124) and the cooling plate (130).

3. The electrical connector assembly (100) according to claim 1, characterized in that The L-shaped busbar (124) is attached to the planar busbar (118) by a threaded fastener (132), wherein the threaded fastener (132) includes a head having an outer surface flush with the second major surface.

4. The electrical connector assembly (100) according to claim 1, characterized in that The L-shaped busbar (118) is attached to the planar busbar (124) by a threaded fastener (132), wherein the threaded fastener (132) includes a head having an outer surface that faces away from the second major surface.

5. The electrical connector assembly (100) according to claim 1, characterized in that The invention also includes a pair of planar busbars (124), a pair of L-shaped busbars (118), and a pair of electrical terminals (16), wherein each planar busbar (124) in the pair of planar busbars (124) is connected to one L-shaped busbar (118) in the pair of L-shaped busbars (118) and one electrical terminal (116) in the pair of electrical terminals (116).

6. The electrical connector assembly (100) according to claim 1, characterized in that The cooling plate holder (134) defines a snap feature (138) configured to secure the cooling plate holder (134) to the cooling plate (130).

7. The electrical connector assembly (100) according to claim 1, characterized in that The cooling plate holder (134) and the cooling plate (130) define alignment features (140) configured to align the cooling plate holder (134) with the cooling plate (130).

8. The electrical connector assembly (100) according to claim 1, characterized in that The cooling plate (130) includes a coolant channel (152) configured to allow liquid coolant to flow into an inlet port (146) of the cooling plate (130), through the coolant channel (152), and out of an outlet port (148) of the cooling plate (130).

9. The electrical connector assembly (100) according to claim 8, characterized in that The cooling plate (130) comprises: a first portion defining the inlet port (146) and the outlet port (148); and A second portion having an outer surface in thermally conductive contact with the first major surface of the planar busbar (124).

10. A method (200) of assembling an electrical connector (100), the method (200) comprising: The step (202) of providing (202) the electrical connector (100), the electrical connector (100) having a connector housing (112), a cooling plate (130), a planar busbar (124) having a rectangular cross-section and defining two opposing major surfaces and four minor surfaces, and an L-shaped busbar (118) partially disposed within the connector housing (112), wherein a first end of the L-shaped busbar (118) is connected to an electrical terminal (116) disposed within the connector housing (112); placing (206) a first major surface of the planar busbar (124) in thermally conductive contact (206) with the cooling plate (130); Attaching (208) the second end (122) of the L-shaped busbar (118) to the second major surface of the planar busbar (124) such that the second end (122) is in close contact with the second major surface (128); securing (216) the cooling plate (130) to the connector housing (112), wherein the cooling plate (130) is configured to reduce the temperature of the planar busbar (124) and the attached L-shaped busbar (118); disposing (212) a cooling plate holder (134) formed of an insulating material between the cooling plate (130) and the connector housing (112); and The cooling plate holder (134) and the cooling plate (130) are separated (214) from the connector housing (112) using a plurality of brackets (136).

11. The method (200) according to claim 10, characterized in that The invention also includes disposing (204) a pad (158) between the second major surface of the planar busbar (124) and the cooling plate (130), wherein the pad (158) is thermally conductive and electrically insulating.

12. The method (200) of claim 10, wherein: Also included is attaching (208) the L-shaped busbar (118) to the planar busbar (124) using threaded fasteners (132).

13. The method (200) of claim 12, wherein: The head of the threaded fastener (132) has an outer surface flush with the second major surface.

14. The method (200) of claim 12, wherein: The head of the threaded fastener (132) has an outer surface that is away from the second major surface.

15. The method (200) of claim 10, wherein: The cooling plate (130) includes a coolant channel (152) configured to allow liquid coolant to flow into the cooling plate (130) via an inlet port (146), pass through the coolant channel (152), and exit the cooling plate (130) through an outlet port (148).

16. An electrical connector assembly (100), comprising: Connector housing (112); a planar busbar (124) having a rectangular cross-section defining two opposing major surfaces and four minor surfaces; an L-shaped busbar (118) partially disposed within the connector housing (112) and having a first end (120) connected to the electrical terminal (116) and a second end (122) attached to and in thermal contact with the second major surface of the planar busbar (124); means (130) for reducing the temperature of the planar busbar (124) and the L-shaped busbar (118); and A retainer is formed of an insulating material and is disposed between the device and the connector housing, the retainer and the device being separated from the connector housing by a plurality of brackets.

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