Temperature sensor assembly for electrical connector

Abstract

An electrical connector (102) includes a housing (110) having a terminal channel (116) in which a power terminal (114) is located. The electrical connector includes a temperature sensor assembly (130) located within a chamber (140). The temperature sensor assembly includes a gasket (300) holding the power terminals and a thermal shunt (302) held by the gasket. A temperature sensor (304) is coupled to the thermal splitter. The gasket has a terminal opening (316) that receives the power terminal. The gasket is thermally coupled to the power terminal and to the thermal shunt. The thermal diverter has a thermal conductivity higher than that of the gasket. A temperature sensor monitors the temperature of the power terminal through a thermal path defined by the gasket and the thermal shunt.

Description

[0001] This invention is a divisional application of the Chinese invention patent application (application number: 201980061326.6, application date: August 20, 2019, invention name: temperature sensor assembly for electrical connector).

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Application No. 62 / 720,501, filed on August 21, 2018, entitled “REDUCED SENSOR TIME CONSTANTFOR HEMS CONNECTORS,” the entire contents of which are incorporated herein by reference. Technical Field

[0004] The subject matter herein generally relates to temperature sensor assemblies for electrical connectors. Background Art

[0005] Electrical connectors, such as power connectors, generate heat when current flows through the terminals and cables of the power connector. For example, an electrical connector for a charging inlet assembly of a battery system for an electric vehicle (EV) or a hybrid electric vehicle (HEV) may generate heat through the terminals and cables of the charging inlet assembly during the charging process. The charging connector is configured to mate with the terminals of the charging inlet assembly to charge the battery system of the vehicle. It is desirable to increase the current transmitted through the terminals to charge the battery. However, at higher currents, the terminals and power cables experience increased temperatures, which may damage components of the charging inlet assembly.

[0006] Some known charging inlet assemblies utilize temperature sensors that are thermally connected to the terminals to control charging. The temperature sensor needs to be electrically isolated from the terminals. Known charging inlet assemblies utilize silicone rubber pads that serve as both a weather seal and a device for conducting heat from the terminals to the temperature sensor. The silicone rubber pads conduct heat from the terminal surface to the temperature sensor. However, the silicone rubber pads provide thermal resistance in the heat flow path. The thermal resistance produces a significant offset error between the time it takes the terminals to reach a specific temperature and the time it takes the temperature sensor to measure that temperature. The thermal resistance and thermal capacitance of the silicone rubber pads represent a long thermal time constant, introducing a significant time delay between the temperature change of the pin and the temperature change measured by the temperature sensor. Summary of the invention

[0007] A problem to be solved is to provide a cost effective and reliable temperature sensor assembly for an electrical connector that provides accurate temperature sensing and fast response time to temperature changes.

[0008] This problem is solved by an electrical connector including a housing extending between a front and a rear portion. The housing has a chamber at the rear portion and a terminal channel between the front and the rear portion. The electrical connector includes a power terminal coupled to the housing. The power terminal includes a mating pin at the front portion of the power terminal and a cable connector at the rear portion of the power terminal. The mating pin is positioned in the terminal channel for mating with the charging connector. The cable connector is positioned in the chamber at the rear portion of the housing. The electrical connector includes a temperature sensor assembly located in the chamber. The temperature sensor assembly includes a sealing pad that holds the power terminal. The temperature sensor assembly includes a thermal shunt held by the sealing pad. The temperature sensor assembly includes a temperature sensor coupled to the thermal shunt. The sealing pad has a terminal opening that receives the power terminal. The sealing pad is electrically insulated. The sealing pad is thermally coupled to the power terminal and thermally coupled to the thermal shunt. The sealing pad has a first thermal conductivity. The thermal shunt has a second thermal conductivity that is higher than the first thermal conductivity. The temperature sensor monitors the temperature of the power terminal through a thermal path defined by the sealing pad and the thermal shunt. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will now be described by way of example with reference to the accompanying drawings:

[0010] Figure 1 is a front perspective view of a charging inlet assembly including an electrical connector according to an exemplary embodiment.

[0011] Figure 2 is a side view of a power terminal of a charging inlet assembly according to an exemplary embodiment.

[0012] Figure 3 is a cross-sectional view of a charging inlet assembly according to an exemplary embodiment.

[0013] Figure 4 is a perspective view of a portion of a temperature sensor assembly showing a sealing gasket and a heat shunt according to an exemplary embodiment.

[0014] Figure 5 is a perspective, partial cross-sectional view of a sealing gasket and a heat spreader according to an exemplary embodiment.

[0015] Figure 6 A rear perspective view of a portion of a charging inlet assembly illustrating a temperature sensor assembly according to an exemplary embodiment.

[0016] Figure 7 A front perspective view of a portion of a charging inlet assembly illustrating a temperature sensor assembly according to an exemplary embodiment.

[0017] Figure 8 is a perspective, partial cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment.

[0018] Fig. 9 is a cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment, showing a sealing gasket, a thermal shunt, a temperature sensor, and a printed circuit board.

[0019] Fig.10 is a cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment.

[0020] Fig.11 is a cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment, showing the temperature sensor assembly mounted to a housing.

[0021] Fig.12 is a cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment.

[0022] Fig.13 is a cross-sectional view of a portion of a temperature sensor assembly according to an exemplary embodiment. DETAILED DESCRIPTION

[0023] Figure 1 is a front perspective view of a charging inlet assembly 100 including an electrical connector 102 according to an exemplary embodiment. Although the electrical connector 102 may be described herein as part of the charging inlet assembly, it should be appreciated that the electrical connector 102 may be another type of electrical connector. The charging inlet assembly 100 is used as a charging inlet for a vehicle, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). The electrical connector 102 of the charging inlet assembly 100 is configured to be received in conjunction with a charging connector (not shown). In an exemplary embodiment, the electrical connector 102 is configured to mate with a DC fast charging connector (e.g., an SAE combined CCS charging connector) in addition to an AC charging connector (e.g., an SAE J1772 charging connector).

[0024] The electrical connector 102 of the charging inlet assembly 100 includes a housing 110 that holds a power terminal 114 that forms a part of the electrical connector 102. The power terminal 114 is electrically connected to a corresponding power cable 118. The power terminal 114 is configured to mate with the charging connector. The power terminal 114 is received in a terminal channel 116 of the housing 110 and is coupled to the housing 110 in the terminal channel 116.

[0025] In an exemplary embodiment, the charging inlet assembly 100 includes a temperature sensor assembly 130 (at Figure 3), is used to monitor the temperature of the power terminal 114 during charging. The charging rate of the charging connector is controlled based on the temperature of the power terminal 114. For example, if the temperature reaches a threshold temperature, the charging rate can be slowed or charging can be stopped to prevent damage to the power terminal 114. The temperature sensor assembly 130 has a fast response time to quickly control the charging process to prevent damage to the power terminal 114. The temperature sensor assembly 130 is located on the rear side of the charging inlet assembly 100, for example, within the interior of the charging inlet assembly 100.

[0026] The charging inlet assembly 100 includes a mounting flange 120 coupled to the housing 110. The mounting flange 120 is used to couple the charging inlet assembly 100 to the vehicle. The mounting flange 120 includes a mounting tab 122 having an opening 124 that receives a fastener (not shown) for securing the charging inlet assembly 100 to the vehicle. Other types of mounting features may be used to secure the charging inlet assembly 100 to the vehicle. The mounting flange 120 may include a seal for sealing the charging inlet assembly 100 to the vehicle.

[0027] The charging inlet assembly 100 includes a terminal cover 126 hingedly coupled to the mounting flange 120 and / or the housing 110. The cover 126 is used to cover the corresponding power terminals 114. The charging inlet assembly 100 may include a rear cover 128 coupled to the rear of the housing 110, the rear cover 128 closing the entrance to the rear of the housing 110. The power cable 118 can pass through the rear cover 128 and / or through the side of the housing 110.

[0028] Figure 2 1 is a side view of the power terminal 114 according to an exemplary embodiment. The power terminal 114 includes a mating pin 200 at a front portion 210 of the power terminal 114 and a cable connector 202 at a rear portion 212 of the power terminal 114. The power terminal 114 extends along a longitudinal axis 204. The mating pin 200 is configured to mate with a charging connector. The cable connector 202 is configured to electrically connect to the power cable 118.

[0029] In various embodiments, the cable connector 202 is separate and discrete from the mating pin 200 and is configured to be mechanically and electrically coupled to the mating pin 200. For example, the cable connector 202 can be press-fit onto the mating pin 200. However, in alternative embodiments, the cable connector 202 can be fixed to the mating pin 200 by other methods, such as friction stir welding, riveting, bolting, etc. In other various embodiments, the cable connector 202 is integral with the mating pin 200, such as formed with the mating pin 200. In various embodiments, the cable connector 202 is configured to be terminated to the power cable 118 by being crimped to the power cable 118. In other various embodiments, the cable connector 202 is terminated to the power cable 118 by other processes, such as being welded to a welding piece at the rear end of the power terminal 114.

[0030] The mating pin 200 is conductive. For example, the mating pin 200 can be made of a metal material such as a copper material. In an exemplary embodiment, the mating pin 200 is threaded. The mating pin 200 can be made of a metal alloy (e.g., a copper alloy) having an additive to increase machinability. In an exemplary embodiment, the mating pin 200 is cylindrical. In an exemplary embodiment, the mating pin 200 includes a cap 216 at the end 218 of the mating pin 200. The cap 216 is made of a dielectric material such as a plastic material. The cap 216 makes the power terminal 114 contact-safe at the front of the housing 110.

[0031] The mating pin 200 includes a mounting head 220 for mounting the mating pin 200 in the housing 110. In the illustrated embodiment, the mounting head 220 has a diameter that is larger than the diameter of the mating pin 200. In an exemplary embodiment, the mounting head 220 includes a latch groove 222 formed circumferentially around the mounting head 220, such as near the front end of the mounting head 220. In an exemplary embodiment, the mounting head 220 includes a sealing groove 226 that accommodates a seal 228. The seal 228 may be located near the rear end of the mounting head 220.

[0032] The cable connector 202 is behind the mounting head 220. In an exemplary embodiment, the cable connector 202 includes a crimp barrel 232 at the cable termination end 240 of the power terminal 114, the crimp barrel 232 being configured to receive the power cable 118. In an alternative embodiment, the cable connector 202 may include a welding tab. The cable connector 202 includes an outer surface 234. The temperature sensor assembly 130 (e.g. Figure 3 The cable terminating end 240 , as shown, may be thermally coupled to the outer surface 234 , for example proximate the cable terminating end 240 at the rear portion 212 of the power terminal 114 .

[0033] Figure 3 is a cross-sectional view of a charging inlet assembly 100 according to an exemplary embodiment. Figure 3One of the power terminals 114 coupled to the housing 110 is shown. The housing 110 extends to a rear portion 138, and a rear cover 128 is coupled to the housing 110 at the rear portion 138. The housing 110 has a chamber 140 at the rear portion 138. The rear cover 128 is behind the chamber 140 and closes the chamber 140. The rear cover 128 may include a cable outlet (e.g., an opening) that receives the power cable 118 and allows the power cable 118 to exit the chamber 140.

[0034] The power terminal 114 is received in the corresponding terminal channel 116. The mating pin 200 is located in the terminal channel 116 for docking with the charging connector inserted into the housing 110. The housing 110 includes a main latch 162 extending into the terminal channel 116 to engage the power terminal 114 and hold it axially in the terminal channel 116. The main latch 162 may be a deflectable latch. The main latch 162 may be integral with the housing 110, for example, co-molded with the housing 110. The main latch 162 prevents the power terminal 114 from being pulled back from the terminal channel 116. The mounting head 220 passes through the terminal channel 116 and engages with the housing 110 by an interference fit to tightly hold the power terminal 114 in the terminal channel 116. In an exemplary embodiment, the seal 228 is sealed to the surface of the housing 110 that defines the terminal channel 116. The power terminal 114 extends into the chamber 140, and the power cable 118 is terminated to the power terminal 114 in the chamber 140. The temperature sensor assembly 130 interfaces with the power terminals 114 in the cavity 140 . In an exemplary embodiment, the temperature sensor assembly 130 may be thermally coupled directly to the outer surface 234 to transfer heat from the power terminals 114 directly into the temperature sensor assembly 130 .

[0035] The temperature sensor assembly 130 includes a sealing gasket 300 holding the power terminal 114, a heat shunt 302 held by the sealing gasket 300, a temperature sensor 304 coupled to the heat shunt 302, and a printed circuit board 306 coupled to the temperature sensor 304. In an exemplary embodiment, the sealing gasket 300 is an elastomeric gasket, such as a silicone rubber gasket. The sealing gasket 300 is configured to be mounted to the housing 110. Optionally, the sealing gasket 300 can be sealed to the housing 110. In an exemplary embodiment, the sealing gasket 300 is sealed to the power terminal 114. The sealing gasket 300 is electrically insulating to electrically insulate the temperature sensor assembly 130 from the power terminal 114. In an exemplary embodiment, the sealing gasket 300 forms a portion of a thermal path between the power terminal 114 and the temperature sensor 304. The sealing gasket 300 is thermally coupled to the power terminal 114, for example, by direct bonding between the sealing gasket 300 and the power terminal 114.

[0036] In an exemplary embodiment, the heat shunt 302 is separated and discrete from the sealing gasket 300. The heat shunt 302 is made of a material having a higher thermal conductivity than the material of the sealing gasket 300. In an exemplary embodiment, the heat shunt 302 is made of a material having a higher diffusivity than the material of the sealing gasket 300. In this way, the heat shunt 302 has a faster response to temperature changes than a temperature sensor assembly that only utilizes a sealing gasket without a heat shunt in the temperature sensing path. The temperature sensor assembly 130 therefore has a smaller tracking error in temperature sensing to improve the transient response to temperature changes. The heat shunt 302 enhances the heat transfer between the power terminal 114 and the temperature sensor 304 to reduce the thermal resistance along the thermal path between the power terminal 114 and the temperature sensor 304. The high thermal conductivity and higher thermal diffusivity of the heat shunt 302 reduce the temperature response time of the temperature sensor assembly 130. In an exemplary embodiment, the temperature sensor 304 is a resistive temperature device; however, other types of temperature sensors may be used in alternative embodiments.

[0037] Figure 4 is a perspective view of a portion of a temperature sensor assembly 130 showing a sealing gasket 300 and a heat shunt 302 according to an exemplary embodiment. Figure 5 is a perspective, partial cross-sectional view of a sealing gasket 300 and a heat spreader 302 according to an exemplary embodiment.

[0038] The gasket 300 includes a gasket body 308 extending between a front portion 310 and a rear portion 312. The gasket 300 includes a terminal bushing 314 located at the front portion 310, and the terminal bushing 314 has a terminal opening 316 (eg, Figure 3 ). The number of terminal openings 316 may correspond to the number of power terminals 114 provided. In an exemplary embodiment, the terminal bushing 314 includes ribs 318 along an inner surface defining the terminal opening 316. The ribs 318 are compressible. The ribs 318 within the terminal opening 316 are configured to seal to the power terminal 114. Optionally, the terminal bushing 314 may include ribs on an outer surface of the terminal bushing 314 that are configured to seal to the housing 110 (e.g., Figure 3 In an exemplary embodiment, the terminal bushing 314 and / or the pad body 308 directly engage the power terminal 114 to thermally couple the sealing gasket 300 to the power terminal 114. In various other embodiments, a thermal interface material may be provided between the power terminal 114 and the terminal bushing 314 and / or the pad body 308.

[0039] In an exemplary embodiment, the gasket 300 includes a diverter bushing 320 that receives the heat diverter 302. For example, the diverter bushing 320 includes a diverter opening 322 that receives the heat diverter 302. The diverter bushing 320 extends from the rear portion 312. The diverter bushing 320 may additionally or alternatively extend from the front portion 310. In an exemplary embodiment, the diverter bushing 320 extends to a distal end 332 of the heat diverter 302. In various embodiments, the diverter bushing 320 may cover a portion of the distal end 332 of the heat diverter 302. In other embodiments, the distal end 332 of the heat diverter 302 is uncovered and may extend beyond the diverter bushing 320. The heat diverter 302 is separate and discrete from the gasket 300. The heat diverter 302 may be pressed into the diverter bushing 320. In various other embodiments, the sealing gasket 300 may be formed at a suitable location around the heat spreader 302 .

[0040] The heat shunt 302 extends between a base end 330 and a distal end 332. The base end 330 is coupled to the sealing gasket 300, such as the gasket body 308 of the sealing gasket 300. The distal end 332 is located away from the base end 330. The distal end 332 is configured to be coupled to the temperature sensor 304. In various embodiments, the temperature sensor 304 can directly engage the base end 332 of the heat shunt 302. In alternative embodiments, a thermal interface material can be provided between the temperature sensor 304 and the distal end 332.

[0041] The heat shunt 302 is made of a material with high thermal conductivity and high thermal diffusivity. The heat shunt 302 is arranged in the heat flow path between the power terminal 114 and the temperature sensor 304. In an exemplary embodiment, the heat shunt 302 is a cylinder. However, in alternative embodiments, the heat shunt 302 can have other shapes. For example, the heat shunt 302 can be rectangular, triangular, elliptical, D-shaped, or have other shapes or features, such as angle features, to increase the surface area of ​​the heat shunt 302. The cross-sectional area and / or cross-sectional shape of the heat shunt 302 can vary along the height of the heat shunt 302. The shape of the heat shunt 302 can provide a bonding of the heat shunt 302 within the sealing gasket 300 and / or a locking of the heat shunt 302 in a specific rotational orientation within the sealing gasket 300.

[0042] In an exemplary embodiment, the heat shunt 302 is made of a material having a higher thermal conductivity and a higher thermal diffusivity than the material of the sealing gasket 300. In various embodiments, the material of the heat shunt 302 can have a lower thermal resistance than the material of the sealing gasket 300. For example, the heat shunt 302 can be made of alumina having a thermal conductivity of approximately 140-170 W / m`K, while the sealing gasket 300 can be made of silicone rubber having a thermal conductivity of approximately 0.7 W / m`K. The higher thermal conductivity of the heat shunt 302 produces a lower overall thermal resistance along the heat transfer path, which results in a lower temperature measurement by the temperature sensor 304. For example, the addition of the heat shunt 302 reduces the thermal resistance from approximately 78 K / W to 2.2 K / W compared to a temperature sensor assembly using only the sealing gasket 300 without the heat shunt 302.

[0043] In an exemplary embodiment, the heat diverter 302 is formed by a heat diffusivity of about 12.0 mm 2 / s is made of alumina material, and the sealing gasket 300 has a thermal diffusivity of about 0.1mm 2 In alternative embodiments, the heat diverter 302 and / or the sealing gasket 300 may be made of other materials.

[0044] In an exemplary embodiment, the heat shunt 302 is made of an electrically insulating material to maintain electrical insulation between the power terminal 114 and the temperature sensor 304. The heat shunt 302 may be made of other high thermal conductivity materials besides alumina, such as aluminum nitride, mullite, thermally conductive plastic, etc. In various other embodiments, the heat shunt 302 may be made of a metal material, such as aluminum or copper, or a ceramic material.

[0045] In an exemplary embodiment, the thermal shunt 302 is placed proximate to the terminal opening 316 and, therefore, proximate to the power terminal 114. In this way, the thermal path through the lower thermal conductivity material of the sealing gasket 300 is reduced (e.g., effectively minimized), and the thermal path through the higher thermal conductivity material of the thermal shunt 302 is increased (e.g., effectively maximized). In an exemplary embodiment, a majority of the thermal path between the power terminal 114 and the temperature sensor 304 passes through the thermal shunt 302, as opposed to the sealing gasket 300. The thermal path through the thermal shunt 302 has a certain length, such as between the top and bottom of the thermal shunt 302. The sealing gasket 300 has a thermal path having a length between the power terminal 114 and the thermal shunt 302. In various embodiments, the thermal path length of the thermal shunt 302 may be approximately 10 times the thermal path length of the sealing gasket 300 (at the closest area between the thermal shunt 302 and the power terminal 114). In an exemplary embodiment, the thermal shunt 302 is used as a thermal path for a plurality of power terminals 114 (e.g., a pair of power terminals 114). The thermal shunt 302 may be located approximately in the center between the power terminals 114 to provide a thermal path for the two power terminals 114. The temperature sensor 304 is configured to be thermally coupled to the thermal shunt 302 to sense the temperature of the two power terminals 114. However, in alternative embodiments, a separate thermal shunt 302 and corresponding temperature sensor 304 may be provided for each power terminal 114.

[0046] Figure 6 is a rear perspective view of a portion of the charging inlet assembly 100 , illustrating a temperature sensor assembly 130 according to an exemplary embodiment. Figure 7 is a front perspective view of a portion of the charging inlet assembly 100 , illustrating a temperature sensor assembly 130 according to an exemplary embodiment.

[0047] The temperature sensor assembly 130 includes a sealing gasket 300, a heat shunt 302, a printed circuit board 306, and a temperature sensor 304 coupled to the printed circuit board 306. The printed circuit board 306 includes a front portion 340 and a rear portion 342. The temperature sensor 304 is mounted to the front portion 340 of the printed circuit board 306 and is aligned with the heat shunt 302 so that when the temperature sensor assembly 130 is assembled within the housing 110, the temperature sensor 304 is thermally coupled to the heat shunt 302.

[0048] In an exemplary embodiment, the temperature sensor assembly 130 includes a sensor connector 344 coupled to a rear portion 342 of the printed circuit board 306. The sensor connector 344 is electrically connected to the temperature sensor 304 through a sensor circuit defined by traces, vias, pads, etc. of the printed circuit board 306. The sensor connector 344 may be soldered or press-fitted to the printed circuit board 306. Wires (not shown) may extend from the sensor connector 344, for example, to the control circuitry of the charging inlet assembly 100.

[0049] The printed circuit board 306 includes terminal openings 350 therethrough that receive the power terminals 114. Optionally, the terminal openings 350 can be oversized to accommodate the power terminals 114. In an exemplary embodiment, the printed circuit board 306 includes bridges 352 between the terminal openings 350. The bridges 352 support the temperature sensor 304. The printed circuit board 306 includes mounting openings 354 that receive mounting posts 356 of the housing 110. The mounting posts 356 support the printed circuit board 306 in the chamber 140. Other types of mounting features may be used in alternative embodiments.

[0050] During assembly, the power terminals 114 are loaded into the terminal openings 350 in the printed circuit board 306 and the terminal openings 316 in the sealing gasket 300. The power terminals 114 are loaded into the terminal passages 116 in the housing 110. When assembled, the sealing gasket 300 can seal against the rear portion 138 of the housing 110. Optionally, the terminal bushings 314 can extend into the terminal passages 116 to seal against the housing 110. The printed circuit board 306 is configured to be mounted to the housing 110 behind the sealing gasket 300. When assembled, the temperature sensor 304 is coupled to the heat shunt 302. The rear cover 128 is configured to be mounted to the housing 110 behind the temperature sensor assembly 130. The rear cover 128 can be used to secure the printed circuit board 306 within the chamber 140.

[0051] During the charging operation, current flows through the power terminal 114. When current flows through the power terminal 114, the power terminal 114 is heated. The temperature sensor assembly 130 is used to monitor the temperature of the power terminal 114. The temperature sensor 304 of the temperature sensor assembly 130 is thermally connected to the power terminal 114 through a thermal path defined by the thermal shunt 302 and the sealing gasket 300. The higher thermal conductivity and higher thermal diffusivity of the thermal shunt 302 provide an effective and efficient thermal path between the temperature sensor 304 and the power terminal 114. The sealing gasket 300 provides electrical insulation between the power terminals 114 and between the temperature sensor 304 and the power terminals 114.

[0052] Figure 8is a perspective partial cutaway view of a portion of a temperature sensor assembly 130 according to an exemplary embodiment. In the illustrated embodiment, the heat shunt 302 is a multi-piece heat shunt (e.g., a split pin). The heat shunt 302 includes a first heat shunt member 360 and a second heat shunt member 362. The first heat shunt member 360 is positioned proximate to a first terminal opening 316 receiving a first power terminal 114, and the second heat shunt member 362 is positioned proximate to a second terminal opening 316 receiving a second power terminal 114. The first heat shunt member 360 defines a thermal path between the first power terminal 114 and the first power sensor 304a. The second heat shunt member 362 defines a thermal path between the second power terminal 114 and the second power sensor 304b. In this way, the temperature sensor assembly 130 is capable of separately and independently monitoring the temperature of the first and second power terminals 114.

[0053] In an exemplary embodiment, both the first and second heat diverter members 360, 362 are received in the diverter bushing 320. In an alternative embodiment, the gasket 300 includes a separate diverter bushing 320 that receives the corresponding heat diverter members 360, 362. In an exemplary embodiment, the first heat diverter member 360 is separated from the second heat diverter member 362 by a heat separator 364. In this way, the heat transfer between the heat diverter members 360, 362 is reduced or minimized. The heat separator 364 can be a band (e.g., a polyimide band) or a pad located between the heat diverter members 360, 362 and loaded into the diverter bushing 320 together with the heat diverter 302. The heat separator 364 can be used to mechanically fix the heat diverter members 360, 362 together. In various other embodiments, the heat separator 364 can be integral with the gasket 300 and the diverter bushing 320, for example, molded together with the gasket 300 and the diverter bushing 320. In various embodiments, the heat separator 364 may include a heat break 366, such as a cutout or window formed in the heat separator 364. Optionally, the heat break 366 may include an air gap 368 that introduces air between the heat diverter members 360, 362.

[0054] Fig. 9 1 is a cross-sectional view of a portion of the temperature sensor assembly 130 according to an exemplary embodiment, showing the sealing gasket 300, the heat shunt 302, the temperature sensor 304 and the printed circuit board 306. The temperature sensor assembly 130 is mounted on the housing 110. In the illustrated embodiment, Figure 8The diverter bushing 320 is relatively short compared to the diverter bushing shown in FIG. The diverter bushing 320 extends a short distance along the heat diverter 302 between the base end 330 and the distal end 332. The heat diverter 302 extends rearwardly at the distal end of the diverter bushing 320. The outer surface of the heat diverter 302 is uncovered and exposed to the air, rather than being completely encapsulated in the diverter bushing 320 of the gasket 300.

[0055] In an exemplary embodiment, a thermal interface material 370 is disposed at the interface between the heat diverter 302 and the sealing gasket 300. For example, the thermal interface material 370 is disposed along the diverter bushing 320 and along the pad body 308 that receives the base end 330 of the heat diverter 302, and the thermal interface material 370 may be thermal grease, thermal paste, phase change wax, thermal tape, or other types of thermal gap fillers.

[0056] In an exemplary embodiment, the heat diverter 302 is pressed into the opening of the sealing gasket 300 to provide an effective mechanical and thermal interface between the heat diverter 302 and the sealing gasket 300. For example, when the heat diverter 302 is pressed into the heat diverter opening in the sealing gasket 300, the sealing gasket 300 can be compressed against the heat diverter 302. The diverter bushing 320 exerts a compliant radial normal force on the heat diverter 302 to retain the heat diverter 302 in the sealing gasket 300. Optionally, the base end 330 of the heat diverter 302 can be tapered or chamfered to guide the loading of the heat diverter 302 into the opening of the sealing gasket 300. The sealing gasket 300 can have a complementary shape for effective heat transfer along the surface area of ​​the heat diverter 302. For example, the sealing gasket 300 can include a tapered seat that receives the tapered base end 330 of the heat diverter 302. In an exemplary embodiment, the sealing gasket 300 may exert a force on the heat shunt 302 to press the heat shunt 302 outwardly against the temperature sensor 304 .

[0057] Fig.10 is a cross-sectional view of a portion of a temperature sensor assembly 130 according to an exemplary embodiment. In the exemplary embodiment, the temperature sensor assembly 130 includes a compression member 372 for compressing the gasket 300 against the heat diverter 302. The compression member 372 engages the gasket 300 to press the gasket 300 inwardly against the heat diverter 302. In the illustrated embodiment, the compression member 372 is a compression ring around the diverter bushing 320 that presses the diverter bushing 320 inwardly against the heat diverter 302. Other types of compression members may be used in alternative embodiments.

[0058] Fig.11is a cross-sectional view of a portion of a temperature sensor assembly 130 according to an exemplary embodiment, showing the temperature sensor assembly 130 mounted to a housing 110. In an exemplary embodiment, the housing 110 includes a well 380. The diverter bushing 320 of the gasket 300 extends into the well 380. The walls defining the well 380 compress the diverter bushing 320 and press the diverter bushing 320 against the thermal diverter 302. Optionally, the base end 330 of the thermal diverter 302 can extend into the well 380 to compress the diverter bushing 320 between the thermal diverter 302 and the walls defining the well 380.

[0059] Fig.12 is a cross-sectional view of a portion of the temperature sensor assembly 130 according to an exemplary embodiment. In the exemplary embodiment, the diverter bushing 320 includes a recess 384 that forms an air gap 386 between the diverter bushing 320 and the heat diverter 302. The air recess reduces heat loss from the heat diverter 302 between the base end 330 and the distal end 332, provides a more accurate temperature reading by the temperature sensor 304, and reduces the response time of the temperature sensor 304.

[0060] Fig.13 is a cross-sectional view of a portion of a temperature sensor assembly 130 according to an exemplary embodiment. In an exemplary embodiment, the base end 330 of the heat shunt 302 includes a retaining feature 388 for retaining the heat shunt 302 in the heat shunt opening of the sealing gasket 300. During assembly, the retaining feature 388 can snap into the heat shunt opening in the sealing gasket 300. In an exemplary embodiment, the retaining feature 388 is defined by an undercut that forms a groove around the base end 330. The retaining feature 388 can engage the sealing gasket 300 to resist forward and rearward movement of the heat shunt 302 relative to the sealing gasket 300. The heat shunt opening in the sealing gasket 300 can have a shape that is complementary to the base end 330 and the retaining feature 388. The sealing gasket 300 can fit around the base end 330 and the retaining feature 388 to adopt the shape of the base end 330 and the retaining feature 388.

[0061] In the illustrated embodiment, the distal end 332 of the heat shunt 302 is raised to interface with the temperature sensor 304. The distal end 332 has a convex shape. Alternatively, the heat shunt 302 can be highest at the center of the distal end 332 to interface with the middle of the temperature sensor 304. In alternative embodiments, the distal end 332 can have other shapes.

Claims

1. A temperature sensor assembly for monitoring the temperature of a power terminal, include: A sealing gasket having a front portion and a rear portion, the sealing gasket being provided with a terminal opening extending therethrough for receiving a power terminal, so that a mating pin of the power terminal extends forwardly out of the sealing gasket to mate with a charging connector, and a cable connector of the power terminal extends rearwardly out of the sealing gasket to terminate to a power cable, the sealing gasket being an elastomer, the elastomer being electrically insulating and thermally conductive, having a first thermal conductivity, and the sealing gasket being thermally coupled to the power terminal; A heat diverter is separated and discrete from the sealing gasket, the heat diverter is held by the sealing gasket and extends backward from the rear portion of the sealing gasket to a distal end, the heat diverter is thermally coupled to the sealing gasket, and the heat diverter has a second thermal conductivity higher than the first thermal conductivity; A temperature sensor is coupled to a distal end of the thermal shunt, wherein the temperature sensor is configured to monitor a temperature of the power terminal through a thermal path defined by the sealing gasket and the thermal shunt. 2 . The temperature sensor assembly of claim 1 , wherein the sealing gasket has a first thermal diffusivity, and the heat shunt has a second thermal diffusivity higher than the first thermal diffusivity. 3 . The temperature sensor assembly of claim 1 , wherein the gasket comprises a bushing, the heat shunt being received within the bushing, the bushing being compressed between the heat shunt and the housing. 4 . The temperature sensor assembly of claim 1 , wherein the sealing gasket comprises a bushing receiving the heat shunt, the bushing having a recess, the recess comprising an air gap between the sealing gasket and the heat shunt. 5 . The temperature sensor assembly of claim 1 , wherein the heat shunt includes a distal end, the distal end is raised, and the temperature sensor abuts against the raised distal end.

6. A charging inlet assembly, include: a housing extending between the front portion and the rear portion, the housing having a mounting flange for mounting the housing to a vehicle, the housing having a charging port configured to receive a charging connector, the housing including a cavity at the rear portion; an electrical connector located in the charging port of the housing, the electrical connector including a terminal channel opened at a front portion to receive the charging connector, the electrical connector including power terminals received in the terminal channels, each power terminal including a mating pin located at a front portion of the power terminal and a cable connector located at a rear portion of the power terminal, the mating pin being positioned in a corresponding terminal channel to mate with the charging connector, the cable connector extending into the chamber for electrical connection with a power cable; a temperature sensor assembly located within the chamber, the temperature sensor assembly comprising a sealing pad holding an electrical terminal, the temperature sensor assembly comprising a thermal shunt held by the sealing pad, the temperature sensor assembly comprising a temperature sensor coupled to the thermal shunt, the sealing pad having a terminal opening for receiving the electrical terminal, the sealing pad being electrically insulating to electrically isolate the electrical terminal, the sealing pad being thermally coupled to the electrical terminal and to the thermal shunt, the sealing pad having a first thermal conductivity, the thermal shunt having a second thermal conductivity higher than the first thermal conductivity, the sealing pad having a first thermal diffusivity, the thermal shunt having a second thermal diffusivity higher than the first thermal diffusivity, wherein the temperature sensor monitors the temperature of the electrical terminal through the sealing pad and the thermal shunt.

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