Electrical connector assembly with modular cooling features

Abstract

An electrical connector assembly (10) includes a connector housing (16) that defines a cavity (18) in which at least two electrical terminals (12) are interconnected. The connector housing (16) defines an opening configured to receive a cover (100) configured to protect the at least two electrical terminals (12) and thermally manage heat within the cavity (18). The connector housing (16) may be configured to receive one of a plurality of different cover configurations (100). A first cover configuration (100) of the plurality of different cover configurations (100) provides a different mechanism to thermally manage heat within the cavity (18) than a second cover configuration (200) of the plurality of different cover configurations (100).

Description

[0001] This application is a divisional application of patent application No. 202010102378.8, filed on February 19, 2020, entitled "Electrical Connector Assembly with Modular Cooling Features".

[0002] Cross-references to related applications

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 807,267, filed February 19, 2019; U.S. Provisional Patent Application No. 62 / 827,425, filed April 1, 2019; U.S. Provisional Patent Application No. 62 / 897,571, filed September 9, 2019; and U.S. Patent Application No. 16 / 792,929, filed February 18, 2020, the entire disclosure of each of which is incorporated herein by reference. Technical Field

[0004] This invention relates to electrical connector assemblies, and in particular to electrical connector assemblies configured to accommodate a variety of different modular cooling features. Technical Field

[0005] This invention relates to electrical connectors, and more particularly to electrical connectors configured to accommodate a variety of different modular cooling features. Background Technology

[0006] High-power electrical connector assemblies, such as those used in fast-charging systems for electric vehicles, must be designed to handle 90 kilowatts or more of power. Contact resistance between the electrical terminal elements within the connector assembly can cause power loss, which is converted into heat within the assembly. This heat can cause the temperature inside the connector assembly to rise, potentially damaging the assembly if it exceeds its thermal limits.

[0007] The topics discussed in the background section should not be considered prior art simply because they are mentioned there. Similarly, problems mentioned in or related to the topics in the background section should not be assumed to have been previously discovered in the prior art. The topics in the background section represent different solutions, which may themselves be inventions. Summary of the Invention

[0008] According to a first embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening in the cavity configured to receive a cover configured to enclose the cavity, thereby protecting the at least two electrical terminals and thermally managing heat within the cavity.

[0009] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the connector housing is also configured to receive one cover configuration selected from a plurality of different cover configurations. The first cover configuration among the plurality of different cover configurations provides a different mechanism for thermally managing heat within the cavity compared to a second cover configuration among the plurality of different cover configurations.

[0010] In an exemplary embodiment of an electrical connector assembly having one or more features of the preceding paragraph, a first cover configuration of a plurality of different cover configurations is configured to passively manage heat within the cavity, and a second cover configuration of a plurality of different cover configurations is configured to actively manage heat within the cavity.

[0011] In an exemplary embodiment of an electrical connector assembly having one or more features of the preceding paragraph, a first cover configuration of a plurality of different cover configurations is configured to manage heat within the cavity using airflow, and a second cover configuration of a plurality of different cover configurations is configured to manage heat within the cavity using fluid flow.

[0012] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the cover includes at least one thermal management mechanism selected from the group consisting of one or more cooling fins, one or more thermoelectric cooling plates, one or more airflow ports configured to receive airflow, and one or more liquid ports configured to receive liquid coolant flow.

[0013] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the cover includes a coolant tube configured to carry liquid coolant flowing therethrough. The coolant tube has a liquid inlet port and a liquid outlet port.

[0014] In an exemplary embodiment of an electrical connector assembly having one or more features of the preceding paragraph, the aforementioned coolant pipe is characterized by a serpentine path running through the cover.

[0015] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the electrical connector assembly further includes an electrically insulating member in thermal communication with one of at least two electrical terminals. The electrically insulating member includes a coolant channel configured to carry a flow of liquid coolant therethrough. The coolant channel has a liquid inlet port and a liquid outlet port. The cover defines an aperture through which the liquid inlet port and the liquid outlet port exit the cavity.

[0016] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the liquid inlet port and the liquid outlet port are interconnected with the liquid cooling system of the electric vehicle.

[0017] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the inner surface of the cover defines a baffle configured to guide airflow within the cavity.

[0018] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the airflow inlet port is interconnected with the airflow generating device of the electric vehicle.

[0019] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the cover is formed of a thermally conductive material.

[0020] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the cavity is filled with a thermally conductive potting material in thermal communication with the cover.

[0021] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the cavity is filled with a phase change material in thermal communication with the cover.

[0022] According to a second embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening in the cavity. The electrical connector assembly further includes means for enclosing the cavity, thereby protecting the at least two electrical terminals and means for thermally managing heat within the cavity.

[0023] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the means for thermally managing heat within the cavity is an active means for managing heat within the cavity.

[0024] In an exemplary embodiment of the electrical connector assembly having one or more features of the preceding paragraph, the means for thermally managing heat within the cavity is a passive means for managing heat within the cavity.

[0025] According to a third embodiment of the present invention, a method for assembling an electrical connector assembly is provided. The method includes the step of providing a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening in the cavity, said opening being configured to receive a cover configured to enclose the cavity, thereby protecting the at least two electrical terminals and thermally managing heat within the cavity. The method further includes the step of selecting a cover configuration from a plurality of different cover configurations. A first cover configuration among the plurality of different cover configurations provides a different mechanism for thermally managing heat within the cavity compared to a second cover configuration among the plurality of different cover configurations. The method further includes the step of configuring a cover configuration within the opening of the connector housing.

[0026] In an exemplary embodiment having one or more features of the method described in the preceding paragraph, a plurality of different cover configurations include at least one thermal management mechanism selected from the group consisting of cooling fins, thermoelectric cooling plates, airflow ports configured to receive airflow, and liquid ports configured to receive liquid coolant flow. Attached Figure Description

[0027] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0028] Figure 1 This is a front perspective view of an electrical connector assembly according to an embodiment of the present invention;

[0029] Figure 2 yes Figure 1 An exploded perspective rear view of an electrical connector assembly, showing several different cover constructions according to one embodiment of the invention;

[0030] Figure 3 This is according to one embodiment of the present invention. Figure 1 An enlarged perspective rear view of the opening in the connector housing of the electrical connector assembly;

[0031] Figure 4 This is according to one embodiment of the present invention. Figure 1 A perspective left view of the electrical connector assembly, showing a cover with a coolant tube passing through it;

[0032] Figure 5 This is according to one embodiment of the present invention. Figure 4 A three-dimensional right view of the electrical connector assembly;

[0033] Figure 6 This is according to one embodiment of the present invention. Figure 4 A three-dimensional rear view of the electrical connector assembly;

[0034] Figure 7 This is according to one embodiment of the present invention. Figure 6 A three-dimensional bottom view of the lid;

[0035] Figure 8 This is according to one embodiment of the present invention. Figure 4 A schematic diagram showing the interconnection of the coolant pipes of the electrical connector assembly with the cooling system of an electric vehicle;

[0036] Figure 9 According to one embodiment of the present invention, a thermoelectric device is included. Figure 4 Exploded view of the electrical connector assembly;

[0037] Figure 10 This is according to one embodiment of the present invention. Figure 1An exploded view of the electrical connector assembly, showing a component having coolant channels terminated by a pair of liquid ports;

[0038] Figure 11 According to one embodiment of the present invention is Figure 10 A perspective left view of the electrical connector assembly, showing a cover having a pair of liquid ports extending through a hole in the cover;

[0039] Figure 12 This is according to one embodiment of the present invention. Figure 1 A perspective right view of the electrical connector assembly, showing a cover having a pair of airflow ports passing through it;

[0040] Figure 13 This is according to one embodiment of the present invention. Figure 12 A partial exploded view of the electrical connector assembly, showing the interconnection and cover between a pair of terminals;

[0041] Figure 14 This is according to one embodiment of the present invention. Figure 12 A perspective bottom view of the cover of the electrical connector assembly, showing the baffle;

[0042] Figure 15 This is according to one embodiment of the present invention. Figure 1 A perspective rear view of the electrical connector assembly, showing a cover having multiple cooling fins extending from it;

[0043] Figure 16 This is according to one embodiment of the present invention. Figure 15 A cross-sectional view of the electrical connector assembly;

[0044] Figure 17 This is an exploded perspective view of an electrical connector assembly according to one embodiment of the present invention;

[0045] Figure 18 This is according to one embodiment of the present invention. Figure 17 A separate view of the liquid cooling plate of the electrical connector assembly;

[0046] Figure 19 According to one embodiment of the present invention, when conducting 500 amperes... Figure 18 Exploded view of the liquid cooling plate;

[0047] Figure 20 This is according to one embodiment of the present invention. Figure 17 A cross-sectional view of the electrical connector assembly;

[0048] Figure 21 This is according to one embodiment of the present invention. Figure 17Temperature diagram of each component and electrical connector assembly when conducting 500 amperes;

[0049] Figure 22 This is according to one embodiment of the present invention. Figure 17 Temperature diagram of each component's electrical connector assembly when conducting 600 amperes;

[0050] Figure 23 Compared to an alternative cooling system according to one embodiment of the present invention, Figure 17 Temperature diagrams of the electrical connector assemblies for each component;

[0051] Figure 24A This is according to one embodiment of the present invention. Figure 18 A top view of the temperature gradient of the liquid cooling plate; and

[0052] Figure 24B This is according to one embodiment of the present invention. Figure 18 A top view of the temperature gradient of the liquid cooling plate. Detailed Implementation

[0053] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. Numerous specific details are set forth in the following detailed description to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments can be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks have not been described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0054] Figures 1 to 16 A non-limiting example of an electrical connector assembly embodying the features of the present invention is shown. The illustrated example of the electrical connector assembly (hereinafter referred to as Assembly 10) serves as a charging port for an electric vehicle. As used herein, the term "electric vehicle" can refer to a purely electric vehicle driven solely by an electric motor or a hybrid vehicle driven by a combination of an electric motor and an internal combustion engine. As shown, Assembly 10 conforms to the Society of Automotive Engineers (SAE) specification J1772 Combined Charging System. Figure 1 As shown, component 10 has a combination of electrical terminals 12 for low-power alternating current (AC) charging of the vehicle battery and a pair of DC terminals 14 for high-power direct current (DC) charging of the vehicle battery. Other charging port standards, such as those published by the Japan Electric Vehicle Charging Association (CHAdeMO), use a similar pair of DC terminals.

[0055] like Figure 2 As shown, the assembly includes a connector housing (hereinafter referred to as housing 16) that defines a cavity 18 in which a DC terminal 14 is disposed. (See reference...) Figure 3 , Figure 8 and Figure 16 It is understood that the DC terminal 14 is interconnected with the cable terminal 20 of the insulated wires and cables that connect the assembly 10 to the battery pack 22 of the vehicle. The DC terminal 14 carries a power level of 90 kW or higher, which can cause the temperature inside the cavity 18 to rise during battery charging operation. The assembly 10 also includes a cover configured to enclose the cavity 18, thereby protecting the DC terminal 14 and the cable terminal 20. The cover is also configured to thermally manage the heat inside the cavity 18 by removing heat energy from the cavity 18.

[0056] The housing 16 is designed to receive and accommodate multiple different cover structures 100, 200, 300, 400, and 500. Each cover structure 100, 200, 300, 400, and 500 uses a different thermal management mechanism to thermally manage the heat within the cavity 18. The cover structures 100, 200, 300, 400, and 500 include: active thermal management (processing) mechanisms, such as one or more liquid port ports configured to receive a flow of liquid coolant within the cavity 18, one or more thermoelectric cooling plates, and / or one or more airflow ports configured to receive an airflow within the cavity 18; and / or passive thermal management (processing) mechanisms, such as one or more cooling fins 502 extending from the cover 500.

[0057] In such Figures 4-8 In the first cover configuration 100 shown with an active thermal management mechanism, the cover 100 includes an active thermal management system characterized as an enclosed coolant pipe 102 configured to carry liquid coolant flowing through the cover 100. The coolant pipe has a liquid inlet 104 and a liquid outlet 106 interconnected with a vehicle cooling system 24, such as a liquid cooling system for cooling a vehicle battery pack 22 and / or vehicle power electronics equipment. Figure 8 As shown. The vehicle's cooling system 24 includes a pump or other fluid movement device that directs liquid coolant through coolant lines. Figure 4 , Figure 6 and Figure 7 As shown, the coolant pipe passes through the cover in a serpentine path, thereby increasing the length of the coolant pipe and increasing the amount of heat energy that the coolant flowing through the cover can absorb from the cavity 18. The cover can preferably be formed on a material with high thermal conductivity, such as an aluminum or copper-based material, to provide sufficient heat transfer between the cavity 18 and the liquid coolant. Alternatively, the cover can be formed from a thermally conductive polymer.

[0058] according to Figure 9The second cover configuration 200 shown has an active thermal management mechanism. Cover 200 includes a thermoelectric device 202 that actively cools the cavity 18 using the Peltier effect. A voltage is applied to the thermoelectric device 202, causing the side 204 facing inwards from the cavity 18 to be cooled, while the other side 206 facing outwards is heated due to the heat removed from the cooled side 204. The thermoelectric device 202 can serve as the sole thermal management mechanism in assembly 10, or in combination with any of the described cover configurations 100, 300, 400, and 500.

[0059] exist Figure 10 and Figure 11 In the third cover configuration 300 with active thermal management shown, component 10 further includes an electrically insulating terminal position guarantee (TPA) member 302, which encloses a portion of the DC terminal 14 and is in thermal communication with it. The TPA member 302 includes a coolant passage configured to carry liquid coolant flowing through it. The TPA member 302 provides the benefit of directly removing heat from the DC terminal 14, one of the primary heat sources within the cavity 18. The coolant passage has a liquid inlet port 304 and a liquid outlet port 306 interconnected with a vehicle cooling system 24, such as a liquid cooling system for cooling a vehicle battery pack 22 and / or vehicle power electronics, similar to... Figure 8 As shown. The vehicle's cooling system 24 includes a pump that flows liquid coolant through coolant pipes. A cover 300 defines an opening 308 through which a liquid inlet port 304 and a liquid outlet port 306 exit the cavity 18. In an alternative embodiment, the liquid inlet port 304 and the liquid outlet port 306 may be interconnected with a cooling system dedicated to the cooling assembly 10.

[0060] Figures 12-14 The diagram illustrates a fourth cover configuration 400 with an active thermal management mechanism. Cover 400 is in pneumatic and thermal communication with cavity 18. Cover 400 includes: an airflow inlet port 402 through which airflow at vehicle ambient temperature enters cavity 18; and an airflow outlet port 404 through which airflow exits cavity 18. Airflow inlet port 402 is interconnected with an airflow generating device of the vehicle, such as a ducted fan. Airflow through cavity 18 removes some heat energy from cavity 18, thereby reducing the temperature within cavity 18. The inner surface of cover 400 defines a baffle 406 configured to guide airflow within cavity 18. Baffle 406 also includes an arcuate surface 408 that facilitates the generation of turbulent airflow within cavity 18. Cover 400 and baffle 406 may preferably be formed of a dielectric polymer material to prevent contact between any terminals within cavity 18 and baffle 406 that could cause a short circuit.

[0061] Figure 15 and Figure 16 A fifth cover configuration 500 with a passive thermal management mechanism is shown. The cover 500 is formed of a thermally conductive material such as an aluminum or copper-based material and has a plurality of parallel cooling fins 502 extending from the cover 500. Alternatively, the cover 500 may be formed of a thermally conductive polymer. In this configuration, the cavity 18 is filled with a dielectric thermally conductive potting material 504, such as an epoxy or silicone-based material in thermal communication with the cover 500. A silicone thermal grease may be applied between the inner surface 506 of the cover 500 and the potting material 504.

[0062] In an alternative embodiment, cavity 18 may be filled with a dielectric phase change material (PCM). PCM is a substance with a high heat of fusion, such as paraffin or esters. PCM melts and solidifies at a nearly constant temperature, storing and releasing a large amount of heat energy. When electricity flows through terminals 14, 20, heat is absorbed in cavity 18 as PCM gradually changes from a solid to a liquid state, and then when electricity ceases to flow through terminals 14, 20, heat is gradually released through cover 500 as PCM changes from a liquid to a solid state.

[0063] The potting material 504 and phase change material used must have a breakdown voltage higher than the charging voltage of the vehicle charging system to which component 10 is connected.

[0064] Alternative implementations of the assembly 10, which combines the various elements described above, are conceivable. For example, the heat-sealing material 504 or PCM of the fifth cover structure 500 may be incorporated into the first cover structure 100, the second cover structure 200, or the third cover structure 300. In alternative implementations, the cooling fins 502 of the fifth cover structure 500 may be integrated into the first cover structure 100, the second cover structure 200, the third cover structure 300, or the fourth cover structure 400.

[0065] exist Figures 17 to 24B In the sixth cover structure 600 with an active thermal management mechanism shown, the cover 600 is in close contact with the DC terminal 14 and is thermally connected to the DC terminal 14 inside the cavity 18. Figure 18 As shown, cover 600 includes a top cover 626 having a liquid inlet port 604 and a liquid outlet port 606, which are interconnected with a vehicle cooling system 24, such as a liquid cooling system for cooling a vehicle battery pack 22 and / or vehicle power electronics equipment, similar to... Figure 8As shown. The vehicle's cooling system 24 includes a pump that flows liquid coolant through coolant pipes. In an alternative embodiment, the liquid inlet port 604 and the liquid outlet port 606 may be interconnected with a cooling system dedicated to the cooling assembly 10. The top cover 626 may advantageously be formed of a polymer material to reduce the weight of the top cover 626 and to provide better electrical isolation compared to a metal top cover 626.

[0066] like Figure 19 As shown, the cover 600 also includes a bottom cover 628, which defines a coolant channel having a plurality of cooling fins 630, the cooling fins 630 defining a plurality of coolant channels 632, such as... Figure 20 Ideally, as shown, the liquid coolant flows through this channel 632 from the liquid inlet port 604 to the liquid outlet port 606. The bottom cover 628 can advantageously be formed of a metallic material to optimize heat transfer between the cooling fins 630 and the liquid coolant. Figure 20 As shown, the bottom cover 628 is in close contact with the DC terminal 14. The bottom cover 628 also includes: a dielectric thermal interface material layer 634 in direct contact with the DC terminal 14, and an additional dielectric material layer 636 between the dielectric thermal interface material layer 634 and the coolant channel 632. The dielectric thermal interface material layer 634 and the additional dielectric material layer 636 provide stable electrical isolation between the DC terminal 14 and the metal bottom cover 628.

[0067] The cover 600 also includes a main coolant seal 638 between the top cover 626 and the bottom cover 628, and an auxiliary seal 640 between the cover 600 and the cavity 18 to ensure that liquid coolant does not enter the cavity 18. Liquid coolant entering the cavity 18 may cause a short circuit between the DC terminals 14.

[0068] The experimental results of the cooling performance of Gaussian 600 are as follows: Figures 21-2 As shown in Figure 4. Figure 21 The temperature 642 of one of the electrical terminals 12, the temperature 644 of one of the terminals 14, and the inlet coolant temperature 646 are shown when component 10 is operating at a current of 500 amps. Figure 22 The diagram shows the temperatures of one of the electrical terminals 12 (648°C), one of the terminals 14 (650°C), and the inlet coolant temperature (652°C) when component 10 operates at a current of 500 amps. Figure 23 The diagram shows a comparison of the following when the assembly 10 is under similar operating conditions: a passively cooled cover, a temperature of 656 in one of the terminals 14 such as cover 100, and a temperature of 654 in one of the electrical terminals 12, with a temperature of 658 in one of the electrical terminals 12, a temperature of 660 in one of the terminals 14, and an inlet coolant temperature of 662. Figure 24AThe thermal gradient between the liquid outlet port 606 and the liquid inlet port 604 of the top cover 626 is shown when the power dissipation is 100 watts. Figure 24B The thermal gradient between terminal 14 and top cover 626 is shown when the power dissipation is 100 watts.

[0069] Alternative implementations that include the features of the several implementations described above are conceivable. Table 1 below describes at least some possible combinations.

[0070] Table 1 - Cover Construction

[0071] type Cavity contents Cover construction Add-ons Passive type 1 still air polymer none Passive type 2 Hot potting materials Thermally conductive polymers none Passive type 3 Hot potting materials metal of peripheral fins none Passive type 4 Phase change materials Thermally conductive polymers none Passive type 5 Phase change materials metal of peripheral fins none Passive type 6 still air Thermally conductive polymers thermal interface materials Passive type 7 still air metal of peripheral fins thermal interface materials Active type 1 flowing air Polymer with ports and baffles none Active type 2 Hot potting materials Cooling plate none Active Type 3 Hot potting materials Cooling plate Thermoelectric device Active Type 4 still air Through slot Cooled polymer terminal position protection device Active Type 5 still air Through slot Cooled metal-isolated terminal position protection device Active Type 6 still air Cooling plate thermal interface materials Active 7 still air Cooling plate with internal fins Thermal interface material layer, insulation layer, primary and secondary seals

[0072] Although the example of the electrical connector assembly 10 shown is a vehicle charging port, other embodiments of the invention are conceivable for use with many other types of electrical connector assemblies.

[0073] Therefore, an electrical connector assembly 10 is provided. Assembly 10 provides the temperature benefits of thermal management. Assembly 10 also provides a common housing 16 that accepts cover configurations 100, 200, 300, 400, 500, and 600 with different thermal management mechanisms, allowing assembly 10 to be customized for specific applications based on heat load and cooling infrastructure, such as the availability of liquid coolant and airflow availability.

[0074] While the invention has been described according to preferred embodiments, it is not intended to be limited thereto, but rather to be limited only by the scope set forth in the following claims. For example, the embodiments described above (and / or aspects thereof) may be used in combination with each other. Furthermore, various modifications may be made to adapt specific circumstances or materials to the teachings of the invention without departing from its main scope. The dimensions, 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 merely prototypical embodiments.

[0075] Having read the above description, various other embodiments and variations within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the invention is defined only by the appended claims and the full scope of their equivalents.

[0076] As used herein, “one or more” includes functions performed by a single element, functions performed by more than one element in a distributed manner, functions performed by a single element, functions performed by several elements, or combinations thereof.

[0077] It should also be understood that although the terms first, second, etc., are used in some cases to describe various elements herein, 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 embodiments described above, 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.

[0078] The terminology used in the description of the various embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the various embodiments described, 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” includes any and all combinations of one or more of the associated listed items. It should also be understood that the term “comprising” as used herein specifically means the presence of the stated features, integrals, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof.

[0079] As used herein, the term "if" may optionally be interpreted as "when," "in response to a decision," or "in response to a detection," depending on the context. Similarly, the phrase "if a decision" or "if a condition or event described above is detected" may optionally be interpreted as "when a decision is made," "in response to a decision," "when [the aforementioned condition or event] is detected," or "in response to the detection of [the aforementioned condition or event]," depending on the context.

[0080] Furthermore, while this document may use terms of regulation or orientation, these elements should not be limited by such terms. Unless otherwise stated, all regulations or orientations are for the purpose of distinguishing one element from another and, unless otherwise stated, do not indicate any particular order, sequence of operations, direction, or orientation.

Claims

1. An electrical connector assembly, comprising: A connector housing that defines a cavity from which a pair of electrical terminals extend and are partially disposed; as well as A cover configured to enclose the cavity, thereby protecting the paired electrical terminals and thermally managing heat within the cavity, wherein the cover has an integral thermal management mechanism including one or more liquid ports configured to receive a flow of liquid coolant.

2. The electrical connector assembly as claimed in claim 1, characterized in that, The cover includes a coolant tube having a liquid inlet port and a liquid outlet port, configured to carry the liquid coolant flow therethrough.

3. The electrical connector assembly as claimed in claim 1, characterized in that, The cover is formed of an electrically insulating material.

4. The electrical connector assembly as claimed in claim 1, characterized in that, The cover is formed of a thermally conductive polymer.

5. The electrical connector assembly as claimed in claim 1, characterized in that, The cover is made of a thermally conductive material.

6. The electrical connector assembly as claimed in claim 1, characterized in that, The cavity is filled with a thermally conductive potting material that is in thermal communication with the cover.

7. The electrical connector assembly as claimed in claim 1, characterized in that, The cavity is filled with a phase change material that is in thermal communication with the cover.

8. An electrical connector assembly, comprising: A connector housing defining a cavity in which a pair of electrical terminals are disposed; as well as A cover configured to enclose the cavity, thereby protecting the paired electrical terminals and thermally managing heat within the cavity, wherein the cover has a thermal management mechanism including one or more liquid ports configured to receive a flow of liquid coolant, wherein the cover includes a coolant tube having a liquid inlet port and a liquid outlet port configured to carry the flow of liquid coolant therethrough, and wherein the coolant tube is characterized by following a serpentine path through the cover.

9. An electrical connector assembly, comprising: A connector housing that defines a cavity in which a pair of electrical terminals are disposed; as well as A cover configured to enclose the cavity, thereby protecting the paired electrical terminals and thermally managing heat within the cavity, wherein the cover has a thermal management mechanism including one or more liquid ports configured to receive a flow of liquid coolant, wherein the cover includes a top cover having a liquid inlet port and a liquid outlet port and a bottom cover defining a coolant passage.

10. The electrical connector assembly as claimed in claim 9, characterized in that, The top cover is made of polymer material.

11. The electrical connector assembly as claimed in claim 9, characterized in that, The bottom cover is made of metal.

12. The electrical connector assembly as claimed in claim 9, characterized in that, It also includes a main coolant seal located between the top cover and the bottom cover.

13. The electrical connector assembly as claimed in claim 9, characterized in that, It also includes an auxiliary seal located between the cover and the cavity.

14. The electrical connector assembly as claimed in claim 9, characterized in that, The liquid inlet port and the liquid outlet port are interconnected with the liquid cooling system of the electric vehicle.

15. The electrical connector assembly as claimed in claim 9, characterized in that, The bottom cover includes a plurality of cooling fins that define a plurality of coolant channels within the coolant channels.

16. The electrical connector assembly as claimed in claim 15, characterized in that, It also includes a dielectric thermal interface material layer that is in direct contact with the paired electrical terminals, wherein the dielectric thermal interface material layer is disposed between the bottom cover and the paired electrical terminals.

17. The electrical connector assembly as claimed in claim 16, characterized in that, The dielectric thermal interface material layer is in direct contact with the bottom cover.

18. The electrical connector assembly as claimed in claim 16, characterized in that, It also includes an additional dielectric material layer disposed between the dielectric thermal interface material layer and the plurality of coolant channels.

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