Connector Assembly Temperature Sensor Interference Fit
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Solution Overview
Problem
Current high current connectors in energy storage systems lack integrated temperature sensors, leading to inaccurate temperature monitoring, complex installation processes, and increased risk of fires due to high temperatures, as well as susceptibility to thermal interference from non-target components.
Innovation Solution
A connector assembly with a temperature sensor that includes a shell with an interference fit portion and a temperature sensing element, allowing for precise temperature detection of conductive terminals while minimizing thermal interference from other components, integrated directly into the connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are added to high current connectors, then temperature monitoring capability is improved, but device complexity and installation cost increase
Solution Approach 1:
The temperature sensor is integrated directly into the connector housing, merging the temperature monitoring function with the existing connector structure. This eliminates the need for separate mounting brackets, spring clips, and locks, thereby reducing device complexity while maintaining temperature monitoring capability
Solution Approach 2:
The connector housing itself serves as the mounting structure for the temperature sensor, with the sensor slot and interference fit portion providing self-contained installation features. This self-service approach eliminates the need for additional fastening components and simplifies the overall structure
2Reliability
If additional fixing parts are used to install temperature sensor, then fixation reliability is improved, but device complexity and cost increase
Solution Approach 1:
The fixing function is extracted from separate components (brackets, spring clips, locks) and integrated directly into the connector housing structure through the sensor slot and interference fit portion. This extraction simplifies the system by eliminating unnecessary intermediate components while maintaining reliable fixation
Solution Approach 2:
The interference fit portion acts as an intermediary mechanism between the temperature sensor and connector housing, providing reliable mechanical connection through friction and geometric interlocking without requiring additional fastening parts
3Measurement precision
If temperature sensor is placed close to conductive terminal, then temperature detection accuracy is improved, but thermal interference from other components increases
Solution Approach 1:
The sensor slot is designed with specific local characteristics: the first sidewall is in thermal contact with the conductive terminal for accurate temperature sensing, while the second sidewall includes an interference fit portion that creates thermal isolation from other components. This local differentiation allows the sensor to be close to the target while avoiding thermal interference
4Ease of manufacture
If integrated temperature sensor design is used, then manufacturing cost is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The sensor slot and interference fit portion are pre-designed with precise dimensions and tolerances in the connector housing manufacturing process. This preliminary action ensures that the temperature sensor will fit correctly and function properly without requiring additional precision machining or adjustment steps later
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides reliable, accurate, and cost-effective real-time temperature monitoring of high current connectors, reducing the risk of fires and improving the safety and efficiency of energy storage systems.
Implementation Method 1
The interference fit portion forms an interference fit with an inner wall of the sensor slot
Implementation Method 2
a first sidewall in thermal contact with the conductive terminal
Data Source
AI summary
A connector assembly comprises a connector and a temperature sensor. The connector includes a connector housing formed with a sensor slot, and a conductive terminal arranged in the connector housing. The temperature sensor is inserted into the sensor slot and is adapted to detect a temperature of the conductive terminal in the connector. The sensor includes a shell having a first sidewall in thermal contact with the conductive terminal, and a second sidewall opposite to the first sidewall. The second sidewall defines an interference fit portion extending from an outer surface thereof. The interference fit portion forms an interference fit with an inner wall of the sensor slot. A remaining portion of the second sidewall except for the interference fit portion is separated from the inner wall of the sensor slot by a predetermined gap. The sensor further includes a temperature sensing element arranged in the shell.