Temperature Sensor Assembly Thermal Shunt for Electrical Connector
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Solution Overview
Problem
Existing temperature sensor assemblies for electrical connectors, such as those in charging inlet assemblies for electric vehicles, face challenges with thermal resistance and time lag due to the use of silicone rubber pads, which introduce significant errors in temperature measurement.
Innovation Solution
A temperature sensor assembly with a thermal shunt having higher thermal conductivity than the sealing pad, providing a direct and efficient thermal path for temperature monitoring, while maintaining electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silicone rubber pad is used to thermally couple the temperature sensor to the terminal, then electrical isolation is achieved, but thermal resistance increases causing significant measurement error and time lag
Solution Approach 1:
A thermal shunt made of highly thermally conductive material (such as aluminum or copper) is introduced as an intermediary component between the terminal and the temperature sensor. The thermal shunt has high thermal conductivity (k ≥ 100 W/m·K) to rapidly conduct heat from the terminal to the sensor, while the silicone rubber pad maintains electrical isolation. This mediator resolves the contradiction by providing a thermal pathway that minimizes measurement error and time lag while preserving electrical isolation through the pad.
Solution Approach 2:
The thermal coupling path is segmented into distinct functional zones: the silicone rubber pad segment provides electrical isolation, while the thermal shunt segment provides high-speed heat conduction. This segmentation allows each component to optimize its specific function without compromising the other, achieving both reliable electrical isolation and precise temperature measurement.
2Reliability
If a silicone rubber pad is used to thermally couple the temperature sensor to the terminal, then electrical isolation is achieved, but response time increases due to thermal capacitance
Solution Approach 1:
The thermal shunt acts as a thermal mediator with high conductivity and low thermal mass, rapidly transferring heat from the terminal to the temperature sensor. This intermediary component reduces the thermal time constant of the system, enabling fast response time while the silicone rubber pad maintains electrical isolation throughout the process.
Solution Approach 2:
The thermal conductivity parameter of the coupling path is dramatically changed by introducing the thermal shunt material (k ≥ 100 W/m·K) compared to the silicone rubber pad alone. This parameter change reduces thermal resistance and thermal time constant, achieving sub-second response times while preserving electrical isolation properties of the pad.
3Productivity
If higher current is transmitted through the terminals for charging, then charging speed increases, but temperature increases causing potential damage to components
Solution Approach 1:
The temperature sensor assembly provides real-time feedback on terminal temperature to the charging control system. This feedback enables dynamic adjustment of charging current based on actual thermal conditions, allowing maximum charging speed to be achieved while preventing temperature from exceeding safe thresholds that would damage components.
Solution Approach 2:
The temperature sensor is pre-positioned in thermal communication with the terminal through the thermal shunt, enabling early detection of temperature rise before damage occurs. This preliminary monitoring allows the charging system to take preventive action by reducing current or interrupting charging before critical temperature damage can happen.
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 configuration reduces thermal resistance and response time, enabling accurate and rapid temperature sensing, thus preventing damage to electrical components during high-current charging.
Implementation Method 1
The thermal shunt has a second thermal conductivity 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.
Implementation Method 2
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.
Data Source
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AI summary
An electrical connector (102) including a housing (110) having a terminal channel (116) with a power terminal (114) in the terminal channel. The electrical connector includes a temperature sensor assembly (130) positioned in the chamber (140). The temperature sensor assembly includes a sealing pad (300) holding the power terminal and a thermal shunt (302) held by the sealing pad. A temperature sensor (304) is coupled to the thermal shunt. The sealing pad is electrically insulative and has a terminal opening (316) receiving the power terminal. The sealing pad is thermally coupled to the power terminal and thermally coupled to the thermal shunt. The thermal shunt has a thermal conductivity higher than a thermal conductivity of the sealing pad. The temperature sensor monitors the temperature of the power terminal through a thermal path defined by the sealing pad and the thermal shunt.