阅读说明：本技术 具有模块化冷却特征的电连接器组件 (Electrical connector assembly with modular cooling features ) 是由 N·A·杜斯 T·马修斯 H·路易 W·C·洛维茨 P·J·里迪 于 2020-02-19 设计创作，主要内容包括：一种电连接器组件(10),上述电连接器组件(10)包括连接器壳体(16),上述连接器壳体(16)限定了至少两个电气端子(12)互连在其中的腔体(18)。连接器壳体(16)限定了构造成接纳盖(100)的开口,上述盖(100)构造成保护至少两个电气端子(12)并在腔体(18)内热管理热量。连接器壳体(16)可以构造成接纳多个不同盖构造(100)中的一个盖(100)构造。与多个不同盖构造(100)中的第二盖构造(200)相比,多个不同盖构造(100)中的第一盖构造(100)提供了不同的机构来热管理腔体(18)内的热量。(An electrical connector assembly (10), the electrical connector assembly (10) comprising a connector housing (16), the connector housing (16) defining 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), the 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 construction (100) of the plurality of different cover constructions (100) provides a different mechanism to thermally manage heat within the cavity (18) than a second cover construction (200) of the plurality of different cover constructions (100).)

1. An electrical connector assembly (10) comprising:

a connector housing (16), the connector housing (16) defining a cavity (18) in which at least two electrical terminals (12) are interconnected, wherein the connector housing (16) defines an opening of the cavity (18) configured to receive a cover (100) configured to enclose the cavity (18) to protect the at least two electrical terminals (12) and thermally manage heat within the cavity (18).

2. The electrical connector assembly (10) of claim 1, wherein the opening in the connector housing (16) is further configured,

receiving a selected one of a plurality of different lid configurations (100), wherein a first lid configuration (100) of the plurality of different lid configurations provides a different mechanism to thermally manage heat within the cavity (18) than a second lid configuration (200) of the plurality of different lid configurations.

3. The electrical connector assembly (10) of claim 2, wherein the first cover configuration (500) in the plurality of different cover configurations is configured to passively manage heat within the cavity (18), and the second cover configuration (100, 200, 300, 400, 500, 600) in the plurality of different cover configurations is configured to actively manage heat within the cavity (18).

4. The electrical connector assembly (10) of claim 2, wherein the first cover configuration (300, 400) of the plurality of different cover configurations is configured to manage heat within the cavity (18) with airflow, and the second cover configuration (100, 200, 600) of the plurality of different cover configurations is configured to manage heat within the cavity (18) with fluid flow.

5. The electrical connector assembly (10) of claim 1, wherein the cover (100, 200, 300, 400, 600) includes at least one thermal management mechanism selected from the group consisting of:

one or more cooling fins (502)

One or more thermoelectric cooling plates (202);

one or more airflow ports (402, 404), the airflow ports (402, 404) configured to receive an airflow; and

one or more liquid ports (104, 106), the liquid ports (104, 106) configured to receive a flow of liquid coolant.

6. The electrical connector assembly (10) of claim 5, wherein the cover (100) includes a coolant tube (102), the coolant tube (102) being configured to carry the liquid coolant flowing therethrough, the coolant tube (102) having a liquid inlet port (104) and a liquid outlet port (106).

7. The electrical connector assembly (10) of claim 6, wherein the coolant tube (102) is characterized by traversing the cap (100) along a serpentine path.

8. The electrical connector assembly (10) of claim 7, wherein the electrical connector assembly (10) further comprises an electrically insulative member (302) in thermal communication with one of the at least two electrical terminals (12), wherein the electrically insulative member (302) comprises a coolant channel configured to carry a flow of liquid coolant therethrough, the coolant channel having the liquid inlet port (304) and the liquid outlet port (306), and wherein the cover (300) defines an aperture (308), the liquid inlet port (304) and the liquid outlet port (306) exiting the cavity (18) through the aperture (308).

9. The electrical connector assembly (10) of claim 8, wherein the liquid inlet port (304) and the liquid outlet port (306) are interconnected with a liquid cooling system of an electric vehicle.

10. The electrical connector assembly (10) of claim 1, wherein the cover (400) is in pneumatic and thermal communication with the cavity (18) and comprises: a gas flow inlet port (402) through which gas flow enters the cavity (18); and an airflow outlet port (404), through which airflow is discharged from the cavity (18).

11. The electrical connector assembly (10) of claim 10, wherein an inner surface of the cover (400) defines a baffle (406), the baffle (406) being configured to direct the flow of air within the cavity (18).

12. The electrical connector assembly (10) of claim 10, wherein the airflow inlet (402) is interconnected with an airflow generating device of an electric vehicle.

13. The electrical connector assembly (10) of claim 1, wherein the cover (500) is formed of a thermally conductive material.

14. The electrical connector assembly (10) of claim 13, wherein the cavity (18) is filled with a thermally conductive potting material (504) in thermal communication with the cover (500).

15. The electrical connector assembly (10) of claim 13, wherein the cavity (18) is filled with a phase change material in thermal communication with the cover (500).

16. A method of assembling an electrical connector assembly (10), comprising the steps of:

providing a connector housing (16), the connector housing (16) defining a cavity (18) in which at least two electrical terminals (12) are interconnected, wherein the connector housing (16) defines an opening of the cavity (18) configured to receive a cover (100) configured to enclose the cavity (18) to protect the at least two electrical terminals (12) and thermally manage heat within the cavity (18); and

selecting one lid (100) configuration from a plurality of different lid configurations, wherein a first lid configuration (100) in the plurality of different lid configurations provides a different mechanism to thermally manage heat within the cavity (18) than a second lid configuration (200) in the plurality of different lid configurations; and

the selected cover configuration is disposed within an opening of the connector housing (16).

17. The method of claim 16, wherein the plurality of different lid configurations includes at least one thermal management mechanism selected from the group consisting of:

cooling fins (502);

a thermoelectric cooling plate (202);

an airflow port (402, 404), the airflow port (402, 404) configured to receive an airflow; and

a liquid port (104, 106, 304, 306, 604, 606), the liquid port (104, 106, 304, 306, 604, 606) configured to receive a flow of liquid coolant.

Technical Field

The present invention relates to electrical connector assemblies, and more particularly to electrical connector assemblies configured to accommodate a variety of different modular cooling features.

Background

High power electrical connector assemblies, such as those used in rapid charging systems for electric vehicles, must be designed to be able to carry 90 kilowatts or more of electrical power. Contact resistance between electrical terminal elements in an electrical connector assembly may result in power losses that are converted to thermal energy within the connector assembly. This heat energy can cause a temperature rise within the electrical connector assembly, which can damage the assembly if the thermal limit is exceeded.

The subject matter discussed in the background section should not be admitted to be prior art merely by virtue of its mention in the background section. Similarly, problems mentioned in the background section or related to the subject matter of the background section should not be considered as having been previously discovered in the prior art. The subject matter in the background section merely represents different scenarios that may themselves be inventions.

Disclosure of Invention

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 of 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.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the connector housing is further configured to receive a selected one of a plurality of different cover configurations. A first lid construction of the plurality of different lid constructions provides a different mechanism to thermally manage heat within the cavity as compared to a second lid construction of the plurality of different lid constructions.

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

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, a first cover configuration of the plurality of different cover configurations is configured to manage heat within the cavity with an air flow and a second cover configuration of the plurality of different cover configurations is configured to manage heat within the cavity with a fluid flow.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous 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 an airflow, and one or more liquid ports configured to receive a flow of liquid coolant.

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

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the coolant tube is characterized by a serpentine path through the cover.

In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the electrical connector assembly further includes an electrically insulative member in thermal communication with one of the 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 cap defines an aperture through which the liquid inlet port and the liquid outlet port exit the cavity.

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

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

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

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

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

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

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 to the cavity. The electrical connector assembly further comprises means for enclosing the cavity, thereby protecting the at least two electrical terminals and means for thermally managing heat within the cavity.

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

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

According to a third embodiment of the present invention, a method of 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 of 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. The method also provides the step of selecting one of a plurality of different lid configurations. A first lid construction of the plurality of different lid constructions provides a different mechanism to thermally manage heat within the cavity as compared to a second lid construction of the plurality of different lid constructions. The method also provides the step of disposing a cover structure within the opening of the connector housing.

In an exemplary embodiment having one or more features of the method of the previous paragraph, the plurality of different lid configurations includes at least one thermal management mechanism selected from the group consisting of a cooling fin, a thermoelectric cooling plate, an air flow port configured to receive an air flow, and a liquid port configured to receive a flow of liquid coolant.

Drawings

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

fig. 1 is a front perspective view of an electrical connector assembly according to one embodiment of the present invention;

FIG. 2 is an exploded rear perspective view of the electrical connector assembly of FIG. 1 illustrating a plurality of different cover configurations in accordance with one embodiment of the present invention;

fig. 3 is an enlarged perspective rear view of an opening in a connector housing of the electrical connector assembly of fig. 1, in accordance with one embodiment of the present invention;

fig. 4 is a perspective left side view of the electrical connector assembly of fig. 1 showing the cover with a coolant tube passing through the cover in accordance with one embodiment of the present invention;

fig. 5 is a right side perspective view of the electrical connector assembly of fig. 4 according to one embodiment of the present invention;

fig. 6 is a perspective rear view of the electrical connector assembly of fig. 4 according to one embodiment of the present invention;

FIG. 7 is a bottom perspective view of the cover of FIG. 6, according to one embodiment of the present invention;

fig. 8 is a schematic illustration of the coolant tube of the electrical connector assembly of fig. 4 interconnected with a cooling system of an electric vehicle, in accordance with an embodiment of the present invention;

FIG. 9 is an exploded view of the electrical connector assembly of FIG. 4 including a thermoelectric device according to one embodiment of the present invention;

fig. 10 is an exploded view of the electrical connector assembly of fig. 1 showing a member having a coolant channel terminated by a pair of liquid ports, according to one embodiment of the present invention;

fig. 11 is a perspective left side view of the electrical connector assembly of fig. 10 showing the cover having a pair of liquid ports extending through apertures in the cover in accordance with one embodiment of the present invention;

fig. 12 is a perspective right side view of the electrical connector assembly of fig. 1 showing the cover having a pair of airflow ports therethrough in accordance with one embodiment of the present invention;

fig. 13 is a partial exploded view of the electrical connector assembly of fig. 12 showing the interconnection and cover between a pair of terminals in accordance with one embodiment of the present invention;

fig. 14 is a bottom perspective view of the cover of the electrical connector assembly of fig. 12 showing a baffle in accordance with one embodiment of the present invention;

fig. 15 is a perspective rear view of the electrical connector assembly of fig. 1 showing the cover having a plurality of cooling fins extending therefrom in accordance with one embodiment of the present invention;

fig. 16 is a cross-sectional view of the electrical connector assembly of fig. 15, according to one embodiment of the present invention;

fig. 17 is an exploded perspective view of an electrical connector assembly according to one embodiment of the present invention;

fig. 18 is an isolated view of a liquid cooled plate of the electrical connector assembly of fig. 17, in accordance with an embodiment of the present invention;

FIG. 19 is an exploded view of the liquid cooled plate of FIG. 18 when conducting 500 amps according to one embodiment of the invention;

fig. 20 is a cross-sectional view of the electrical connector assembly of fig. 17, in accordance with one embodiment of the present invention;

figure 21 is a temperature profile of the respective component electrical connector assembly of figure 17 at 500 amps conduction, in accordance with one embodiment of the present invention;

FIG. 22 is a temperature profile of the various component electrical connector assemblies of FIG. 17 conducting 600 amps in accordance with one embodiment of the present invention;

FIG. 23 is a temperature map of the various component electrical connector assemblies of FIG. 17 as compared to an alternative cooling system according to an embodiment of the present invention;

FIG. 24A is a temperature gradient top view of the liquid-cooled plate of FIG. 18, according to one embodiment of the invention; and

FIG. 24B is a bottom temperature gradient view of the liquid cooling plate of FIG. 18, according to one embodiment of the present invention.

Detailed Description

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 various described embodiments. It will be apparent, however, to one skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail as not to unnecessarily obscure aspects of the embodiments.

Fig. 1-16 illustrate non-limiting examples of electrical connector assemblies embodying features of the invention. The illustrated example of an electrical connector assembly (hereinafter assembly 10) is used as a charging port for an electric vehicle. As used herein, the term "electric vehicle" may refer to a pure electric vehicle driven by an electric motor alone or a hybrid vehicle driven by an electric motor in combination with an internal combustion engine. As shown, the assembly 10 conforms to the american Society of Automotive Engineers (SAE) specification J1772 combination charging system. As shown in fig. 1, the assembly 10 has a combination of electrical terminals 12 for low power Alternating Current (AC) charging of the vehicle battery and a pair of direct current terminals 14 for high power Direct Current (DC) charging of the vehicle battery. Other charging port standards, such as those promulgated by the japan electric vehicle charging association (CHAdeMO), use a similar pair of dc terminals.

As shown in fig. 2, the assembly includes a connector housing (hereinafter referred to as housing 16) defining a cavity 18 in which the dc terminals 14 are disposed. As can be seen with reference to fig. 3, 8 and 16, the dc terminal 14 is interconnected with a cable terminal 20 of an insulated wire cable that connects the assembly 10 to a battery pack 22 of a vehicle. The dc terminals 14 carry power levels of 90 kilowatts or more, which can cause the temperature within the cavity 18 to increase during battery charging operations. The assembly 10 also includes a cover configured to enclose the cavity 18, thereby protecting the dc terminals 14 and the cable terminals 20. The cover is also configured to thermally manage heat within the cavity 18 by removing thermal energy from the cavity 18.

The housing 16 is designed to receive and house a plurality of different cover configurations 100, 200, 300, 400, 500. Each cover construction 100, 200, 300, 400, 500 uses a different thermal management mechanism to thermally manage heat within the cavity 18. The lid construction 100, 200, 300, 400, 500 comprises: active thermal management (treatment) 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.

In a first cover configuration 100 having an active thermal management mechanism, as shown in fig. 4-8, the cover 100 includes an active thermal management system characterized by an enclosed coolant tube 102, the coolant tube 102 configured to carry a liquid coolant flowing through the cover 100. The coolant tube has a liquid inlet 104 and a liquid outlet 106 that interconnect with the vehicle cooling system 24, such as the vehicle battery pack 22 and/or the vehicle power electronics, of the vehicle cooling system 24, as shown in fig. 8. The vehicle's cooling system 24 includes a pump or other fluid moving device that flows liquid coolant through a coolant tube. As shown in fig. 4, 6 and 7, the coolant tubes follow a serpentine path through the cap, thereby increasing the length of the coolant tubes and increasing the amount of thermal energy that can be absorbed from the cavity 18 by the coolant flowing through the cap. The cover may preferably be formed on a material having a high thermal conductivity, such as aluminum or a copper-based material, to provide sufficient heat transfer between the cavity 18 and the liquid coolant. Alternatively, the cover may be formed of a thermally conductive polymer.

According to a second cover configuration 200 with an active thermal management mechanism, shown in fig. 9, the cover 200 comprises a thermoelectric device 202, which thermoelectric device 202 uses the Peltier effect (Peltier effect) to actively cool the cavity 18. A voltage is applied to the thermoelectric device 202 such that one side 204 of the thermoelectric device 202 facing into the cavity 18 is cooled while the other side 206 of the thermoelectric device 202 facing outward is heated due to the thermal energy removed from the cooled side 204. The thermoelectric device 202 may be used as the sole thermal management mechanism in the assembly 10, or in combination with any of the described cover configurations 100, 300, 400, 500.

In a third cover configuration 300 with an active thermal management mechanism shown in fig. 10 and 11, the assembly 10 further comprises an electrically insulating Terminal Position Assurance (TPA) member 302, the member 302 enclosing a portion of the dc terminals 14 and being in thermal communication with the dc terminals 14. The TPA member 302 includes coolant passages configured to carry liquid coolant that flows through the TPA member 302. The TPA member 302 provides the benefit of removing thermal energy directly from the dc terminals 14, which dc terminals 14 are one of the primary heat sources within the cavities 18. The coolant channels have a liquid inlet port 304 and a liquid outlet port 306 that interconnect with the vehicle cooling system 24, such as the vehicle battery pack 22 and/or the vehicle power electronics cooling system 24, similar to that shown in fig. 8. The cooling system 24 of the vehicle includes a pump that flows liquid coolant through a coolant tube. The cover 300 defines an aperture 308 through which the liquid inlet port 304 and the liquid outlet port 306 exit the cavity 18. In alternative embodiments, the liquid inlet port 304 and the liquid outlet port 306 may be interconnected with a cooling system dedicated to cooling the assembly 10.

A fourth cover configuration 400 having an active thermal management mechanism is shown in fig. 12-14. The cover 400 is in pneumatic and thermal communication with the cavity 18. The cover 400 includes: an airflow inlet port 402 through which airflow at the ambient temperature of the vehicle enters the cavity 18; and an airflow outlet port 404 through which airflow is discharged from the cavity 18. The airflow inlet port 402 is interconnected with an airflow generating device of the vehicle, such as a ducted fan. The flow of air through the cavity 18 removes a portion of the thermal energy from the cavity 18, thereby reducing the temperature within the cavity 18. The inner surface of the cover 400 defines a baffle 406, the baffle 406 being configured to direct the airflow within the cavity 18. The baffle 406 also includes an arcuate surface 408 that helps to create turbulent airflow within the cavity 18. The cover 400 and the flap 406 may preferably be formed of a dielectric polymer material to avoid shorting by contact between any terminals within the cavity 18 and the flap 406.

Fig. 15 and 16 show a fifth cover configuration 500 having a passive thermal management mechanism. The cover 500 is formed of a thermally conductive material, such as aluminum or a 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 silicon-based material in thermal communication with the lid 500. Silicone thermal grease may be applied between inner surface 506 of lid 500 and potting material 504.

In an alternative embodiment, the 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 lipid. PCMs melt and solidify at an almost constant temperature, and can store and release a large amount of thermal energy. As power flows through the terminals 14, 20, heat is absorbed in the cavity 18 as the PCM gradually changes from a solid to a liquid, and then as power no longer flows through the terminals 14, 20, heat is gradually released through the cap 500 as the PCM changes from a liquid to a solid.

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

Alternative embodiments of the assembly 10 combining the various elements described above are contemplated. For example, the thermal potting material 504 or PCM of the fifth lid construction 500 may be incorporated in the first lid construction 100, the second lid construction 200 or the third lid construction 300. In an alternative embodiment, the cooling fins 502 of the fifth lid construction 500 may be integrated into the first lid construction 100, the second lid construction 200, the third lid construction 300 or the fourth lid construction 400.

In the sixth cover configuration 600 with an active thermal management mechanism shown in fig. 17-24B, the cover 600 is in intimate contact with the dc terminals 14 and is in thermal communication with the dc terminals 14 within the cavities 18. As shown in fig. 18, the cover 600 includes a top cover 626, the top cover 626 having a liquid inlet port 604 and a liquid outlet port 606 that interconnect with a vehicle cooling system 24, such as a liquid cooling system that cools the vehicle battery pack 22 and/or vehicle power electronics, similar to that shown in fig. 8. The cooling system 24 of the vehicle includes a pump that flows liquid coolant through a coolant tube. In an alternative embodiment, the liquid inlet port 604 and the liquid outlet port 606 may be interconnected with a cooling system dedicated to cooling the assembly 10. The cap 626 may advantageously be formed from a polymer material to reduce the weight of the cap 626 and may provide better electrical isolation than a metal cap 626.

As shown in fig. 19, the cover 600 further includes a bottom cover 628, the bottom cover 628 defining a coolant channel having a plurality of cooling fins 630, the cooling fins 630 defining a plurality of coolant channels 632, as best shown in fig. 20, through which channels 632 liquid coolant flows from the liquid inlet port 604 to the liquid outlet port 606. Bottom cover 628 may advantageously be formed from a metallic material to optimize heat transfer between cooling fins 630 and the liquid coolant. As shown in fig. 20, the bottom cover 628 is in close contact with the dc terminal 14. Bottom cover 628 further includes: a dielectric thermal interface material layer 634 in direct contact with the dc terminals 14, and an additional dielectric material layer 636 intermediate the dielectric thermal interface material layer 634 and the coolant channels 632. Dielectric thermal interface material layer 634 and additional dielectric material layer 636 provide stable electrical isolation between dc terminals 14 and metal bottom cover 628.

The cover 600 also includes a main coolant seal 638 between the top cover 626 and the bottom cover 628, and a secondary seal 640 between the cover 600 and the cavity 18 to ensure that liquid coolant does not enter the cavity 18. The entry of liquid coolant into the cavity 18 may cause a short circuit between the dc terminals 14.

The experimental results of the cooling performance of the cover 600 are shown in fig. 21 to 24. Fig. 21 shows 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 when the assembly 10 is operating at 500 amps of current. Fig. 22 shows the temperature 648 of one of the electrical terminals 12, the temperature 650 of one of the terminals 14, and the inlet coolant temperature 652 when the assembly 10 is operating at 500 amps of current. Fig. 23 shows a comparison of a temperature 656 of one of the terminals 14 and a temperature 654 of one of the electrical terminals 12 of a cover, such as the cover 100, having passive cooling to a temperature 658 of one of the electrical terminals 12, a temperature 660 of one of the terminals 14, and an inlet coolant temperature 662, when the assembly 10 is under similar operating conditions. Fig. 24A shows the thermal gradient between the liquid outlet port 606 and the liquid inlet port 604 of the top cap 626 when the dissipated power is 100 watts. Fig. 24B shows the thermal gradient between the terminal 14 and the top cover 626 when the dissipated power is 100 watts.

Alternative embodiments may be envisaged which include the features of several of the embodiments described above. Table 1 below describes at least some of the possible combinations.

TABLE 1-Cap construction

Although the illustrated example of the electrical connector assembly 10 is a vehicle charging port, other embodiments of the present invention are contemplated for use with many other types of electrical connector assemblies.

Thus, an electrical connector assembly 10 is provided. The assembly 10 provides the temperature benefits of the thermal management assembly 10. The assembly 10 also provides a common housing 16, the housing 16 accepting the number of cover configurations 100, 200, 300, 400, 500, 600 having different thermal management mechanisms, allowing the assembly 10 to be customized for a particular application of the assembly 10 based on thermal load and cooling infrastructure, e.g., liquid coolant availability, airflow availability.

While the present invention has been described in accordance with its preferred embodiments, it is not intended to be limited thereto, but rather only by the scope set forth in the following claims. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. The dimensions, types, orientations of the various components, and numbers and locations of the various components described herein are intended to define the parameters of the particular embodiment, are not meant to be limiting, but rather are merely prototype embodiments.

Various other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art upon reading the foregoing description. The scope of the invention is, therefore, indicated by the appended claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, "one or more" includes a function performed by one element, such as a function performed by more than one element in a distributed fashion, a function performed by one element, a function performed by several elements, or a combination of these.

It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various above-described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

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 described embodiments, 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 will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term "if" is optionally to be interpreted to mean "when … …" or "when. Similarly, the phrase "if it is decided" or if [ a stated condition or event ] is detected "is optionally to be interpreted as meaning" upon decision.. or "in response to a decision" or "upon detection of [ the above condition or event ] or" in response to detection of [ the above condition or event ], depending on the context. "

Additionally, although terms of ordinance or orientation may be used herein, these elements should not be limited by these terms. All terms or orientations are used for the purpose of distinguishing one element from another, unless otherwise stated, and do not imply any particular order, sequence of operations, direction, or orientation, unless otherwise stated.