Patent Publication Number: US-2018038741-A1

Title: Temperature sensor with overmolded connector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not applicable. 
     BACKGROUND 
     Mass produced cars and trucks use temperature sensors in one or more places in the vehicle to detect, for example, one or more of engine coolant temperature, transmission oil temperature, intake air temperature, and the like. The temperature indications may be used by vehicle systems to detect and warn vehicle operators of vehicle conditions that may damage the vehicle (e.g., engine overheating) or that may be dangerous. The temperature indications may be used by vehicle systems to adapt fuel air mixing systems and ignition timings to achieve fuel efficiency and/or performance objectives. These temperature sensors may be manufactured in large quantities for use by a variety of different vehicle manufacturers and in a variety of vehicles. Desirably, the temperature sensors are inexpensive, compact, amenable to installation on an assembly line, and reliable. Further, temperature sensors are used in aerospace applications including engines, auxiliary power units, environmental control systems, and/or braking systems; industrial applications in oil refineries, air compressors, food industry equipment, injection molding, metal processing, and other industries that have temperature critical processes. 
     SUMMARY 
     In an embodiment, a temperature sensor is disclosed. The sensor comprises a metal mounting port having a threaded portion, an electrical terminal, a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port, and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. In an embodiment, the metal mounting port is a forged metal mounting port. 
     In another embodiment, a system is disclosed. The system comprises a temperature sensor that comprises a metal mounting port having a threaded portion and having a shoulder for supporting the metal mounting port in a plastic injection mold machine during fabrication, an electrical terminal, a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port, and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. In another embodiment, the system further comprises an engine into which the sensor is installed. In another embodiment, the system further comprises a motor vehicle into which the engine is installed. In an embodiment, the metal mounting port is a forged metal mounting port. 
     In yet another embodiment, a temperature sensor is disclosed. The sensor comprises a metal mounting port having a threaded portion and an open end comprising axial ribs, an electrical terminal, a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port, and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. In an embodiment, the metal mounting port is a forged metal mounting port. 
     These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. 
         FIG. 1  is an illustration of a temperature sensor in cross-section view according to an embodiment of the disclosure. 
         FIG. 2A  is an illustration of a metal port according to an embodiment of the disclosure. 
         FIG. 2B  is an illustration of a temperature sensor according to an embodiment of the disclosure. 
         FIG. 2C  is an illustration of a metal port and a relationship between an engagement feature of the metal port and a torque transfer shoulder of an overmolded plastic connector according to an embodiment of the disclosure. 
         FIG. 3  is an illustration of another metal part according to an embodiment of the disclosure. 
         FIG. 4  is an illustration of yet another metal part according to an embodiment of the disclosure. 
         FIG. 5A  is an illustration of a forged metal part prior to machining according to an embodiment of the disclosure. 
         FIG. 5B  is an illustration of a forged metal part after machining according to an embodiment of the disclosure. 
         FIG. 6A  is an illustration of a first phase of a temperature sensor manufacturing process according to an embodiment of the disclosure. 
         FIG. 6B  is an illustration of a second phase of a temperature sensor manufacturing process according to an embodiment of the disclosure. 
         FIG. 6C  is an illustration of a third phase of a temperature sensor manufacturing process according to an embodiment of the disclosure. 
         FIG. 7  is an illustration of an exemplary use of a temperature sensor in a motor vehicle according to an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents. 
     The present disclosure teaches a temperature sensor that incorporates novel structures that promote reducing sensor unit costs. The cost reduction process is focused on reducing subassembly part count and on reducing processing steps in manufacturing. The interplay between these cost reduction tactics and the novel structures that are the subject of the patent claims will be commented upon hereinafter, but it is pointed out that it is the novel structures and process steps that are claimed and not the cost reduction tactics per se. 
     The temperature sensor comprises a metal part (i.e., a metal mounting port) that retains a temperature sensing element in an interior cavity and has threads configured for screwing into a motor vehicle system, for example, a threaded receptacle in an engine block. The temperature sensing element may be a thermistor or other temperature transducer. The temperature sensing element is operable to transduce temperature to an electrical state or property. The temperature sensor further comprises an overmolded plastic connector that comprises a torque transfer shoulder. The overmolded plastic connector may be formed by injection of plastic material into a mold that retains the metal part, the temperature sensing element, temperature sensing element wires, and temperature sensing element terminals. The injection molding process is performed while the metal part is maintained in a vertical position. The injected plastic material flows into the mold, into the interior cavity of the metal part, surrounds the temperature sensing element and temperature sensing element wires, and partially surrounds the temperature sensing element terminals. The metal part defines a shoulder on which the part rests in the mold and is secured to the mold by engagement pistons during the injection molding process. 
     The torque transfer shoulder of the overmolded plastic connector may be used by assembly tools to screw the temperature sensor into the motor vehicle system and to tighten to a desired torque specification. The torque transfer shoulder may have a hexagonal shape, a pentagonal shape, a square shape, or some other shape suitable for being engaged by mass assembly tools. The metal part may comprise ribs, ridges, lands, protruding studs, and/or protruding buttons over which the torque transfer shoulder is molded. These features of the metal part may aid in transferring torque from the torque transfer shoulder to the metal part. 
     In an embodiment, the metal part (i.e., metal mounting port) is a forged metal part. By using a forged metal part, machining operations involved in manufacturing the temperature sensor can be reduced, and material wastage can be reduced. For example, prior art methods machined like metal parts out of bar stock, which wasted the metal removed during basic shaping of the part and consumed time. By relying on a torque transfer shoulder in the overmolded connector, the process step of machining a hex shape on the forged metal part can be avoided, saving machining time and wasted metal. The ribs, ridges, lands, studs, or buttons described above may be provided in the forged metal part before machining. Alternatively, in other embodiments the metal part (i.e., metal mounting port) may be made by a different process, for example by die casting, machining, MIM, or other process. 
     Prior art methods may use a plastic jig in which the temperature sensing element, temperature sensing element wires, and temperature sensing element terminals are retained. This plastic jig may then support the metal part when it is placed over the temperature sensing element during injection molding. The present disclosure teaches omitting the jig, thereby reducing a part count and saving the time of inserting the temperature sensing element, temperature sensing element wires, and temperature sensing element terminals into the jig. The shoulder defined by the metal part assumes the role of providing support for the metal part (instead of the jig) during injection molding. In an embodiment, the temperature sensing element wires use heavier gauge wire, relative to the prior art, to support the temperature sensing element and the temperature sensing element wires during the initial phases of injection molding. 
     Turning now to  FIG. 1 , a temperature sensor  100  is described. The temperature sensor  100  may be suitable for mass manufacturing and for assembly into one or more systems of a motor vehicle, such as an automobile, a truck, a bus, a sport utility vehicle, a minivan, a power boat, an item of construction equipment, and other motor vehicles comprising internal combustion engines. Further, the temperature sensor may be used in aerospace applications including engines, auxiliary power units, environmental control systems, and/or braking systems; industrial applications in oil refineries, air compressors, food industry equipment, injection molding, metal processing, and other industries that have temperature critical processes. 
     In an embodiment, the sensor  100  comprises a metal mounting port  108 , a temperature sensing element component  102 , temperature sensing element wires  104 , temperature sensing element terminals  106 , and an overmolded plastic connector  116 . The temperature sensing element wires comprise a first temperature sensing element wire  104   a  connected to a first temperature sensing element terminal  106   a  and a second temperature sensing element wire  104   b  connected to the second temperature sensing element terminal  106   b . The temperature sensing element wires  104  may be connected to the temperature sensing element terminals  106  by solder, welding, crimping, or by another connection. In some contexts, the temperature sensing element terminals  106  may be referred to as electrical terminals. In an embodiment, the temperature sensing element component  102  may be a thermistor. 
     The metal mounting port  108  defines an interior cavity  109 , a threaded portion  110 , a shoulder  114 , and a torque engagement feature  112 . The torque engagement feature  112  may take a variety of implementations which are discussed further below. The torque engagement feature  112  promotes transfer of torque applied to a torque transfer shoulder  118  of the overmolded plastic connector  116  to the threaded portion  110  while avoiding the overmolded plastic connector  116  slipping over the metal mounting port  108 . The overmolded plastic connector  116  defines a connector receptacle  120 . The ends of the temperature sensing element terminals  106  project free of the interior of the overmolded plastic connector  116  and are configured to mate with an electrical socket that is plugged into the sensor  100 , for example, a portion of an electrical wiring harness of a motor vehicle. 
     Turning now to  FIG. 2A - FIG. 2C , further details of the temperature sensor  100  are described. The metal mounting port  108  is seen to comprise the threaded portion  110 , the engagement feature  112 , and the shoulder  114 . In  FIG. 2A  and  FIG. 2C , the engagement feature  112  is illustrated as ribs or slots, but it is understood that in some embodiments, different shapes may be employed to provide the desired engagement and no-slip behavior. The torque transfer shoulder  118  is illustrated in  FIG. 2B  and  FIG. 2C  as a hexagonal shape, but it is understood that in another embodiment, the torque transfer shoulder  118  may take other shapes, such as pentagonal, square, or other shapes. The right hand side of  FIG. 2B  best illustrates the no slip structure of the mating between the engagement feature  112  and the torque transfer shoulder  118  of the overmolded plastic connector  116 . It is understood that the plastic of the overmolded plastic connector  116  fills into the interstices of the engagement feature  112  during injection molding formation of the overmolded plastic connector  116 .  FIG. 2C  best illustrates the relationship between the engagement feature  112  and the overmolded plastic connector  116  and more specifically how torque applied (e.g., by a power tool or hand operated wrench) to the torque transfer shoulder  118  of the overmolded plastic connector  116  may be transferred to the engagement feature  112  and hence to the metal mounting port  108 , for example to tighten the temperature sensor  100  into a threaded receiving hole. 
     Turning now to  FIG. 3 , an alternative embodiment of the engagement feature  112  of the metal mounting port  108  is described. In an embodiment, the engagement feature  112  may take a hexagonal shape over which the overmolded plastic connector  116  is injection molded. 
     Turning now to  FIG. 4 , another alternative embodiment of the engagement feature  112  of the metal mounting port  108  is described. In an embodiment, the engagement feature  112  may take a knurled shape over which the overmolded plastic connector  116  is injection molded. 
     In some but not all embodiments, the metal mounting port  108  is a forged metal part. Turning now to  FIG. 5A  and  FIG. 5B , a forged metal mounting port  108  is discussed. In  FIG. 5A , the forged metal mounting port  108  is depicted prior to machining as forging  140 . The general shape of forging  140  conforms generally with the finished machined shape of the forged metal mounting port  108 . Considering that the prior art port is made from bar stock, it can readily be appreciated that less waste metal is generated in machining the forged metal mounting port  108  out of the forging  140  than in machining the same item from bar stock and further machining a hexagonal shape as in the prior art. In the forged metal mounting port  108  of the present disclosure, the engagement feature  112  is cast into the forged metal mounting port  108  during forging. In  FIG. 5B , the forging  140  depicted in  FIG. 5A  is machined to provide the threaded portion  110 . While these features cannot be seen in  FIG. 5B , the machining of the forged metal mounting port  108  further provides the shoulder  114  and the interior cavity  109 . The forged metal mounting port  108  may comprise aluminum, steel, stainless steel, brass, and/or other metals. 
     Turning now to  FIG. 6A ,  FIG. 6B , and  FIG. 6C , injection molding of the overmolded plastic connector  116  is described. The temperature sensing element  102  may be sourced from a supplier with temperature sensing element wires  104 . The temperature sensing element wires  104  may be of a sufficient stoutness to support the temperature sensing element  102  in a vertical alignment, without the use of a jig. In an embodiment, the temperature sensing element wires  104  may be 26 AWG gauge wire. Alternatively, the temperature sensing element wires  104  may be 28 AWG gauge wire. Alternatively, the temperature sensing element wires may be 24 AWG gauge wires. The temperature sensing element wires  104  may be connected to the temperature sensing element terminals  106 . As illustrated in  FIG. 6A , the temperature sensing element terminals  106  are installed into a replaceable tool insert  150  in a plastic injection molding machine. The assembly of the temperature sensing element  102 , the temperature sensing element wires  104 , and the temperature sensing element terminals  106  as illustrated in  FIG. 6A  may be said to be a jigless assembly. In  FIG. 6B , side core components  152   a  and  152   b  are positioned, and the shoulder  114  of the metal mounting port  108  is placed on a receiving lip  153  of the side core component  152 . The receiving lip  153  supports the metal mounting port  108  and hence holds the port  108  off of the temperature sensing element  102  and temperature sensing element wires  104 . 
     In  FIG. 6C , a portion  154  of the injection molding machine is deployed to hold the metal mounting port  108  securely on the side core components  152 . The overmolded plastic connector  116  is then formed by injecting plastic material into the side core components  152  and into the interior cavity  109  of the metal mounting port  108 . The plastic that flows into the interior cavity  109  of the metal mounting port  108  both mechanically stabilizes the temperature sensing element  102  and temperature sensing element wires  104  as well as electrically insulating and/or isolating the wires  104 . The temperature sensing element  102  and temperature sensing element wires  104  may be said to be enclosed in the interior cavity  109  in a jigless assembly. In an embodiment, thermal heat transfer paste may first be injected into the interior cavity  109  of the metal mounting port  108 , and then the plastic may be injected to complete the overmolded plastic connector  116 . Such thermal heat transfer paste may comprise one or more of silicon paste, epoxy, silicone RTV, and/or other materials. The plastic may comprise plastic resins, epoxies, thermoset materials, or ceramics. 
     After the overmolded plastic connector  116  has been formed, the sensor  100  is removed from the injection molding machine. Some surplus plastic material may be removed after freeing the sensor  100  from the injection molding machine, for example, possibly after the overmolded plastic connector  116  has cooled. 
     A method of making or manufacturing the sensor  100  may comprise the following. The metal mounting port  108  is provided. The metal mounting port  108  is machined to define the threaded portion  110  and to define the interior cavity  109 . The temperature sensing element terminals  106  are inserted into the replaceable tool insert  150  that is held in a plastic injection molding machine. The temperature sensing element wires  104  and the temperature sensing element extend upwards from the injection molding machine. The metal mounting port  108  is placed over the temperature sensing element  102  and temperature sensing element wires  104 , and the shoulder  114  of the metal mounting port  108  is supported on the receiving lip  153  of the side component  152  of the injection molding machine. In some embodiments, the temperature sensing element  102  and the temperature sensing element wires  104  may not be supported by any other or additional part or carrier during a subsequent molding process. A portion  154  of the injection molding machine deploys to engage with and hold in place the metal mounting port  108  on the side core components  152 . Plastic or resin is injected into the injection molding machine and into and over the metal mounting port  108  to form the overmolded plastic connector  116 . In an embodiment, thermal heat transfer paste may be flowed into or injected into the interior cavity  109  before injecting plastic or resin into the injection molding machine. The plastic flows over and engages closely with the torque engagement feature  112  of the metal mounting port  108  and further forms the torque transfer shoulder  118  of the overmolded plastic connector  116 . The manufactured sensor  100  is then removed from the injection molding machine and is ready for use. In embodiment, the overmolded plastic connector  116  is worked to remove any burrs or flashing. 
     A method of using the sensor  100  may comprise one or more of the following actions. One or more sensors  100  is installed into a motor vehicle, for example into an engine block, into an engine oil pan, or into a transmission. For example, this may be performed during manufacturing or assembling of the motor vehicle. The engine of the motor vehicle is turned on. One or more of the sensors  100  disposed in the vehicle is heated. For example, coolant circulating in the engine absorbs heat of fuel combustion from the block of the engine, and the coolant transfers heat to the sensor  100 . The sensor  100  senses or determines a temperature of the engine block or of the coolant and provides an indication of that temperature, for example to an in-vehicle central computer, to an engine control system, or to one or more other systems. Likewise, the sensor  100  may sense or determine an engine oil temperature and provide an indication of that temperature to a central computer, engine control system, or other system. Likewise, the sensor  100  may sense or determine a transmission oil or fluid temperature and provide an indication of that temperature to a central computer, engine control system, or other system. 
     Turning now to  FIG. 7 , a motor vehicle  200  is described. In an embodiment, the motor vehicle  200  comprises an engine comprising an engine block  202  and an engine oil pan  203 . The motive force (e.g., torque) of the engine may be transferred to drive wheels of the vehicle  200  by a transmission  204 . It is understood that the motor vehicle  200 , engine block  202 , engine oil pan  203 , and transmission  204  may have different configurations than those illustrated in  FIG. 7 . For example, the motor vehicle may have a different form than an automobile, for example the form of a pick-up truck, a sport utility vehicle, a minivan, a delivery truck, a tractor unit of a tractor trailer rig, a bus, or other motor vehicle powered by an internal combustion engine. 
     In an embodiment, the engine block  202  has a first temperature sensor receptacle  206  into which a first temperature sensor  100   a  may be assembled. The first temperature sensor  100   a  may sense an engine coolant temperature or an engine block temperature and provide the temperature sense value to another component of the vehicle  200 , for example to a control unit of the vehicle  200 , such as a fuel control system or a central computing system of the vehicle  200 . The temperature sense value may be used to modulate engine operation parameters, such as a control input to determine a fuel air mix or other engine operation parameter. The temperature sense value may be used to provide a temperature indication in a dashboard of the vehicle  200 . The temperature sense value may be used to generate an engine temperature overheat alert light indication in the dashboard or elsewhere in the vehicle  200 . It is understood that the first temperature sensor receptacle  206  may be located anywhere in the engine block  202  or in a coolant system. 
     In an embodiment, the engine oil pan  203  has a second temperature sense receptacle  208  into which a second temperature sensor  100   b  may be assembled. The second temperature sensor  100   b  may sense an engine oil temperature and provide the oil temperature sense value to a control unit of the vehicle  200  and/or to a dashboard of the vehicle  200 . It is understood that the second temperature sense receptacle  208  may be located anywhere in the oil pan  203  or in a flow path of the engine oil. In an embodiment, the transmission  204  has a third temperature sense receptacle  210  into which a third temperature sensor  100   c  is assembled. The third temperature sensor  100   c  may sense a transmission oil or transmission fluid temperature and provide the transmission temperature to a control unit of the vehicle  200  and/or to a dashboard of the vehicle  200 . It is understood that the third temperature sense receptacle  210  may be located anywhere in the transmission  204  or in the flow path of the transmission oil or fluid. It will be appreciated that while the above description of assembling the temperature sensor  100  into a system was written directed to the use case of an internal combustion engine, like assembly processes may be used to insert the temperature sensors into other systems, such as in aerospace applications including engines, auxiliary power units, environmental control systems, and/or braking systems; industrial applications in oil refineries, air compressors, food industry equipment, injection molding, metal processing, and other industries that have temperature critical processes. 
     The temperature sensors  100   a ,  100   b ,  100   c  may be provided using any of the temperature sensors described above. The temperature sensors  100   a ,  100   b ,  100   c  may be assembled into the vehicle  200  by inserting the end of the metal mounting port  108  into the appropriate receptacle  206 ,  208 ,  210  and threading the threaded portion of the sensor into the threads of the receptacle  206 ,  208 ,  210 . One or more of the temperature sensors  100   a ,  100   b ,  100   c  may be assembled into the vehicle  200  during manufacture and/or assembly of the vehicle, for example by a pneumatic power wrench that engages with the torque transfer shoulder  118  of the sensor  100   a ,  100   b ,  100   c . In some contexts,  FIG. 7  may be said to illustrate a system, where the system comprises a temperature sensor, an engine in which the temperature sensor is disposed, and a motor vehicle in which the engine is disposed. 
     Having described various methods and systems herein, specific embodiments can include, but are not limited to: 
     In a first embodiment, a temperature sensor comprises: a metal mounting port having a threaded portion; an electrical terminal; a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port; and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. 
     A second embodiment can include the sensor of the first embodiment, wherein the sensor is a mass produced sensor. 
     A third embodiment can include the sensor of the first embodiment, wherein the sensor is operable for use in sensing one of engine coolant temperature, engine oil temperature, or transmission oil temperature. 
     A fourth embodiment can include the sensor of the third embodiment, wherein the torque transfer shoulder defines a hexagonal shape, and wherein the metal mounting port defines a torque engagement feature. 
     A fifth embodiment can include the sensor of the fourth embodiment, wherein the torque engagement feature of the metal mounting port is one of a ribbed feature and a knurled feature. 
     A sixth embodiment can include the sensor of the fourth embodiment, wherein the metal mounting port further comprises a shoulder for supporting the metal mounting port in a plastic injection mold machine during fabrication. 
     A seventh embodiment can include the sensor of the first embodiment, wherein the temperature sensing element is configured to be assembled into the cavity without a jig. 
     An eighth embodiment can include the sensor of the first embodiment, wherein the plastic of the plastic connector molded over the metal mounting port fills the cavity defined by the mounting port around the temperature sensing element. 
     A ninth embodiment can include the sensor of the first embodiment, wherein a thermal heat transfer paste fills an end of the cavity defined by the metal mounting port around the temperature sensing element and the plastic of the plastic connector molded over the metal mounting port partially fills the remainder of the cavity that is not filled with the thermal heat transfer paste. 
     A tenth embodiment can include the sensor of the first embodiment, wherein a metal housing is disposed around the sensing element. 
     An eleventh embodiment can include the sensor of the first embodiment, wherein the metal housing is made of a single integral part or an assembly of many parts of any combination of materials and manufacturing methods. 
     A twelfth embodiment can include the sensor of the first embodiment, wherein the sensing element is attached to electrical terminals by any means of fusion and non-fusion joining methods like crimping, auto splicing, welding, brazing, and/or soldering. 
     A thirteenth embodiment can include the sensor of the first embodiment, wherein the sensing element is attached to electrical terminals by any means, such as additional electrical wire, ribbon, or rods, with or without wire insulation. 
     A fourteenth embodiment can include the sensor of the first embodiment, wherein the metal housing is of any ferrous or non-ferrous type of material. 
     A fifteenth embodiment can include the sensor of the first embodiment, wherein the metal housing has a connection mechanism, such as threads, flanges, or the like. 
     A sixteenth embodiment can include the sensor of the first embodiment, wherein the metal housing has a variety of sensor tip shapes like straight, stepped diameters, finned, and/or the sensor tip has perforated holes. 
     In a seventeenth embodiment, a system comprises a temperature sensor, comprising: a metal mounting port having a threaded portion and having a shoulder for supporting the metal mounting port in a plastic injection mold machine during fabrication; an electrical terminal; a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port; and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. 
     An eighteenth embodiment can include the system of the seventeenth embodiment, further comprising an engine in which the temperature sensor is disposed. 
     A nineteenth embodiment can include the system of the eighteenth embodiment, further comprising a motor vehicle in which the engine is disposed. 
     A twentieth embodiment can include the system of the seventeenth embodiment, wherein the plastic connector molded over the metal mounting port fills the cavity defined by the metal mounting port and surrounds the temperature sensing element. 
     A twenty first embodiment can include the system of the twentieth embodiment, wherein the temperature sensing element is configured to be enclosed in the cavity in a jigless assembly. 
     A twenty second embodiment can include the system of the seventeenth embodiment, wherein the metal mounting port comprises a torque engagement feature. 
     A twenty third embodiment can include the system of the twenty second embodiment, wherein the torque engagement feature of the metal mounting port is one of a ribbed feature and a knurled feature. 
     In a twenty fourth embodiment, a temperature sensor comprises: a metal mounting port having a threaded portion and an open end comprising axial ribs; an electrical terminal; a temperature sensing element electrically connected to the electrical terminal and enclosed within a cavity defined by the metal mounting port; and a plastic connector molded over the metal mounting port, where the plastic encases at least a portion of the electrical terminal and where the plastic connector defines a torque transfer shoulder. 
     A twenty fifth embodiment can include the temperature sensor of the twenty fourth embodiment, wherein the temperature sensing element is electrically connected to the electrical terminal by two wires. 
     A twenty sixth embodiment can include the temperature sensor of the twenty fifth embodiment, wherein the two wires are 26 AWG gauge wires. 
     A twenty seventh embodiment can include the temperature sensor of the twenty fourth embodiment, wherein the torque transfer shoulder has a hexagonal shape. 
     While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system, or certain features may be omitted or not implemented. 
     Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.