Patent Description:
High power electrical connector assemblies, such as those used in electrical vehicles, may be required to conduct <NUM> kilowatts or more of electrical power. Electrical contact resistance between electrical elements in the electrical connector assembly causes power losses which are converted to thermal energy within the connector assembly. This thermal energy can cause a temperature rise within the electrical connector assembly that may damage the electrical connector assembly and/or surrounding components by overheating if thermal limits are exceeded. In order to prevent damage from overheating, the conductive components of the electrical connector assembly, including the electrical cables, are upsized to carry additional current, thereby "derating" the connector to compensate for the resistive heating.

With previous cooled inlet liquid cooling plate designs, in order to ensure that high voltage electrical terminals are fully electrically isolated from liquid cooling plate, a dielectric conformal coating was applied between the electrical terminals and the cooling plate in addition to a dielectric thermal interface material. This conformal coating reduced thermal performance (given the additional insulation barrier) of the cooling plate due to reduced heat transfer between the heat source (electrical terminals) and the heat sink (cooling plate).

Publication <CIT> discloses an electrical connector assembly that includes a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening configured to receive a cover that is configured to protect the at least two electrical terminals and thermally manage heat within the cavity. The connector housing is configured to receive one cover configuration of a plurality of different cover configurations. A first cover configuration in the plurality of different cover configurations provides different mechanism to thermally manage heat within the cavity electrical connector assembly than a second cover configuration in this plurality of different cover configurations. Publication <CIT> pertains to a connector with cooling elements that are contained in a cover.

According to one or more aspects of the present disclosure, an electrical connector assembly includes a connector housing in which a pair of electrically conductive busbars are disposed and a metallic cooling plate in that is in thermal communication with major surfaces of the pair of electrically conductive busbars. The electrical connector assembly further includes a dielectric structure that is configured to prevent electrical contact between the pair of electrically conductive busbars and the cooling plate.

The dielectric structure includes an isolator ring surrounding the cooling plate. The isolating ring defines a pair of openings through which the cooling plate thermally communicates with the major surfaces of the pair of electrically conductive busbars.

The isolator ring defines a separating fin disposed between one busbar of the pair of electrically conductive busbars and another busbar of the pair of electrically conductive busbars. The separating fin is configured to prevent electrical contact between the pair of electrically conductive busbars.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, a portion of the isolating ring defining the pair of openings extends beyond the cooling plate in a direction perpendicular to the major surfaces of the pair of electrically conductive busbars.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the isolator ring is formed from an electrically insulative material.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the isolator ring is formed from a <NUM>% glass filled polybutylene terephthalate material.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the isolator ring defines two separating fins separated from one another and arranged parallel to one another.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the cooling plate includes a coolant channel in fluidic communication with an inlet port and an outlet port.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the cooling plate comprises a plurality of coolant channels that are in fluidic communication with an inlet port and an outlet port.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, a plurality of cooling fins extend into the plurality of coolant channels.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the cooling plate includes a coolant seal disposed between the cooling plate and the connector housing.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the cooling plate includes a first section formed of a polymeric material and a second section formed of a metallic material.

In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the inlet port and the outlet port are interconnected to a liquid cooling system of an electrically propelled vehicle.

However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without all of these specific details.

A non-limiting example of an embodiment of an electrical connector assembly is illustrated in <FIG>, hereinafter referred to as the connector <NUM>. The connector <NUM> includes an electrically insulative connector housing <NUM> in which a pair of L-shaped busbars <NUM> are disposed. As used herein "L-shaped" means that the busbars <NUM> have a first planar end <NUM> that is arranged generally perpendicularly to a second planar end <NUM>. The connector <NUM> further contains a cooling plate <NUM> configured for reducing a temperature of the busbars <NUM> which includes that is sized, shaped, and arranged to be in conductive thermal contact with a first major surface <NUM> of the first planar ends <NUM> of each of the busbars <NUM>.

As shown in <FIG> and <FIG>, the cooling plate <NUM> includes a bottom section <NUM> having a liquid inlet port <NUM> and a liquid outlet port <NUM> that may be interconnected with the vehicle's cooling system, e.g., a liquid cooling system that cools the vehicle battery pack and/or the vehicle's power electronics (not shown). The vehicle's cooling system includes a pump that causes the liquid coolant to flow through the cooling plate. In an alternative embodiment, the liquid inlet port <NUM> and the liquid outlet port <NUM> may be interconnected with a cooling system dedicated to cooling the connector <NUM>. The bottom section <NUM> may be advantageously formed of a polymeric material to reduce weight and provide better electrical isolation.

The cooling plate <NUM> also includes a top section <NUM> that defines a coolant channel <NUM> having a plurality of cooling fins <NUM> through which a liquid coolant flows from the liquid inlet port <NUM> to the liquid outlet port <NUM>. The top section <NUM> may be advantageously formed of a metallic material to optimize heat transfer between the cooling fins <NUM> and the liquid coolant and between the busbars <NUM> and the cooling plate <NUM>.

The cooling plate <NUM> also includes a coolant seal <NUM> between the cooling plate <NUM> and the housing <NUM> to ensure that the liquid coolant does not enter the housing <NUM>. The coolant seal <NUM> is advantageously formed of a compliant material, such as a silicone-based rubber material. The coolant seal <NUM> inhibits ingress of the liquid coolant into the housing <NUM> that could cause a short circuit between the busbars <NUM>.

The connector <NUM> further includes an isolator ring <NUM> that is designed with special features to allow for robust electrical isolation between the cooling plate <NUM> and the busbars <NUM>. The isolator ring <NUM> surrounds the outer edges of the cooling plate <NUM> and defines a pair of openings <NUM> in a top surface <NUM> of the isolator ring <NUM> through which the pair of busbars thermally communicate with the cooling plate. As shown in <FIG> and <FIG>, the openings <NUM> provide a small air gap <NUM> between busbars <NUM> and the cooling plate <NUM> that electrically isolates the busbars <NUM> from the cooling plate <NUM> while allowing thermal communication between busbars <NUM> and the cooling plate <NUM>, i.e., heat transfer from the busbars <NUM> to the cooling plate <NUM>. The length and width of the openings <NUM> is less than the length and width of the first major surfaces <NUM> of the busbars <NUM>. The size of the openings <NUM> ensures that the busbars <NUM> always contact the isolator ring <NUM> first, thereby preventing contact between the busbars <NUM> and the metallic top section <NUM> of the cooling plate <NUM> which could cause a short circuit between the busbars <NUM>.

As best shown in <FIG>, the isolator ring <NUM> also defines a pair of separating fins <NUM> that project between the busbars <NUM> and are configured to prevent electrical contact between the busbars <NUM> which could cause a short circuit between the busbars <NUM>. The pair of separating fins <NUM> also ensure proper positioning of the busbars <NUM> over the pair of openings <NUM> in the top surface <NUM> of the isolator ring <NUM>.

The isolator ring <NUM> is formed of an electrically insulative material, e.g., <NUM>% glass filled polybutylene terephthalate (PBT). The isolator ring <NUM> can be attached to the cooling plate <NUM> by an adhesive material or alternatively may be co-molded over the cooling plate <NUM>.

While the illustrated embodiment of the connector <NUM> is configured to conduct a liquid coolant, other embodiments of the connector <NUM> may be envisioned that are configured to conduct a gaseous coolant. In yet other embodiments of the connector <NUM>, the cooling plate <NUM> may contain external cooling fins (not shown) and rely on passive cooling rather than an active coolant flow.

Accordingly, the connector <NUM> is provided. The connector <NUM> provides the benefits of thermally managing the temperature of the connector <NUM> and associated components, such as the wire cables. By reducing the temperature of the connector <NUM>, it is no longer necessary to derate the connector <NUM> and therefore smaller connector components may be used, thereby reducing material costs and reducing the weight and size of the connector <NUM>. In addition, since the cables that are attached to the connectors <NUM> no longer need to provide a heat sink, the cable's gauge may also be reduced, further reducing material costs and reducing the weight and size of the cables. The isolator ring <NUM> provides the benefit of maintaining robust electrical isolation without compromising thermal performance of the cooling plate <NUM> while also providing excellent dielectric strength.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. 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 configure a situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments.

Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, 'one or more' includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various 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 described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and/or "comprising," when used in this specification, 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, construed to mean "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" is, optionally, construed to mean "upon determining" or "in response to determining" or "upon detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]," depending on the context.

Claim 1:
An electrical connector assembly (<NUM>), comprising:
a connector housing (<NUM>) in which a pair of electrically conductive busbars (<NUM>) are disposed;
a metallic cooling plate (<NUM>) in thermal communication with major surfaces (<NUM>) of the pair of electrically conductive busbars (<NUM>); and
a dielectric structure configured to prevent electrical contact between the pair of electrically conductive busbars (<NUM>) and the cooling plate (<NUM>),
characterized in that the dielectric structure includes an isolator ring (<NUM>) surrounding the cooling plate (<NUM>) and wherein the isolating ring (<NUM>) defines a pair of openings (<NUM>) through which the cooling plate (<NUM>) thermally communicates with the major surfaces (<NUM>) of the pair of electrically conductive busbars (<NUM>), and
wherein the isolator ring (<NUM>) defines a separating fin (<NUM>) disposed between one busbar of the pair of electrically conductive busbars (<NUM>) and another busbar of the pair of electrically conductive busbars (<NUM>) and wherein the separating fin (<NUM>) is configured to prevent electrical contact between the pair of electrically conductive busbars (<NUM>).