WO2017137826A1

WO2017137826A1 - Charging connector, terminal fitting and method of fixing a sensor to a terminal fitting

Info

Publication number: WO2017137826A1
Application number: PCT/IB2017/000087
Authority: WO
Inventors: Tooru Shimizu; Heiko Schmidt
Original assignee: Sumitomo Wiring Systems Ltd
Current assignee: Sumitomo Wiring Systems Ltd
Priority date: 2016-02-11
Filing date: 2017-02-09
Publication date: 2017-08-17
Anticipated expiration: 2018-08-11
Also published as: JP6601566B2; DE102016001572A1; US20190036278A1; CN108701946A; JP2019500733A; US10644462B2

Abstract

The present invention relates to a charging connector for charging a battery installed in a vehicle comprising: a housing (51) comprising at least one accommodating chamber (64a) for at least partly accommodating at least one terminal fitting (10), and at least one sensor (S) mounted to at least one terminal fitting (10) by means of a shrinking tube (20). Further, the invention relates to a corresponding method and a corresponding terminal fitting (10).

Description

The present invention relates to a charging connector for charging a battery installed in a vehicle, in particular for an electric driven vehicle or a hybrid vehicle. Further, the invention relates to a terminal fitting to be applied in a charging connector and to a method of fixing a sensor to a terminal fitting.

Electric vehicles contribute to cleaner air in cities because they produce no harmful emissions. An electric vehicle (EV) recharged from the US grid electricity in 2008 emits about 1 15 grams of CO₂ per kilometer, whereas a conventional US-market gasoline powered car emits about 250 grams of C0₂ per kilometer. The concept "Vehicle to Grid" provides electric cars and hybrid vehicles as energy reservoir for the public power grid. In this concept, vehicles parking most time of their life, may be used as energy source and accumulator so as to compensate for peak loads in the public power grid. This concept however, requires a reliable electric connection of the vehicles with the public power grid, even under wet and hot/cold weather conditions of the parking space where the vehicle is parked.

Charging connectors for charging a vehicle-side battery installed e.g. in a hybrid vehicle or an electric vehicle are known. In these known connector systems, a vehicle-side connector is fixedly mounted in or at the vehicle and is connected with the battery of the vehicle. For charging the battery of the vehicle via an external charging cable from an external power source, a charging connector provided at an end of the charging cable may be connected with the vehicle-side connector so as to provide an electric connection between the external power source and the battery installed within the vehicle.

Upon charging, the charging connector is connected to the vehicle-side connector, the two connectors are held in a connected state by locking a lock-receiving portion provided on the vehicle-side connector and the locking portion to each other and charging is performed. After charging is completed, the unlocking portion is pushed to cancel the locked state of the locking portion and the lock-receiving portion, whereby the charging connector can be separated from the vehicle-side connector.

As high currents may flow when charging the battery, the charging connector as well as a wire might get hot. A too high temperature of the wire and the charging connector increase an electric resistance and might even damage the charging connector or the wire or other components. Accordingly, a charging current might be restricted to a low current so as to avoid such high temperatures. However, restricting the charging current to a low value extends a charging time so as to deteriorate an operability of the vehicle.

Accordingly, there is a need to improve this situation. In particular, it is an object to allowing a reliable measurement of conditions prevailing at a connector to particularly allow for a short charging time when applying high currents while avoiding problematic conditions (such as too high temperatures) during charging. This object is solved according to the invention by the features of the independent claims. Particular embodiments of the invention are subject of the dependent claims. According to a first aspect, there is provided a charging connector for charging a battery installed in a vehicle comprising:

a housing comprising at least one accommodating chamber for at least partly accommodating at least one terminal fitting, and

at least one sensor mounted to at least one terminal fitting wherein said sensor is placed into a mounting bracket, sleeve or clamp which is/can be prefixed to an outer surface of the terminal fitting and the sensor is then mounted and affixed to the terminal fitting by means of at least one shrinking tube.

By mounting the sensor to the terminal fitting by means of the at least one shrinking tube, a condition of the terminal fitting such as a temperature, vibration and/or humidity thereof may be precisely detected in an easy and reliable manner. In other words, the sensor is in abutment or contact with the terminal fitting such that the close disposition of the sensor and/or the direct contact of the sensor with the terminal fitting by means of the shrinking tube leads to a precise and reliable detection of the condition of the terminal fitting. Moreover, the shrinking tube allows to easily mechanically affix the sensor to the terminal fitting thereby allowing a good (particularly direct or indirect) coupling thereof to the terminal fitting in view of a reliable sensing by the sensor. In other words, the arrangement (particularly direct contact or the close positioning) of the sensor may be easily performed by the application or use of the shrinking tube, in particular by placing the terminal fitting together with the sensor within not yet shrinked shrinking tube and, subsequently heating the shrinking tube so as to reduce a dimension or diameter thereof such that the sensor is (particularly directly or indirectly) fixed or mechanically positioned onto the terminal fitting, preferably onto an outer surface thereof.

Moreover, the shrinking tube may also ensure the proper insulation of the portion of the terminal fitting bearing the sensor such as electrical insulation, insulation against humidity or water and the like. In other words, the shrinking tube particularly provides good electrical insulation and/or protection from dust, solvents and other foreign materials, particularly in addition to mechanical strain relief, wherein the sensor is mechanically held in place on the. terminal fitting by the tight fit of the shrinking tube.

According to a particular embodiment, the charging connector further comprises at least one thermal coupling member for mounting said sensor to the terminal fitting.

Accordingly, a good thermal coupling between the terminal fitting and the sensor can be achieved (particularly by increasing the surface and/or mass achieving the thermal heat transfer to the sensor), thereby improving the measuring accuracy of the sensor (particularly of a temperature sensor). This may be specifically useful in a context of DC charging of electric or hybrid vehicles in which high currents (e.g. currents exceeding about 125 A, particularly exceeding about 200 A) flow through the charging connector. Accordingly, it is advantageously possible to reliably detect the temperature of the terminal fitting also when high currents flow therethrough, so that a reliable temperature control can be performed and, thus, overheating can be efficiently and safely detected. Particularly, the thermal coupling member comprises at least one of a sleeve, a mounting bracket and a clamp. Further particularly, the thermal coupling member having said sensor being at least partly arraged therein is fixed or mounted to the terminal fitting by the at least one shrinking tube.

Further particularly, said sensor at least partly is arranged in or by means of at least one of said sleeve, said mounting bracket and said clamp, and the sleeve, mounting bracket and/or clamp is fixed or mounted to the terminal fitting by the at least one shrinking tube. More specifically, the sensor is placed into a sleeve or a mounting bracket or a clamp and the sleeve, mounting bracket or clamp is fixed to the terminal fitting by the shrinking tube. The sleeve, mounting bracket or clamp may protect the sensor when applying the shrinking tube and when inserting the terminal fitting into the accommodating chamber of the connector housing.

Accordingly, a particularly effective and simple mounting of the sensor to the terminal fitting can be achieved, while particularly ensuring a proper (e.g. thermal) coupling to the terminal fitting. Further particularly, the thermal coupling member (particularly the sleeve, mounting bracket and/or clamp) is made of a material (particularly a metal such as Cu) having good thermal conductivity, such that the mounting bracket, sleeve or clamp may increase a heat dissipation from the terminal fitting towards the sensor so as to improve the detection of the terminal fittings condition. Particularly, the sensor (at least party) is placed into a clamp which can be fixed to an outer surface of the terminal fitting. By fixing the clamp to an outer surface of the terminal fitting before applying the shrinking tube, a prefixing of the sensor may be achieved. Accordingly, manufacturing of the charging connector is facilitated and a positioning failure of the sensor may be avoided.

According to a further aspect, there is provided a method of fixing a sensor to a terminal fitting, in particular used in connection with a method of producing a charging connector according to the above aspect of the invention or a particular embodiment thereof, comprising the steps of:

placing the sensor into a mounting bracket, sleeve or clamp,

prefixing said mounting bracket, sleeve or clamp to an outer surface of the terminal fitting,

placing at least one shrinking tube over or on said outer surface and the sensor, and heating said shrinking tube(s) such that the diameter of the shrinking tube(s) decreases so as to fix the sensor on the outer surface of the terminal fitting.

According to a particular embodiment, the method further comprises a step of thermally coupling the sensor to the terminal fitting by means of a thermal coupling member, particularly by placing said sensor in the thermal coupling member before placing or mounting it on the outer surface of the terminal fitting.

According to a still further aspect, there is provided a terminal fitting comprising:

a wire connection portion (particularly comprising a crimping, welding and/or soldering part) to be connected with a wire, a connecting part to be connected with a mating terminal fitting, and

a sensor mounted on an outer surface of the terminal fitting by means of a mounting bracket, sleeve or clamp and at least one shrinking tube. According to a particular embodiment, the terminal fitting further comprises at least one thermal coupling member for mounting said sensor to the terminal fitting.

Accordingly, a good thermal coupling between the terminal fitting (particularly its outer surface) and the sensor can be achieved (particularly by increasing the surface and/or mass achieving the thermal heat transfer to the sensor), thereby improving the measuring accuracy of the sensor (particularly of a temperature sensor).

Particularly, the sensor is placed at least partly onto an outer surface of the wire connection portion, particularly of the crimping, welding and/or soldering part.

Further particularly, the terminal fitting further comprises a groove in said wire connection portion (particularly said crimping, welding and/or soldering part), said groove extending substantially along an axial direction of the terminal fitting. The groove may fulfil a double function, i.e. crimping of the wire and positioning of the sensor on the outer surface of the terminal fitting.

Further particularly, the sensor is a temperature sensor such as a NTC sensor or a PTC sensor or a PT sensor. These and other objects, features and advantages of the present invention will become more apparent upon reading of the following detailed description of preferred embodiments and accompanying drawings. It should be understood that even though embodiments are separately described, single features thereof may be combined to additional embodiments. Fig. 1 shows a cross sectional view of a terminal fitting of a charging connector according to a first embodiment, wherein Fig. 1 a shows a cross sectional view along a longitudinal axis of the terminal fitting and Fig. 1 b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting. Fig. 2 shows a cross sectional view of a terminal fitting of a charging connector according to a second embodiment, wherein Fig. 2a shows a cross sectional view along a longitudinal axis of the terminal fitting and Fig. 2b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting. Fig. 3 shows a perspective view of a mounting bracket applied in the terminal fitting of Fig. 2.

Fig. 4 shows a cross sectional view of a terminal fitting of a charging connector according to a third embodiment, wherein Fig. 4a shows a cross sectional view along - a longitudinal axis of the terminal fitting and Fig. 4b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting.

Fig. 5 shows a perspective view of a sleeve applied in the terminal fitting of Fig. 4. Fig. 6 shows a cross sectional view of a terminal fitting of a charging connector according to a fourth embodiment, wherein Fig. 6a shows a cross sectional view along a longitudinal axis of the terminal fitting and Fig. 6b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting.

Fig. 7 shows a perspective view of a clamp applied in the terminal fitting of Fig. 6.

· Fig. 8 shows a cross sectional view of a terminal fitting of a charging connector according to a fifth embodiment, wherein Fig. 8a shows a cross sectional view along a longitudinal axis of the terminal fitting and Fig. 8b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting.

Fig. 9 shows a perspective view of a clamp applied in the terminal fitting of Fig. 8.

Fig. 10 shows a cross sectional view of a terminal fitting of a charging connector according to a sixth embodiment, wherein Fig. 10a shows a cross sectional view along a longitudinal axis of the terminal fitting and Fig. 10b shows a cross sectional view perpendicular to the longitudinal axis of the terminal fitting.

Fig. 11 shows a perspective view of a clamp applied in the terminal fitting of Fig. 10. Fig. 12 shows an example of a charging connector having at least one terminal fitting according to any one of the embodiments.

Hereinafter, particular embodiments of the present invention are described with reference to the accompanying drawings. The following embodiments are specific examples of the present invention and are not meant to limit the technical scope of the present invention as defined in the claims. A first particular embodiment will be described with reference to Figure 1 . Figure 1 a shows a longitudinal cross-sectional view of a terminal fitting 10 comprising a sensor S. Figure 1 b shows a cross-sectional view of the terminal fitting 10 perpendicular to a longitudinal axis of the terminal fitting 10 in the area of the sensor S.

As shown in Figure 1 , the terminal fitting 10 comprises wire connection portion (particularly comprising at least one crimping, welding and/or soldering part 12) at or near a back side of the terminal fitting 10 so as to connect the terminal fitting 10 with a wire W of a cable. In order to connect the wire W with the terminal fitting 10, a wire sheathing WS is removed e.g. at a tip part of the wire W. The exposed wire W arranged at the wire connection portion,^" particularly at least partly is inserted into the crimping, welding and/or soldering part 12 of the terminal fitting 10. Subsequently, the arranged (inserted) part of wire W is electrically connected to the wire connection portion, particularly crimped, welded or soldered within the crimping, welding and/or soldering part 12 and/or the crimping, welding and/or soldering part 12 is crimped onto the wire W so as to establish the (particularly electric) connection between the wire W of the cable and the terminal fitting 10. The terminal fitting 10 further comprises a connecting part 14 at or near a front portion thereof. This connecting part 14 is connected or connectable with a mating terminal fitting of a mating connector (not shown). In this embodiment, the connecting part 14 is a male terminal fitting part, however, the invention is not limited to a male terminal fitting, but may also be applied to a female terminal fitting. At lest one stopper 16 limits an insertion of the connecting part 14 into the mating terminal fitting.

At least one sensor S, such as a humidity, vibration and/or temperature sensor S is placed on an outer surface of the terminal fitting 10, particularly on or near the wire connection portion (particularly the crimping, welding and/or soldering part 12). The sensor S is connected to a sensor cable SC extending towards the backside and towards and/or along the cable of the terminal fitting 10. The sensor S is mechanically fixed or mounted onto the terminal fitting 10, particularly the outer surface of the crimping, welding and/or soldering part 12, by means of at least one shrinking tube 20. This shrinking tube 20 is placed on the outer surface of the crimping, welding and/or soldering part 12 with the sensor S sandwiched between the shrinking tube 20 and the crimping, welding and/or soldering part 12.

The sensor S may comprise (not shown) an outer sheath (comprising particularly a polytetrafluoroethylene (PTFE) tube such as a Teflon tube) in order to protect the sensor from external influences e.g. from chemical reagents, humidity or the like. Specifically, a material of the outer sheath may have thermal shrinking properties so that the outer sheath may be shrunk onto the sensor S before arranging the sensor S at or on the terminal fitting 10 (e.g. inserted into a mounting bracket 30, as will, be described below in connection with Figures 2 and 3). Further specifically, the outer sheath particularly in the form of a tube (e.g. PTFE tube) may be sealed by means of a suitable adhesive so as to be fluid- or waterproof.

By applying heat to the shrinking tube 20 (e.g. by a hot air gun or other source of hot gas or fluid flow), the shrinking tube 20 shrinks and conforms to the size and shape of the substrate (i.e. the terminal fitting and sensor(s)) beneath or inside it thereby providing a good and secure fixing of the sensor S onto the outer surface of the terminal fitting 10, particularly the crimping, welding and/or soldering part 12. While the shrinking tube 20 snugly fits on the outer portion of the terminal fitting and/or sensor, it should be understood that the enclosed Figures for simplicity reasons do not show the full extent of shrinking or snug-fit of the shrinking tube 20. Preferably, the shrinking tube 20 extends toward the wire W or cable so as to at least partly surround the wire sheathing WS. Accordingly, the shrinking tube 20 not only fixes the sensor S onto the crimping, welding and/or soldering part 12, but also provides a fluid- or water-tight connection between the wire sheathing WS and the terminal fitting 10. The shrinking tube 20 may be made from a thermoplastic material such as polyolefin, fluoropolymer (such as FEP, PTFE or Kynar), PVC, neoprene, silicone elastomer and/or Viton. Specifically, PTFE (fluoropolymer) has a wide operating temperature range from approximately -55 °C to approximaetely 175 °C, a low coefficient of friction and high resistance to chemicals and punctures. Further specifically, Viton has high chemical resistance. Viton is highly flexible and comprises a very wide operating temperature range of approximately -55 °C to approximately 220 °C. However, the shrinking tube 20 may also be made from other materials such as PVDF (Polyvinylidene), FEP (Fluorinated Ethylene Propylene), Silicone rubber, Polyolefin, Nylon or PVC (Poly Vinyl Chlorid). The shrinking tube 20 is preferably formed such that it shrinks substantially radially when heated but not longitudinally, to between one-half and one-sixth of the diameter thereof.

A second particular embodiment will now be explained with reference to Figures 2 and 3. The similar or substantially same components as in the first embodiment are designated by the same reference numerals in the second embodiment.

In the second embodiment, the sensor S is also mounted to the terminal fitting 10, particularly to an outer surface of the wire connection portion (particularly the crimping, welding and/or soldering part 12) of the terminal fitting 10. However, a mounting bracket 30, as shown in Fig. 3 is used as a particular thermal (or heat) coupling member to fix or mount the sensor S onto the terminal fitting 10. The mounting bracket 30 particularly is of a substantially circular or disk-shaped form and/or comprises a mounting hole 32 particularly at an outer circumference thereof.

The sensor S at least partly is placed or inserted within the mounting hole 32 of the mounting bracket 30 (and particularly secured therein by press-fitting and/or by means of an adhesive or the like specifically having appropriate thermal conductivity properties) before placing the sensor S onto the terminal fitting 10, particularly the outer surface of the crimping, welding and/or soldering part 12. Accordingly, a safe mounting is ensured while particularly a damage of the sensor S may be prevented during mounting the sensor S and/or during inserting the terminal fitting 10 into an accommodating chamber of a connector housing. Moreover, the mounting bracket 30 as a particular thermal (or heat) coupling member provides a good heat transfer from the terminal fitting 10 to the sensor S (particularly in case the sensor is a thermosensor), as the mounting bracket 30 is made from a material having good thermal conductivity, such as copper (Cu), aluminium (Al) or the like. The invention is not limited to the mounting bracket 30 having the substantially circular or disk-shape form, but the mounting bracket 30 may also have any other form or shape such as a rectangular. block (with/without rounded edges), a building block, an elliptic block or the like. A third particular embodiment is now described with reference to Figures 4 and 5. The substantially same or similar components as in the first and second embodiments are designated by the same reference numerals in the third embodiment, shown in Figures 4 and 5, In this embodiment, the terminal fitting 10, particularly the crimping, welding and/or soldering part 12, comprises a groove or recess 12a, as shown in Figure 4b. The groove or recess 12a may be obtained by milling and/or embossing of a corresponding portion of the terminal fitting 10. The sensor S at least partly is placed within a sleeve 40 as a particular thermal (or heat) coupling member particularly substantially having a cylindrical shape (see e.g. Fig. 5). The sleeve 40 particularly has a shape substantially conforming a shape of the groove or recess 12a thereby ensuring as a particular thermal (or heat) coupling member a good heat transfer between terminal fitting 10 and sensor S. Specifically, the cylindrical shape of sleeve 40 particularly substantially has a diameter in correspondence with a radius of curvature of the groove 12a of the crimping, welding and/or soldering part 12, such that a portion of the sleeve 40 contacts substantially the whole surface of groove 12a when being at least partly placed into or arranged in the groove 12a. Further, the sleeve 40 comprises a (particularly bottomed) mounting hole 42 for at least partly inserting the sensor S. The sensor S may be particularly secured in the mounting hole 42 e.g. by means of an adhesive or the like having appropriate thermal conductivity properties. The groove 12a in connection with the sleeve 40 provides an improved positioning of the sensor S as well as an improved thermal conductivity due to a large surface contact between the sleeve 40 and the groove 2a.

A fourth particular embodiment is described with reference to Figures 6 and 7. The substantially same or similar components as in the above described embodiments are designated by the same reference numerals in the fourth embodiment shown in Figures 6 and 7. The fourth embodiment comprises a clamp 50 as a particular thermal (or heat) coupling member having a pair of legs 50a, 50a and a curved portion 50b between the pair of legs 50a, 50a. The curved portion 50b has a radius in correspondence with an outer shape of the sensor S so as to provide a big surface contact between sensor S and the curved portion 50b of the clamp 50.

The clamp 50 is preferably made from a material having a good thermal conductivity (e.g. metal), such that the heat produced by the terminal fitting 10 may be easily transferred to the sensor S being displaced between an outer surface of the wire connection portion (particularly the crimping, welding and/or soldering part 12) and the curved portion 50b of the clamp 50 when mounted onto the terminal fitting 10. Moreover, the clamp 50 can protect the sensor S from mechanical forces or impacts acting from outside. The clamp 50 can easily be manufactured from a metal plate such as a copper plate, an aluminium plate or a steel ^'plate or the like. Moreover, the clamp 50 as a particular thermal (or heat) coupling member ensures a good heat transfer between the terminal fitting 10 and the sensor S by enlarging a contact surface with the terminal fitting 10 and/or sensor S. Moreover, the sensor S can be more stably affixed to the terminal fitting 10 by means of the clamp 50.

A fifth particular embodiment will now be described with reference to Figures 8 and 9. The fifth embodiment comprises a modified clamp 52 as a particular thermal (or heat) coupling member having a curved portion 52c similar to the curved portion 50b of the fourth embodiment. However, the clamp 52 of the fifth embodiment comprises a first leg 52a as well as a second leg 52b extending substantially parallel to the first leg 52a and being connected to the first leg 52a by means of an intermediate portion 52d. The intermediate portion 52d is preferably formed as a bent portion (particularly substantially as a half circular. portion) for connecting the first and second legs 52a, 52b.

The first leg 52a and the second leg 52b of the clamp 52 may be arranged on the terminal fitting 10 in such a manner, that the sensor S is clamped by means of the clamp 52 and then mounted and affixed to the terminal fitting 10 by means of the shrinking tube 20. Accordingly, this modified clamp 52 provides the advantage that the sensor S may be prefixed between the first and second legs 52a, 52b before fixing the sensor S by means of the shrinking tube 20 so as to facilitate the operation. Accordingly, clamp 52 is preferably formed of a spring metal material and/or as a leaf spring so as to apply a small spring force onto sensor S when placing the sensor S within the curved portion 52c.

A sixth particular embodiment will now be described with reference to figures 10 and 1 1. The sixth embodiment comprises a further modified clamp 54 as a particular thermal (or heat) coupling member having a first leg 54a which includes a curved portion 54d as well as a second leg 54b and a third leg 54c. The form and dimension of first, second and third legs 54a, 54b, 54c is configured such that the clamp 54 may be prefixed to the terminal fitting 10, particularly onto the crimping, welding and/or soldering part 12, before arranging or applying the shrinking tube 20 and shrinking it. Accordingly, a prefixing of the sensor S onto the outer surface of the terminal fitting 10, particularly the crimping, welding and/or soldering part 12 may be applied with the further modified clamp 54. Moreover, the further modified claim 54 provides a good thermal conductivity such as the clamps 50 and 52 of the preceding embodiments. Particularly, the first and third legs 54a, 54c may be placed on substantially opposite sides of the outer surface of the terminal fitting 10 (as shown in Fig. 10) thereby allowing to clamp the sensor S onto the surface of the terminal fitting 10 particularly to mechanically fix it thereto.

The sensor S of all of the preceding embodiments is particularly configured as a temperature sensor. By detecting the temperature directly on the outer surface of the terminal fitting 10, a too high temperature of the terminal fitting 10 and of the respective charging connector may be prevented by reducing a charging current in case the temperature of the terminal fitting 10 exceeds a specified (predetermined or predeterminable) threshold value.

Accordingly, high currents may be applied with the charging connector and on the other hand, a too high temperature can be avoided by reducing the charging current in case the upper value is exceeded.

The temperature sensor S is preferably configured as a thermistor such as a NTC (Negative Temperature Coefficient) sensor reducing an electrical resistance thereof when increasing the temperature. However, the temperature sensor may also be configured as a PTC (Positive Temperature Coefficient) sensor exceeding its electrical resistance when increasing the temperature or a PT (Platinum Type) sensor or PTR sensor (Platinum Resistance Thermometer) sensor.

It should be understood that the sensor S may also be provided for any type of measurement other than temperature measurement such as vibration measurement, humidity measurement or the like.

Moreover, it should be understood that according to a particular embodiment plural sensors S (not shown) may be mounted to the terminal fitting 10 by means of the shrinking tube 20 in any one of the above embodiments.

The sensor S is connected or connectable to at least one sensor wire or cable SC having the appropriate configuration (particularly number, specification and/or size of wire(s)) for ensuring the sensing function of the sensor S. Particularly, in case of the sensor S comprising a thermistor probe the cable SC may comprise at least to wires for applying a potential to the thermistor probe. As shown in Fig. 12, an exemplary charging connector is configured as a vehicle- side charging connector and comprises a vehicle-side housing 51 being made e.g. of synthetic resin and/or having a mounting plate 57 to be arranged at an opening edge of a vehicle panel so as to mount the housing 51 of the connector at or in a mounting opening of the vehicle. The mounting plate 57 is preferably provided with a glue or a bonding agent such as Sikaflex^® so as to bond and seal the mounting plate 57 to the opening edge of the vehicle panel. Alternatively or additionally, a separate seal may be provided, such as a silicone or rubber made sealing. The mounting plate 57 may also be alternatively or additionally fixed by one or more bolts, clips and/or engaging pawls or the like.

Moreover, the housing 51 is provided with at least one hole or receptacle 53 into which a tower 60 being separately provided can be inserted or mounted from a mounting side, particularly substantially from behind. The tower 60 is made e.g. of synthetic resin similar to the housing 51 , wherein it may be provided of a different material e.g. in view of different electric properties (e.g. in view of providing a low current creepage). Preferably, the hole 53 has a sufficient length or axial extension so as to provide a proper or stiff support of the tower 60 such that a tilting thereof can be avoided. The hole 53 particularly has a length of approximately 10% to approximately 30% of the total length of the tower 60 thereby providing a good support.

Particularly, the cross-section of the tower 60 and the mating hole 53 substantially is cylindrical, rectangular or ellipsoid, such that the outer surface of the tower 60 receives an adequate support at the inner surface of the mating hole 53. In the described embodiment, the cross-section is substantially cylindrical which leads to the advantage that the manufacture thereof is facilitated.

Further, the housing 51 is provided with at least one lock projection 56 for locking a lever of a mating charging connector (not shown) provided at an end of an external charging cable or wire harness. This mating charging connector may be formed like the charging connector of EP 2 626 955 A1 , which document is incorporated by reference. The mating charging connector (not shown) to be connected to the vehicle-side charging connector comprises a case body including a connector fitting portion connectable to the vehicle-side connector; a locking portion for holding the vehicle- side connector and the charging connector in a connected state by being locked or interlocked by the lock projection 56 provided on the vehicle-side connector; an unlocking portion capable of canceling a locked state of the locking portion and the lock projection 56; and an unlocking hole formed in the case body at a position substantially corresponding to the unlocking portion, wherein the unlocking portion at least partly projects to the outside of the case body through the unlocking hole and includes at least one recess at a position substantially facing the peripheral edge of the unlocking hole.

According to this construction, a distance from the recess to the peripheral edge of the unlocking hole is longer as compared with the case where no recess is provided. Thus, even if water enters the recess, the action of surface tension is unlikely and water more easily runs down through the recess. Therefore, water does not stay in the recess and interference with an unlocking operation caused by freezing can be avoided. The tower 60 is provided with at least one accommodating chamber 64 for at least partly accommodating a terminal fitting 80. The terminal fitting 80 particularly is formed of solid copper which may be nickel- and/or silver-plated. The terminal fitting 80 includes at or near a rear side thereof a rear recess into which an end of a charging cable can be inserted and conductively fixed. In the shown embodiment, a plurality of accommodating chambers 64, e.g. five accommodating chambers 64, particularly are provided in the tower 60 so as to at least partly accommodate a corresponding number of terminal fittings 80, e.g. five terminal fittings 80. The terminal fittings 80 are provided with a contact portion 82 at or near a front side thereof and these contact portions 82 at least partly are to be inserted into the accommodating chamber 64 such that the contact portions 82 at least partly are exposed within an exposed portion 64b of the accommodating chamber 64. Further, at least one terminal fitting 10 to be mounted in an accommodating chamber 64a of the housing 51 is provided with the sensor S, as described above (please note that the sensor S and shrinking tube 20 are not shown in Fig. 12).

Specifically, in context of the present vehicle-side charging connector, there are plural standards which may be met. Specifically, SAE J1772 is a standard having the formal title "SAE Surface Vehicle Recommended Practice J1772, SAE Electric Vehicle Conductive Charge Coupler" and covers the general physical, electrical, communication protocol, and performance requirements for the electric vehicle conductive charge system and coupler. SAE J1772 defines a common electric vehicle conductive charging system architecture including operational requirements and the functional and dimensional requirements for the vehicle inlet and mating connector. Specifically, the SAE J1772 standard defines two charging levels, AC Level 1 (single-phase) 120V, 16A providing 1 ,9 kW and AC Level 2 (split-phase) 240 V, 80A providing 19 kW. The SAE J1772 committee has also proposed a DC connector based on the SAE J1772-2009 AC connector shape with additional DC and ground pins to support charging at 200-450 V DC and 80 A (36 kW) for DC Level 1 and up to 200 A (90 kW) for DC Level 2. The SAE DC Level 3 charging levels have not been determined, but the standard as it exists as of 2009 has the potential to charge at 200-600 V DC at a maximum of 400 A (240 kW).

Up to now, national technical committee of auto standardization (NTCAS) have organized and drafted 56 electric vehicle standards (38 national standards and 18 automotive industry standards) which have been approved and released by standardisation authorities. In this context, crash safety and potential dangers from on-board high-energy and potential injury to occupants from high-voltage circuit have to be addressed, as e.g. in ECE-R 100. The charging connector described herein particularly is suitable to meet the requirements of SAE J1772 standard and SAE SAE J1772-2009. Furthermore, the charging connector described herein can also be configured to meet the IEC 62196-3 Fdis standard and/or IEC 62196-2 of the International Electrotechnical Commission.

It should be understood, that the present invention can be applied to different types of charging connectors designed for AC charging connectors (e.g. using SAE J1772™ compliant Level 1 & 2 connector) and/or DC charging connectors. Accordingly, the number and/or configuration of the terminal fittings 80 at least partly accommodated in the accommodating chambers 64 of the tower 60 are variable. The tower 60 separate from the housing 51 may comprise only terminal fittings relating to the AC charging, only terminal fittings relating to the DC charging or terminal fittings relating to .both AC and DC charging (also referred to as combined charging system (CCS) type). Furthermore, two (or more) towers 60 separate from the housing 51 may be provided, such as a first tower accommodating terminal fittings relating to AC charging and a second tower accommodating terminal fittings relating to DC charging in order to provide a vehicle-side charging connector of the combined charging system (CCS) type.

The invention is not limited to a charging connector mounted in a vehicle but may also be applied to a charging connector of a charging station, power source or the like. Although the charging connector of the above-described embodiment is provided with the tower 60 for accommodating the (small) terminal fittings 80 and the (big) terminal fittings 10 having the sensor S, the invention may also be applied to a charging connector having no tower 60 and/or no small terminal fittings 80 without a sensor, but to a charging connector having a simple housing without a tower and with only one kind of terminal fittings 10 with a sensor S.

List of Reference Numerals

10 terminal fitting (with sensor)

12 crimping/welding/soldering part

12a groove

14 connecting part 16 stopper

20 shrinking tube

30 mounting bracket

32 mounting hole

40 sleeve

42 mounting hole

50 clamp

50a leg

50b curved portion

51 housing

52 clamp

52a first leg

52b second leg

52c curved portion

52d intermediate portion

53 receptacle or hole

54 clamp

54a first leg

54b second leg

54c third leg

54d curved portion

55 circumferential wall

55a slit

56 lock projection

57 mounting plate 58 rear cover

58a rear cover

59 abutment portion

59a abutment portion

60 tower

62 groove

64 accommodating chamber

64a accommodating chamber

65 drain opening

66 larger diameter portion

67 small/smaller diameter portion

70 sealing ring (seal member)

80 terminal fitting (without sensor)

82 contact portion

84 flange portion

90 sealing

C coating

S sensor

SC sensor cable

W wire

ws wire sheathing

Claims

1. A charging connector for charging a battery installed in a vehicle comprising: a housing (51 ) comprising at least one accommodating chamber (64a) for at least partly accommodating at least one terminal fitting (10), and

at least one sensor (S) mounted to at least one terminal fitting (10) wherein said sensor (S) is placed into a mounting bracket (30), sleeve (40) or clamp (50; 54) which is/can be prefixed to an outer surface of the terminal fitting (10) and the sensor

(S) is then mounted and affixed to the terminal fitting (10) by means of at least one shrinking tube (20).

2. The charging connector of claim 1 , further comprising at least one thermal coupling member (30; 40; 50; 52; 54) for mounting said sensor (S) to the terminal fitting (10).

3. The charging connector of claim 2, wherein the thermal coupling member (30; 40; 50; 52; 54) comprises at least one of said sleeve (40), said mounting bracket (30) and said clamp (50; 52; 54), and/or wherein the thermal coupling member (30; 40; 50; 52; 54) having said sensor (S) being at least partly arranged therein is fixed to the terminal fitting ( 0) by the at least one shrinking tube (20).

4. The charging connector of claim 2 or 3, wherein the thermal coupling member (30; 40; 50; 52; 54) is made of a material having a good thermal conductivity.

5. A method of fixing a sensor to a terminal fitting comprising the steps of:

placing the sensor (S) into a mounting bracket (30), sleeve (40) or clamp (50; 54),

prefixing said mounting bracket (30), sleeve (40) or clamp (50; 54) to an outer surface of the terminal fitting (10),

placing at least one shrinking tube (20) over said outer surface, and

heating said shrinking tube (20) so as to fix the sensor (S) on the outer surface of the terminal fitting (10).

6. The method of claim 5, further comprising the step of thermally coupling the sensor (S) to the terminal fitting (10) by means of a thermal coupling member (30; 40; 50; 52; 54), particularly by placing said sensor (S) in the thermal coupling member (30; 40; 50; 52; 54) before placing it on the outer surface of the terminal fitting (10).

7. A terminal fitting comprising:

a wire connection portion (12) to be connected with a wire (W),

a connecting part (14) to be connected with a mating terminal fitting, and

a sensor (S) mounted on an outer surface of the terminal fitting (10) by means of a mounting bracket (30), sleeve (40) or clamp (50; 54), and at least one shrinking tube (20).

8. The terminal fitting of claim 7, further comprising at least one thermal. coupling - member (30; 40; 50; 52; 54) for mounting said sensor (S) to the terminal fitting (10).

9. The terminal fitting of claim 7 or 8, wherein said sensor (S) is placed at least partly onto an outer surface of the wire connection portion (12).

10. The terminal fitting of any one of the preceding claims 7 to 9, further comprising a groove (12a) in said wire connection portion (12), said groove (12a) extending substantially along an axial direction of the terminal fitting (10).

1 1 . The charging connector of any one of the preceding claims 1 to 5 or the terminal fitting of any one of the preceding claims 7 to 10, wherein said sensor (S) is a temperature sensor such as a NTC sensor or a PTC sensor or a PT sensor.