WO2024107202A1

WO2024107202A1 - Electrical connector assembly having a sealed housing mechanism and temperature sensor

Info

Publication number: WO2024107202A1
Application number: PCT/US2022/050407
Authority: WO
Inventors: Stefan Maurice MAYER; Sebastian Richter; Nikolai Hannes ZEITLER; Andreas Zimmermann; Ontje Frank WEGMANN
Original assignee: Itt Manufacturing Enterprises Llc
Priority date: 2022-11-18
Filing date: 2022-11-18
Publication date: 2024-05-23

Abstract

An electrical connector, product, assembly, system, and/or method for connecting to a mating electrical receptacle is disclosed that includes a housing; an electrical conductor contained at least partially within the housing; an electrical wire for carrying at least one of a group consisting of electrical power, an electrical signal, and combinations thereof, the electrical wire electrically connected to the electrical conductor; and a sealing member having a first portion surrounding at least a front portion of the electrical wire to form a first water-resistant seal with the electrical wire and a second portion surrounding at least a back portion of the electrical conductor to form a second water-resistant seal with the electrical conductor, the second portion having an enlarged lip located between the housing and the electrical conductor, the enlarged lip configured to form a third water-resistant seal with the housing.

Description

ELECTRICAL CONNECTOR ASSEMBLY HAVING A SEALED HOUSING MECHANISM AND TEMPERATURE SENSOR

BACKGROUND

[0001] The present application relates generally to electrical connector assemblies, preferably for providing electrical power and/or signals to a socket and/or receptacle, which in an example provides power to recharge the batteries in an electrical vehicle (EV).

SUMMARY

[0002] The summary of the disclosure is given to aid understanding of electrical connector assemblies, including electrical connector assemblies having electrical conductors within a housing that receive and are connected to electrical wires for providing electric power and/or receiving and/or providing electrical signals to the electrical connector assembly. The electrical connector assembly in an embodiment is inserted into a mating electrical socket or receptacle, for example, contained within an electrical vehicle (EV) for charging the battery of the EV. The summary of the disclosure is provided as an aid to understanding electrical connector assemblies, and not with an intent to limit the disclosure or the invention. The present disclosure is directed to a person of ordinary skill in the art. Various aspects and features of the disclosure may advantageously be used separately in some instances, or in combination with other aspects and features of the disclosure in other instances. Accordingly, variations and modifications may be made to the electrical connector or assembly and/or methods for connecting electrical cables to the electrical connectors to achieve different effects.

[0003] An electrical connector, assembly, product, and/or technique is disclosed according to one or more embodiments for connecting to a mating electrical socket and/or receptacle to deliver power and/or electrical signals between the electrical connector and the mating electrical socket and/or receptacle. In one or more approaches the electrical connector, assembly, and/or product fits within and/or is received with respect to the mating connector, assembly, and/or product (e.g., a socket and/or receptacle connecter). In one or more arrangements, the electrical connector assembly includes: a housing; one or more electrical conductors contained at least partially within the housing; one or more electrical wires for carrying at least one of a group consisting of electrical power, an electrical signal, and combinations thereof, the one or more electrical wires electrically connected to the one or more electrical conductors; and a sealing member having a first portion surrounding at least a front portion of at least one of the one or more electrical wires to form a first water-resistant seal with the one of the one or more electrical wires and a second portion surrounding at least a back portion of at least one of the one or more electrical conductors to form a second water-resistant seal with the one of the one or more electrical conductors, the second portion having an enlarged lip located between the housing and the at least one of the one or more electrical conductors, the enlarged lip configured to form a third water-resistant seal with the housing. The housing in an aspect includes a front plate and a back casing. In an embodiment, the electrical connector, assembly, and/or product includes a plurality of sealing members wherein the plurality of sealing members are associated with a plurality of the one or more electrical conductors, and in a further arrangement all the plurality of sealing members are each associated with one of the one or more electrical conductors.

[0004] The sealing member in a preferred embodiment is located between the front plate and the at least one of the one or more electrical conductors and is configured to from the third water- resistant seal with the front plate. The sealing member in an embodiment has a length between about ten (10) millimeters and one hundred and fifty (150) millimeters. According to an arrangement is flexible and formed of insulating material, including for example rubber or thermoplastic material. The sealing member preferably is formed and/or configured as a cylindrical sleeve having an inside diameter at the first portion and an inside diameter at the second portion, wherein the first portion inside diameter is sized and configured to fit over and surround the front portion of the at least one of the one or more electrical wires and form the first water-resistant seal with the at least one of the one or more electrical wires and the second portion inside diameter is sized and configured to fit over and surround the back portion of the at least one of the one or more electrical conductors to form the second water-resistant seal with the at least one of the one or more electrical conductors. In an aspect the enlarged lip of the sealing member has a thickness between two (2) millimeters and thirty (30) millimeters.

[0005] In a further embodiment, the electrical connector assembly has an optional retainer element to hold the sealing member in position. The retainer element according to a configuration has one of an extending projection or an opening to hold the retainer element in position within the electrical connector assembly, wherein if the retainer element has the extending projection, the housing has an engagement slot to engage the extending projection and if the retainer element has the opening, the housing has a projection to engage the opening. The retainer element according to an arrangement has one or more extending prongs configured to engage the enlarged lip of the sealing member. The electrical connector assembly according to an embodiment optional includes one or more O-rings located between the front plate and the back casing to facilitate forming a fourth water-resistance seal between the front plate and the back casing.

[0006] The electrical connector assembly optionally includes a temperature sensor assembly having a temperature sensor, wherein the temperature sensor assembly is associated with the at least one of the one or more electrical conductors to measure the temperature of the at least one of the one or more electrical conductors. In an embodiment the temperature sensor of the temperature sensor assembly is retained in position by the sealing member. In a further aspect the temperature sensor further comprises electrical leads to transmit voltage signals from the temperature sensor and the electrical leads extend out the first portion of the sealing member. The temperature sensor according to a further arrangement is located within a bore of the sealing member, wherein the sealing member is not located between the temperature sensor and the at least one of the one or more electrical conductors. The temperature sensor of the temperature sensor assembly in a further configuration is positioned within a channel formed in the sealing member, wherein a section of the sealing member is positioned between the temperature sensor and the at least one of the one or more electrical conductors. In a further aspect, the temperature sensor assembly includes a printed circuit board (PCB) and the temperature sensor is mounted on the PCB as a surface mounted device (SMD). In a specific embodiment, the PCB has a length between twenty (20) millimeters and one hundred (100) millimeters, a width between one (1) millimeter and four (4) millimeters, and a thickness between eight tenths (0.8) of a millimeter to three (3) millimeters, and the PCB includes electrically conductive elements to transmit voltage signals received from the temperature sensor.

[0007] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The various aspects, features, and embodiments of the methods, techniques, products, assemblies, and/or systems that provide electrical power, electrical signals, and/or both, to one or more mating electrical sockets and/or receptacles will be better understood when read in conjunction with the figures provided. More specifically, an electrical connector assembly having a housing that contains one or more electrical conductors that are electrically connected to one or more electrical wires carrying electrical power and/or signals is disclosed. It may be noted that a numbered element in the figures is typically numbered according to the figure in which the element is introduced, is typically referred to by that number throughout succeeding figures, and that like reference numbers generally represent like parts of exemplary embodiments of the invention.

[0009] Embodiments are provided in the figures for the purpose of illustrating aspects, features, and/or various embodiments of the methods, techniques, products, assemblies, and/or systems for connecting to a mating electrical socket, assembly, and/or receptacle for providing electrical power to, for example, an electrical vehicle (EV), but the claims should not be limited to the precise arrangement, configuration, structures, features, aspects, assemblies, subassemblies, systems, embodiments, approaches, methods, processes, devices, uses, and/or implementations shown. The arrangements, configuration, structures, features, aspects, assemblies, subassemblies, systems, embodiments, approaches, methods, processes, and/or devices shown may be used singularly or in combination with other arrangements, configurations, structures, features, aspects, assemblies, subassemblies, systems, embodiments, approaches, methods, processes, devices, and/or other uses and/or implementations.

[0010] FIG. 1 is a Voltage/ Amperage graph showing three different electric vehicle charging classes.

[0011] FIG. 2 is a side perspective view of an electrical charging station used for charging electrical vehicles (EVs) where the electrical charging station has an electrical connector assembly for connecting to a mating electrical socket connector and/or receptacle of, for example, an electrical vehicle (EV), according to an embodiment of the present disclosure.

[0012] FIG. 3 is a side cross-sectional view of a front portion of an electrical connector assembly according to an embodiment of the present invention.

[0013] FIG. 4 is a side perspective view of a temperature sensor assembly, according to an embodiment of the present disclosure.

[0014] FIG. 5 is a side cross-sectional view of a portion of an electrical connector assembly according to another embodiment of the present disclosure implementing the temperature sensor assembly of FIG. 4.

[0015] FIG. 6 is back perspective view of the electrical connector assembly of FIG. 5, according to an embodiment of the present disclosure.

[0016] FIG. 7 is a side perspective view of another embodiment of a temperature sensor assembly, according to an embodiment of the present disclosure.

[0017] FIG. 8 is a is a side cross-sectional view of a portion of an electrical conductor assembly according to a further embodiment of the present disclosure implementing the temperature sensor assembly of FIG. 7. [0018] FIG. 9 is a side perspective view of a further embodiment of a temperature sensor assembly, according to an embodiment of the present disclosure

[0019] FIG. 10 a side cross-sectional view of a portion of electrical conductor assembly, according to a further embodiment of the present disclosure implementing the temperature sensor assembly of FIG. 9.

[0020] FIG. 11 is a is back perspective view of the electrical connector assembly of FIG. 10, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0021] The following description is made for illustrating the general principles of the invention and is not meant to limit the inventive concepts claimed herein. In the following detailed description, numerous details are set forth in order to provide an understanding of methods, techniques, electrical connector products, electrical connector assemblies, and/or electrical connector systems for connecting to an electrical cable or cord that supplies and/or receives electrical power and/or electrical signals where the electrical connector product, assembly and/or system connects to a mating electrical socket and/or receptacle, however, it will be understood by those skilled in the art that different and numerous embodiments of the methods, techniques, products, connectors, assemblies, and/or systems may be practiced without those specific details, and the claims and disclosure should not be limited to the arrangements, configuration, embodiments, features, aspects, assemblies, subassemblies, structures, processes, methods, details, implementations and/or uses specifically described and shown herein. In addition, features described herein can be used in combination with other described features in each of the various possible combinations and permutations.

[0022] Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. It should also be noted that, as used in the specification and the appended claims, the singular forms "a", "an" and "the" include plural referents unless otherwise specified, and 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.

[0023] The following discussion omits or only briefly describes electrical connector products, assemblies, and/or systems for delivering power and signals to a mating electrical socket and/or receptacle, which are apparent to those skilled in the art. It is assumed that those skilled in the art are familiar with electrical connector products, assemblies, and/or systems for delivering and/or receiving power and signals to or from mating electrical sockets and/or receptacles, for example mating electrical sockets and/or receptacles included within an electrical vehicle (EV), including appropriate dimensions, configurations and materials for electrical conductors for carrying various amounts of power and/or signals (e.g., current and/or voltage levels), as well as dimensions, configurations, and materials for electrically insulating and/or isolating the electrical conductors carrying the various amounts of power and/or signals (e.g., current and/or voltage levels).

[0024] Disclosed is an electrical connector product, assembly, system, and/or process for connecting to a mating electrical receptacle and/or socket, for example to provide electrical power and/or electrical signals (e.g., voltage levels) to or from a mating electrical receptacle and/or socket. The electrical connector product, assembly, and/or system can take on numerous different styles and forms and can contain various numbers of electrical power conductors and/or signal conductors.

[0025] In one or more embodiments the electrical connector product, assembly, system and/or technique is directed to delivering electrical power to an electrical vehicle (EV) to charge the batteries of the EV. The electrical connectors, assemblies, products, systems, and/or techniques can be, for example, incorporated into systems and connectors that meet one or more electrical vehicle (EV) charging standards, which may vary by region and/or country. For example, the electrical connectors, assemblies, products, systems, and/or techniques can be incorporated into Combined Charging Systems (CCS) type 1 or type 2 connectors as well as other electrical connectors including electrical connectors and standards not yet developed.

[0026] Currently there are three different electric vehicle charging classes as shown in FIG. 1. AC charging which has maximum power of 30.24 Kilowatts and uses up to 80 Amps and up to 480 Volts. AC charging is generally available using uncooled charging connectors. CCS (Combined Charging Systems) charging which has maximum power of 800 kilowatts and uses up to 800 Amps and up to 1000 Volts. CCS charging is available using uncooled and cooled charging connectors. MCS Charging (Megawatt Charging System) which has a maximum power of 3.75 Megawatts and uses from 500 Amps to 3000 Amps and up to 1250 Volts. MCS charging connectors are available as cooled and uncooled. The electrical connector product, assembly, and/or system preferably can deliver, supply, receive, carry, and/or handle high power alternating current as well as high power direct current, and is configured to handle the power, amperage, and voltages of these different EV charging classes.

[0027] In an embodiment the electrical connector product, assembly, and/or system can deliver, supply, receive, carry, and/or handle thirty (30) kilowatts of alternating current (AC) power (e.g., including eighty (80) amperes of current and 480 volts); five hundred (500) kilowatts of direct current (DC) power (e.g., including five hundred (500) amperes of current and one thousand (1000) volts); and 3.75 Megawatts of power (e.g., including up to three thousand (3000) amperes and 1250 volts), although other power (current and/or voltage) levels are contemplated, particularly as standards change.

[0028] FIG. 2 shows an electrical vehicle charging center 20 having a charging base 25, electrical cable 10, and an electrical connector assembly 100. Although charging base 25 shows a socket connector 26 for receiving one end 12(1) of electrical cable 10, the electrical cable 10 can be connected to the charging center 20 in any number of different ways, including using connections and hard wiring cable 10 so that cable 10 cannot be easily disconnected from charging base 25. The second end 12(2) of the electrical cable 10 is received by and attached to electrical connector assembly 100. More specifically, the second end 12(2) of the electrical cable 10 is inserted into an opening 111 in a back end or cable insertion end 113 of a back casing 112 of a housing 110 of the electrical connector assembly 100. The cable 10 preferably contains one or more electrical wires 15. Electrical wires 15 can be electrical power wires 14 carrying electrical power (voltage and current) and/or electrical signal wires 16 carrying electrical signals. It can be appreciated that the disclosure has application to both electrical power wires 14 and electrical signal wires 16. Cable 10, more specifically electrical wires 15, is attached to electrical connector assembly 100.

[0029] While cable 10 is shown and described as an insulated sheath that contains multiple electrical wires 15 where each electrical wire 15 has an insulated sheath, coating, or covering, it can be appreciated that cable 10 can be multiple, independent electrical wires 15 each preferably having an insulated sheath, coating, or covering, but no main sheath or covering containing the multiple wires 15. If cable 10 comprises several independent electrical wires 15, the housing 110, more specifically the back casing 112, can have one or more openings 111 in the back end 113 of the back casing 112 and/or housing 110 to receive the multiple, independent electrical wires 15. Electrical power wires 14 are generally thicker and are configured to handle more power (e.g., current and voltage) while electric signal wires 16 are generally thinner and configured to carry low voltage and/or low current, typically both low voltage and low current. Each of electrical power wires 14 and electrical signal wires 16 comprise an electrical conductor for carrying the current and an outside insulating or dielectric coating and/or covering. The electrical power wires 14 preferably can carry electric current as high as three thousand (3000) amperes and voltage as high as fifteen hundred (1500) volts. For example, CCS type 2 connectors are supplied with sixty (60) kilowatts to 4.5 Megawatts of power.

[0030] FIG. 3 illustrates a side cross-sectional view of an electrical connector assembly 100 according to an embodiment of the present disclosure that receives an electrical cable 10 having one or more electrical wires 15. Electrical connector assembly 100 includes a housing 110, one or more, preferably a plurality of electrical conductors 120, each for receiving and forming an electrical connection with an electrical wire 15 (e.g., an electrical power wire 14 or an electrical signal wire 16). The electrical connector assembly 100 can further include a sealing member 130 and a retainer element 140. The sealing member 130 forms a first water-resistant seal between the sealing member 130 and the electrical wire 15 received in the electrical conductor 120, a second water-resistant seal between the housing 110 (more specifically front plate 115 of housing 110) and the sealing member 130, and a third water-resistant seal between the sealing member 130 and the electrical conductor 120. The retainer element 140 is configured to hold one or more of the sealing member 130, the electrical conductor 120 and /or the electrical wire 15 in position in the electrical connector assembly 100.

[0031] The electrical connector assembly housing 110, in an embodiment, includes a back casing 112 and a front plate 115. The housing 110, including the back casing 112 and front plate 115, preferably is formed of an insulating and/or dielectric material, for example, plastic, although other materials are contemplated for the housing 110, back casing 112, and front plate 115, including coated conductive materials, composites and the like. The back casing 112 and front plate 115 can be formed of the same material(s) or different material(s). The housing 110 serves to contain the components of the electrical connector assembly 100, preferably in a water- resistant manner so that water can not intrude into the housing 110 and/or connector assembly 100 and cause any short circuits or dangerous situations. While the housing 110 has been shown in FIG. 3 as containing two parts including back casing 112 and front plate 115 it can be appreciated that other arrangements, constructions, and configurations are contemplated including a multi-piece or single piece housing 110, and where the front plate 115 and back casing 112 can have different configurations than illustrated. For example, the sealing member 130 can bear against the back casing 112 as opposed to the front plate 115 as illustrated in FIG.

3.

[0032] An optional protective collar 105 can be provided which in an arrangement can be removably attached to the front plate 115, the back casing 112, and/or other components of the electrical connector assembly 100. In an alternative embodiment, the protective collar 105 can be an integral part of front plate 115, back casing 112, or other components of the electrical connector assembly 100. The protective collar 105 preferably protects the front plate 115 and the electrical conductors 120 from damage from mishandling the electrical connector assembly 100 by users. The protective collar 105 can be shaped, configured, adapted, and/or arranged to meet electrical charging standards and to help with inserting and retaining the electrical assembly connector 100 in a respective mating electrical socket or receptacle. The protective collar 105 can have one or more openings 107 in the front end 106 of the protective collar 105 to receive the conductive elements of the mating electrical socket or receptacle of the electrical vehicle. The protective collar 105 can be formed of a plastic material, although other materials including coated metals, composites, and the like are contemplated.

[0033] The front plate 115 has one or more openings 116 in a front end 117 of the front plate 115 to receive the one or more conductive elements of the respective mating electrical socket or receptacle of the electrical vehicle. The one or more electrical conductors 120 each include a socket 121, preferably substantially cylindrically shaped, in the front end 122 of each of the electrical conductors 120 to receive and make an electrical connection with a conductive element of the mating electrical socket or receptable. The conductive element, typically a prong or projection, of the mating electrical socket is inserted and/or received into the opening 116 of the front plate 115 and into the socket 121 of the electrical conductor 120 where the conductive element makes an electrical connection with the electrical conductor 120.

[0034] In electrical connector assembly 100, each of the one or more electrical conductors 120 are inserted and/or received in a back opening 118 of the front plate 115 and a front end 122. In an embodiment, each of the one or more electrical conductors 120 can abut against a clip 150 attached to each of the electrical conductors 120 as described below. In an alternative embodiment the one or more electrical conductors can abut against a ledge 119 or other structure formed in the front plate 115. The outer surface 123 of each of the electrical conductors 120 can take any form but are preferably substantially cylindrically shaped. The outer surface 123 of each of the electrical conductors 120 preferably is shaped to be received in back opening 118 of the front plate 115 and in an embodiment can abut against ledge 119 to prevent forward movement of the electrical conductor 120.

[0035] The electrical cable 10 or electrical wires 15 are generally inserted into housing 110 through an opening in the back end of the housing 110 or back casing 112 and inserted up and into contact with each respective electrical conductor 120. The cable 10 or the one or more electrical wires 15 preferably form a water-resistant seal with the opening 111 in the housing 110 where the cable 10 or electrical wires 15 are inserted into the electrical connector assembly 100. The water-resistant seal between the electrical cable 10 and/or the one or more electrical wires 15 can be formed in any number of ways, means, and/or by any number of mechanisms. In an embodiment a grommet is used between the cable 10 and/or electrical wires 15 and the housing 110 to facilitate forming a water-resistant seal.

[0036] Each respective electrical wire 15 is electrically connected to a back end 125 of each respective electrical conductor 120. Typically, the electrical connector assembly 100 contains a plurality of electrical conductors 120 and each electrical wire 15 is received by and electrically connected to a respective electrical conductor 120. In an embodiment electrical wire 15 is inserted into a sleeve portion 126 (e.g., a crimp barrel) formed in the back end 125 of the electrical conductor 120. More specifically, sleeve portion 126 forms an opening 127, preferably a cylindrical opening 127, that receives wire 15 and wire 15 is attached to the electrical conductor 120 by one or more of a number of means including crimping the sleeve portion 126, soldering, cementing, pins, and/or crimp tubes, to name just a few. It can be appreciated that the one or more electrical conductors 120 do not have to have sleeve portion(s) 126 or opening(s) 127 and that each wire 15 can be electrically attached to each electrical conductor 120 in any number of different ways and through one or more mechanisms.

[0037] Electrical connector assembly 100 preferably includes one or more, preferably a plurality of, sealing members 130, and in an embodiment a sealing member 130 for each electrical conductor 120, more preferably for each electrical conductor 120/electrical wire 15 connection. Sealing member 130 preferably is flexible, formed of an insulating and/or dielectric material, and in an embodiment formed of rubber or similar compounds. For example, sealing member 130 can be formed of thermoplastic elastomers, such as, for example, Thermoplastic Vulcanisate (TPV), Thermoplastic Elastomer (TPE), and Thermoplastic Polyurethane (TPU), although other compounds are contemplated. The sealing member 130 in an embodiment has a Shore A hardness of 30 to 90.

[0038] Each sealing member 130 preferably is configured, adapted, sized, shaped, dimensioned, and/or arranged to provide a water-resistant seal between the housing 110, the one or more electrical conductors 120, and the one or more electrical wires 15. Sealing member 130 has a length L, which depending upon the application length L can vary between as low as ten (10) millimeters and as high as one hundred fifty (150) millimeters, preferably about seventy (70) millimeters; an inside diameter D, which depending upon the application can vary between as low as two (2) millimeters; and a thickness, which depending upon the application can vary between as low as one tenth (0.1) of a millimeter and as high as ten (10) millimeters, preferably about two (2) millimeters. Sealing member 130 preferably is formed as a sleeve having a bore 132 that extends the length L of the sealing member 130 that has a back opening 133 at back end 134 and front opening 135 at front end 136. The illustrated shape and disclosed dimensions are only exemplary and should not limit the disclosure. For example, although sealing member 130 is shown as generally cylindrical in shape having an inner diameter D, it can be appreciated that other shapes and forms can be used including different outer surface shapes and/or different inner bore 132 shapes.

[0039] A portion of sealing member 130, more specifically back end 134 of the sealing member 130 preferably fits over and surrounds at least a portion of one of the electrical wires 15 and preferably forms a first water-resistant seal with the electrical wire 15 such that water cannot intrude or seep in between the sealing member 130 and electrical wire 15. Sealing member 130 preferably fits over, surrounds, and overlays the insulating sheath, coating, and/or covering of the electrical wire 15 so that none of the electrically conductive material of the electrical wire 15 is exposed and subject to encountering water, should water intrude or seep into housing 100 and/or electrical connector assembly 100. In an example, back end 134 of sealing member 130 is fitted over an end of the wire 15 so that wire 15 is inserted into back opening 133 and into bore 132 of the sealing member 130. Back end 134 of sealing member 130 preferably fits tightly over electrical wire 15 in a manner to form a water-resistant seal. In an embodiment, at least about 1 mm, more preferably about 10 mm of sealing member 130 overlaps the electrical wire 15 (e.g., extends beyond the back end 125 of the electrical conductor 120). In a further embodiment, as low as ten percent (10%) to as high as ninety percent (90%), more preferably about forty percent (40%) to about sixty percent (60%), of the length L of the sealing member 130 extends beyond the back end 125 of the electrical conductor 120 and overlaps the electrical wire 15. In an embodiment, the sealing member 130 overlaps with cable 15 to provide a tight fit that would be water resistant in the event water intrudes into the housing 110.

[0040] A portion of sealing member 130, more specifically front end 136, preferably fits over and surrounds at least a portion of one of the electrical conductors 120 and preferably forms a first water-resistant seal with the electrical conductor 120 such that water cannot intrude and/or seep in between the sealing member 130 and the respective electrical conductor 120. Sealing member 130 preferably fits over, surrounds, and overlays the back end 125 of the electrical conductor 120 including in an embodiment the portion that extends within the back casing 112, preferably up to the location about where the front plate 115 meets and attaches to the front end of the back casing 112. In an example, front end 136 of sealing member 130 is fitted over the back end 125 of electrical conductor 120 so that electrical conductor 120 is inserted into front opening 135 and into bore 132 of the sealing member 130. Back end 136 of sealing member 130 preferably fits tightly over electrical conductor 120 in a manner to form a water-resistant seal.

[0041] In an embodiment, at least about five (5) mm, more preferably about thirty-five (35) mm of sealing member 130 overlaps the electrical conductor 120 (e.g., extends over back end 125 of the electrical conductor 120). In a further embodiment, as low as ten percent (10%) to as high as ninety percent (90%), more preferably about forty percent (40%) to about sixty percent (60 %), of the length L of the sealing member 130 extends over the back end 125 of the electrical conductor 120 and overlaps the electrical conductor 120. While the embodiment of FIG. 2 shows only a portion of the electrical conductor 120 being surrounded by the sealing member 130, it can be appreciated that different amounts and portions of electrical conductor 120 can be surrounded by sealing member 130, and in an embodiment the entire, or substantially the entire, length of the electrical conductor 120 can be surrounded by the sealing member 130.

[0042] Front end 136 of sealing member 130 has an enlarged lip 137 of increased thickness, which depending upon the application can vary from as low as two (2) mm and as high as thirty (30) mm, more preferably having a thickness of about seven (7) mm. The enlarged lip 137 preferably has a lip length LE, which depending upon the application can vary between as low as two (2) mm to as high as fifty (50) mm, more preferably about ten (10) mm. The front end 136 of the sealing member 130, including specifically the enlarged lip 137, is configured, sized, shaped, dimensioned, adapted, and/or arranged to create a third water-resistant seal between housing 110 and the sealing member 120, and more specifically in the embodiment shown a water-resistant seal between the front plate 115 and the sealing member 130, including more specifically a water-resistant seal between the front plate 115 and the enlarged lip 137. It should be appreciated that the front end 136 and/or enlarged lip 137 does not have to be circular shaped as shown and should be shaped and configured to seal with the front plate 115.

[0043] In an approach, the sealing member 130 fits in a channel 103 formed between the electrical wire 15 and electrical conductor 120 combination and the housing 110, including in a configuration front plate 115. The enlarged lip 137 fits snuggly within the channel 103 formed between the electrical conductor 120 and the front plate 112 to form a water-resistant seal between the sealing member 130 and the housing 110, including the front plate 112 and the sealing member 130 and the electrical conductor 120. The water-resistant seals formed by the sealing member 130 provides redundant sealing to protect users if the housing 110 (e.g., the back casing 112) is damaged and water is permitted to intrude and/or seep into the electrical connector assembly 100. The sealing provided by the sealing member 130 with the various components within the electrical connector assembly 100, including with the electrical wire 15 and the electrical conductor 120 provides increased electrical protection due to the live electrical parts being covered by the sealing member 130 and clearance and creepage distances being improved significantly. [0044] To assist with the assembly of the electrical connector assembly 100 and to hold the electrical conductor 120, respective connected electrical wire 15, and respective sealing member 130 in position, a retainer element 140 can be included. Retainer element 140 in an embodiment can be configured as a cylindrically shaped sleeve or ring 142 having one or more prong portions 145 that extends from ring 142. The retainer element 140 can be configured and shaped as a plate which is similar to the shape of the opening in front plate 115 where the conductors 120 and sealing members 130 are located. The one or more prong portions 145 preferably are flexible and engage the enlarged lip 137 on the sealing member 130 to retain the sealing member 130 in position. Retainer element 140 in an arrangement has a circular ring 142 at a back end 141 with a plurality of prong portions 145 that extend from circular ring 142 like fingers. The front end 144 of the prong portions 145 can have a bent portion 146 that helps to engage enlarged lip 137 of the sealing member 130 and form a water-resistant seal between the housing 110 (e.g., front plate 112) and the electrical conductor 120. The prong portions 145, which preferably act like flexible fingers, preferably apply a force to enlarged lip 137, when the retainer element 140 is positioned and assembled within the electrical connector assembly 100, to assist with forming the water- resistant seal with the housing 110 and/or front plate 115. It can be appreciated that the retaining member 140 can be configured, arranged, sized, and shaped differently than illustrated in the various figures. It can further be appreciated that retainer element 140 can fix one or more electrical conductors 120 and electrical wire combinations.

[0045] To hold the retainer element 140 in position one or more projections 148 are included on the retainer element 140 that engage with one or more openings 114 in the housing 110, more specifically engage one or more openings 114 in front plate 115. The number and positioning of the projections 148 can vary and in an embodiment each one of the one or more projections 148 snap fit into one of the one or more openings 114. In one or more embodiments, the projections 148 have a lip or ledge to engage a side wall of the openings 114 to retain the retainer element 140 in position which helps to secure and retain the electrical conductor 120 in position and/or the sealing member 130. While the embodiment in FIG. 2 shows the retainer element 140 having projections 148 and the housing 110 (e.g., the front plate 115) having openings 114 that receive the projections 148, it can be appreciated that projections can be formed on the housing 110 (e.g., the back casing 112 and/or front plate 115) and corresponding openings can be formed on the retainer element 140.

[0046] To assist with assembly and retaining the components, including the one or more electrical conductors 120, within the electrical connector assembly 100 including within the housing 110, the electrical connector assembly 100 can further include a clip 150 (e.g., Cir-Clip or C-ring) that fits around each of the one or more electrical conductors 120, and can fit within a groove formed in an outer surface of the electrical conductors 120 so that the clip 150 when engaged with the electrical conductor 120 forms a shoulder, lip or ledge that abuts against a portion of the front plate 115. In use, clip 150 fits onto and attaches to the electrical conductor 120, and the electrical conductor 120 is inserted into the back end 114 of the front plate 115 and moves forward until the clip 150 engages a portion of the front plate 115. The clip 150 forms a ledge, shoulder, and/or a lip which is engaged by and/or abuts the front end 136 of the sealing member 130. Retainer element 140, more specifically one or more prongs 145, pushes the front end 136 and/or enlarged lip 137 of the sealing member 130 against the shoulder, ledge, and/or lip formed by the clip 150. The clip 150 is preferably “C”-shaped having an opening that is expandable due to the flexible nature of the clip so that the opening fits over the electrical conductor 120 and snaps into position, for example in a groove in the outer surface of the electrical conductor 120. The clip 150 holds the electrical conductor 120 and permits the electrical conductor 120 to have a reduced diameter resulting in a material savings

[0047] The housing 110 is illustrated as comprising a back casing 112 and a front plate 115, and the sealing member 130 forms a water-resistant seal between the sealing member 130 and the front plate 115. It can be appreciated that the electrical connector assembly 100 can be configured so that sealing member 130 forms a seal directly with the housing 100, and/or the back casing 112 and not the front plate 115. In an embodiment, the back casing 112 and front plate 115 can be integral pieces (and/or the front plate 115 is separate from the back casing 112) and the sealing member 130 is positioned to form a water-resistant seal with the housing 110 and/or back casing 112 as opposed to the front plate 115. For example, the front plate 115 may not include a back portion that extends into the back casing 112 and the sealing member 130 can abut against the back casing 112 and/or integral housing 110.

[0048] It can be appreciated that in the multi-piece housing design as illustrated where front plate 115 is attached to back casing 112 or otherwise fitted into back casing 112, the front plate 115 preferably has a water-resistant seal with the back casing 112 to prevent water from impeding and/or seeping into the electrical connector housing 110 and/or electrical connector assembly 100. In an embodiment, the front plate 115 can be configured, shaped, sized, dimensioned, adapted and/or arranged to attach to the back casing 112 in a water-resistant manner by fitting the front plate 115 into the back casing 112 without the assistance of sealing rings and/or additional components. In an embodiment, electrical connector assembly 100 can also include an O-ring 152, preferably formed of rubber that forms a water-resistant seal between the back casing 112 and the front plate 115.

[0049] While FIG. 3 has been described with reference to a sealing member providing water resistant sealing with one of the one or more electrical conductor and electrical wire combinations (e.g., electrical conductor 120 electrically connected to electrical wire 15), it can be appreciated that such an arrangement of sealing member 130, electrical conductor 120, electrical wire 15 and housing portion, e.g., portion of front plate 115, can be formed for a plurality of electrical conductors 120 and preferably with respect to all electrical conductors 120 receiving power wires 14 and/or signal wires 16. It can further be appreciated that while FIG. 3 only shows two electrical conductors 120, electrical connector assembly 110 can include any number of electrical conductors 120 and electrical sealing members 130. It will be clear that the various features of the foregoing systems and/or methodologies may be combined in any way, creating a plurality of combinations fromthe descriptions presented above.

[0050] Electrical connector assembly 100 can be designed and configured to handle high electrical power including high currents and/or high voltage where one or more electrical conductors 120 are connected to high power electrical wires 14 where due to the high current, the one or more electrical conductors 120 can be subject to over-heating. It would be beneficial for such electrical connector assemblies 100 to include one or more temperature sensors, including one or more temperature sensor assemblies. In an embodiment, electrical connector assembly 100 can further optionally include a temperature sensor assembly for detecting and/or measuring temperature in the electrical connector assembly 100, and more specifically the temperature of one or more of the electrical conductors 120 in the electrical connector assembly 100 during use of the electrical connector assembly 100 to, for example, charge an electrical vehicle.

[0051] In one or more embodiments, a temperature sensor assembly can be easily included in the sealing member 130 and in an aspect, can be retained and/or fixed in position in the electrical connector assembly 100 by the sealing member 130. In one or more applications, the sealing member 130 can facilitate electrical isolation for the temperature sensor assembly and reduce cost by removing the need for a special temperature sensor.

[0052] FIG. 4 illustrates a side perspective view of a temperature sensor assembly 360 having a temperature sensor 362, wire leads 364 for transmitting voltage signals from the temperature sensor, and heat shrink tubing 365 for electrically isolating the temperature sensor 362. FIG. 5 illustrates a side cross-sectional view of a portion of the electrical connector assembly 100 and a side view of the temperature sensor assembly 360 positioned within electrical connector assembly 100. More specifically, temperature sensor assembly 360 is inside the bore 132 of the sealing member 130 between the sealing member 130, the electrical conductor 120, and/or the electrical wire 15. Preferably the temperature sensor 362 is placed directly against (e.g., in contact with) the electrical conductor 120, preferably on the sleeve portion 126 of the electrical conductor 120. The sealing member 130 preferably holds and retains the temperature sensor 362 in position, preferably in contact with and against the electrical conductor 120. The temperature sensor 362 preferably has shrink tubing 364 extending over the temperature sensor 362 to electrically isolate the temperature sensor 362 from the electrical conductor 120. As an alternative or in addition to shrink tubing 364, temperature sensor assembly 360 can include an insulating coating over the temperature sensor 362 to maintain electrical isolation between electrical conductor 120 and temperature sensor 362. [0053] The sealing member 130 in the embodiment of FIG. 5 is not located and/or positioned between the temperature sensor 362 and the electrical conductor 120. The sealing member 130 preferably maintains a water-resistant seal around the wire leads 364 of the temperature sensor assembly 360 that extend out of the back end 136 of the sealing member 130, and in this manner sealing member 130 forms a water-resistant seal with electrical wire 15 and the wire leads 364. FIG. 6 illustrates a back perspective view of the wire leads 364 extending out the back end 136 of the sealing tube 130. The wire leads 364 would extend out the back end 136 of the sealing tube 130 adjacent the electrical wire 15 (not shown in FIG. 6). In an embodiment, the temperature sensor 362 is a Pt 1000 temperature sensor and the wire leads 364 are AWG 30 wires with an insulative sheath, coating, and/or covering.

[0054] FIG. 7 shows a side perspective view of another embodiment of a temperature assembly 670 that includes temperature sensor 672 and lead wires 664. Temperature sensor assembly 670 can include a substrate 675 to support temperature sensor 672, which in an embodiment can be a printed circuit board to contain the temperature sensor 670. FIG. 8 is a side cross-sectional view of a portion of electrical connector assembly 100 showing temperature sensor assembly 670 positioned and retained in electrical connector assembly 100. In the embodiment of FIG. 8, the temperature sensor 672 and substrate 675 are inserted into and retained in a channel or passageway 735 in the sealing member 130 such that the temperature sensor 672 does not directly contact, abut, or bear against the electrical conductor 120. In this manner the temperature sensor 672 is electrically isolated from the electrical conductor 120 by the sealing member 130, but close enough to the electrical conductor 120 to obtain temperature readings.

[0055] The wire leads 674 from temperature sensor assembly 670 extend from channel 735 of the sealing member 130 so that the voltage signals from the temperature sensor 672 can be processed. In a preferred embodiment the temperature sensor assembly 670 is positioned relative to the sealing member 130, preferably within sensor passageway or channel 735, in a manner so that the temperature sensor 672 is facing away from the electrical conductor and preferably so that optional substrate 675 is closer to the electrical conductor 120 than the temperature sensor 672. The configuration of the sealing member 130 and placement of temperature sensor 672 relative to the electrical conductor 120 is such that shrink tube 365 and/or insulating coating over the temperature sensor 672 is preferably unnecessary, although the shrink tubing 365 and/or insulative coating over the temperature sensor 672 optionally can be included. In an embodiment, the temperature sensor 362 is a Pt 1000 temperature sensor and the wire leads 364 are AWG 30 wires with an insulative sheath, coating, and/or covering.

[0056] The sealing member 130 of FIG. 8 preferably continues to provide a water-resistant seal with the wire 15 and/or the electrical conductor 120, and in addition the temperature sensor channel 735 in sealing member 130 in an embodiment preferably provides a water-resistant seal with the temperature sensor assembly 670 so that water does not intrude, seep into or otherwise enter the channel 735 and preferably water will not reach the temperature sensor 672.

[0057] FIG. 9 shows a side perspective view of another embodiment of a temperature sensor assembly 880 that includes temperature sensor 882 mounted on a printed circuit board (PCB) 884, more specifically where the temperature sensor 882 is a surface mounted device (SMD) on printed circuit board 884. Printed circuit board 884 is generally relatively thin, of limited width and relatively long where temperature sensor 882 is mounted on a first end 886 of the printed circuit board (PCB) 884 and a printed circuit board (PCB) clamp 887 is mounted on a second end 878 of the printed circuit board (PCB) 884. The PCB 884 has dimensions that can vary with the design considerations and application, and in an example can have a length of as low as twenty (20) mm and as high as one hundred (100) mm, preferably a length of about fifty (50) mm; a width as low as one (1) mm and as high as four (4) mm, preferably as wide as three (3) mm; and a thickness of as low as eight tenths (0.8) of a millimeter and as high as three (3) mm, preferably a thickness of about 1.6 mm.

[0058] FIG. 10 shows a portion of a side cross-sectional view of electrical connector assembly 100 including temperature sensor assembly 880. Temperature sensor assembly 880 is inserted into and/or received by passageway or channel 735 in sealing member 130. In the embodiment of FIG. 10 the temperature sensor 882 is positioned in the passageway 735 of the sealing member 130 and is facing the electrical conductor 120. In other words, the temperature sensor 882 is closer to the electrical conductor 120 than the printed circuit board 884 on which the temperature sensor 882 is mounted. The temperature sensor 882 is electrically isolated from the electrical conductor 120 by the sealing member 130. The printed circuit board 884 contains electrically conductive elements to carry electrical signals and extends out of the passageway 735 in the sealing member 130 adjacent the electric wire 15 to provide the electrical signals from the temperature sensor 882 for processing. In an embodiment, the temperature sensor 882 can be a Pt 100 or PT 1000 temperature sensor as a surface mounted device (SMD) sensor type 0603 and the PCB clamp 887 can be from a Molex Micro Fit. In an embodiment, the temperature sensor 882 as a surface mounted device (SMD) on printed circuit board 884 and contained within channel 735 of the sealing member 130 and not in direct contact with the electrical conductor 120, does not need to be electrically isolated via the shrink tube and/or insulating coating as in the example of FIGS. 4-6.

[0059] The temperature sensor 882 in the embodiment of FIGS. 9-11 is sufficiently close to electrical conductor 120 so that a temperature (e.g., a voltage signal corresponding to the temperature at the electrical conductor) can be measured and the corresponding voltage signal transmitted down the PCB 884 to the clamp 887. In use the clamp 887 connects to further connectors to transmit the voltage signal for processing. The sealing member 130 of FIGS. 10-11 in an embodiment continues to provide a water-resistant seal with the wire 15 and/or the electrical conductor 120, and in addition the temperature sensor channel 735 in sealing member 130 in an embodiment preferably provides a water-resistant seal with the temperature sensor assembly 880 so that water does not intrude, seep into or otherwise enter the channel 735 and preferably does not reach the temperature sensor 882.

[0060] While the disclosure has described at least three embodiments of a temperature sensor assembly, one skilled in the art can appreciate that other configurations, sizes, shapes, dimensions, adaptations, and arrangements of temperature sensor assembly can be implemented. In addition, it can be appreciated that anyone of the disclosed embodiments of the temperature sensor assemblies shown in FIGS. 4-11 can be implemented without sealing member 130 and/or the temperature sensor assemblies can be associated with the sealing member 130 in a different manner. Further, while a single temperature sensor assembly has been shown as associated with a single electrical conductor 120, it can be appreciated that one or more temperature sensor assemblies can be associated with a plurality of electrical conductors 120 and/or a temperature sensor assembly can be associated with each of the electrical conductors 120 in the electrical connector assembly 100 so that all the electrical conductors 120 are associated with a temperature sensor assembly. That is, in an embodiment each electrical conductor 120 is associated with a temperature sensor assembly so that a temperature measurement is made at all the electrical conductors in the electrical connector assembly.

[0061] According to one or more embodiments an electrical connector assembly for connecting to a mating electrical receptacle is provided. The electrical connector assembly in an embodiment includes: a housing; one or more electrical conductors contained at least partially within the housing; and one or more electrical wires for carrying at least one of a group consisting of electrical power, an electrical signal, and combinations thereof, the one or more electrical wires electrically connected to the one or more electrical connectors. A sealing member is provided in the electrical connector assembly according to an arrangement where the sealing member has a first portion surrounding at least a front portion of at least one of the one or more electrical wires to form a first water-resistant seal with the one of the one or more electrical wires and a second portion surrounding at least a back portion of at least one of the one or more electrical conductors to form a second water-resistant seal with the one of the one or more electrical conductors, the second portion having an enlarged lip located between the housing and the at least one of the one or more electrical conductors, the enlarged lip configured to form a third water-resistant seal with the housing.

[0062] The electrical connector assembly according to an embodiment can further include a plurality of sealing members wherein the plurality of sealing members are associated with a plurality of the one or more electrical conductors, and in a further embodiment, all the plurality of sealing members are each associated with one of the plurality of electrical conductors. The sealing member in an aspect has a length between about ten (10) mm and one hundred and fifty (150) mm. Preferably the sealing member is flexible and formed of insulating material, and in an optional embodiment is formed of rubber. The sealing member according to an approach is formed as a cylindrical sleeve having an inside diameter at the first portion and an inside diameter at the second portion. The first portion inside diameter is sized and configured to fit over and surround the front portion of the at least one of the one or more electrical wires and form the first water-resistant seal with the at least one of the one or more electrical wires and the second portion inside diameter is sized and configured to fit over and surround the back portion of the at least one of the one or more electrical conductors to form the second water-resistant seal with the at least one of the one or more electrical conductors. The enlarged lip in an embodiment has a thickness between about two (2) mm and about thirty (30) mm.

[0063] The electrical connector assembly according to one or more aspects includes an optional retainer element to hold the sealing member in position. The retainer element according to an arrangement has one of an extending projection or an opening to hold the retainer element in position within the electrical connector assembly, wherein if the retainer element has the extending prong, the housing has an engagement slot to engage the extending prong, and if the retainer element has the opening, the housing has a projection to engage the opening. The optional retainer element according to a further aspect has one or more extending prongs configured to engage the enlarged lip of the sealing member.

[0064] The housing of the electrical connector assembly according to one or more embodiments includes a front plate and a back casing. In an arrangement, the sealing member is located between the front plate and the at least one of the one or more electrical conductors and is configured to from the third water-resistant seal with the front plate. The electrical connector assembly optionally further includes an O-ring located between the front plate and the back casing to facilitate forming a fourth water-resistance seal between the front plate and the back casing. A clip may also be included in the electrical connector assembly configured to engage the at least one of the one or more electrical conductors to form a ledge that contacts one or more components of the electrical connector assembly to facilitate positioning the at least one of the one or more electrical conductors within the electrical connector assembly. [0065] The electrical connector assembly according to one or more embodiments further includes a temperature sensor assembly having a temperature sensor, wherein the temperature sensor assembly is associated with the at least one of the one or more electrical conductors to measure the temperature of the at least one of the one or more electrical conductors. The temperature sensor of the temperature sensor assembly in an embodiment is retained in position by the sealing member. The temperature sensor according to an arrangement can further include electrical leads to transmit voltage signals from the temperature sensor and the electrical leads extend out the first portion of the sealing member. The optional temperature sensor can be located within a bore of the sealing member, wherein the sealing member is not located between the temperature sensor and the at least one of the one or more electrical conductors. The optional temperature sensor assembly can further include at least one of an insulating group consisting of a shrink tube, an insulating coating, an insulating sheath, and combinations thereof, wherein the insulating group covers the temperature sensor.

[0066] In a further embodiment, the temperature sensor of the optional temperature sensor assembly is positioned within a channel formed in the sealing member, wherein a section of the sealing member is positioned between the temperature sensor and the at least one of the one or more electrical conductors. The optional temperature sensor assembly can further include a printed circuit board (PCB) and the temperature sensor is mounted on the PCB as a surface mounted device (SMD). In an embodiment, the PCB of the optional temperature sensor assembly has a length between about twenty (20) mm and about one hundred (100) mm, a width between one (1) mm and four (4) mm, and a thickness of between about eight tenths (0.8) of a millimeter and about three (3) mm; and the PCB includes electrically conductive elements to transmit voltage signals received from the temperature sensor.

[0067] The description of the embodiments of the present disclosure has been presented for purposes of illustration and description, but the disclosure is not intended to be exhaustive, and the invention should not be limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, and to enable others of ordinary skill in the art to understand the embodiments disclosed herein and to appreciate various modifications as may be suited to the particular uses contemplated.

[0068] It will be clear that the various features of the foregoing systems and/or methodologies may be combined in any way, creating a plurality of combinations from the descriptions presented above. The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed.

Claims

CLAIMS What is claimed is:

1. An electrical connector assembly for connecting to a mating electrical receptacle, the electrical connector assembly comprising: a housing; one or more electrical conductors contained at least partially within the housing; one or more electrical wires for carrying at least one of a group consisting of electrical power, an electrical signal, and combinations thereof, the one or more electrical wires electrically connected to the one or more electrical conductors; and a sealing member having a first portion surrounding at least a front portion of at least one of the one or more electrical wires to form a first water-resistant seal with the one of the one or more electrical wires and a second portion surrounding at least a back portion of at least one of the one or more electrical conductors to form a second water-resistant seal with the one of the one or more electrical conductors, the second portion having an enlarged lip located between the housing and the at least one of the one or more electrical conductors, the enlarged lip configured to form a third water-resistant seal with the housing.

2. The electrical connector assembly according to Claim 1, wherein the sealing member has a length as low as ten (10) millimeters and as high as one hundred and fifty (150) millimeters.

3. The electrical connector assembly according to any one of Claims 1-2, wherein the sealing member is flexible and formed of insulating material.

4. The electrical connector assembly according to any one of Claims 1-3, wherein the sealing member is formed of rubber.

5. The electrical connector assembly according to any one of the preceding claims, wherein the sealing member is formed as a cylindrical sleeve having an inside diameter at the first portion and an inside diameter at the second portion, wherein the first portion inside diameter is sized and configured to fit over and surround the front portion of the at least one of the one or more electrical wires and form the first water-resistant seal with the at least one of the one or more electrical wires and the second portion inside diameter is sized and configured to fit over and surround the back portion of the at least one of the one or more electrical conductors to form the second water-resistant seal with the at least one of the one or more electrical conductors.

6. The electrical connector assembly according to any one of the preceding claims, wherein the enlarged lip has a thickness of as low as two (2) millimeters to as large as thirty (30) millimeters.

7. The electrical connector assembly according to any one of the preceding claims, further comprising a retainer element to hold the sealing member in position.

8. The electrical connector assembly according to Claim 7, wherein the retainer element has one of an extending projection or an opening to hold the retainer element in position within the electrical connector assembly, wherein if the retainer element has the extending projection, the housing has an engagement slot to engage the extending projection and if the retainer element has the opening, the housing has a projection to engage the opening.

9. The electrical connector assembly according to anyone of claims 7 or 8, wherein the retainer element has one or more extending prongs configured to engage the enlarged lip of the sealing member.

10. The electrical connector assembly according to any one of the preceding claims, wherein the housing comprises a front plate and a back casing.

11. The electrical connector assembly according to Claim 10, wherein the sealing member is located between the front plate and the at least one of the one or more electrical conductors and is configured to from the third water-resistant seal with the front plate.

12. The electrical connector assembly according to any one of Claims 10 or 11, further comprising an O-ring located between the front plate and the back casing to facilitate forming a fourth water-resistance seal between the front plate and the back casing.

13. The electrical connector assembly according to any one of the preceding claims, further comprising a clip configured to engage the at least one of the one or more electrical conductors to form a ledge that contacts one or more components of the electrical connector assembly to facilitate positioning the at least one of the one or more electrical conductors within the electrical connector assembly.

14. The electrical connector assembly according to any one of the preceding claims, further comprising a temperature sensor assembly having a temperature sensor, wherein the temperature sensor assembly is associated with the at least one of the one or more electrical conductors to measure the temperature of the at least one of the one or more electrical conductors.

15. The electrical connector assembly according to Claim 14, wherein the temperature sensor of the temperature sensor assembly is retained in position by the sealing member.

16. The electrical connector assembly according to any one of Claims 14 or 15, wherein the temperature sensor further comprises electrical leads to transmit voltage signals from the temperature sensor and the electrical leads extend out the first portion of the sealing member.

17. The electrical connector assembly according to anyone of Claims 14-16, wherein the temperature sensor is located within a bore of the sealing member, wherein the sealing member is not located between the temperature sensor and the at least one of the one or more electrical conductors.

18. The electrical connector assembly according to anyone of Claims 14-17, wherein the temperature sensor assembly further comprising at least one of an insulating group consisting of a shrink tube, an insulating coating, an insulating sheath, and combinations thereof, wherein the insulating group covers the temperature sensor.

19. The electrical connector assembly according to any one of Claims 14-16, wherein the temperature sensor of the temperature sensor assembly is positioned within a channel formed in the sealing member, wherein a section of the sealing member is positioned between the temperature sensor and the at least one of the one or more electrical conductors.

20. The electrical connector assembly according to any one of Claims 14-16 or 19, wherein the temperature sensor assembly further comprises a printed circuit board (PCB) and the temperature sensor is mounted on the PCB as a surface mounted device (SMD).

21. The electrical connector assembly according to Claim 20, wherein the PCB has a length as low as twenty (20) millimeters and as high as one hundred (100) millimeters, a width as low as one (1) millimeter and as high as four (4) millimeters, and a thickness as low as eight tenths (0.8) of a millimeter to as high as three (3) millimeters, and the PCB includes electrical conductive elements to transmit voltage signals received from the temperature sensor.

22. The electrical connector assembly according to any one of the preceding claims, further comprising a plurality of sealing members wherein the plurality of sealing members are associated with a plurality of the one or more electrical conductors.

23. The electrical connector assembly according to Claim 22, wherein all the plurality of sealing members are each associated with one of the one or more electrical conductors.