Electrical contact thermal sensing system and method

A thermal sensing system comprising:

• an electrical contact configured to releasably connect to a mating contact at a mating interface for establishing a conductive path across the mating interface, the electrical contact defining a channel therein that extends from an opening along an outer surface of the electrical contact;
• a working material within the channel of the electrical contact, the working material having a temperature-dependent expansive property;
• a sensing element disposed at least partially outside of the channel and operably connected to the channel through the opening, the working material configured to force the sensing element to undergo a position change relative to the electrical contact based on a temperature within the channel exceeding a designated threshold temperature, wherein sensing element is an expansion tip having one or more side walls configured to expand based on a force exerted by the working material in response to the temperature within the channel exceeding the designated threshold temperature;
• and
• at least one position sensor spaced apart from the electrical contact and configured to detect the position change of the sensing element, indicating that the temperature within the channel exceeds the designated threshold temperature.

A thermal sensing system comprising:

• an electrical contact configured to releasably connect to a mating contact at a mating interface for establishing a conductive path across the mating interface, the electrical contact defining a channel therein that extends from an opening along an outer surface of the electrical contact;
• a working material contained within a tube that has an interior end within the channel of the electrical contact and an exterior end outside of the channel, the working material having a temperature-dependent expansive property;
• a noncondensable gas contained within the tube, the working material configured to force the noncondensable gas to undergo a position change relative to the electrical contact based on a temperature within the channel exceeding a designated threshold temperature;
• and
• at least one position sensor spaced apart from the electrical contact and configured to detect the position change of the noncondensable gas by measuring a temperature of the tube at one or more axial locations outside of the channel.

A thermal sensing system for a charging inlet, the thermal sensing system comprising:

• an electrical contact held by a housing of the charging inlet, the electrical contact being terminated to a power cable and configured to releasably connect to a mating contact of an external power source at a mating interface for establishing a conductive path across the mating interface, the electrical contact defining a channel therein that extends from an opening along an outer surface of the electrical contact;
• a sensing element that protrudes through the opening such that an interior segment of the sensing element is within the channel and an exterior segment of the sensing element is outside of the channel, the sensing element comprising one of a bimetallic strip or a shape memory alloy wire, the exterior segment of the sensing element configured to undergo a position change relative to the electrical contact based on a temperature increase within the channel that exceeds a designated threshold temperature;
• and
• at least one position sensor disposed within a cavity of the charging inlet defined at least partially by the housing, the at least one position sensor spaced apart from the electrical contact and configured to detect the position change of the exterior segment of the sensing element, indicating that the temperature within the channel exceeds the designated threshold temperature.

A thermal sensing system comprising:

• an electrical contact configured to releasably connect to a mating contact at a mating interface for establishing a conductive path across the mating interface, the electrical contact defining a channel therein that extends from an opening along an outer surface of the electrical contact;
• a metallic sensing element that protrudes through the opening of the electrical contact such that an interior segment of the metallic sensing element is within the channel and an exterior segment of the metallic sensing element is outside of the channel, wherein the metallic sensing element is one of a bimetallic strip or a shape memory alloy wire, the metallic sensing element configured to undergo a position change relative to the electrical contact based on a temperature increase within the channel that exceeds a designated threshold temperature;
• and
• at least one position sensor spaced apart from the electrical contact and configured to detect the position change of the exterior segment of the metallic sensing element, indicating that the temperature within the channel exceeds the designated threshold temperature.