High-voltage joint waterproof protection with capture bus

Abstract

A vehicle waterproof protection assembly includes a vehicle battery pack having an outer wall and an inner compartment. A rechargeable energy storage system (RESS) connector assembly includes a housing mounted within an inner compartment to an inner surface of an outer wall. An external adapter mounted to an outward facing surface of the outer wall communicates with the RESS connector assembly through the outer wall. The first cylindrical bus bar and the second cylindrical bus bar are disposed within the housing. First and second vent pipes defining an integral extension of the housing have a first cylindrical bus bar extending through the housing via the first vent pipe and extending outwardly from the housing, and a second cylindrical bus bar extending through the housing via the second vent pipe and extending outwardly from the housing. At least one O-ring is positioned on the second cylindrical busbar to mitigate fluid ingress into the interior cavity of the housing.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a rechargeable energy storage system (RESS) connector. BACKGROUND

[0002] For vehicle use, a rechargeable energy storage system (RESS) defines a system that provides energy (including battery power) rather than propulsion fuel as its primary use. RESS connectors are used in high voltage (HV) junctions, with voltage ranges typically ranging from about 50 volts to 200 volts direct current (VDC) for hybrid vehicles and typically ranging from about 400 volts to 800 volts direct current (VDC) for battery electric vehicles. Backshells are typically used within RESS connectors that are not sealed for the internal environment of the RESS, but have face seals at the location of the HV junction mounting bolt to mitigate ingress of external liquids through the HV junction mounting bolt into the HV junction or vehicle battery.

[0003] Thus, while the current systems and methods of preventing water ingress into a RESS system achieve their intended purpose, there is still a need for a new and improved system and method of mitigating moisture intrusion into a rechargeable energy storage system (RESS) connector assembly. SUMMARY

[0004] According to several aspects, a rechargeable energy storage system (RESS) connector assembly includes a housing of a non-conductive material. A first cylindrical busbar and a second cylindrical busbar are disposed within the housing. First and second breather tubes defining an overall extension of the housing have the first cylindrical busbar extending through and outwardly from the housing via the first breather tube, respectively, and the second cylindrical busbar extending through and outwardly from the housing via the second breather tube, respectively. First and second high voltage fittings are secured to and extend from the first and second cylindrical busbars, respectively, wherein the high voltage defines a direct current (DC) voltage of at least about 50 volts direct current (VDC).

[0005] In another aspect of the present disclosure, the first and second cylindrical busbars provide a primary conductive path to a high voltage junction, including a battery electric vehicle (BEV) battery pack.

[0006] In another aspect of the present disclosure, first and second three-hand features are connected to the housing and secured to a housing wall of the battery pack to releasably retain the RESS connector assembly to the battery pack, respectively.

[0007] In another aspect of the disclosure, a front portion of the first three-hand feature is slidably inserted into a first receiving aperture created in an end wall of the battery pack until a first biasing member of the first three-hand feature defining the front portion is elastically displaced in a first outward direction to capture the first biasing member against an outward facing surface of the end wall. An extension of the second three-hand feature is slidably inserted into a second receiving aperture created in the end wall of the battery pack until a second biasing member of the second three-hand feature defining the extension is elastically displaced in a second outward direction to capture the second biasing member against the outward facing surface.

[0008] In another aspect of the disclosure, the plurality of threaded inserts includes a first threaded insert, a second threaded insert, a third threaded insert, and a fourth threaded insert located on a perimeter of the housing. The plurality of threaded inserts allows the housing to be releasably mounted to a housing wall of a vehicle battery pack using threaded fasteners.

[0009] In another aspect of the disclosure, a press-to-engage (PIP) seal is located proximate to a perimeter wall of the housing that mitigates fluid ingress into an internal cavity of the housing when the housing is pressed into contact with an outer wall of a vehicle battery pack. A plurality of face seals includes a first face seal, a second face seal, a third face seal, and a fourth face seal that create a fluid boundary seal at individual ones of the first threaded insert, the second threaded insert, the third threaded insert, and the fourth threaded insert when the housing is pressed into contact with the outer wall.

[0010] In another aspect of the disclosure, a first bolt extending through the first cylindrical bus creates a clamping load between mating busses including the first high voltage fitting and is releasably secured to a first adapter bus of an external adapter engaged with the RESS connector assembly using a first fastening nut. A second bolt extending through the second cylindrical bus creates a clamping load between mating busses including the second high voltage fitting and is releasably secured to a second adapter bus of the external adapter using a second fastening nut.

[0011] In another aspect of the disclosure, a first O-ring is located on an outer wall of the second cylindrical bus, a second O-ring is located on the outer wall of the second cylindrical bus, the first O-ring and the second O-ring mitigate fluid ingress into an internal cavity of the housing, the second O-ring is positioned above the first O-ring and defines a maximum height protection that prevents fluid ingress into the internal cavity of the housing.

[0012] In another aspect of the disclosure, the first vent tube and the second vent tube define high voltage insulation for the first cylindrical bus and the second cylindrical bus and provide an additional insulation extension of the first cylindrical bus and the second cylindrical bus without exposing conductive material of the first cylindrical bus or the second cylindrical bus.

[0013] In another aspect of the disclosure, the outer shell is molded defining a non-conductive polymeric material including polyhexamethylene adipamide. The first cylindrical busbar and the second cylindrical busbar define a T-shape and define a conductive material.

[0014] According to aspects, a vehicle waterproofing protection assembly includes a vehicle battery pack having an outer wall and an inner compartment. A rechargeable energy storage system (RESS) connector assembly has an outer shell mounted within the inner compartment to an inward facing surface of the outer wall. An external adapter is mounted to an outward facing surface of the outer wall and is in communication with the RESS connector assembly through the outer wall. A first cylindrical busbar and a second cylindrical busbar are disposed primarily within the outer shell. First and second vent tubes defining an overall extension of the outer shell have the first cylindrical busbar extending through and outward from the outer shell via the first vent tube, respectively, and the second cylindrical busbar extending through and outward from the outer shell via the second vent tube, respectively. At least one O-ring positioned on the outer wall of the second cylindrical busbar mitigates fluid ingress into an inner cavity of the outer shell.

[0015] In another aspect of the disclosure, a press-to-place (PIP) seal is located proximate to a peripheral wall of the outer shell that mitigates fluid ingress into an inner cavity of the outer shell when the outer shell is pressed into contact with an inward facing surface of an outer wall of a battery pack.

[0016] In another aspect of the disclosure, the at least one O-ring includes a first O-ring located on the outer wall of the second cylindrical busbar and a second O-ring located on the outer wall of the second cylindrical busbar, the second O-ring positioned above the first O-ring and defining a maximum height protection against fluid ingress into an inner cavity of the outer shell.

[0017] In another aspect of the disclosure, a first bolt extending through the first cylindrical busbar creates a clamping load between mating busbars including a first high voltage fitting and is releasably secured to a first adapter busbar of an external adapter engaged with the RESS connector assembly using a first fastening nut. A second bolt extending through the second cylindrical busbar creates a clamping load between mating busbars including a second high voltage fitting and is releasably secured to a second adapter busbar of the external adapter using a second fastening nut. The high voltage defines a direct current (DC) voltage of at least 50 volts DC.

[0018] In another aspect of the disclosure, a plurality of threaded inserts includes a first threaded insert, a second threaded insert, a third threaded insert, and a fourth threaded insert located on a periphery of the outer shell, the plurality of threaded inserts allowing the outer shell to be releasably mounted to an inward facing surface of an outer wall of a vehicle battery pack using threaded fasteners. A plurality of face seals includes a first face seal, a second face seal, a third face seal, and a fourth face seal that create a fluid boundary seal at individual ones of the first threaded insert, the second threaded insert, the third threaded insert, and the fourth threaded insert when the outer shell is pressed into contact with the outer wall.

[0019] In another aspect of the disclosure, a first three-handed feature and a second three-handed feature are connected to the housing and are respectively secured to the outer wall of the battery pack to releasably retain the RESS connector assembly to the battery pack. A portion of the first three-handed feature is slidably inserted into a first receiving aperture created in the outer wall of the battery pack. A portion of the second three-handed feature is slidably inserted into a second receiving aperture created in the outer wall of the battery pack.

[0020] In another aspect of the disclosure, a first high voltage fitting and a second high voltage fitting are secured to and respectively extend from the first cylindrical busbar and the second cylindrical busbar. High voltage defines a direct current (DC) voltage of at least about 50 volts direct current (VDC).

[0021] According to several aspects, a method for providing waterproof protection for a vehicle battery includes positioning a battery pack within a vehicle, the battery pack having an outer wall and an inner compartment; creating a rechargeable energy storage system (RESS) connector assembly having a housing mounted within the inner compartment to an inward facing surface of the outer wall; mounting an external adapter to an outward facing surface of the outer wall and in communication with the RESS connector assembly through the outer wall; providing a first cylindrical busbar and a second cylindrical busbar primarily disposed within the housing; providing an overall extension of the housing including a first vent tube and a second vent tube; extending the first cylindrical busbar through and outward from the housing via the first vent tube and the second cylindrical busbar through and outward from the housing via the second vent tube, respectively; and positioning at least one O-ring on the outer wall of the second cylindrical busbar to mitigate fluid ingress into an internal cavity of the housing.

[0022] In another aspect of the disclosure, the method further includes providing a press-to- install (PIP) seal proximate a peripheral wall of the housing to mitigate fluid ingress into an internal cavity of the housing when the housing is pressed into contact with the inward facing surface of the outer wall of the battery pack; positioning a plurality of threaded inserts at the peripheral wall of the housing to allow the housing to be releasably mounted to the inward facing surface of the outer wall of the battery pack using threaded fasteners; and positioning a plurality of face seals that create a fluid boundary seal at the plurality of threaded inserts when the housing is pressed into contact with the housing wall.

[0023] In another aspect of the disclosure, the method further includes connecting a first three-handed feature and a second three-handed feature to the housing and respectively securing to the outer wall of the battery pack to releasably retain the RESS connector assembly to the battery pack; slidably inserting a portion of the first three-handed feature into a first receiving aperture created in the outer wall of the battery pack; and slidably inserting a portion of the second three-handed feature into a second receiving aperture created in the outer wall of the battery pack.

[0024] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0025] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 is an elevation front view of a RESS connector assembly according to exemplary aspects;

[0027] Figure 2 is a perspective assembly view of a RESS connector assembly incorporating an external adapter for a high pressure connector assembly Figure 1 is an elevation cross-sectional side view of a RESS connector of

[0028] Figure 3 is a perspective assembly view of a RESS connector assembly of Figure 1

[0029] Figure 4 is a left upper perspective view of a vehicle with a battery pack suitable for a RESS connector assembly of Figure 1

[0030] Figure 5 is a top perspective view of a battery pack suitable for a RESS connector assembly of Figure 1

[0031] Figure 6 is an elevation cross-sectional end view taken along section 6 of Figure 5

[0032] Figure 7 is an elevation end view of a wall portion of a battery pack of Figure 5

[0033] Figure 8 is an elevation cross-sectional side view of Figure 3 further showing a maximum liquid level

[0034] Figure 9 is a perspective assembly view of components of Figure 2

[0035] Figure 10 is a perspective assembly view of another aspect of a RESS connector assembly and a high pressure connector assembly similar to Figure 8 DETAILED DESCRIPTION

[0036] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0037] Reference is made to Figure 1 ​​​​​​​A rechargeable energy storage system (RESS) connector assembly 10 includes a housing 12 that can be molded from a non-conductive polymer material such as polyhexamethylene adipamide (nylon). In accordance with several aspects, first and second cylindrical busbars 14, 16 can be formed from a conductive material such as copper and are disposed within and partially extend out of the housing 12. The first and second cylindrical busbars 14, 16 provide the primary conductive path to high voltage terminals, for example, as referenced in Figure 5 A high voltage terminal of a battery electric vehicle battery pack is shown and described in greater detail. The first and second cylindrical busbars 14, 16 have a T-shape and extend through and outwardly from the housing 12 via a first vent tube 18, as referenced in Figure 2 and Figure 3 A second vent tube 19 is shown and described in greater detail, as well as the first and second cylindrical busbars 14, 16, which define an overall extension of the molded housing 12. The first and second vent tubes 18, 19 provide high voltage insulation for the first and second cylindrical busbars 14, 16. Another function of the first and second vent tubes 18, 19 is to provide additional insulating extensions of the first and second cylindrical busbars 14, 16 without exposing the conductive material of the first or second cylindrical busbars 14, 16.

[0038] The RESS connector assembly 10 also includes a first high voltage fitting 20, as referenced in Figure 3 A second high voltage fitting 21 is shown and described in greater detail, as well as the first and second cylindrical busbars 14, 16, which are secured to and extend from the first and second cylindrical busbars 14, 16, respectively. First and second tri-hand features 22, 24, which can be made of a polymer material or a metal material, are secured to the housing 12, respectively, the function of which is referenced in Figure 7 are described in greater detail. A plurality of threaded inserts including first, second, third, and fourth threaded inserts 26a, 26b, 26c, 26d are positioned on the perimeter of the housing 12, which allows the housing 12 to be releasably mounted to a battery pack structure using, for example, threaded fasteners, as referenced in Figure 5 and Figures 9-10 A press-to-place (PIP) seal 28 is shown and described in greater detail. The PIP seal 28 is positioned proximate to a perimeter wall 30 of the housing 12 and extends completely around the perimeter wall 30 of the housing 12 to mitigate fluid ingress into an interior cavity 32 of the housing 12. The PIP seal 28 is augmented by the further addition of a plurality of face seals including first, second, third, and fourth face seals 34a, 34b, 34c, 34d, which provide a fluid boundary seal at the perimeter of the individual threaded inserts of the first, second, third, and fourth threaded inserts 26a, 26b, 26c, 26d.

[0039] Referring Figure 2 and again to Figure 1 , the RESS connector assembly 10 can be releasably connected to an external adapter 36 located outside of, for example, a vehicle battery pack, to form a high voltage connector assembly 38. An outer wall 40, for example of a metallic material, separates the vehicle battery pack interior space from the outside environment. The first and second three-hand features 22 and 24 are configured to temporarily mount the RESS connector assembly 10 to the outer wall 40 prior to mounting the external adapter 36.

[0040] A first bolt 42 extends through the first cylindrical busbar 14 to provide a clamping load between mating busbars including the first high voltage fitting 20, and is releasably secured to a first adapter busbar 46 of the external adapter 36 using a first fastening nut 44. A second bolt 48 extends through the second cylindrical busbar 16 to provide a clamping load between mating busbars including the second high voltage fitting 21, and is releasably secured to a second adapter busbar 52 of the external adapter 36 using a second fastening nut 50. Figure 1

[0041] To mitigate fluid ingress into the interior cavity 32 of the housing 12, the first and second cylindrical busbars 14 and 16 include O-ring seals located on the outer walls of the busbars. For example, the first cylindrical busbar 14 includes a first O-ring 54 and a second O-ring 56 located within preconfigured O-ring grooves created in the outer wall 58 of the first cylindrical busbar 14. Fluid present within the battery pack, for example due to a source of leaking coolant, can accumulate to a level that at least partially submerges the RESS connector assembly 10. The second O-ring 56 is positioned above the first O-ring 54 and defines a maximum height protection against fluid ingress into the interior cavity 32 of the housing 12.

[0042] Referring Figure 3 and again to Figure 1 and Figure 2 , the first and second three-hand features 22 and 24 define a biasing member configured to initially hold the RESS connector assembly 10 prior to mounting the external adapter 36 during installation of the RESS connector assembly 10, as described with reference to Figure 2 . The first and second three-hand features 22 and 24 are held within the receiving apertures in use, molded into the housing 12, as shown and described with reference to Figure 7

[0043] Referring Figure 4 and again to Figure 1 and Figure 2 ​​A battery pack having a RESS connector assembly 10 is installed in a vehicle 66. According to aspects, the vehicle 66 can be a battery electric vehicle (BEV) or a hybrid electric vehicle. The vehicle 66 can be any vehicle type, including a sedan, a sport utility vehicle, a van, a truck, etc.

[0044] Referring to Figure 5 and referring again to Figures 1-4 , the battery pack 64 includes a housing 68 having at least one end wall 70. Referring to Figure 2 The external adapter 36 of the high voltage connector assembly 38 shown and described is releasably secured to the end wall 70.

[0045] Referring to Figure 6 and referring again to Figures 1-5 , Referring to Figures 1-3 The housing 12 of the RESS connector assembly 10 shown and described is releasably secured to an inner surface 72 of the end wall 70 of the battery pack 64. Referring to Figure 1 The PIP seal 28 shown and described is positioned against the inner surface 72 to form a fluid resistant seal between the internal cavity 32 of the housing 12 and the inner surface 72. If a coolant leak occurs within the interior space 74, the interior space 74 of the battery pack 64 can collect an amount of fluid, such as coolant. Referring to Figure 2 The second O-ring 56 of the first cylindrical busbar 14 shown and described mitigates fluid intrusion into the internal cavity 32 of the housing 12 through the cylindrical busbar beyond a fluid level 76.

[0046] Referring to Figure 7 and referring again to Figure 3 , Figure 5 and Figure 6 During installation of the RESS connector assembly 10, the forward portion of the first thumb feature 22 is slidably inserted into a first receiving aperture 77 created in the end wall 70 until a first biasing member 78 defining the forward portion of the first thumb feature 22 is elastically snapped in a first outward direction 80 to capture the first biasing member 78 against an outward facing surface 82 of the end wall 70. Simultaneously, the extension of the second thumb feature 24 is slidably inserted into a second receiving aperture 84 created in the end wall 70 until a second biasing member 86 defining the extension of the second thumb feature 24 is elastically snapped in a second outward direction 88 to capture the second biasing member 86 against the outward facing surface 82. The first biasing member 78 and the second biasing member 86 thereby releasably retain the housing in place against the inner surface 72 of the end wall 70, shown and described with reference to Figure 2 and shown and described with reference to Figure 2The outer adapter 36 of the high voltage connector assembly 38 shown and described is releasably secured to the end wall 70 and the housing 12. An opening 90 formed through the end wall 70 at the installed position of the RESS connector assembly 10 provides open communication between the internal cavity 32 of the RESS connector assembly housing 12 and the electrical connection features of the outer adapter 36.

[0047] With reference to Figure 8 and with further reference to Figure 1 and Figure 2 With reference to Figure 2 The outer adapter 36 of the high voltage connector assembly 38 shown and described is releasably secured to the end wall 70 and the housing 12. The housing 12 is shown abutting the inner surface 72 of the end wall 70. As previously noted with reference to Figure 6 With reference to Figure 2 The second O-ring 56 of the first cylindrical busbar 14 shown and described mitigates fluid intrusion into the internal cavity 32 of the housing 12 by the cylindrical busbar up to a maximum fluid level 76.

[0048] With reference to Figure 9 and with further reference to Figure 1 , Figure 2 and Figure 8 To further mitigate fluid intrusion into the internal cavity 32 of the housing 12, in addition to the first O-ring 54 and the second O-ring 56 provided with the first cylindrical busbar 14, the second cylindrical busbar 16 has similar O-rings, including a first O-ring 54' and a second O-ring 56'. The outer adapter 36 of the high voltage connector assembly 38 can be coupled to the housing 12 using a plurality of threaded fasteners, including a first threaded fastener 92a threadedly engaged with the first threaded insert 26a, and additional threaded fasteners 92b, 92c, and 92d threadedly engaged with the second threaded insert 26b, the third threaded insert 26c, and the fourth threaded insert 26d.

[0049] With reference to Figure 10 and with further reference to Figure 1 and Figure 2 According to aspects, the RESS connector assembly 94 is modified from the RESS connector assembly 10 to include a housing 96 larger than the housing 12, and has a first cylindrical busbar 98 and a second cylindrical busbar 100 modified in length from the first cylindrical busbar 14 and the second cylindrical busbar 16, and further includes a first O-ring 54" and a second O-ring 56". The high voltage connector assembly 102 is modified from the high voltage connector assembly 38 to include a first adapter busbar 104 larger than the first adapter busbar 46 and a second adapter busbar 106 larger than the second adapter busbar 52. The high voltage connector assembly 102 can be coupled to the housing 96 using a plurality of threaded fasteners, including a first threaded fastener 108.

[0050] The RESS connector assembly 10 and the RESS connector assembly 94 function as a backplane for a high voltage RESS connector or joint and provide the sealing geometry of the backplane. When liquid intrudes the RESS connector assembly, the sealing geometry can protect the high voltage joint from the liquid. The electrical conductors within the sealing assembly can also be protected from liquid intrusion. The vent tube device is used to create continuity with the high voltage circuit, lifting the conductors above the anticipated high liquid level in the battery pack to protect them from liquid intrusion. In addition, the standard face seal is replaced with a PIP seal that has two functions. The first PIP seal function is to prevent liquid intrusion through the HV joint bolt path. The second PIP seal function is to prevent liquid intrusion from the battery pack internal environment.

[0051] To aid in assembly, the vent tube contains a captive cylindrical busbar. The cylindrical busbar is embedded within the vent tube, providing a low resistance connection path between the protected high voltage joint and the internal busbar of the RESS. By capturing the busbar, the assembly operation at the battery pack assembly plant is simplified, requiring fewer loose parts to assemble. An O-ring is used in the vent tube assembly for the busbar to connect with the captive busbar. The O-ring has a dual purpose. The first O-ring is to capture the busbar during the RESS connector assembly process. The second O-ring is to prevent liquid ingress through the vent tube assembly, which can be due to the presence of fluids, such as a cooling system leak in the internal volume of the battery pack.

[0052] By using a combination of T-shaped busbar geometry and O-ring, the captive busbar is effectively fixed in place prior to assembly. In addition, the O-ring also prevents liquid intrusion through the vent tube into the sealed backplane. Conventional RESS operations can further produce condensation that can eventually collect within the sealed vent tube assembly, resulting in an electrical hazard. By using the O-ring, liquid ingress through the vent tube due to condensation or splashing can be significantly reduced.

[0053] The RESS connector assembly 10 of the present disclosure, in conjunction with the external adapter 36 forming a high voltage connector assembly 38, defines a vehicle waterproofing protection assembly wherein the RESS connector assembly 10 replaces the HV junction backplate in the seal assembly. The seal backplate prevents liquid intrusion through the RESS external bolt and RESS internal water ingress. The seal backplate has the three-hand functionality of the existing RESS connector and can be easily assembled. The seal backplate with cylindrical busbar and outwardly extending housing vent tube isolates the high voltage conductor from RESS internal fluid failure. The seal backplate with vent tube and captive busbar improves battery pack assembly plant assembly. The seal backplate with vent tube, cylindrical busbar, and O-ring further protects the seal backplate assembly from liquid intrusion, such as condensation or splash, from the vent tube. The seal backplate with vent tube, T-shaped cylindrical busbar, and O-ring are used in combination to capture the busbar and hold the busbar in place during shipping. The seal backplate with vent tube allows the O-ring to compress in both shipping and installed states, thus giving the O-ring dual functionality of a capture device and a seal device.

[0054] The RESS connector assembly of the present disclosure provides a number of advantages. These advantages include: protection of the RESS high voltage junction from liquid exposure. The "vent tube" provides a sealed waterproof space that liquids cannot enter. The vent tube can also be used as a backplate for the high voltage RESS connector (junction). The design of the present disclosure also includes assembly aid features, including a third hand clamp feature. Additionally, the combination of the PIP and O-ring seals ensures that the system remains sealed from various liquid ingress paths. The high voltage junction is protected from RESS liquid intrusion. Thus, the high voltage junction can be placed anywhere regardless of the liquid intrusion risk. The design of the captive busbar simplifies the assembly of the vent tube. By adding the O-ring to the vent tube design, condensation / splash protection for the high voltage junction is also provided.

Claims

1. A rechargeable energy storage system (RESS) connector assembly comprising: a non-conductive material outer shell; a first cylindrical busbar and a second cylindrical busbar disposed within the outer shell; a first vent tube and a second vent tube defining an overall extension of the outer shell, with the first cylindrical busbar extending through and outwardly from the outer shell via the first vent tube, respectively, and the second cylindrical busbar extending through and outwardly from the outer shell via the second vent tube, respectively; and a first high voltage fitting and a second high voltage fitting secured to and extending from the first cylindrical busbar and the second cylindrical busbar, respectively, wherein high voltage defines a direct current (DC) voltage of at least about 50 volts DC (VDC).

2. The RESS connector assembly of claim 1, wherein, The first cylindrical busbar and the second cylindrical busbar provide a primary conductive path to a high voltage junction, the high voltage junction comprising a vehicle battery pack.

3. The RESS connector assembly of claim 2, comprising a first three-hand feature and a second three-hand feature connected to the outer shell and secured to an outer shell wall of the battery pack to releasably retain the RESS connector assembly to the battery pack, respectively.

4. The RESS connector assembly of claim 3, comprising: a forward portion of the first three-hand feature slidably inserted into a first receiving aperture created in an end wall of the battery pack until a first biasing member of the first three-hand feature defining the forward portion is elastically displaced in a first outward direction to capture the first biasing member against an outward facing surface of the end wall; and an extension of the second three-hand feature slidably inserted into a second receiving aperture created in an end wall of the battery pack until a second biasing member of the second three-hand feature defining the extension is elastically displaced in a second outward direction to capture the second biasing member against the outward facing surface.

5. The RESS connector assembly of claim 1, further comprising a plurality of threaded inserts including a first threaded insert, a second threaded insert, a third threaded insert, and a fourth threaded insert located on a perimeter of the outer shell, the plurality of threaded inserts allowing the outer shell to be releasably mounted to an outer shell wall of a vehicle battery pack using threaded fasteners.

6. The RESS connector assembly of claim 5, comprising: a press-to-place (PIP) seal located proximate to a perimeter wall of the outer shell that mitigates fluid ingress into an internal cavity of the outer shell when the outer shell is pressed into contact with an outer wall of the vehicle battery pack; and a plurality of face seals including a first face seal, a second face seal, a third face seal, and a fourth face seal that create a fluid boundary seal at individual ones of the first threaded insert, the second threaded insert, the third threaded insert, and the fourth threaded insert when the outer shell is pressed into contact with the outer wall.

7. The RESS connector assembly of claim 1, further comprising: a first bolt extending through the first cylindrical bus creating a clamping load between mating busses including a first high voltage fitting and releasably secured to a first adapter bus of an external adapter engaged with the RESS connector assembly using a first captive nut; and and a second bolt extending through the second cylindrical bus creating a clamping load between mating busses including a second high voltage fitting and releasably secured to a second adapter bus of the external adapter using a second captive nut.

8. The RESS connector assembly of claim 1, further comprising a first O-ring positioned on an outer wall of the second cylindrical bus and a second O-ring positioned on the outer wall of the second cylindrical bus, the first and second O-rings mitigating fluid ingress into an internal cavity of the housing, the second O-ring positioned above the first O-ring and defining a maximum height protection against the fluid ingress into the internal cavity of the housing.

9. The RESS connector assembly of claim 1, wherein, The first and second vent tubes define high voltage insulation for the first and second cylindrical busses and provide additional insulation extension of the first and second cylindrical busses without exposing conductive material of the first or second cylindrical busses.

10. The RESS connector assembly of claim 1, wherein: the housing is molded defining a non-conductive polymer material including polyhexamethylene adipamide; and the first and second cylindrical busses define a T-shape and define a conductive material.

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