Hybrid electric charging inlet

An electrical connector assembly, comprising:

• a connector housing defining a cavity and an opening providing access to the cavity:
• first and second direct current (DC) terminals disposed within the cavity;
• first and second busbars electrically and mechanically attached directly to the first and second DC terminals respectively, the first and second busbars each having a rectangular cross section and the first and second busbars extending through the opening such that portions of the first and second busbars are outside of the connector housing;
• and
• a modular faceplate configured to communicate with an electronic controller in the electrical connector assembly via a digital communication bus.

A method of manufacturing an electrical connector assembly, comprising:

• disposing first and second direct current (DC) terminals within a cavity of a connector housing;
• attaching first and second wire cables to connection ends of first and second busbars, respectively;
• inserting the first and second busbars through an opening in the connector housing providing access to the cavity and arranging the first and second busbars to extend from the cavity through the opening such that portions of the first and second busbars are disposed outside of the connector housing, wherein the first and second busbars each have a rectangular cross section;
• and
• electrically and mechanically attaching attachment ends of the first and second busbars which are distinct from the connection ends directly to the first and second DC terminals respectively, the attachment of the attachment ends of the first and second busbars to the first and second DC terminals being made within the cavity.