High Voltage Connector Assembly

A connector assembly comprising:

• an electrical connector configured to be mated to a second electrical connector, the electrical connector comprising:
• a housing having a chamber therein;
• a first insert subassembly having a first insert holding a first terminal, the first terminal having a mating end;
• and
• a second insert subassembly having a second insert holding a second terminal, the second terminal having a mating end;
• wherein the mating ends of the first and second terminals have different diameters;
• and
• wherein the housing is sized and shaped to securely receive and retain the first insert and wherein the housing is sized and shaped to securely receive and retain the second insert, the first insert subassembly and the second insert subassembly being alternatively received in the chamber;
• and
• a high voltage interlock (HVIL) conductor coupled to at least one of the housing, the first insert and the second insert, the HVIL conductor being configured to be electrically connected to a corresponding HVIL conductor of the second electrical connector when the electrical connector is mated to the second electrical connector.

A connector assembly comprising:

• a mating connector having a mating housing and a mating insert held within the mating housing, the mating housing extending along a longitudinal axis to a mating end at a front of the mating housing, the mating insert holding a mating terminal along the longitudinal axis, the mating housing having a locking finger proximate to the mating end, the mating housing having a seal shroud at the mating end at the front, the seal shroud being positioned axially forward of the locking finger, the mating connector having a high voltage interlock (HVIL) conductor;
• and
• a plug connector mated to the mating connector, the plug connector configured to be terminated to a high voltage cable, the plug connector having a HVIL conductor electrically connected to the HVIL conductor of the mating connector when the plug and mating connectors are coupled together, the plug connector comprising a plug housing and a plug insert held within the plug housing, the plug housing extending along a longitudinal axis to a mating end at a front of the plug housing, the mating end of the plug housing being coupled to the mating end of the mating housing, the plug insert holding a plug terminal along the longitudinal axis, the plug housing having a locking aperture that receives the locking finger to lock the plug connector to the mating connector, the locking aperture being proximate to the mating end, the plug housing having a seal well internal of the plug housing, the seal well holding an interfacial seal, the seal well receiving the seal shroud of the mating housing with the interfacial seal providing sealing between the mating housing and the plug housing, the seal well being positioned axially rearward of the locking aperture.