Connector assembly for vehicle charging

1. A connector assembly comprising:

a body forming an inlet, an internal cavity, and an outlet;

a plate oriented in the internal cavity adjacent to the outlet, the plate having a base with a plurality of apertures formed therethrough and a boss formed about each aperture and extending from the base;

a harness partially extending through the inlet, into the internal cavity, and connected to the plate;

a molded material disposed over the harness within the internal cavity on an inlet side of the plate; and

a plug with a first end attached to the outlet of the body, and a second end oriented opposite to the first end adapted to engage a vehicle charging receptacle, wherein the plate encloses the internal cavity to maintain the molded material on the inlet side;

wherein a conductor of the harness extends through each boss and aperture, and wherein a tube is disposed over each boss and extends over a portion of the corresponding conductor to form a seal between the internal cavity and the plug.

2. The connector assembly of claim 1 wherein the body comprises a ledge extending radially inward and into the internal cavity, the ledge being longitudinally spaced from the outlet to abut the plate.

3. The connector assembly of claim 1 further comprising a latching mechanism connected to an external portion of the body for selectively attaching to a vehicle charging receptacle.

4. The connector assembly of claim 1 further comprising a lever having an elongate shape with a trigger formed at a first end and a latch formed at a second end, with an intermediate portion therebetween, the lever being pivotally connected to the body about the intermediate portion.

5. The connector assembly of claim 4 further comprising a shell disposed over the body, the shell having an aperture formed through and oriented with the trigger such that the trigger is externally accessible.

6. The connector assembly of claim 5 wherein the shell further comprises indicia formed therein and adjacent to the aperture, such that the indicia are externally visible.

7. A connector assembly comprising:

a body forming an inlet, an internal cavity, and an outlet;

a plate oriented in the internal cavity and adjacent to the outlet, the plate having a base with a plurality of apertures formed therethrough and a boss formed about each aperture and extending from the base;

a harness partially extending through the inlet, into the internal cavity;

a molded material disposed over the harness within the internal cavity, the molded material having an integrally formed grommet oriented at the inlet of the body for providing strain relief to the harness; and

a plug with a first end attached to the outlet of the body, and a second end opposite the first end for engaging a vehicle charging receptacle;

wherein a conductor of the harness extends through each boss and aperture, and wherein a tube is disposed over each boss and extends over a portion of the corresponding conductor to form a seal between the internal cavity and the plug.

8. The connector assembly of claim 7 further comprising a lever having an elongate shape with a trigger formed at a first end and a latch formed at a second end, with an intermediate portion therebetween, the lever being pivotally connected to the body about the intermediate portion.

9. The connector assembly of claim 8 further comprising a shell disposed over the body, the shell having an aperture formed through and oriented with the trigger such that the trigger is externally accessible.

10. The connector assembly of claim 9 wherein the shell further comprises indicia formed therein and adjacent to the aperture, such that the indicia are externally visible.

11. A method for assembling a connector assembly, the method comprising:

selecting a harness type from a plurality of harness types;

installing a jumper harness of the selected harness type to a plug;

inserting the jumper harness into a plate of the selected harness type; and

connecting the jumper harness to a main harness of the selected harness type.

12. The method of claim 11 further comprising:

installing at least one tube of the selected harness type over a conductor of the jumper harness;

orienting the tube over a connection between the jumper harness and the main harness; and

heating the tube, whereby the tube shrinks to form a seal over the connection.

13. The method of claim 11 further comprising:

installing at least one tube of the selected harness type over a conductor of the jumper harness;

orienting the tube over an interface between the jumper harness and the plate; and

heating the tube, whereby the tube shrinks to form a seal over the interface.

14. The method of claim 11 further comprising:

providing a body having an inlet, an internal cavity, and an outlet;

connecting the plug to the outlet of the body such that the jumper harness and the main harness extend through the internal cavity formed in the body; and

molding a material within the internal cavity that encapsulates the main harness and the jumper harness, wherein the plate prevents the material from entering the plug.

15. The method of claim 14 further comprising:

providing a lever having a first end, a second end and an intermediate portion extending therebetween; and

connecting the intermediate portion of the lever to an upper portion of the body.

16. The method of claim 14 further comprising:

selecting a shell type from a plurality of shell types, wherein each shell type comprises an upper shell portion having indicia formed therein; and

attaching the upper shell portion to the body.

17. The method of claim 16 further comprising:

selecting an insert corresponding to the indicia of the selected shell type;

attaching the inset to a die; and

molding the upper shell portion of the selected shell type.