Abstract: A high voltage interlock bypass connector for use with a female high voltage connector having an interlock is provided and includes a metal connector pin having a substantially U-shape with a connected end and a pair of terminal ends; and a handle formed around and enclosing the connected end of the connector pin opposite the terminal ends such that the terminal ends extend beyond the handle. The handle is configured to provide insulation from a voltage carried by the metal pin and is transparent such that the connected end of the metal pin enclosed by the handle is visible within the handle. The interlock bypass connector is configured to be inserted into the interlock to complete a high voltage interlock circuit without having to connect a corresponding male high voltage connector having integrated interlock pins.

Abstract: Systems and methods for an adapter for a high voltage (HV) battery system of an electrified vehicle (EV) involve an adapter housing configured to physically interface between (i) a battery module-side low voltage (LV) connector and (ii) a cell monitoring circuit (CMC) harness-side LV connector and a plurality of connector pins disposed within the adapter housing and being configured to, at their first ends, electrically connect to the module-side LV connector, at their opposing second ends, electrically connect to the harness-side LV connector, and act as a fuse such that at least one of the plurality of connector pins breaks an electrical connection therethrough in response to a current spike. In response to a blown fuse malfunction, the adapter could be replaced by a new adapter having a new adapter housing with a new plurality of connector pins disposed therein.