Method and apparatus for coupling a sheathed heater to a power harness

1. A sheathed heater assembly for an appliance, said sheathed heater assembly comprising:

a sheathed heating element; and

a cold pin electrically coupled to said sheathed heating element, said cold pin including a free end comprising an electrical connector configured to mate with a mating connector to electrically connect the sheathed heating element to a wiring harness, said electrical connector having a circumferential groove and a longitudinal axis, said electrical connector longitudinal axis coextensive with a central longitudinal axis of said cold pin, said electrical connector comprising an endmost tip portion positioned alone said electrical connector longitudinal axis.

2. A sheathed heater in accordance with claim 1 wherein said electrical connector is unitarily formed with said cold pin.

3. A sheathed heater in accordance with claim 1 wherein said electrical connector has a circular cross section and includes a tapered mating end.

4. A sheathed heater in accordance with claim 3 wherein said circumferential groove is positioned between said tapered mating end and said cold pin.

5. A connector assembly for electrically coupling a sheathed heater assembly to a wiring harness, said connector assembly comprising:

a pin connector formed on an end of the sheathed heater assembly such that said pin connector and the end of the sheathed heater assembly have a common centerline, said pin connector including a circumferential groove, and an endmost tip portion positioned along the common centerline; and

a receptacle connector having a mating end and a wire receiving end, said wire receiving end configured to be joined to a wiring harness conductor, said pin connector configured to mate with said receptacle connector.

6. A connector assembly in accordance with claim 5 wherein said sheathed heater assembly includes a cold pin, said pin connector unitarily formed with said cold pin.

7. A connector assembly in accordance with claim 5 wherein said pin connector includes a tapered mating end.

8. A connector assembly in accordance with claim 7 wherein said sheathed heater assembly includes a cold pin, said circumferential groove positioned between said tapered mating end and said cold pin.

9. A connector assembly in accordance with claim 5 wherein said mating end of said receptacle connector includes a substantially cylindrical hollow body defining an interior therein, said body having a longitudinally extending seam and a dimple formed at said seam, said dimple extending toward said interior of said body.

10. A connector assembly in accordance with claim 9 wherein said dimple configured to engage said groove on said pin connector.

11. A connector assembly in accordance with claim 9 wherein said dimple configured to provide a desired separating force required to separate said pin connector from said receptacle connector when said pin connector is mated with said receptacle connector.

12. A connector assembly in accordance with claim 5 wherein said receptacle connector includes a wire barrel and an insulation barrel for coupling said receptacle to an insulated conductor.

13. A method for coupling a sheathed heater assembly to a wiring harness comprising:

providing a sheathed heating element;

joining a cold pin to the sheathed heating element such that the cold pin has a free end;

forming a pin connector on the free end of the cold pin, the pin connector defining a circumferential groove and having an endmost tip portion positioned along a central longitudinal axis of the pin connector;

forming a receptacle connector having a substantially cylindrical mating end sized to receive the pin connector;

attaching the receptacle connector to a wiring harness; and

mating the pin connector with the receptacle connector.

14. A method in accordance with claim 13 wherein forming the pin connector comprises unitarily forming the pin connector with the cold pin.

15. A method in accordance with claim 13 wherein forming the pin connector comprises forming the pin connector using a stamping process.

16. A method in accordance with claim 13 wherein forming the receptacle connector comprises forming the receptacle connector from a flat tab.

17. A method in accordance with claim 16 wherein forming the receptacle connector from a flat tab comprises forming the receptacle connector with a seam.

18. A method in accordance with claim 17 wherein forming the receptacle connector with a seam further comprises forming the receptacle connector with a dimple at the seam.

19. A method in accordance with claim 13 wherein attaching the receptacle to a wiring harness comprises crimping the receptacle to a conductor in the wiring harness.