Connector assembly and method of assembling same

1. A connector assembly, comprising:

a mat seal shaped to fit within an opening in a connector housing, the mat seal defining a seal passage extending therethrough; and

a conductor seal defining a conductor passage extending therethrough and configured to receive an end of a conductor, wherein the conductor seal is received within the seal passage and wherein the mat seal and the conductor seal cooperate to inhibit intrusion of contaminants into the connector housing, wherein the conductor seal is configured to extend beyond the connector housing when the conductor seal is fully inserted within the mat seal.

2. The connector assembly according to claim 1 , wherein the conductor seal is configured to inhibit bending of the end of the conductor as the conductor seal is received within the seal passage.

3. The connector assembly according to claim 1 , wherein an inner wall of the conductor passage defines a plurality of inner grooves.

4. The connector assembly according to claim 1 , wherein the conductor is an insulated wire cable having an electrical terminal attached thereto and wherein the electrical terminal has a first crimping feature attached to an inner wire of the insulated wire cable and a second crimping feature attached to the conductor seal.

5. The connector assembly according to claim 4 , wherein an outer wall of the conductor seal defines an outer groove and wherein the second crimping feature is disposed within the outer groove.

6. A connector assembly, comprising:

a mat seal shaped to fit within an opening in a connector housing, the mat seal defining a seal passage extending therethrough; and a conductor seal defining a conductor passage extending therethrough and configured to receive an end of a conductor, wherein the conductor seal is received within the seal passage and wherein the mat seal and the conductor seal cooperate to inhibit intrusion of contaminants into the connector housing, wherein the seal passage is a first seal passage, the conductor is a first conductor, the conductor seal is a first conductor seal, and the conductor passage is a first conductor passage, wherein the mat seal defines a second seal passage extending therethrough, wherein the connector assembly further comprises a second conductor seal defining a second conductor passage extending therethrough and configured to receive an end of a second conductor, wherein the second conductor seal is received within the second seal passage, and wherein a first inner diameter of the first conductor passage is different than a second inner diameter of the second conductor passage.

7. The connector assembly according to claim 6 , wherein a first outer diameter of the first conductor seal is equal to a second outer diameter of the second conductor seal and wherein the first inner diameter of the first conductor passage is not equal to the second inner diameter of the second conductor passage.

8. The connector assembly according to claim 6 , wherein a first diameter of the first seal passage is equal to a second diameter of the second seal passage.

9. The connector assembly according to claim 6 , wherein the first conductor seal and the second conductor seal are formed of a silicone-based material.

10. A method of forming an electrical connector assembly, comprising the steps of:

a) inserting an electrical cable having an elongate conductive core surrounded by an insulative sheath into a conductor seal defining a conductor passage extending therethrough;

b) with a first crimping feature, crimping an electrical terminal to the conductive core;

c) with a second crimping feature, crimping the electrical terminal to an end of the conductor seal;

d) providing a connector housing defining an opening in which a mat seal is disposed, said mat seal defining a seal passage extending therethrough; and

e) inserting the conductor seal within the seal passage, wherein the mat seal and the conductor seal cooperate to inhibit intrusion of contaminants into the connector housing, wherein the conductor seal extends beyond the connector housing when the conductor seal is fully inserted within the mat seal.

11. The method according to claim 10 , wherein the conductor seal is configured to inhibit bending of the end of the electrical cable during step e).

12. The method according to claim 10 , wherein an inner wall of the conductor passage defines a plurality of grooves.

13. The method according to claim 10 , wherein an outer wall of the conductor seal defines a plurality of grooves.

14. The method according to claim 10 , wherein the electrical cable is a first electrical cable, the electrical terminal is a first electrical terminal, the conductor seal is a first conductor seal, and the seal passage is a first seal passage, wherein the mat seal defines a second seal passage extending therethrough, and wherein the method further comprises the steps of:

f) inserting a second electrical cable having an elongate conductive core surrounded by an insulative sheath into a second conductor seal;

g) with the first crimping feature, crimping a second electrical terminal to the conductive core of the second electrical cable;

h) with the second crimping feature, crimping the second electrical terminal to an end of the second conductor seal; and

i) inserting the second conductor seal within the second seal passage, wherein the mat seal and the second conductor seal cooperate to inhibit intrusion of contaminants into the connector housing.

15. The method according to claim 14 , wherein the first conductor seal and the second conductor seal are formed of a silicone-based material.

16. A method of forming an electrical connector assembly, comprising the steps of:

a) inserting an electrical cable having an elongate conductive core surrounded by an insulative sheath into a conductor seal defining a conductor passage extending therethrough;

b) with a first crimping feature, crimping an electrical terminal to the conductive core;

c) with a second crimping feature, crimping the electrical terminal to an end of the conductor seal;

d) providing a connector housing defining an opening in which a mat seal is disposed, said mat seal defining a seal passage extending therethrough;

e) inserting the conductor seal within the seal passage, wherein the mat seal and the conductor seal cooperate to inhibit intrusion of contaminants into the connector housing, wherein the electrical cable is a first electrical cable, the electrical terminal is a first electrical terminal, the conductor seal is a first conductor seal, and the seal passage is a first seal passage, wherein the mat seal defines a second seal passage extending therethrough, and wherein the method further comprises the steps of:

f) inserting a second electrical cable having an elongate conductive core surrounded by an insulative sheath into a second conductor seal defining a second conductor passage, wherein the connector passage is a first connector passage;

g) with the first crimping feature, crimping a second electrical terminal to the conductive core of the second electrical cable;

h) with the second crimping feature, crimping the second electrical terminal to an end of the second conductor seal; and

i) inserting the second conductor seal within the second seal passage, wherein the mat seal and the second conductor seal cooperate to inhibit intrusion of contaminants into the connector housing, wherein a first outer diameter of the first conductor seal is equal to a second outer diameter of the second conductor seal and wherein a first diameter of the first conductor passage is not equal to a second diameter of the second conductor passage.

17. The method according to claim 16 , wherein a first diameter of the first seal passage is equal to a second diameter of the second seal passage.