Electrical connector assembly with plug and cavity assembly and method of ultrasonically welding

A connector assembly, comprising:

• a plug configured to be at least partially disposed in a cavity of a connector at a front end of the connector, the plug coupled to the connector in a configuration, the plug comprising:
• a body comprising a first end and a second end;
• the first end at least partially disposed in the cavity of the connector;
• the second end opposite the first end;
• an inset portion extending axially into the second end of the body, the inset portion forming a recess within the inset portion, the recess having a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity, wherein the plug encloses the cavity with a second closed surface of the first end, such that the cavity is free from receiving a terminal or an electrical wire in the configuration;
• a cap formed at the second end and extending annularly outward from the body;
• and
• a collar formed annularly about the body, the collar configured to engage a receiving wall of the connector, the collar having a sloped surface extending towards the first end configured to interface with the receiving wall having a complementary sloped surface.

A method of assembling an electrical connector assembly, the method comprising:

• providing a connector defining a front end, an opposing rear end, and a cavity defined in the connector and extending from the front end to the rear end,
• inserting a plug at least partially into the cavity, the plug comprising:
• a body comprising a first end and a second end located opposite the first end, the first end insertable into the cavity of the connector;
• an inset portion extending axially into the second end of the body, the inset portion forming a recess within the inset portion, the recess having a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity, wherein the plug encloses the cavity with a second closed surface of the first end, such that the cavity is free from receiving a terminal or an electrical wire in the configuration;
• and
• a collar formed annularly about the body and having a diameter, the collar configured to engage a receiving wall of the connector, the collar having a sloped surface extending towards the first end configured to interface with the receiving wall having a complementary sloped surface, the receiving wall having an outer edge diameter which matches the diameter of the collar and is greater than an interior diameter of the cavity;
• and
• coupling the plug to the connector.