Electrical connector and method of making an electrical connection

An aftertreatment system comprising:

• a heater comprising a conductor pin;
• a heater power source comprising a wire;
• and
• an electrical connector comprising:
• a male connector comprising:
• a wire connection portion configured to be connected to the wire, and
• a pin connection portion having an outer diameter less than that of the wire connection portion, the pin connection portion being configured to contact the conductor pin in an electrically conductive manner, the pin connection portion comprising male threads;
• a collar configured to surround the conductor pin, the collar comprising:
• a collar cylindrical body portion, and
• a collar outer flange having an outer diameter larger than that of the collar cylindrical body portion, the collar outer flange having a first surface configured to contact the pin connection portion of the male connector, and a second surface opposite the first surface;
• a nut configured to surround the pin connection portion of the male connector, the collar outer flange, and part of the collar cylindrical body portion, the nut comprising:
• a nut cylindrical body portion, and
• a nut inner flange having an inner diameter less than that of the nut cylindrical body portion, the nut inner flange having a first surface that faces the second surface of the collar outer flange;
• a first seal that surrounds the collar cylindrical body portion and is positioned between the second surface of the collar outer flange and the first surface of the nut inner flange;
• and
• a second seal that surrounds the pin connection portion of the male connector and is positioned between an end surface of the nut cylindrical body portion and a first surface of the wire connection portion that faces the collar.

A method of making an electrical connection, the method comprising:

• providing an electrical connector comprising:
• a male connector comprising:
• a wire connection portion configured to be connected to a wire, and
• a pin connection portion having an outer diameter less than that of the wire connection portion, the pin connection portion being configured to contact a conductor pin in an electrically conductive manner, the pin connection portion comprising male threads;
• a collar configured to surround the conductor pin, the collar comprising:
• a collar cylindrical body portion, and
• a collar outer flange having an outer diameter larger than that of the collar cylindrical body portion, the collar outer flange having a first surface configured to contact the pin connection portion of the male connector, and a second surface opposite the first surface;
• a nut configured to surround the pin connection portion of the male connector, the collar outer flange, and part of the collar cylindrical body portion, the nut comprising:
• a nut cylindrical body portion, and
• a nut inner flange having an inner diameter less than that of the nut cylindrical body portion, the nut inner flange having a first surface that faces the second surface of the collar outer flange;
• a first seal that surrounds the collar cylindrical body portion and is positioned between the second surface of the collar outer flange and the first surface of the nut inner flange;
• and
• a second seal that surrounds the pin connection portion of the male connector and is positioned between an end surface of the nut cylindrical body portion and a first surface of the wire connection portion that faces the collar;
• inserting the conductor pin into the collar so that the conductor pin contacts the pin connection portion of the male connector;
• crimping the collar cylindrical body portion to the conductor pin;
• attaching the collar outer flange to the conductor pin;
• attaching the wire to the wire connection portion of the male connector;
• and
• tightening the nut to connect the pin connection portion of the male connector, the collar, the conductor pin, the first seal, and the second seal.