Single conductor sealed connector for high pressure gas pressure applications

A method for establishing a sealed connection to a wire in a high-pressure gas environment, the method comprising:

• disposing the wire through a first end of a boot, wherein the boot includes a body having a first body portion and a second body portion, wherein the first body portion includes an interior cavity having a connection portion and a sealing surface, wherein the second body portion is comprised of elastomer having a bore, wherein the elastomer of the second body portion is bonded to the first body portion, wherein the disposing includes extending the wire through the bore within the second body portion, and wherein the second body portion is configured to seal against the wire;
• crimping the wire within a first end of an insert such that the wire is coupled to the insert, wherein the insert is configured to transmit electrical signals and energy;
• seating the crimped wire and insert within the body of the boot;
• disposing a seal on an outer diameter of a terminal, wherein the terminal includes a connection portion and a seal portion;
• disposing the terminal into a second end of the boot such that the terminal penetrates into the interior cavity of the first body portion;
• and
• mechanically coupling the terminal to the body of the boot such that a first end of the terminal contacts a second end of the insert and the seal of the terminal seals against the sealing surface of the first body portion of the body, wherein the mechanically coupling the terminal to the body of the boot includes coupling the connection portion of the first body portion to the connection portion of the terminal.