Environmentally sealed contact

An electrical contact assembly comprising:

• a contact body having a mating portion and a barrel portion configured for receiving an end of an electrical conductor;
• the barrel portion including a wall defining a bore having a closed end and open end, the bore including a core receiver portion for receiving the core of an electrical conductor and a plug receiver portion adjacent the closed end of the bore;
• a hole formed in the barrel portion proximate the closed end of the bore and extending into the plug receiver portion of the bore through the wall;
• a plug having a body portion configured to be inserted into the bore and to engage the plug receiver portion of the bore, the plug further configured for being inserted into an end of the plug receiving portion to seal the plug receiving portion of the bore and the hole from the rest of the bore, the plug being disposed in the end of the plug receiver portion;
• an insulation receiver portion disposed near the open end of the bore;
• a wire having a conductive core covered in an insulation, wherein the core is disposed within the core receiver portion and the insulation is disposed within the insulation receiver portion;
• and
• a primary crimp region disposed radially coincident to the core receiver portion and impressed with one or more crimp distortions and a secondary crimp region radially coincident with the insulation receiver portion and impressed with one or more crimp distortions.

A method for producing an environmentally sealed electrical contact assembly using a contact including a contact body having a mating portion and a barrel portion configured for receiving an end of an electrical conductor;

• the barrel portion including a wall defining a bore having a closed end and open end, the bore including a core receiver portion for receiving the core of an electrical conductor and a plug receiver portion adjacent the closed end of the bore;
• a hole formed in the barrel portion proximate the closed end of the bore and extending into the plug receiver portion of the bore through the wall;
• an insulation receiver portion disposed near the open end of the bore;
• and
• a primary crimp region disposed radially coincident to the core receiver portion and configured to receive one or more crimp distortions and a secondary crimp region radially coincident with the insulation receiver portion and configured to receive one or more crimp distortions;
• the method comprising:
• inserting a plug having a body portion into the open end of the bore;
• pressing the plug into an end of the plug receiving portion to seal the plug receiving portion of the bore and the hole from the rest of the bore;
• inserting a core of a wire into the core receiver portion and inserting an insulation of the wire into the insulation receiver portion;
• and
• impressing one or more crimp distortions into a primary crimp region disposed radially coincident to the core receiver portion, and impressing one or more crimp distortions into a secondary crimp region radially coincident with the insulation receiver portion to establish an environmental seal between the bore and the insulation.