Dust plugs for sealing multiport terminals and methods of fabricating the same

A dust plug assembly comprising:

• a dust plug body;
• a sealing sleeve attached to an end of the dust plug body, wherein:
• the sealing sleeve has a passageway therethrough;
• the sealing sleeve comprises a first latch arm and a second latch arm;
• and
• the dust plug body and the sealing sleeve define a primary groove;
• a lanyard comprising a barb, wherein:
• the first latch arm and the second latch arm retain the barb;
• and
• the lanyard and the sealing sleeve define a secondary groove;
• a primary sealing member disposed in the primary groove;
• and
• a secondary sealing member disposed in the secondary groove.

A multiport assembly comprising:

• a housing comprising a plurality of ports;
• a dust plug assembly inserted in a at least one port of the plurality of ports, the dust plug assembly comprising:
• a dust plug body comprising a lanyard receiving feature;
• a sealing sleeve attached to an end of the dust plug body, wherein:
• the sealing sleeve has a passageway therethrough;
• the lanyard receiving feature is disposed within the passageway;
• and
• the dust plug body and the sealing sleeve define a primary groove;
• and
• a lanyard comprising an attachment feature, wherein:
• the attachment feature is coupled to the lanyard receiving feature;
• the lanyard and the sealing sleeve define a secondary groove;
• a primary sealing member disposed within the primary groove, wherein the primary sealing member provides a primary seal within an interior of the port;
• and
• a secondary sealing member disposed within the secondary groove, wherein the secondary sealing member provides a secondary seal at an opening of the port.

A method of fabricating a dust plug assembly, the method comprising:

• disposing a sealing sleeve over an end of a dust plug body, wherein:
• the sealing sleeve comprises a bonding ring and an energy directing feature extending from the bonding ring;
• the dust plug body comprises an inner mating surface disposed within a passageway of the sealing sleeve;
• and
• the dust plug body and the sealing sleeve define a primary groove;
• applying ultrasonic energy to the bonding ring such that the energy directing feature melts and forms an ultrasonic weld joint between the bonding ring and the inner mating surface;
• disposing a primary sealing member in the primary groove;
• disposing a secondary sealing member on an end of the sealing sleeve;
• and
• inserting an attachment feature of a lanyard into the passageway of the sealing sleeve and into a lanyard receiving feature of the dust plug body such that the lanyard receiving feature secures the attachment feature and the secondary sealing member is disposed within a secondary groove defined by the lanyard and the sealing sleeve.