High temperature, high pressure subsea electrical connector system

A harsh environment electrical connector assembly, comprising:

• an outer shell having a central longitudinal axis and at least one through bore and having a first end configured for exposure to a relatively low pressure environment and a second end configured for exposure to a high pressure subsea environment;
• a feed-through conductor pin extending through the at least one bore and having opposite first and second ends, the pin having a central longitudinal axis, a first end portion projecting out through the first end of the shell up to the first end, a second end portion projecting out through the second end of the shell up to the second end, and an intermediate portion extending between the first and second end portions through the bore in the shell;
• the conductor pin comprising a conductive shaft of one or more parts extending from the first end to the second end of the pin, and first and second axially spaced insulation layers each extending over respective parts of the length of the shaft;
• the first insulation layer having first and second ends and extending along part of the intermediate portion of the pin with the second end spaced inwardly from the second end of the shell;
• the second insulation layer having a first end on the intermediate portion spaced from the second end of the first insulation layer and a second end on the second end portion spaced from the second end of the conductive pin;
• the first and second insulation layers being of first and second different insulating materials, the first insulating material having a higher heat deflection temperature than the second insulating material;
• and
• the first insulation layer being thicker than the second insulation layer over at least a major part of its length.

A conductor pin for a harsh environment connector or penetrator, comprising:

• a conductive shaft of one or more pieces, the shaft having first and second ends;
• an outer layer of non-conductive, insulating material extending over the conductive shaft along at least a major part of the length of the shaft and having first and second ends spaced from the respective first and second ends of the shaft;
• the outer layer being of non uniform diameter along its length and having an intermediate portion of enlarged, non-circular cross-section;
• the intermediate portion having diametrically opposed, outward projections of greater thickness than the remainder of the intermediate portion, the outward projections comprising load bearing shoulders.