Abstract: A wire connector assembly configured to provide a hermetic seal between two distinct environments and a method of constructing same is presented. The assembly includes insulated wire cables having ends that are spaced apart and joined by a wire splice element within a connector body, thereby interrupting a fluid leak path through the strands of the wire cables. The connector body formed of a fiberglass filled epoxide epoxy material may be over-molded the wire splice elements having a matte tin plated finish. A portion of connector body or the wire splice element may be disposed intermediate to the ends of the wire cables, providing an additional physical barrier to the fluid leak path. The materials selected and the shape of the wire splice elements are selected to mitigate the formation of microcracks between the connector body and splice elements that could allow the infiltration of gases through the connector assembly.

Abstract: A wire connector assembly includes a connector body and at least one wire arrangement that communicates with the connector body. The wire arrangement includes at least one electrically-conductive element formed of a continuous solid mass of material throughout. The at least one solid mass element defines a plurality of bores in which at least a portion of the solid mass element separates at least one of the bores from the other bores in the plurality of bores. A plurality of wire cables is received in the plurality of bores and respectively electrically and mechanically connected to the solid mass element. The portion, grooves defined along the portion, and O-ring seals surroundingly disposed on the connector body combine to prevent fluid flow through the assembly when the assembly is disposed in a fluid environment. A pair of methods to construct the wire connector assembly are also presented.