Heater wire assemblies and methods of manufacture thereof

Abstract

Heater wire assemblies and methods of manufacture thereof are provided herein. In some implementations, a heater wire assembly can include a first wire, a second wire, and a sleeve disposed circumferentially around the first assembly.

Description

HEATER WIRE ASSEMBLIES AND METHODS OF MANUFACTURE THEREOFCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 632,269, filed April 10, 2024, entitled “Heater Wire Assemblies and Methods of Manufacture Thereof,” which is incorporated by reference herein in its entirety and for all purposes.FIELD

[0002] The subject matter described herein generally relates to electric heater wire assemblies.BACKGROUND

[0003] Heater wire assemblies are used to connect a resistive heater wire to a lead wire delivering electrical current from a power source. Conventionally design heater wire assemblies often utilize a splice connector to electrically couple the lead wire to a terminal pin of the resistive heater wire, which extends from a metal tube. The electrical junction is covered by an sleeve comprising an elastomer, such as neoprene or hypalon. In some cases, the neoprene sleeve is held in place relative to the wire junction by a neoprene adhesive.

[0004] During use, however, heater wire assemblies constructed using existing methods and designs can be susceptible to moisture infiltration into the heater wire assembly. While moisture infiltration can occur in existing heater wire assemblies on its own over time, the risk of moisture infiltration is greatly increased by movement of the neoprene sheath and / or other components of the heater wire assembly, which can occur as a result of handling and pulling on the wires during installation of the heater wire assembly or during equipment maintenance. Moisture infiltration is a significant challenge for heater wire assemblies, as moisture contacting the electrical wires, the heater wire, or the junction between the two can cause corrosion in between the metals of the electrical joint, which can lead to electrical short circuits and a risk of failure of the assembly and / or a risk of fire. This is a particularly worrisome technical challenge in environments such as heater wire assemblies of refrigeration units, where condensation on component surfaces from reduced temperatures is common and flammable or explosive chemicals, such as isobutane refrigerants, can be present.

[0005] Improved heater wire assemblies are needed to reduce the risk of moisture infiltration into heater wire assemblies.SUMMARY

[0006] Devices and methods for manufacturing heater wire assemblies are disclosed herein.

[0007] A wire assembly can include: a first assembly including: a first wire electrically coupled to an electrical current source, a second wire electrically coupled to a heating element, wherein the second wire is electrically coupled to the first wire, one or more first seals, wherein each of the one or more first seals is disposed circumferentially around at least a portion of the first wire, and one or more second seals, wherein each of the one or more second seals is disposed circumferentially around at least a portion of the second wire; and a sleeve including an outer surface and an inner surface, wherein the sleeve is disposed circumferentially around the first assembly such that the inner surface is in contact with, the one or more first seals and the one or more second seals. In some embodiments, a wire assembly can include a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire. In some embodiments, the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire. In some embodiments, the connector is a splice connector. In some cases, the sleeve includes an electrically non- conductive material. In some embodiments, the sleeve is configured to electrically isolate the connector from an outside environment. In some embodiments, the wire assembly can include a first clamp disposed circumferentially around and in contact with at least a portion of the outer surface of the sleeve. In some embodiments, the wire assembly can include a second clamp disposed circumferentially around and in contact with at least a portion of the outer surface of the sleeve. In some embodiments, each of the one or more first seals have an inner diameter that is at most 85% of an outer diameter of the first wire. In some embodiments, each of the one or more second seals have an inner diameter that is at most 85% of an outer diameter of the second wire. In some embodiments, the one or more first seals includes a plurality of first seals. In some embodiments, the one or more second seals includes a plurality of second seals. In some embodiments, the one or more first seals are o- rings. In some embodiments, the one or more second seals are o-rings. In some embodiments, at least one of the one or more first seals includes an electrically non-conductive material. In some embodiments, at least one of the one or more first seals includes a first chemically inertmaterial. In some embodiments, at least one of the one or more second seals includes an electrically non-conductive material. In some embodiments, at least one of the one or more second seals includes a first chemically inert material. In some embodiments, the chemically inert material is selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some embodiments, the material has been subjected to vulcanization. In some embodiments, at least one of the one or more first seals includes the same electrically non-conductive material as at least one of the one or more second seals. In some embodiments, at least one of the one or more first seals includes a different electrically non- conductive material as at least one of the one or more second seals. In some embodiments, at least one of the one or more first seals includes the same chemically inert material as at least one of the one or more second seals. In some embodiments, at least one of the one or more first seals includes a different chemically inert material as at least one of the one or more second seals. In some embodiments, the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some embodiments, the material has been subjected to vulcanization. In some embodiments, the sleeve includes a first segment, a second segment, and a third segment, the first segment having a first inner diameter, the second segment having a second inner diameter that is less than the first inner diameter, and the third segment having a third inner diameter that is less than the second inner diameter, and wherein the second segment is interposed between the first segment and the third segment. In some embodiments, the first wire includes an electrical wire, the electrical wire including an electrically conductive material. In some embodiments, at least a portion of the electrical wire is coated with a non-conductive material. In some embodiments, the non-conductive material is polyvinyl chloride (PVC). In some embodiments, the second wire includes a resistive heater wire. In some embodiments, the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire. In some embodiments, the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction. In some embodiments, the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing. In some embodiments, the connector is electrically coupled to the terminal pin. In some embodiments, the wire assembly has a longitudinal axis and the first clamp is disposed circumferentially around the sleeve at a position along thelongitudinal axis at which the one or more first seals are disposed. In some embodiments, the wire assembly has a longitudinal axis and the second clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which the one or more second seals are disposed. In some embodiments, the first clamp is configured to apply radial compressive pressure on a portion of the sleeve and the one or more first seals. In some embodiments, the second clamp is configured to apply radial compressive pressure on a portion of the sleeve and the one or more second seals. In some embodiments, at least a portion of the inner surface of the sleeve is coupled to at least a portion of the first assembly using an adhesive.

[0008] A wire assembly can include: a first assembly including: a first wire electrically coupled to an electrical current source; and a second wire electrically coupled to a heating element; a sleeve including an outer surface and an inner surface, wherein the inner surface is disposed circumferentially around and in contact with at least a portion of the first assembly, wherein the inner surface includes one or more first protrusions extending radially inward from the inner surface and one or more second protrusions extending radially inward from the inner surface, wherein the one or more first protrusions are in contact with the first wire and the one or more second protrusions are in contact with the second wire. In some embodiments, the one or more first protrusions include an inner diameter that is no greater than 85% of an outer diameter of the first wire. In some embodiments, the one or more second protrusions include an inner diameter that is no greater than 85% of an outer diameter of the second wire. In some embodiments, the one or more first protrusions includes a plurality of first protrusions. In some embodiments, the one or more second protrusions includes a plurality of second protrusions. In some embodiments, the wire assembly includes a first clamp disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more first protrusions is disposed. In some embodiments, the wire assembly includes a second clamp disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more second protrusions is disposed. In some embodiments, the sleeve includes a first segment and a second segment, the first segment having an inner diameter that is less than an inner diameter of the second segment. In some embodiments, the inner diameter of the first segment is at most 85% of an outer diameter of the first wire. In some embodiments, the inner diameter of the second segment is at most 85% of an outer diameter of the second wire. In some embodiments, the first assembly furtherincludes a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire. In some embodiments, the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire. In some embodiments, the connector is a splice connector. In some embodiments, the sleeve includes an electrically non-conductive material. In some embodiments, the sleeve is configured to electrically isolate the connector from an outside environment. In some embodiments, the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some embodiments, the material has been subjected to vulcanization. In some embodiments, the first wire includes an electrical wire, the electrical wire including an electrically conductive material. In some embodiments, at least a portion of the electrical wire is coated with a non-conductive material. In some embodiments, the non-conductive material is polyvinyl chloride (PVC). In some embodiments, the second wire includes a resistive heater wire. In some embodiments, the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire. In some embodiments, the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction. In some embodiments, the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing. In some embodiments, the connector is electrically coupled to the terminal pin. In some embodiments, the wire assembly has a longitudinal axis and the first clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which at least one of the one or more first protrusions is disposed. In some embodiments, the wire assembly has a longitudinal axis and the second clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which at least one of the one or more second protrusions is disposed. In some embodiments, the first clamp is configured to apply radial compressive pressure on the one or more first protrusions of the sleeve. In some embodiments, the second clamp is configured to apply radial compressive pressure on the one or more second protrusions of the sleeve. In some embodiments, at least a portion of the inner surface is coupled to at least a portion of the first assembly using an adhesive.

[0009] A heater wire assembly can include: a first assembly including: a first wire electrically coupled to an electrical current source; and a second wire electrically coupled to a heatingelement; a sleeve including an outer surface and an inner surface, wherein the inner surface is disposed circumferentially around and in contact with at least a portion of the first assembly, wherein the sleeve includes a first segment, a second segment, and a third segment, the first segment having a first inner diameter, the second segment having a second inner diameter that is less than the first inner diameter, and the third segment having a third inner diameter that is less than the second inner diameter, and wherein the second segment is interposed between the first segment and the third segment. In some embodiments, the first inner diameter is at most 85% of the outer diameter of the first wire. In some embodiments, the second inner diameter is at most 85% of the outer diameter of the connector. In some embodiments, the third inner diameter is at most 85% of the outer diameter of the second wire. In some embodiments, the first assembly further includes a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire. In some embodiments, the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire. In some embodiments, the connector is a splice connector. In some embodiments, the sleeve includes an electrically non-conductive material. In some embodiments, the sleeve is configured to electrically isolate the connector from an outside environment. In some embodiments, the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some embodiments, the material has been subjected to vulcanization. In some embodiments, the first wire includes an electrical wire, the electrical wire including an electrically conductive material. In some embodiments, at least a portion of the electrical wire is coated with a non-conductive material. In some embodiments, the non-conductive material is polyvinyl chloride (PVC). In some embodiments, the second wire includes a resistive heater wire. In some embodiments, the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire. In some embodiments, the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction. In some embodiments, the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing. In some embodiments, the connector is electrically coupled to the terminal pin. In some embodiments, at least aportion of the inner surface is coupled to at least a portion of the first assembly using an adhesive.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain implementations of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings,

[0011] FIG. 1A is an exterior view schematic of a wire assembly consistent with implementations of the current subject matter;

[0012] FIG. IB is a cross-sectional view of the wire assembly shown in FIG. 1A, consistent with implementations of the current subject matter;

[0013] FIG. 2A shows a first wire including a coating material consistent with implementations of the current subject matter;

[0014] FIG. 2B shows a first wire coupled to a connector consistent with implementations of the current subject matter;

[0015] FIG. 2C shows a second wire including a tube and a terminal pin, consistent with implementations of the current subject matter;

[0016] FIG. 2D shows a second wire including a tube, a terminal pin, and a bushing, consistent with implementations of the current subject matter;

[0017] FIG. 2E shows a perspective view of the second wire shown in FIG. 2D, consistent with implementations of the current subject matter;

[0018] FIG. 3A is a schematic of a first assembly including a first wire, a second wire, and a connector, consistent with implementations of the current subject matter;

[0019] FIG. 3B is a schematic of a first assembly including a plurality of first seals and a second seal, consistent with implementations of the current subject matter;

[0020] FIG. 3C is a schematic of a wire assembly including a first wire, a second wire, and a sleeve, consistent with implementations of the current subject matter;

[0021] FIG. 3D is a cross-sectional schematic of a wire assembly including a first wire, a second wire, and a sleeve, consistent with implementations of the current subject matter;

[0022] FIG. 4A is a sleeve for use in a wire assembly, consistent with implementations of the current subject matter;

[0023] FIG. 4B is an end-view along a longitudinal axis of the sleeve shown in FIG. 4A, consistent with implementations of the current subject matter;

[0024] FIG. 4C shows a cross-sectional view of a sleeve having a first segment, a second segment, and a third segment, consistent with implementations of the current subject matter;

[0025] FIG. 4D is a cross-sectional view of a wire assembly including the sleeve of FIG. 4C consistent with implementations of the current subject matter;

[0026] FIG. 5A is a cross-sectional view of a wire assembly including a plurality of first seals disposed circumferentially around a first wire, consistent with implementations of the current subject matter;

[0027] FIG. 5B is a cross-sectional view of the wire assembly of FIG. 5A at a different point along a longitudinal axis of the wire assembly, consistent with implementations of the current subject matter;

[0028] FIG. 6A is an exterior view of a sleeve, consistent with implementations of the current subject matter;

[0029] FIG. 6B is a cross-sectional view of the sleeve shown in FIG. 6A, consistent with implementations of the current subject matter;

[0030] FIG. 7A is a cross-sectional view of a wire assembly, consistent with implementations of the current subject matter;

[0031] FIG. 7B is a cross-sectional view of the wire assembly of FIG. 7A taken at a different point along a longitudinal axis of the wire assembly, consistent with implementations of the current subject matter;

[0032] FIG. 8A is a first assembly of a wire assembly, consistent with implementations of the current subject matter;

[0033] FIG. 8B is a cross-sectional view of the first assembly shown in FIG. 8A, consistent with implementations of the current subject matter;

[0034] FIG. 8C is a wire assembly including a first wire, a second wire, and a sleeveg, consistent with implementations of the current subject matter;

[0035] FIG. 8D is a cross-sectional view of the wire assembly shown in FIG. 8C, consistent with implementations of the current subject matter;

[0036] FIG. 8E is a wire assembly including a first wire, a second wire, a sleeve, a first clamp, and a second clamp, consistent with implementations of the current subject matter;

[0037] FIG. 8F is a cross-sectional view of the wire assembly shown in FIG. 8E, consistent with implementations of the current subject matter;

[0038] FIG. 9A shows a first assembly including a first wire, a second wire, and a connector, consistent with implementations of the current subject matter;

[0039] FIG. 9B shows a cross-sectional image of the first assembly shown in FIG. 9A, consistent with implementations of the current subject matter;

[0040] FIG. 9C shows a wire assembly including a first wire, a second wire, and a sleeve, consistent with implementations of the current subject matter;

[0041] FIG. 9D shows a cross-sectional view of a wire assembly including a first wire, a second wire, and a sleeve, consistent with implementations of the current subject matter.

[0042] FIG. 9E shows a wire assembly including a first wire, a second wire, a sleeve, a first clamp, and a second clamp, consistent with implementations of the current subject matter;

[0043] FIG. 9F shows a cross-sectional view of a wire assembly shown in FIG. 9E, consistent with implementations of the current subject matter.DETAILED DESCRIPTION

[0044] Disclosed herein are wire assemblies and methods of manufacture thereof, that may include a first wire electrically coupled to an electrical current source, a second wire electrically coupled to a heating element, and a sleeve disposed circumferentially around at least a portion of the first wire and at least a portion of the second wire. For instance, a first end of the first wire can be electrically coupled to a first end of the second wire at a wire junction, and the sleeve can be disposed circumferentially around the wire junction and at least a portion of the first end of the first wire and at least a portion of the first end of the second wire. In some embodiments, wire assemblies disclosed herein and / or methods of manufacture thereof result in assemblies and systems with lower risk of electrical short circuit, fire, and / or system or component failure. In some embodiments, methods of manufacture described herein can allow for lower cost of manufacture and / or fewer steps in a manufacturing process for producing wire assemblies with lower risk of electrical short circuit, fire, and / or system or component failure.

[0045] Turning to FIG. 1A and FIG. IB, a wire assembly 100 can include a first assembly including a first wire 102 and a second wire 106, wherein the second wire is electrically coupled to the first wire. The first wire can be electrically coupled to an electrical current source, and the second wire can be electrically coupled to a heating element. In some cases, the second wire can include a heating element. The first assembly can include one or more first seals 118a, 118b and one or more second seals 119. Each of the one or more first seals can be disposed circumferentially around at least a portion of the first wire. Each of the one or more second seals can be disposed circumferentially around at least a portion of the second wire. In some embodiments, the first assembly can include a plurality of first seals. Forinstance, FIG. IB shows a wire assembly including first seal 118a and first seal 118b disposed circumferentially around and in contact with an outer surface of first wire 102. In some embodiments, the first assembly can include a plurality of second seals (e.g., wherein the plurality of second seals are in contact with the tube 116 of the second wire 106).

[0046] The first assembly can further include a connector 110 in contact with at least a portion of the first wire 102 (e.g., a first end 104 of the first wire) and at least a portion of the second wire 106 (e.g., a first end 108 of the second wire) of the first assembly. Connector 110 can be electrically coupled to terminal pin 114. Connector 110 can be electrically coupled to an electrically conductive portion of first wire 102. The connector can be configured to electrically couple the first wire to the second wire. In some cases, the connector can include an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire. For example, the connector 110 can couple an electrically conductive portion of the first wire to a terminal pin 114 at the first end of the second wire. For example, connector 110 can be coupled to a first end of terminal pin 114, for example, to allow conduction of electrical energy from first wire 102 to terminal pin 114 via connector 110. In some cases, the connector 110 can be a splice connector.

[0047] The second wire 106 can comprise terminal pin 114. For example, second wire 106 can comprise a terminal pin at the first end 108 of second wire 106. As shown herein, terminal pin 114 can be held in position (e.g., relative to a tube 116 of the second wire 106) at first end 108 of second wire 106 by a fitting 112, which may be or may comprise a bushing 112 and / or an epoxy resin 112 (e.g., FIGs. IB, 2D, 2E, 3D, 7A, and 8B). The fitting 112 (e.g., bushing or epoxy resin) can function to seal the interior of tube 116 from humidity or liquid (e.g., water) intrusion. In some embodiments, the fitting 112 can maintain the terminal pin 114 in a central position (radially) within tube 116. Terminal pin 114 can comprise an electrically conductive material, such as an electrically conductive metal.

[0048] Second wire 106 can comprise a resistive wire, for example, wherein the resistive wire is at least partially disposed within tube 116 of the second wire 106. The resistive wire can be disposed at least partially within a heating element of the wire assembly. Terminal pin 114 can be coupled to the resistive wire, for example, at a second end of terminal pin 114 (e.g., wherein the second end of terminal pin 114 is located at an opposing end of terminal pin 114 relative to the first end of the terminal pin). In some embodiments, the resistive wire can produce thermal (e.g., heat) energy when an electrical current is passed through the resistive wire. In some embodiments, terminal pin 114 can be coupled to the resistive wire(e.g., wherein terminal pin 114 is electrically coupled to an electrical power source, for example, via connector 110 and first wire 102), for example, to allow electrical current to be passed through the resistive wire in order to produce heat energy within a heating element of the wire assembly.

[0049] A second wire 106 of a wire assembly 100 can include a tube 116. Tube 116 can be disposed around at least a portion of terminal pin 114. Tube 116 can be disposed around at least a portion of a resistive wire of the second wire 106. Tube 116 can be disposed around at least a portion of a bushing or epoxy resin 112, for example, as shown in FIG. 8 A and FIG. 8B. In some embodiments, a filler material can be disposed between terminal pin 114 and an interior surface of tube 116. In some cases, the filler material can be a dielectric insulation material. In some cases, the filler material (e.g., the dieletric insulation material) can efficiently and advantageously transfer heat (e.g., when the filler material is compacted around the terminal pin 114 and / or the resistive wire and within the tube 116). In some cases, the filler material (e.g., the dielectric insulation material) can advantageously be an electrical insulator, for instance, wherein the filler material does not conduct electrical current efficiently (e.g., while also efficiently conducting thermal energy). The filler material can comprise magnesium oxide. In some embodiments, tube 116 can protect the filler material, the terminal pin 114, and / or the resistive wire from damage. For instance, tube 116 can protect the filler material, the terminal pin 114, and / or the resistive wire from damage resulting from water intrusion, physical impact, or chemical degradation (e.g., corrosion), which can in some cases adversely affect the advantageous properties of the filler material.

[0050] A wire assembly 100 can include a sleeve 120 disposed circumferentially around the first assembly such that an inner surface 122 of the sleeve is in contact with one or more first seals and / or one or more second seals of the first assembly. For example, FIG. 5A shows a first seal 118b providing a tight fit between first wire 102 and an inner surface of sleeve 120 (FIG. 5B shows that a gap can be present between one first seal 118a and another first seal 118b, which can aid in maintaining isolation of the electrical connection between the first wire and the second wire from an outside environment). In some cases, the sleeve 120 can be configured (e.g., shaped and sized relative to the first wire, the second wire, the one or more first seals, and / or the one or more second seals) to exert a radially compressive force on a portion of the first wire, a portion of the second wire, one or more of the first seals, and / or one or more of the second seals. In some cases, thusly configuring the size and shape of sleeve 120 can result in a sleeve that is configured to electrically isolate the electrical connection between the first wire and the second wire (e.g., which can include connector 110)from an outside environment. Contact between an inner surface of the sleeve 120 and the one or more first seals and / or the one or more second seals can maintain barrier function (e.g., prevent moisture or liquid intrusion) into a connection between the first and second wire disposed between the one or more first seals and the one or more second seals, for example, even after manipulation during manufacture and / or installation.

[0051] Sleeve 120 can include an electrically non-conductive material, which can aid in reducing the risk of a short circuit and / or failure of the assembly and / or a heating device including the assembly. Sleeve 120 can be configured to electrically isolate the connection between the first wire and the second wire (e.g., including connector 110) from an outside environment, which may include condensation of liquids. Sleeve 120 can include a material that is chemically resistant or chemically inert. In some cases, sleeve 120 can include a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some cases, sleeve 120 can be comprise a material that is an elastomer, such as polychloroprene (e.g., neoprene) or a chloro sulfonated polyethylene synthetic rubber (e.g., Hypalon). Sleeve 120 can include a materially that is electrically non-conductive. In some cases, sleeve 120 can include a material that has been subjected to vulcanization. For example, sleeve 120 can comprise a vulcanized polychloroprene or a vulcanized chloro sulfonated polyethylene synthetic rubber.

[0052] The wire assembly 100 can include a first clamp 126 disposed circumferentially around and in contact with at least a portion of an outer surface 124 of the sleeve. The wire assembly can include a second clamp 128 disposed circumferentially around and in contact with at least a portion of the outer surface 124 of the sleeve. In some cases, the first clamp and / or the second clamp can be configured to exert a radially compressive force on at least a portion of the outer surface of the sleeve, which can aid in preventing liquid intrusion into the connection between the first wire and the second wire.

[0053] In some cases, a method of manufacturing a wire assembly can include providing a first wire 102, for example, wherein first wire 102 includes a coating material 103, e.g., as shown in FIG. 2A. In some cases, a coating material 103 of the first wire can be an electrically non-conductive material, such as polyvinyl chloride (PVC). Connector 110 can be coupled to an electrically conductive portion of first wire 102, for example, as shown in FIG. 2B. A method of manufacturing a wire assembly 100 can include providing a second wire, which may include terminal pin 114 and / or tube 116, for example, as shown in FIG. 2C. Tube 116 can be useful in protecting and / or electrically or thermally isolating an electricallyconductive portion of second wire 106 from an outside environment. Second wire 106 can comprise (e.g., be fitted with) bushing 112. In some cases, second wire 106 can comprise an epoxy resin 112 in place of or in addition to a bushing. In some cases, bushing 112 can comprise polytetrafluoroethylene (PTFE). Bushing 112 can include an aperture therethrough, allowing the bushing to slide over terminal pin 114, for example, as shown in FIG. 2D and FIG. 2E. Bushing 112 can provide a tight fitting between tube 116 and an electrically conductive portion of the second wire 106. In some cases, bushing 112 can provide space between connector 110 and tube 116. Bushing 112 can include an electrically non-conductive material.

[0054] First wire 102 can be electrically coupled to second wire 106, for instance via connector 110 (e.g., as shown in FIG. 3A). One or more first seals 118a, 118b can be placed circumferentially around and in contact with an outer surface of first wire 102, and one or more second seals 119 can be placed circumferentially around and in contact with an outer surface of second wire 106 (or tube 116 thereof), for example, as shown in FIG. 3B. Sleeve 120 can be placed circumferentially around and in contact with at least a portion of the first wire 102 and at least a portion of the second wire 106, e.g., as shown in FIG. 3C. Sleeve 120 can be in contact with the one or more first seals 118 (e.g., 118a, 118b, 118c, etc.), the one or more second seals 119, connector 110, terminal pin 114, and / or bushing 112. First clamp 126 and second clamp 128 can be added circumferentially around and in contact with an outer surface of sleeve 120, for example, as shown in FIG. 3D. In some cases, it can be advantageous to position first clamp 126 circumferentially around the sleeve at a position along a longitudinal axis of the wire assembly 100 at which the one or more first seals are disposed (e.g., as shown in FIG. 3D). In some cases, this can maximize the radially compressive force exerted by the sleeve on the one or more first seals, which can improve the wire assembly’s ability to reduce a risk of liquid intrusion into and / or failure of the electrical connection between the first wire and the second wire. In some cases, it can be advantageous to position second clamp 128 circumferentially around the sleeve at a position along a longitudinal axis of the wire assembly 100 at which the one or more second seals are disposed (e.g., as shown in FIG. 3D). In some cases, this can maximize the radially compressive force exerted by the sleeve on the one or more second seals, which can improve the wire assembly’s ability to reduce a risk of liquid intrusion and / or failure of the electrical connection between the first wire and the second wire. Sleeve 120 or a portion thereof (e.g., all or a portion of inner surface 122 of sleeve 120 can be coupled to at least a portion of the first assembly (e.g., a portion of first wire 102, a portion of second wire 106, connector 110,one or more first seals 118, and / or one or more second seals 119) using an adhesive, such as a neoprene adhesive.

[0055] Turning to FIGs. 4A-4D, sleeve 120 can include one or more of: a first segment 130, a second segment 132, and a third segment 134. In some cases, the first segment 130 can have a first inner diameter, the second segment 132 can have a second inner diameter that is less than the first inner diameter, and the third segment 134 can have a third inner diameter that is less than the second inner diameter, wherein the second segment 132 is interposed along a longitudinal axis of the wire assembly between the first segment 130 and the third segment 134, for instance as shown in FIG. 4B, FIG. 4C, FIG. 4D, and FIG. 9D. The first segment 130 can be disposed circumferentially around and in contact with at least a portion of first wire 102 for example, as shown in FIG. 4D. The second segment 132 can be disposed circumferentially around (and, optionally, in contact with) at least a portion of connector 110 for example, as shown in FIG. 4D. The third segment 134 can be disposed circumferentially around and in contact with at least a portion of second wire 106 (e.g., at least a portion of tube 116), for example, as shown in FIG. 4D.

[0056] At least one of the one or more first seals can include an electrically non-conductive material. At least one of the one or more first seals can include a chemically resistive or chemically inert material. At least one of the one or more second seals can include an electrically non-conductive material. At least one of the one or more second seals can include a chemically resistive or chemically inert material. In some cases, the chemically inert or chemically resistant material can be selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM). In some cases, one or more of the first seals and / or one or more of the second seals can include a material that has been vulcanized. In some cases, at least one of the one or more first seals can include the same electrically non-conductive material as at least one of the one or more second seals. In some cases, at least one of the one or more first seals can include a different electrically non-conductive material as at least one of the one or more second seals. In some cases, one or more of the first seals and / or one or more of the second seals can include a material that has been vulcanized. In some cases, at least one of the one or more first seals can include the same chemically inert or chemically resistant material as at least one of the one or more second seals. In some cases, at least one of the one or more first seals can include a different chemically inert or chemically resistant material as at least one of the one or more second seals.

[0057] In some cases, two or more of the first seals can include the same electrically non- conductive material as each other. In some cases, two or more of the second seals can include the same electrically non-conductive material as each other. In some cases, two or more of the first seals can include the same chemically inert or chemically resistant material as each other. In some cases, two or more of the second seals can include the same chemically inert or chemically resistant material as each other.

[0058] In some cases, two or more of the first seals can include different electrically non- conductive materials than one other. In some cases, two or more of the second seals can include the different electrically non-conductive material than one other. In some cases, two or more of the first seals can include different chemically inert or chemically resistant material than one other. In some cases, two or more of the second seals can include different chemically inert or chemically resistant material than one other. In some cases, including two or more first seals including different materials can improve the range of environments in which the wire assembly can be protected from liquid intrusion, short circuit or failure. In some cases, including two or more second seals including different materials can improve the range of environments in which the wire assembly can be protected from liquid intrusion, short circuit or failure.

[0059] In some cases, the one or more first seals can have an inner diameter that is at most 50%, at most 60%, at most 75%, at most 85%, at most 90%, at most 95% or at most 100% of an outer diameter of the first wire 102. In some cases, the one or more second seals can have an inner diameter that is at most 50%, at most 60%, at most 75%, at most 85%, at most 90%, at most 95% or at most 100% of an outer diameter of the second wire 106 and / or tube 116. In some cases, using a first seal or second seal with an inner diameter smaller than that of the wire on which it is installed can improve the seals’ ability to resist liquid intrusion and / or failure of the wire assembly. In some cases, the one or more first seals and / or one or more second seals can be o-rings.

[0060] A sleeve can include a contoured inner surface. For example, FIG. 6B shows a cross- sectional view of a sleeve 120 including one or more first protrusions 136a, 136b extending radially inward from the inner surface of sleeve 120 and one or more second protrusions 138a, 138b extending radially inward from the inner surface of sleeve 120. In some cases, the one or more first protrusions and / or the one or more second protrusions can be sized and shaped to exert a radially compressive force on the first assembly. For instance, the one or more first protrusions can be in contact with the first wire and can be sized and shaped to exert a radially compressive force on the first wire when sleeve 120 is installedcircumferentially around the first assembly (e.g., as shown in FIG. 6A and FIG. 6B). The one or more second protrusions can be in contact with the second wire and can be sized and shaped to exert a radially compressive force on the second wire when sleeve 120 is installed circumferentially around the first assembly (e.g., as shown in FIG. 6A and FIG. 6B). In some cases, sleeve 120 can include a plurality of first protrusions. In some cases, sleeve 120 can include a plurality of second protrusions.

[0061] In some cases, inclusion of one or more first projections 136 and / or one or more second projections 138 can reduce or eliminate the risk of liquid intrusion and / or failure of the wire assembly due to liquid intrusion, even if no first seals 118 or second seals 119 are utilized in the wire assembly 100. Thus, in some embodiments, a wire assembly including one or more first protrusions and / or one or more second protrusions and having no first seals or second seals can reduce or eliminate the risk of liquid intrusion and / or failure of the wire assembly due to liquid intrusion.

[0062] In some cases, the one or more first protrusions can have an inner diameter that is at most 50%, at most 60%, at most 75%, at most 85%, at most 90%, at most 95% or at most 100% of an outer diameter of the first wire 102. In some cases, the one or more second protrusions can have an inner diameter that is at most 50%, at most 60%, at most 75%, at most 85%, at most 90%, at most 95% or at most 100% of an outer diameter of the second wire 106 and / or tube 116. In some cases, sizing the protrusions thusly can improve resistance of the wire assembly to liquid intrusion and / or failure.

[0063] In some cases, a first clamp can be disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more first protrusions is disposed. In some cases, a second clamp can be disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more second protrusions is disposed. FIG. 7A shows a second protrusion 138a providing a tight fit against tube 116 of second wire 106. FIG. 7B shows that a gap 139 can be present before or after a first protrusion or second protrusion, which can aid in maintaining isolation of the electrical connection between the first wire and the second wire from an outside environment, for instance, when the gap 139 is between one second protrusion and another second protrusion or between one first protrusion and another first protrusion.

[0064] Turning to FIGs. 8A-8F, an outer surface 124 of a sleeve 120 can include one or more features 140, which may include textures, channels, or grooves to guide placement (e.g.,visually and / or tactile guidance) of a first clamp and / or a second clamp around the outer surface of the sleeve. In some cases, this can be helpful in properly placing the clamp(s) at the same position along the longitudinal axis of the wire assembly as the one or more first seals, the one or more second seals, the one or more first protrusions, and / or the one or more second protrusions, e.g., so that an effective amount of radially compressive force is applied via the seals and / or protrusions to the first wire and / or second wire.

[0065] Turning to FIGs. 9A-9D, a wire assembly can include an inner assembly (e.g., as shown in FIGs. 9A and 9B) surrounded by a sleeve having a first segment 130, a second segment 132, and a third segment 134 (e.g., as described above and / or as shown in FIG. 4A, FIG. 4B, and FIG. 4C) without protrusions or seals. In some cases, the flat inner walls of such sleeves can be easier to manufacture and install, for instance, using an adhesive such as neoprene adhesive. In some cases, a wire assembly that includes an inner assembly surrounded by a sleeve having a first segment, a second segment, and a third segment can comprise one, two, or more than two clamps 126, 128, for example, as shown in FIGs. 9E and 9F.Terminology

[0066] In the descriptions above and in the claims, phrases such as “at least one of’ or “one or more of’ may occur followed by a conjunctive list of elements or features. The term “and / or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and / or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and / or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0067] In the descriptions above and in the claims, the term “circumferentially around” can mean an object or a portion of an object that surrounds or substantially surrounds the periphery of another object. In some cases, the surrounded or substantially surrounded objectcan have a periphery that is circular. In some cases, the surrounded or substantially surrounded object can have a periphery that is square, rectangular, or in another polygonal shape.

[0068] The subject matter described herein can be embodied in systems, apparatus, methods, computer programs and / or articles depending on the desired configuration. Any methods or the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with implementations related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and / or variations can be provided in addition to those set forth herein. The implementations described above can be directed to various combinations and subcombinations of the disclosed features and / or combinations and subcombinations of further features noted above. Furthermore, above described advantages are not intended to limit the application of any issued claims to processes and structures accomplishing any or all of the advantages.

[0069] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and / or position to indicate that the value and / or position described is within a reasonable expected range of values and / or positions. For example, a numeric value may have a value that is + / - 0.1% of the stated value (or range of values), + / - 1% of the stated value (or range of values), + / - 2% of the stated value (or range of values), + / - 5% of the stated value (or range of values), + / - 10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “X” is disclosed the “less than or equal to X” as well as “greater than or equal to X” (e.g., where X is a numerical value) is also disclosed. It is also understood that the throughout the application, data is provided in a number of different formats, and that this data, represents endpoints and starting points, and ranges for anycombination of the data points. For example, if a particular data point “10” and a particular data point “15” are disclosed, it is understood that greater than, greater than or equal to, less than, less than or equal to, and equal to 10 and 15 are considered disclosed as well as between 10 and 15. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0070] Spatially relative terms, such as “forward”, “rearward”, “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[0071] Additionally, section headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically, and by way of example, although the headings refer to a “Technical Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, the description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference to this disclosure in general or use of the word “invention” in the singular is not intended to imply any limitation on the scope of the claims set forth below. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby.

Claims

CLAIMSWhat is claimed is:

1. A wire assembly including: a first assembly including: a first wire electrically coupled to an electrical current source, a second wire electrically coupled to a heating element, wherein the second wire is electrically coupled to the first wire, one or more first seals, wherein each of the one or more first seals is disposed circumferentially around at least a portion of the first wire, and one or more second seals, wherein each of the one or more second seals is disposed circumferentially around at least a portion of the second wire; and a sleeve including an outer surface and an inner surface, wherein the sleeve is disposed circumferentially around the first assembly such that the inner surface is in contact with, the one or more first seals and the one or more second seals.

2. The wire assembly of claim 1, further including a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire.

3. The wire assembly of claim 2, wherein the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire.

4. The wire assembly of claim 2 or claim 3, wherein the connector is a splice connector.

5. The wire assembly of any one of the preceding claims, wherein the sleeve includes an electrically non-conductive material.

6. The wire assembly of any one of the preceding claims, wherein the sleeve is configured to electrically isolate the connector from an outside environment.

7. The wire assembly of any one of the preceding claims, further including a first clamp disposed circumferentially around and in contact with at least a portion of the outer surface of the sleeve.

8. The wire assembly of any one of the preceding claims, further including a second clamp disposed circumferentially around and in contact with at least a portion of the outer surface of the sleeve.

9. The wire assembly of any one of the preceding claims, wherein each of the one or more first seals have an inner diameter that is at most 85% of an outer diameter of the first wire.

10. The wire assembly of any one of the preceding claims, wherein each of the one or more second seals have an inner diameter that is at most 85% of an outer diameter of the second wire.

11. The wire assembly of any one of the preceding claims, wherein the one or more first seals includes a plurality of first seals.

12. The wire assembly of any one of the preceding claims, wherein the one or more second seals includes a plurality of second seals.

13. The wire assembly of any one of the preceding claims, wherein the one or more first seals are o-rings.

14. The wire assembly of any one of the preceding claims, wherein the one or more second seals are o-rings.

15. The wire assembly of any one of the preceding claims, wherein at least one of the one or more first seals includes an electrically non-conductive material.

16. The wire assembly of any one of the preceding claims, wherein at least one of the one or more first seals includes a first chemically inert material.

17. The wire assembly of any one of the preceding claims, wherein at least one of the one or more second seals includes an electrically non-conductive material.

18. The wire assembly of any one of the preceding claims, wherein at least one of the one or more second seals includes a first chemically inert material.

19. The wire assembly of any one of the preceding claims, wherein the chemically inert material is selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM).

20. The wire assembly of any one of the preceding claims, wherein the material has been subjected to vulcanization.

21. The wire assembly of any one of the preceding claims, herein at least one of the one or more first seals includes the same electrically non-conductive material as at least one of the one or more second seals.

22. The wire assembly of any one of the preceding claims, wherein at least one of the one or more first seals includes a different electrically non-conductive material as at least one of the one or more second seals.

23. The wire assembly of any one of the preceding claims, wherein at least one of the one or more first seals includes the same chemically inert material as at least one of the one or more second seals.

24. The wire assembly of any one of the preceding claims, wherein at least one of the one or more first seals includes a different chemically inert material as at least one of the one or more second seals.

25. The wire assembly of any one of the preceding claims, wherein the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM).

26. The wire assembly of any one of the preceding claims, wherein the material has been subjected to vulcanization.

27. The wire assembly of any one of the preceding claims, herein the sleeve includes a first segment, a second segment, and a third segment, the first segment having a first inner diameter, the second segment having a second inner diameter that is less than the first inner diameter, and the third segment having a third inner diameter that is less than the second inner diameter, and wherein the second segment is interposed between the first segment and the third segment.

28. The wire assembly of any one of the preceding claims, wherein the first wire includes an electrical wire, the electrical wire including an electrically conductive material.

29. The wire assembly of any one of the preceding claims, wherein at least a portion of the electrical wire is coated with a non-conductive material.

30. The wire assembly of any one of the preceding claims, wherein the non- conductive material is polyvinyl chloride (PVC).

31. The wire assembly of any one of the preceding claims, wherein the second wire includes a resistive heater wire.

32. The wire assembly of any one of the preceding claims, wherein the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire.

33. The wire assembly of any one of the preceding claims, wherein the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction.

34. The wire assembly of any one of the preceding claims, wherein the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing.

35. The wire assembly of any one of the preceding claims, wherein the connector is electrically coupled to the terminal pin.

36. The wire assembly of any one of the preceding claims, wherein the wire assembly has a longitudinal axis and the first clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which the one or more first seals are disposed.

37. The wire assembly of any one of the preceding claims, wherein the wire assembly has a longitudinal axis and the second clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which the one or more second seals are disposed.

38. The wire assembly of any one of the preceding claims, wherein the first clamp is configured to apply radial compressive pressure on a portion of the sleeve and the one or more first seals.

39. The wire assembly of any one of the preceding claims, wherein the second clamp is configured to apply radial compressive pressure on a portion of the sleeve and the one or more second seals.

40. The wire assembly of any one of the preceding claims, wherein at least a portion of the inner surface of the sleeve is coupled to at least a portion of the first assembly using an adhesive.

41. A wire assembly including: a first assembly including: a first wire electrically coupled to an electrical current source; and a second wire electrically coupled to a heating element; a sleeve including an outer surface and an inner surface, wherein the inner surface is disposed circumferentially around and in contact with at least a portion of the first assembly, wherein the inner surface includes one or more first protrusions extending radially inward from the inner surface and one or more second protrusions extending radially inward from the inner surface, wherein the one or more first protrusions are in contact with the first wire and the one or more second protrusions are in contact with the second wire.

42. The wire assembly of claim 41, wherein the one or more first protrusions include an inner diameter that is no greater than 85% of an outer diameter of the first wire.

43. The wire assembly of claim 41 or claim 42, wherein the one or more second protrusions include an inner diameter that is no greater than 85% of an outer diameter of the second wire.

44. The wire assembly of any one of claims 41-43, wherein the one or more first protrusions includes a plurality of first protrusions.

45. The wire assembly of any one of claims 41-44, wherein the one or more second protrusions includes a plurality of second protrusions.

46. The wire assembly of any one of claims 41-45, further including a first clamp disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more first protrusions is disposed.

47. The wire assembly of any one of claims 41-46, further including a second clamp disposed circumferentially around and in contact with a portion of the outer surface of the sleeve at a position along a longitudinal axis of the wire assembly at which at least one of the one or more second protrusions is disposed.

48. The wire assembly of any one of claims 41-47, wherein the sleeve includes a first segment and a second segment, the first segment having an inner diameter that is less than an inner diameter of the second segment.

49. The wire assembly of claim 48, wherein the inner diameter of the first segment is at most 85% of an outer diameter of the first wire.

50. The wire assembly of claim 48 or claim 49, wherein the inner diameter of the second segment is at most 85% of an outer diameter of the second wire.

51. The wire assembly of any one of claims 41-50, wherein the first assembly further includes a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire.

52. The wire assembly of claim 51, wherein the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire.

53. The wire assembly of claim 51 or claim 52, wherein the connector is a splice connector.

54. The wire assembly of any one of claims 41-53, wherein the sleeve includes an electrically non-conductive material.

55. The wire assembly of any one of claims 41-54, wherein the sleeve is configured to electrically isolate the connector from an outside environment.

56. The wire assembly of any one of claims 41-55, wherein the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM).

57. The wire assembly of any one of claims 41-56, wherein the material has been subjected to vulcanization.

58. The wire assembly of any one of claims 41-57, wherein the first wire includes an electrical wire, the electrical wire including an electrically conductive material.

59. The wire assembly of any one of claims 41-58, wherein at least a portion of the electrical wire is coated with a non-conductive material.

60. The wire assembly of claim 59, wherein the non-conductive material is polyvinyl chloride (PVC).

61. The wire assembly of any one of claims 41-60, wherein the second wire includes a resistive heater wire.

62. The wire assembly of claim 61, wherein the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire.

63. The wire assembly of any one of claims 41-62, wherein the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction.

64. The wire assembly of any one of claims 41-63, wherein the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing.

65. The wire assembly of any one of claims 63-64, wherein the connector is electrically coupled to the terminal pin.

66. The wire assembly of any one of claims 41-65, wherein the wire assembly has a longitudinal axis and the first clamp is disposed circumferentially around the sleeve at a position along the longitudinal axis at which at least one of the one or more first protrusions is disposed.

67. The wire assembly of any one of claims 41-66, wherein the wire assembly has a longitudinal axis and the second clamp is disposed circumferentially around the sleeve at aposition along the longitudinal axis at which at least one of the one or more second protrusions is disposed.

68. The wire assembly of any one of claims 66-67, wherein the first clamp is configured to apply radial compressive pressure on the one or more first protrusions of the sleeve.

69. The wire assembly of any one of claims 67-68, wherein the second clamp is configured to apply radial compressive pressure on the one or more second protrusions of the sleeve.

70. The wire assembly of any one of claims 41-69, wherein at least a portion of the inner surface is coupled to at least a portion of the first assembly using an adhesive.

71. A heater wire as sembly including : a first assembly including: a first wire electrically coupled to an electrical current source; and a second wire electrically coupled to a heating element; a sleeve including an outer surface and an inner surface, wherein the inner surface is disposed circumferentially around and in contact with at least a portion of the first assembly, wherein the sleeve includes a first segment, a second segment, and a third segment, the first segment having a first inner diameter, the second segment having a second inner diameter that is less than the first inner diameter, and the third segment having a third inner diameter that is less than the second inner diameter, and wherein the second segment is interposed between the first segment and the third segment.

72. The wire assembly of claim 70, wherein the first inner diameter is at most 85% of the outer diameter of the first wire.

73. The wire assembly of claim 70 or claim 71, wherein the second inner diameter is at most 85% of the outer diameter of the connector.

74. The wire assembly of any one of claims 70-72, wherein the third inner diameter is at most 85% of the outer diameter of the second wire.

75. The wire assembly of any one of claims 70-73, wherein the first assembly further includes a connector in contact with at least a portion of the first wire and at least a portion of the second wire, wherein the connector is configured to electrically couple the first wire to the second wire.

76. The wire assembly of claim 75, wherein the connector includes an electrically conductive material in direct contact with an electrically conductive portion of the first wire and an electrically conductive portion of the second wire.

77. The wire assembly of claim 75 or claim 76, wherein the connector is a splice connector.

78. The wire assembly of any one of claims 70-77, wherein the sleeve includes an electrically non-conductive material.

79. The wire assembly of any one of claims 70-78, wherein the sleeve is configured to electrically isolate the connector from an outside environment.

80. The wire assembly of any one of claims 70-79, wherein the sleeve includes a material selected from polychloroprene, ethylene-propylene rubber, polytetrafluoroethylene (PTFE), latex, rubber latex, nitrile rubber, or Fluorine Kautschuk Material (FKM).

81. The wire assembly of any one of claims 70-80, herein the material has been subjected to vulcanization.

82. The wire assembly of any one of claims 70-81, wherein the first wire includes an electrical wire, the electrical wire including an electrically conductive material.

83. The wire assembly of claim 82, wherein at least a portion of the electrical wire is coated with a non-conductive material.

84. The wire assembly of claim 83, wherein the non-conductive material is polyvinyl chloride (PVC).

85. The wire assembly of any one of claims 70-84, wherein the second wire includes a resistive heater wire.

86. The wire assembly of any one of claims 70-85, wherein the second wire includes a tube disposed circumferentially around at least a portion of the resistive heater wire.

87. The wire assembly of any one of claims 70-86, wherein the tube includes a first end and the second wire includes a terminal pin at a first end of the second wire, the terminal pin extending beyond the first end of the tube in a longitudinal direction.

88. The wire assembly of any one of claims 70-87, wherein the first assembly further includes a bushing, wherein the bushing includes an aperture therethrough, and wherein the terminal pin extends through the aperture of the bushing.

89. The wire assembly of any one of claims 70-88, wherein the connector is electrically coupled to the terminal pin.

90. The wire assembly of any one of claims 70-89, wherein at least a portion of the inner surface is coupled to at least a portion of the first assembly using an adhesive.

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