Patent Publication Number: US-10770813-B2

Title: Environmentally sealed, reusable connector for printed flexible electronics

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This patent application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 62/537,056 filed Jul. 26, 2017, and entitled “ENVIRONMENTALLY SEALED, REUSABLE CONNECTOR FOR PRINTED FLEXIBLE ELECTRONICS,” which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The field of the disclosure relates generally to electrical connectors, and more particularly, to environmentally sealed, reusable connectors for flexible circuits. 
     At least some known connectors for flexible cables or circuits, such as flat flexible cables (FFCs), are not environmentally sealed and reusable. Typical sealed FFC connectors require an electrical terminal to be pressed into or otherwise connected to the FFC, a wire to be attached to the electrical terminal, and a permanent sealant (e.g., epoxy, plastic, resin, and the like) disposed or permanently affixed around the connector in an overmold process. By using, for example, an epoxy as the sealing agent, the FFC and connector cannot be reused. As such, there is a need for a reusable and an environmentally sealed connector for electrically coupling an FFC to one or more wires and that can withstand extreme outdoor environments, including submersion under water for extended periods. 
     BRIEF DESCRIPTION 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present disclosure will be apparent from the following detailed description of the embodiments and the accompanying drawing figures. 
     In one aspect, an environmentally sealed connector is provided. The environmentally sealed connector includes a spring-loaded terminal and a connector cap having a terminal cavity for receiving at least a portion of the spring-loaded terminal in order to electrically couple the spring-loaded terminal to a flexible circuit. Furthermore, the environmentally sealed connector includes a connector base releasably coupled to the connector cap. The connector base covers the terminal cavity and the portion of the spring-loaded terminal. Moreover, the environmentally sealed connector includes an elastic member disposed between the connector cap and the connector base. The elastic member is in sealing engagement therewith and surrounds the terminal cavity and the portion of the spring-loaded terminal. 
     In another aspect, another environmentally sealed connector is provided. The environmentally sealed connector includes a spring-loaded terminal having a conductive component coupled thereto, a connector base, a connector cap, and first and second elastic members. The connector base includes a terminal cavity for receiving at least a portion of the spring-loaded terminal in order to electrically couple the spring-loaded terminal to a flexible circuit. The connector base also includes a central cavity for receiving an electrically conductive element therein. The connector cap releasably is coupled to the connector base and covers the central cavity, terminal cavity, and the portion of the spring-loaded terminal. The first elastic member is disposed between the connector cap and the connector base. In addition, the first elastic member is in sealing engagement therewith and surrounds the terminal cavity and the portion of the spring-loaded terminal. The second elastic member is disposed between the connector cap and the connector base, and is in sealing engagement therewith, surrounding the central cavity. 
     In yet another aspect, a method for releasably coupling a flexible circuit to a connector is provided. The method includes removably inserting the flexible circuit into a connector housing. The flexible circuit contacts a spring-loaded terminal of the connector to form an electrical connection within the connector housing. The method also includes sealing around the electrical connection to provide ingress protection. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is an exploded top perspective view of an exemplary flexible cable assembly, in accordance with one embodiment of the disclosure; 
         FIG. 2  is an exploded bottom perspective of the flexible cable assembly of  FIG. 1 ; 
         FIG. 3  is a sectional view of the flexible cable assembly of  FIG. 1 , illustrating an electrical connection enclosed therein; 
         FIG. 4  is a front view of a connector cap of a connector of the flexible cable assembly of  FIG. 1 ; 
         FIG. 5  is a bottom view of the connector cap of  FIG. 4 ; 
         FIG. 6  is a section view of the connector cap taken along line  6 - 6  of  FIG. 5 ; 
         FIG. 7  is another section view of the connector cap taken along line  7 - 7  of  FIG. 5 ; 
         FIG. 8  is a bottom perspective view of a connector base of the connector of the flexible cable assembly of  FIG. 1 ; 
         FIG. 9  is a top view of the connector base of  FIG. 8 ; 
         FIG. 10  is a section view of the connector base taken along line  10 - 10  of  FIG. 9 ; 
         FIG. 11  is another section of the connector base taken along line  11 - 11  of  FIG. 9 ; 
         FIG. 12  is a perspective view of a four-position connector cap that may be used with the connector of the flexible cable assembly shown in  FIG. 1 ; 
         FIG. 13  is an exploded top perspective view of another flexible cable assembly; 
         FIG. 14  is an exploded bottom perspective of the flexible cable assembly of  FIG. 13 ; 
         FIG. 15  is a bottom view of a connector cap of a connector of the flexible cable assembly shown in  FIG. 13 ; 
         FIG. 16  is a top view of the connector cap of  FIG. 15 ; 
         FIG. 17  is a section view of the connector cap taken along line  17 - 17  of  FIG. 15 ; 
         FIG. 18  is a top view of a connector base of the connector of the flexible cable assembly shown in  FIG. 13 ; 
         FIG. 19  is a bottom view of the connector base of  FIG. 18 ; 
         FIG. 20  is a section view of the connector base taken along line  20 - 20  of  FIG. 18 ; 
         FIG. 21  is a perspective view of yet another flexible cable assembly; and 
         FIG. 22  is a perspective view of a connector base of the flexible cable assembly shown in  FIG. 21 . 
     
    
    
     Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein. While the drawings do not necessarily provide exact dimensions or tolerances for the illustrated components or structures, the drawings are to scale with respect to the relationships between the components of the structures illustrated in the drawings. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     The following detailed description of embodiments of the disclosure references the accompanying figures. The embodiments are intended to describe aspects of the disclosure in sufficient detail to enable those with ordinary skill in the art to practice the disclosure. The embodiments of the disclosure are illustrated by way of example and not by way of limitation. Other embodiments may be utilized, and changes may be made without departing from the scope of the claims. The following description is, therefore, not limiting. The scope of the present disclosure is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled. 
     In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features referred to are included in at least one embodiment of the disclosure. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are not mutually exclusive unless so stated. Specifically, a feature, component, action, step, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, particular implementations of the present disclosure can include a variety of combinations and/or integrations of the embodiments described herein. 
     In the following specification and the claims, reference will be made to several terms, which shall be defined to have the following meanings. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. “Optional” or “optionally” means that the subsequently described feature, event, or circumstance may or may not be required or occur, and that the description includes instances with or without such element. 
     Approximating language, as used herein throughout the specification and the claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. 
     As used herein, directional references, such as, “top,” “bottom,” “front,” “back,” “side,” and similar terms are used herein solely for convenience and should be understood only in relation to each other. For example, a component might in practice be oriented such that faces referred to herein as “top” and “bottom” are in practice sideways, angled, inverted, etc. relative to the chosen frame of reference. 
     Broadly, the present disclosure describes a reusable, resealable enclosure or connector that contains the contacts of an electrically conductive element (e.g., a flexible circuit or sensor), an O-ring or other elastic member, and one or more spring-loaded terminals to electrically connect the electrically conductive element to another conductor (e.g., one or more wires). This arrangement allows the electrically conductive element to be removed by opening or loosening the enclosure or connector. 
       FIG. 1  is an exploded top perspective view of an exemplary flexible cable assembly  100 ;  FIG. 2  is an exploded bottom perspective of the flexible cable assembly  100 ; and  FIG. 3  is a sectional view of the flexible cable assembly  100  illustrating the electrical connection enclosed therein. In the exemplary embodiment, the flexible cable assembly  100  includes a flexible circuit or cable (FC)  102  electrically coupled to one or more conductive components  104  via respective spring-loaded terminals  106  within an environmentally sealed, reusable connector  108 . As used herein, the phrase “flexible circuit” and its abbreviation “FC” includes, for example, and without limitation, flat printed circuitry (FPC), flat flexible circuits or cables, sensors, flexible printed circuit boards, flex circuits, flex print, flexi-circuits, rigid flexible circuits, and flexible electronic components having one or more electrical connection portions proximate an end of the flexible circuit. Typical FCs consist of a thin insulating polymer film having conductive circuits formed thereon and are typically supplied with a thin polymer coating disposed over at least a portion of the conductive circuits to provide protection thereof. The FCs described herein may include one or more passive and/or active components integrated therein, thereby providing passive and/or active functions respectively. The conductive component  104  described herein includes, for example, and without limitation, wires, flexible printed circuit boards, printed non-wire components, and the like. In some embodiments, the conductive component  104  may include a wire coated, for example, with an insulating material, such as an insulating sheath or insulating film. 
     In the exemplary embodiment, the reusable connector  108  includes a connector base  110  and a connector cap  112  defining a connector housing, an elastic member  114 , and one or more fastener assemblies  116 . In the exemplary embodiment, the fastener assembly  116  includes a screw  118  and a nut  120  releasably secured to each other via threaded connection. Alternatively, the fastener assembly  116  may include rivets, bolts, pins, clamps, adhesive, and any other type of fastener that enables the connector  108  to function as described herein. In alternative embodiments, the one or more fastener assemblies  116  may be formed as part of the connector base  110  and/or the connector cap  112 . In addition, the elastic member  114  may include, for example, a gasket, an O-ring, or a sealable foil to provide sealing engagement between the connector base  110  and the connector cap  112 . The elastic member  114  may be fabricated from a resilient material including, for example, without limitation, perfluoro elastomers, Viton®, Extreme Viton® Type A, nitrile (Buna-N), hydrogenated nitrile, silicone rubber, silicone, fluorosilicone, ethylene propylene, butyl rubber, Neoprene®, urethane, Teflon®, styrene butadiene, natural rubber, acrylic rubber, and ethylene acrylic. 
     Each conductive component  104  (e.g., a wire, cable, etc.) may be electrically and mechanically coupled to a respective spring-loaded terminal  106  via a crimp connection, solder connection, or any other connection that enables the cable assembly  100  to function as described herein. As best shown in  FIG. 3 , the spring-loaded terminal  106  with the conductive component  104  coupled thereto, is inserted into the connector cap  112  as further described below. The spring-loaded terminal  106  expands after full insertion to facilitate retaining the spring-loaded terminal  106  and conductive component  104 . Elastic member  114  is positioned within the connector cap  112 , the FC  102  is positioned on the connector base  110 , and the connector cap  112  is coupled to the connector base  110 . More specifically, the connector cap  112  is coupled to the connector base  110  such that the elastic member  114  is compressed against the FC  102  and the spring-loaded terminals  106  are in electrical contact with the FC  102 . As described in more detail below, the elastic member  114  surrounds the electrical connections between the FC  102  and the portion of the spring-loaded terminals  106  contacting the FC  102  such that the electrical connections are sealed from the outside environment. The connector cap  112  is releasably coupled to the connector base  110  via the one or more fastener assemblies  116 . It will be appreciated that the position of the configuration of the connector  108  could be revised, i.e., the connector base  110  could contain the elastic member  114  and the spring-loaded terminals  106  and conductive components  104 . The use of the elastic member  114  surrounding the electrical connection between the FC  102  and the spring-loaded terminals  106  is advantageous in that the sealed connector  108  does not utilize a permanent sealant (e.g., epoxy, plastic, resin, and the like) to encapsulate the electrical connection, therefore enabling the FC  102  to be removed and replaced in the reusable connector  108 . 
     The connector cap  112  is illustrated in more detail in  FIGS. 4-7 , where  FIG. 4  is a front view of the connector cap  112 ,  FIG. 5  is a bottom view,  FIG. 6  is a section view taken along line  6 - 6  of  FIG. 5 , and  FIG. 7  is another section view taken along line  7 - 7  of  FIG. 5 . In the exemplary embodiment, the connector cap  112  is substantially symmetrical with respect to a vertical line A, which, when viewed from the front, is substantially centered on the connector cap  112 . Alternatively, the connector cap  112  may include features and/or elements that are not symmetrical with respect to each other. As described above, the terms top, bottom, front, rear, left, and right are used only for convenience to indicate relative positional relationships. 
     In the exemplary embodiment, the connector cap  112  may be fabricated as an integrally formed solid structure, for example, using an additive manufacturing process, such as, binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization. These processes may include technologies such as fused deposition modelling, direct metal laser melting, direct metal laser sintering, selective laser sintering, selective laser melting, electron beam melting, binder jet, and/or any other additive manufacturing technology. Alternatively, the connector cap  112  may be fabricated using a molding process. Accordingly, the features of the connector cap  112  described herein may have a draft angle associated with each wall and/or cavity to promote removal of the connector cap  112  from a mold. 
     The connector cap  112  may be fabricated from any generally rigid solid material or materials, including, but not limited to, metal, plastic, glass, and ceramic. Suitable metals may include, but are not limited to, aluminum, stainless steel, galvanized steel, alloys of tin, and combinations thereof. Suitable plastics may include, but are not limited to, one or more of acrylonitrile butadiene styrenes (ABS), poly lactic acids (PLA), styrenics, acrylics, polytetrafluoroethylenes (PTFE), perfluoroalkoxy alkanes (PFA), polyesters, polycarbonates (PET, PEN), polysulfones (PSU), polyether sulfones (PES), polyether imides (PEI), polyvinyl chlorides (PVC), chlorinated polyvinyl chlorides (CPVC), polyethylenes (PE, HDPE, LDPE, UPE), polypropylenes (PP), polyether etherketones (PEEK), fluorinated ethylene propylenes (FEP), ethylene tetrafluoroethylenes (ETFE), ethylene chlorotrifluoroethylenes (ECTFE), polyphenylene sulfides (PS), nylons, polyurethanses, and thermoplastics containing reinforcing fibers such as glasses, carbon fibers, and metal oxides. Suitable glasses may include, but are not limited to, quartz, soda lime, silicate, borosilicate, and combinations thereof. Suitable ceramics may include, but are not limited to, oxides of alumina, beryllia, ceria, and zirconia and nonoxides such as carbides, borides, nitrides, and silicides. Composite materials may also be used such as particulate-reinforced or fiber-reinforced oxides and nonoxides and combinations thereof. It is to be appreciated, however, that the connector cap  112  may be fabricated from any material that enables the connector  108  to function as described herein. Furthermore, the connector cap  112  may be fabricated by methods other than additive manufacturing and molding, including, e.g., machining, and therefore may not have a draft angle associated with the features as described herein. 
     In the exemplary embodiment, the connector cap  112  is a generally cuboid-shaped structure that broadly includes a curved front wall  122 , a rear wall  124 , a first end wall  126 , and an opposing second end wall  128 . While the connector cap  112  is described as being generally cuboid-shaped, it is noted that the connector cap  112  can be any shape that enables the connector  108  to function as described herein. As shown in  FIG. 4 , the connector cap  112  has a height “H 1 ” that is preferably in the range between and including about 3 millimeters (mm) and about 10 mm. In the exemplary embodiment, the height H 1  is more preferably in the range between and including about 4 mm and about 6 mm. With reference to  FIG. 5 , the connector cap  112  also has a length “L 1 ” that is preferably in the range between and including about 15 mm and about 50 mm. In the exemplary embodiment, the length L 1  is more preferably in the range between and including about 20 mm and about 30 mm. Furthermore, the connector cap  112  has a width “W 1 ” that is preferably in the range between and including about 15 mm and about 35 mm. In the exemplary embodiment, the width W 1  is more preferably in the range between and including about 15 mm and about 25 mm. 
     With reference to  FIG. 4 , a cable access hole  130  is defined in the front wall  122 , generally centered between a top surface  131  and a bottom surface  133  of the connector cap  112  and that is substantially symmetrical with respect to vertical line A. The cable access hole  130  extends partially through the connector cap  112  a predefined depth and is configured to receive the conductive components  104  and spring-loaded terminals  106  therethrough (See, e.g.,  FIG. 3 ), and a potting material therein to facilitate sealing the spring-loaded terminals  106  from the outside environment. The potting material attaches to the conductive components  104  and the connector cap  112  to form a seal therebetween. In the exemplary embodiment, the cable access hole  130  is generally rectangular in shape, although it is contemplated that the cable access hole  130  can have any shape that enables the connector cap  112  to function as described herein. 
     With reference to  FIG. 5 , the connector cap  112  includes a first terminal cavity  132  and a second terminal cavity  134  that is substantially symmetrical to first terminal cavity  132  with respect to line A. Alternatively, the connector cap  112  may include any number of cavities that enable the connector cap  112  to function as described herein (See, e.g.,  FIG. 12 ). In the exemplary embodiment, the first and second terminal cavities  132  and  134  extend partially through the connector cap  112  to a depth “D 1 ,” as best shown in  FIG. 6 . The first and second terminal cavities  132  and  134  are sized and shaped to receive at least a portion of a spring-loaded terminal  106 , as illustrated in  FIG. 3 . The first terminal cavity  132  is coupled to the cable access hole  130  by a channel  136  defined within the connector cap  112 . Furthermore, the second terminal cavity  134  is coupled to the cable access hole  130  by a channel  138 . As shown in  FIG. 4 , the channels  136  and  138  are square in shape, although it is contemplated that the channels can include any perimeter shape that enables the connector cap  112  to function as described herein. 
     With reference back to  FIG. 5 , the bottom surface  133  (the mating surface) of the connector cap  112  includes a groove  140  that surrounds the first and second terminal cavities  132  and  134 . The groove  140  is sized and shaped to receive the elastic member  114 , as described further herein. In the exemplary embodiment, the groove  140  is substantially circular in shape, although other shapes are contemplated, including, for example, rectangular, polygonal, etc. As shown in  FIG. 6 , the groove  140  extends into the connector cap  112  a predetermined depth but does not extend into the channels  136  and  138 . In some embodiments, it is contemplated that the groove  140  may extend into the channels  136  and  138 . In addition, the groove  140  has a cross-sectional shape that is substantially rectangular. Alternatively, the cross-sectional shape of the groove  140  can be any shape that enables the connector  108  to function as described herein. 
     Extending away from the bottom surface  133  is a locating member  142 , which is sized and shaped to physically engage with a slot  162  formed in the connector base  110 , as best shown in  FIG. 3 . The locating member  142  is configured to locate the connector cap  112  with respect to the connector base  110  and to function as an insertion hard stop for the FC  102  to facilitate the electrical connection between the spring-loaded terminals  106  and the FC  102 . In the exemplary embodiment, the locating member  142  is generally centered on the connector cap  112  with respect to the line A, as illustrated in  FIGS. 4 and 5 . The locating member  142  is generally an elongated member having a substantially rectangular shape with walls that taper inward as the locating member  142  extends away from the bottom surface  133 . It is noted that the locating member  142  may have any shape so long as the slot  162  is complementary to facilitate locating the connector cap  112  with respect to the connector base  110 . In the exemplary embodiment, the tapered walls of the locating member  142  engage upper edges of the slot  162  to facilitate controlled positioning of the connector cap  112 . 
     With reference to  FIG. 5 , the exemplary connector cap  112  includes a substantially symmetrical pair of apertures  144  with respect to line A. The apertures  144  are generally positioned on either side of the locating member  142 , proximate the front wall  122  of the connector cap  112 . The apertures  144  are substantially circular in shape and extend through the connector cap  112 , from the top surface  131  to the bottom surface  133 . While the apertures  144  are illustrated as circular, in other embodiments, the apertures  144  may have other shapes, including, for example, and without limitation, rectangular, polygonal, and the like. The apertures  144  may be used to facilitate coupling the connector  108  to another structure and or additional connectors. It is noted that the connector cap  112  may include fewer or greater than two apertures  144 . 
     In addition, the connector cap  112  includes a substantially symmetrical pair of fastener holes  146  with respect to line A. The fastener holes  146  are generally positioned on either side of the groove  140  and terminal cavities  132  and  134  to facilitate providing a compression force across the groove  140  and terminal cavities  132  and  134  when the connector  108  is assembled for use. Each fastener hole  146  is sized and shaped to receive a respective screw  118  (shown in  FIGS. 1 and 2 ). In the exemplary embodiment, the fastener holes  146  are countersink holes for receiving a countersink faster, although other types of holes are contemplated, including, for example, counterbore holes. The fastener holes  146  extend through the connector cap  112 , from the top surface  131  to the bottom surface  133 . In the exemplary embodiment, the countersink configuration facilitates positioning the head of the screw  118  at or below the top surface  131  of the connector cap  112 . It is noted that the connector cap  112  may include fewer or greater than two fastener holes  146 . 
     The connector base  110  is illustrated in  FIGS. 8-11 , where  FIG. 8  is a bottom perspective view of the connector base  110 ,  FIG. 9  is a top view,  FIG. 10  is a section view taken along line  10 - 10  of  FIG. 9 , and  FIG. 11  is another section view taken along line  11 - 11  of  FIG. 9 . In the exemplary embodiment, the connector base  110  is substantially symmetrical with respect to the line  10 - 10  of  FIG. 9 , which is substantially centered on the connector base  110 . Alternatively, the connector base  110  may include features and/or elements that are not symmetrical with respect to each other. As described above, the terms top, bottom, front, rear, left, and right are used only for convenience to indicate relative positional relationships. 
     In the exemplary embodiment, like the connector cap  112  described above, the connector base  110  may be fabricated as an integrally formed solid structure, for example, using any of the described additive manufacturing processes and/or technologies for the connector cap  112 . Alternatively, the connector base  110  may be fabricated using a molding process. Accordingly, the features of the connector base  110  described herein may have a draft angle associated with each wall and/or cavity to promote removal of the connector base  110  from a mold. Furthermore, like the connector cap  112 , the connector base  110  may be fabricated from any generally rigid solid material or materials, including, but not limited to the above described metals, plastics, glasses, ceramics, and/or combinations thereof. Composite materials may also be used such as particulate-reinforced or fiber-reinforced oxides and nonoxides and combinations thereof. It is to be appreciated, however, that the connector base  110  may be fabricated from any material that enables the connector  108  to function as described herein. Moreover, the connector base  110  may be fabricated by methods other than additive manufacturing and molding, including, e.g., machining, and therefore may not have a draft angle associated with the features as described herein. 
     In the exemplary embodiment, the connector base  110  has a perimeter shape that is generally complementary to that of the connector cap  112 . More particularly, the connector base  110  is a generally cuboid-shaped structure that broadly includes a curved front wall  150 , a rear wall  152 , a first end wall  154 , and an opposing second end wall  156 . While the connector base  110  is described as being generally cuboid-shaped, it is noted that the connector base  110  can be any shape that enables the connector  108  to function as described herein. As shown in  FIG. 10 , the connector base  110  has a height “H 2 ” that is preferably in the range between and including about 3 mm and about 10 mm. In the exemplary embodiment, the height H 2  is more preferably in the range between and including about 4 mm and about 6 mm. With reference to  FIG. 9 , the connector base  110  also has a length “L 2 ” that is preferably in the range between and including about 15 mm and about 50 mm. In the exemplary embodiment, the length L 2  is more preferably in the range between and including about 20 mm and about 30 mm. Furthermore, the connector base  110  has a width “W 2 ” that is preferably in the range between and including about 15 mm and about 35 mm. In the exemplary embodiment, the width W 2  is more preferably in the range between and including about 15 mm and about 25 mm. 
     With reference to  FIG. 9 , the connector base  110  includes an alignment channel  158  defined in a top surface  160  (the mating surface) of the connector base  110  for aligning the one or more electrical connection portions of the FC  102  with the spring-loaded terminals  106 . In the exemplary embodiment, the alignment channel  158  has a width “W 3 ” that is slightly larger than a width of the FC  102 . In addition, as best shown in  FIG. 10 , the alignment channel  158  extends partially through the connector base  110  to a depth “D 2 ,” that is slightly larger than a thickness of the FC  102 . As such, the alignment channel  158  is sized and shaped to receive at least a portion of the FC  102 , as illustrated in  FIG. 3 . The alignment channel  158  extends from the rear wall  152  of the connector base  110  to a slot  162  defined in the top surface  160 , as illustrated in  FIGS. 9 and 10 . 
     In the exemplary embodiment, the slot  162  sized and shaped to engage with the locating member  142  of the connector cap  112  (shown in  FIGS. 4-7 ), as described above. The slot  162  is configured to locate the connector base  110  with respect to the connector cap  112  to facilitate the electrical connection between the spring-loaded terminals  106  and the FC  102 . In the exemplary embodiment, the slot  162  is generally centered on the connector base  110  with respect to the line  10 - 10 , as illustrated in  FIG. 9 . The slot  162  is generally an elongate slot having a substantially rectangular shape. It is noted that the slot  162  may have any shape so long as the locating member  142  is complementary to facilitate locating the connector base  110  with respect to the connector cap  112 . The slot  162  has a predetermined depth “D 3 ” configured to receive the locating member  142  such that the top surface  160  of the connector base  110  may engage in face-to-face contact with the bottom surface  133  of the connector cap  112  (shown in  FIG. 5 ). 
     With reference to  FIGS. 8, 9, and 11 , the exemplary connector base  110  includes a substantially symmetrical pair of apertures  164  with respect to line  10 - 10 . The apertures  164  are generally positioned on either side of the slot  162 , proximate the front wall  150  of the connector base  110 . The apertures  164  are substantially circular in shape and extend through the connector base  110 , from a bottom surface  165  to the top surface  160 . While the apertures  164  are illustrated as circular, in other embodiments, the apertures  164  may have other shapes, including, for example, and without limitation, rectangular, polygonal, and the like. The apertures  164  are sized, shaped, and positioned to be substantially complementary to the apertures  144  of the connector cap  112  and may be used to facilitate coupling the connector  108  to another structure and or additional connectors. In one embodiment, the apertures  164  and coaxial with the apertures  144  of the connector cap  112 . It is noted that the connector base  110  may include fewer or greater than two apertures  164 . 
     In addition, the connector base  110  includes a substantially symmetrical pair of fastener holes  166  with respect to line  10 - 10 . The fastener holes  166  are generally positioned on either side of the alignment channel  158  proximate the rear wall  152  to facilitate providing a compression force across the FC  102  when the connector  108  is assembled for use. Each fastener hole  166  is sized and shaped to receive a respective screw  118  (shown in  FIGS. 1 and 2 ) therethrough. As shown in  FIGS. 8 and 11 , the fastener holes  166  include a counterbored cavity  168  defined in the bottom surface  165 . Each counterbored cavity  168  is formed substantially concentric with a respective fastener hole  166 . In the exemplary embodiment, the counterbored cavity  168  is sized and shaped to receive a nut  120  (shown in  FIGS. 1 and 2 ) of the fastener assembly  116  therein. The counterbored cavity  168  may be sized to provide an interference fit to facilitate securing the nut  120  to the connector base  110 . In other embodiments, the fit may be a slip fit or any other fit that enables the connector base  110  to function as described herein. Additionally or alternatively, the nut  120  may be coupled to the connector base  110  via the counterbored cavity  168  through use of a glue or adhesive. In some embodiments, the counterbored cavity  168  may have a different shape configured to receive a different type of component of the fastener assembly  116 , or the counterbored cavity  168  may be omitted entirely. It is noted that the connector base  110  may include fewer or greater than two fastener holes  166 . 
       FIG. 12  is a perspective view of a four-position connector cap  200  that may be used with the connector  108 . The four-position connector cap  200  is fabricated substantially similar to the connector cap  112  illustrated in  FIGS. 4-7 , and as such, only the differences will be described below. The four-position connector cap  200  includes four spring-terminal cavities: a first cavity  202 , a second cavity  204 , a third cavity  206 , and a fourth cavity  208 . In the exemplary embodiment, the cavities  202 ,  204 ,  206 , and  208  extend partially through the four-position connector cap  200  to a predefined depth, for example, the depth “D 1 ,” as shown in  FIG. 6 . The cavities  202 ,  204 ,  206 , and  208  are sized and shaped substantially similar to the first and second terminal cavities  132  and  134  of the connector cap  112  to receive at least a portion of a spring-loaded terminal  106 , as illustrated in  FIG. 3 . Like the connector cap  112 , the cavities  202 ,  204 ,  206 , and  208  are coupled to a sealing cavity (not shown) by a respective channel (not shown) defined within the four-position connector cap  200 . 
     A bottom surface  210  of the four-position connector cap  200  includes a groove  212  that surrounds the cavities  202 ,  204 ,  206 , and  208 . The groove  212  is sized and shaped to receive an elastic member, such as the elastic member  114 . The groove  212  is generally annular-shaped. The term “annular,” as used herein, is not limited to the description of circular ring-shaped openings. Rather, it is contemplated that annular shapes include, for example, and without limitation, shapes that are round, polygonal, rectangular, oval, and/or racetrack-like with two generally parallel sides joined by rounded ends. As shown in  FIG. 12 , the groove  212  extends into the four-position connector cap  200  a predetermined depth. In addition, the groove  212  has a cross-sectional shape that is substantially rectangular. Alternatively, the cross-sectional shape of the groove  212  can be any shape that enables the connector  108  to function as described herein. 
       FIG. 13  is an exploded top perspective view of an exemplary flexible cable assembly  300  and  FIG. 14  is an exploded bottom perspective of the flexible cable assembly  300 . In the exemplary embodiment, the cable assembly  300  includes the flexible circuit or cable (FC)  102  electrically coupled to one or more conductive components  104  via respective spring-loaded terminals  106  within an environmentally sealed connector  308 . 
     In the exemplary embodiment, the connector  308  includes a connector base  310  and a connector cap  312  defining a connector housing, an elastic member  314 , and one or more fastener assemblies  116 , including the screw  118  and the nut  120  releasably secured to each other via threaded connection. In alternative embodiments, the one or more fastener assemblies  116  may be formed as part of the connector base  310  and/or the connector cap  312 . In addition, the elastic member  314  may include, for example, a gasket, an O-ring, or a sealable foil to provide sealing engagement between the connector base  310  and the connector cap  312 . The elastic member  314  may be fabricated from a resilient material including, for example, without limitation, perfluoro elastomers, Viton®, Extreme Viton® Type A, nitrile (Buna-N), hydrogenated nitrile, silicone rubber, silicone, fluorosilicone, ethylene propylene, butyl rubber, Neoprene®, urethane, Teflon®, styrene butadiene, natural rubber, acrylic rubber, and ethylene acrylic. 
     Like the cable assembly  100  described above, the spring-loaded terminal  106  with the conductive component  104  coupled thereto, is inserted into the connector cap  312  as further described below. The spring-loaded terminal  106  expands after full insertion to facilitate retaining the spring-loaded terminal  106  and conductive component  104 . The elastic member  314  is positioned within the connector cap  312 , the FC  102  is positioned on the connector base  310 , and the connector cap  312  is coupled to the connector base  310 . More specifically, the connector cap  312  is coupled to the connector base  310  such that the elastic member  314  is compressed against the FC  102  and a portion of the spring-loaded terminals  106  are in electrical contact with the FC  102 . As described in more detail below, the elastic member  314  surrounds the electrical connections between the FC  102  and the portion of the spring-loaded terminals  106  contacting the FC  102  such that the electrical connections are sealed from the outside environment. The connector cap  312  is releasably coupled to the connector base  310  via the one or more fastener assemblies  116 . It will be appreciated that the position of the configuration of the connector  308  could be revised, i.e., the connector base  310  could contain the elastic member  314  and the spring-loaded terminals  106  and conductive components  104 . 
     The connector cap  312  is illustrated in more detail in  FIGS. 15-17 , where  FIG. 15  is a bottom view of the connector cap  312 ,  FIG. 16  is a top view, and  FIG. 17  is a section view taken along line  17 - 17  of  FIG. 15 . In the exemplary embodiment, the connector cap  312  is substantially symmetrical with respect to a horizontal line B, which is substantially centered on the connector cap  312 . Alternatively, the connector cap  312  may include features and/or elements that are not symmetrical with respect to each other. As described above, the terms top, bottom, front, rear, left, and right are used only for convenience to indicate relative positional relationships. 
     In the exemplary embodiment, like the connector cap  112  described above, the connector cap  312  may be fabricated as an integrally formed solid structure, for example, using any of the described additive manufacturing processes and/or technologies for the connector cap  112 . Alternatively, the connector cap  312  may be fabricated using a molding process. Accordingly, the features of the connector cap  312  described herein may have a draft angle associated with each wall and/or cavity to promote removal of the connector cap  312  from a mold. Furthermore, like the connector cap  112 , the connector cap  312  may be fabricated from any generally rigid solid material or materials, including, but not limited to the above described metals, plastics, glasses, ceramics, and/or combinations thereof. Composite materials may also be used such as particulate-reinforced or fiber-reinforced oxides and nonoxides and combinations thereof. It is to be appreciated, however, that the connector cap  312  may be fabricated from any material that enables the connector  308  to function as described herein. Moreover, the connector cap  312  may be fabricated by methods other than additive manufacturing and molding, including, e.g., machining, and therefore may not have a draft angle associated with the features as described herein. 
     In the exemplary embodiment, the connector cap  312  is a generally cuboid-shaped structure that broadly includes a front wall  322 , a rear wall  324 , a first sidewall  326 , and an opposing second sidewall  328 . While the connector cap  312  is described as being generally cuboid-shaped, it is noted that the connector cap  312  can be any shape that enables the connector  308  to function as described herein. As shown in  FIG. 17 , the connector cap  312  has a height “H 3 ” that is preferably in the range between and including about 3 millimeters (mm) and about 10 mm. In the exemplary embodiment, the height H 3  is more preferably in the range between and including about 4 mm and about 6 mm. With reference to  FIG. 16 . the connector cap  312  also has a length “L 3 ” that is preferably in the range between and including about 15 mm and about 50 mm. In the exemplary embodiment, the length L 3  is more preferably in the range between and including about 25 mm and about 35 mm. Furthermore, the connector cap  312  has a width “W 4 ” that is preferably in the range between and including about 15 mm and about 35 mm. In the exemplary embodiment, the width W 4  is more preferably in the range between and including about 15 mm and about 25 mm. 
     An internal sealing cavity  330  is defined within the connector cap  312  and is coupled to a cable access hole  329  defined in the front wall  322 . The cable access hole  329  is generally centered between a top surface  331  and a bottom surface  333  of the connector cap  312  and that is substantially symmetrical with respect to horizontal line B. The internal sealing cavity  330  in generally centered about line B and extends from the bottom surface  333  partially through the connector cap  312  a predefined depth. The internal sealing cavity  330  is configured to receive the conductive components  104  and spring-loaded terminals  106  therethrough and a potting material therein to facilitate sealing the spring-loaded terminals  106  from the outside environment. In the exemplary embodiment, the sealing cavity  330  is generally rectangular in shape, although it is contemplated that the sealing cavity  330  can have any shape that enables the connector cap  312  to function as described herein. 
     With reference to  FIG. 15 , the connector cap  312  includes a first terminal cavity  332  and a second terminal cavity  334  that is substantially symmetrical to the first terminal cavity  332  with respect to line B. Alternatively, the connector cap  312  may include any number of cavities that enable the connector cap  312  to function as described herein (See, e.g.,  FIG. 12 ). In the exemplary embodiment, the first and second terminal cavities  332  and  334  extend partially through the connector cap  312  to a depth “D 4 ,” as best shown in  FIG. 17 . The first and second terminal cavities  332  and  334  are sized and shaped to receive at least a portion of a spring-loaded terminal  106 , as illustrated in  FIG. 3 . The first and second terminal cavities  332  and  334  are coupled to the sealing cavity  330  by a channel  336  defined within the connector cap  312 . As shown in  FIG. 14 , the channel  336  is generally rectangular in shape, although it is contemplated that the channel can include any shape that enables the connector cap  312  to function as described herein. 
     With reference back to  FIG. 15 , the bottom surface  333  of the connector cap  312  includes a groove  340  that surrounds the first and second terminal cavities  332  and  334 . The groove  340  is sized and shaped to receive the elastic member  314  therein, as described further herein. In the exemplary embodiment, the groove  340  is generally annular-shaped, although other shapes are contemplated, including, for example, circular, polygonal, etc. As shown in  FIG. 17 , the groove  340  extends into the connector cap  312  a predetermined depth but does not extend into the channel  336 , although in some embodiments, it is contemplated that the groove  340  may extend into the channel  336 . In addition, the groove  340  has a cross-sectional shape that is generally rectangular with slightly inwardly-tapered sidewalls to facilitate retaining the elastic member  314  therein. Alternatively, the cross-sectional shape of the groove  340  can be any shape that enables the connector  308  to function as described herein. 
     The exemplary connector cap  312  includes a substantially symmetrical pair of apertures  344  with respect to line B. The apertures  344  are generally positioned centrally on the connector cap  312  along the line B. The apertures  344  are substantially circular in shape and extend through the connector cap  312 , from the top surface  331  to the bottom surface  333 . While the apertures  344  are illustrated as circular, in other embodiments, the apertures  344  may have other shapes, including, for example, and without limitation, rectangular, polygonal, and the like. The apertures  344  may be used to facilitate coupling the connector  308  to another structure and or additional connectors. 
     In addition, the connector cap  312  includes a substantially symmetrical set of fastener holes  346  with respect to line B. The fastener holes  346  are generally positioned proximate the corners of the connector cap  312 , with one pair positioned on either side of the groove  340  and terminal cavities  332  and  334  to facilitate providing a compression force across the groove  340  and terminal cavities  332  and  334  when the connector  308  is assembled for use. Each fastener hole  346  is sized and shaped to receive a respective screw  118  (shown in  FIGS. 13 and 14 ). In the exemplary embodiment, the fastener holes  346  are countersink holes for receiving a countersink faster, although other types of holes are contemplated, including, for example, counterbore holes. The fastener holes  346  extend through the connector cap  312 , from the top surface  331  to the bottom surface  333 . In the exemplary embodiment, the countersink configuration facilitates positioning the head of the screw  118  at or below the top surface  331  of the connector cap  312 . 
     The connector base  310  is illustrated in  FIGS. 18-20 , where  FIG. 18  is a top view of the connector base  310 ,  FIG. 19  is a bottom view, and  FIG. 20  is a section view taken along line  20 - 20  of  FIG. 18 . In the exemplary embodiment, the connector base  310  is substantially symmetrical with respect to a horizontal line C, which is substantially centered on the connector base  310 . Alternatively, the connector base  310  may include features and/or elements that are not symmetrical with respect to each other. As described above, the terms top, bottom, front, rear, left, and right are used only for convenience to indicate relative positional relationships. 
     In the exemplary embodiment, like the connector cap  312  described above, the connector base  310  may be fabricated as an integrally formed solid structure, for example, using any of the described additive manufacturing processes and/or technologies for the connector cap  312 . Alternatively, the connector base  310  may be fabricated using a molding process. Accordingly, the features of the connector base  310  described herein may have a draft angle associated with each wall and/or cavity to promote removal of the connector base  310  from a mold. Furthermore, like the connector cap  312 , the connector base  310  may be fabricated from any generally rigid solid material or materials, including, but not limited to the above described metals, plastics, glasses, ceramics, and/or combinations thereof. Composite materials may also be used such as particulate-reinforced or fiber-reinforced oxides and nonoxides and combinations thereof. It is to be appreciated, however, that the connector base  310  may be fabricated from any material that enables the connector  308  to function as described herein. Moreover, the connector base  310  may be fabricated by methods other than additive manufacturing and molding, including, e.g., machining, and therefore may not have a draft angle associated with the features as described herein. 
     In the exemplary embodiment, the connector base  110  has a perimeter shape that is generally complementary to that of the connector cap  312 . More particularly, the connector base  310  is a generally cuboid-shaped structure that broadly includes a front wall  350 , a rear wall  352 , a first sidewall  354 , and an opposing second sidewall  356 . While the connector base  310  is described as being generally cuboid-shaped, it is noted that the connector base  310  can be any shape that enables the connector  308  to function as described herein. As shown in  FIG. 20 , the connector base  310  has a height “H 4 ” that is preferably in the range between and including about 3 mm and about 10 mm. In the exemplary embodiment, the height H 4  is more preferably in the range between and including about 4 mm and about 6 mm. With reference to  FIG. 18 , the connector base  310  also has a length “L 4 ” that is preferably in the range between and including about 15 mm and about 50 mm. In the exemplary embodiment, the length L 4  is more preferably in the range between and including about 25 mm and about 35 mm. Furthermore, the connector base  310  has a width “W 5 ” that is preferably in the range between and including about 15 mm and about 35 mm. In the exemplary embodiment, the width W 5  is more preferably in the range between and including about 15 mm and about 25 mm. 
     With reference to  FIG. 18 , the connector base  310  includes a channel  358  defined in a top surface  360  of the connector base  310 . In the exemplary embodiment, the channel  358  extends partially through the connector base  110  to a predetermined depth, as best shown in  FIG. 13 , that is slightly larger than a thickness of the FC  102 . In addition, the channel  358  has a width “W 6 ” that is slightly larger than a width of the FC  102 . As such, the channel  358  is sized and shaped to receive at least a portion of the FC  102 , as illustrated in  FIG. 13 . The channel  358  extends from the rear wall  352  of the connector base  310  a predetermined distance along the top surface  360 . 
     With reference to  FIGS. 18 and 19 , the exemplary connector base  310  includes a substantially symmetrical pair of apertures  364  with respect to line C. The apertures  364  are generally positioned centrally on the connector base  310  along the line C. The apertures  364  are substantially circular in shape and extend through the connector base  310  from a bottom surface  365  to the top surface  360 . While the apertures  364  are illustrated as circular, in other embodiments, the apertures  364  may have other shapes, including, for example, and without limitation, rectangular, polygonal, and the like. The apertures  364  are sized, shaped, and positioned to be substantially complementary to the apertures  344  of the connector cap  312  and may be used to facilitate coupling the connector  308  to another structure and or additional connectors. 
     In addition, the connector base  310  includes a substantially symmetrical set of fastener holes  366  with respect to line C. The fastener holes  366  are generally positioned proximate the corners of the connector base  310 , with one pair positioned on either side of the channel  358  proximate the rear wall  352  to facilitate providing a compression force across the FC  102  when the connector  308  is assembled for use. Each fastener hole  366  is sized and shaped to receive a respective screw  118  (shown in  FIGS. 13 and 14 ) therethrough. As shown in  FIGS. 14, 19, and 20 , the fastener holes  366  include a counterbored cavity  368  defined in the bottom surface  365 . Each counterbored cavity  368  is formed substantially concentric with a respective fastener hole  366 . In the exemplary embodiment, the counterbored cavity  368  is sized and shaped to receive a nut  120  (shown in  FIGS. 13 and 14 ) of the fastener assembly  116  therein. The counterbored cavity  368  may be sized to provide an interference fit to facilitate securing the nut  120  to the connector base  310 . In other embodiments, the fit may be a slip fit or any other fit that enables the connector base  310  to function as described herein. Additionally or alternatively, the nut  120  may be coupled to the connector base  310  via the counterbored cavity  368  through use of a glue or adhesive. In some embodiments, the counterbored cavity  368  may have a different shape configured to receive a different type of component of the fastener assembly  116 , or the counterbored cavity  368  may be omitted entirely. 
       FIG. 21  is a perspective view of an alternative flexible cable assembly  400  and  FIG. 22  is a perspective view of a connector base  404  of the flexible cable assembly  400  of  FIG. 21 . In this embodiment, the cable assembly  400  includes two FCs  102  attached to a connector  402 . The connector  402  includes the connector base  404  and a connector cap  406  that may be releasably coupled to the connector base  404  via one or more fasteners  408 . 
     As illustrated in  FIG. 22 , the connector base  404  includes a central cavity  410  configured to receive, for example, and without limitation, an electrically conductive element therein, such as a printed circuit board (PCB), printed wire board (PWB), microchip, flexible hybrid electronics (FHE), and the like. A connection portion  412  extends from a side of the connector base  404 . The connection portion  412  includes elements similar to the connector cap  112  for facilitating an electrical connection between the electrically conductive element contained in the central cavity  410  and the FCs  102 . For example, the connection portion  412  may include one or more pairs of cavities, similar to terminal cavities  132  and  134 , for receiving a respective spring-loaded terminal  106 . The terminal cavities  132  and  134  are connected to the central cavity  410  to facilitate an electrical connection between the electrically conductive element contained therein and the FCs  102 . Surrounding the terminal cavities  132  and  134  is the groove  140  configured to receive a sealing element, such as sealing element  114 . 
     The connector base  404  includes a second groove  414  that surrounds the central cavity  410 . The second groove  414  is sized and shaped to receive a second elastic member (not shown) to facilitate sealing the central cavity  410  from the outside environment. The second groove  414  extends into the connector base  404  a predetermined depth and has a cross-sectional shape that is substantially rectangular. Alternatively, the cross-sectional shape of the second groove  414  can be any shape that enables the connector  402  to function as described herein. 
     Advantageously, the illustrated embodiment provides easy access to change the FCs  102 . For instance, where the FC  102  is a printed sensor, the connector  402  may be removed from the invasive environment, and the FC  102  may be removed by simply loosening one or more of the fasteners  408  that couple the connector cap  406  to the connector base  404  and pulling the FC  102  out. A new FC  102  can then be connected by sliding it into the space between the connector cap  406  and the connector base  404  so that the FC&#39;s electrodes are in contact with the spring-loaded terminals  106 . The fastener  408  or fasteners  408  can then be retightened. 
     In operation, with particular reference to  FIGS. 1-11 , the conductive components  104  and the spring-loaded terminals  106  are inserted into the connector cap  112  through the cable access hole  130  and latched into place in the terminal cavities  132  and  134 . When the spring-loaded terminals  106  are pushed through the channels  136  and  138 , arms of the spring-loaded terminals  106  compress slightly. When the spring-loaded terminals  106  are pushed through the channels  136  and  138 , the arms spring back to their natural position, extending at least partially through the terminal cavities  132  and  134  slightly beyond the bottom surface  133  and locking the spring-loaded terminals  106  into the terminal cavities  132  and  134 . In embodiments with wires having insulating material thereon, the insulating material of the wires may extend at least partially into the cable access hole  130 . In the exemplary embodiment, the cable access hole  130  is filled with a potting material that facilitates preventing the ingress of environmental influences (e.g., water, solvent, etc.). As described herein, suitable potting materials include two-part epoxy/amine resins, photocurable acrylates, silicone caulks, two-part polyurethane casting resins, polyurethanes, urethanes, and foam sealants. 
     The elastic member  114  is positioned between the connector cap  112  and the connector base  110  such that it surrounds the spring-loaded terminals  106  in the plane that is coplanar with the space between the connector cap  112  and the connector base  110 . The groove  140  may be provided in the connector cap  112  or the connector base  110  to hold the elastic member  114  in place. The connector cap  112  and the connector base  110  are loosely coupled together via one or more fastener assemblies  116 . More specifically, the locating member  142  of the connector cap  112  is inserted into the slot  162  of the connector base  110  to align the connector cap  112  with the connector base  110  and the one or more fasteners  118  are loosely threadedly coupled to a respective nut  120  contained in the connector base  110 . The fastener assemblies  116  are selected to facilitate holding the connector cap  112  and the connector base  110  together tightly enough to compress the elastic member  114  and prevent environmental ingress into the region containing the spring-loaded terminals  106 . The FC  102  is then clamped between the connector cap  112  and the connector base  110  in electrical contact with one or more spring-loaded terminals  106 . More particularly, the FC  102  is inserted between the connector cap  112  and the connector base  110  via the alignment channel  158  defined in the connector base  110  and pushed against the locating member  142  to facilitate positioning the FC  102  in electrical contact with the spring-loaded terminals  106 . The connector cap  112  and the connector base  110  are then tightly coupled together using the fastener assemblies  116  to compress the elastic member  114  and form a complete seal around the area containing the spring-loaded terminals  106 . Compressing the elastic member  114 , which surrounds the electrical connection between the FC  102  and the spring-loaded terminals  106 , is advantageous in that the elastic member  114  provides a sealed area around the electrical connection to provide ingress protection. As such, the sealed connector  108  does not utilize a permanent sealant (e.g., epoxy, plastic, resin, and the like) to encapsulate the electrical connection, therefore enabling the FC  102  to be removed and replaced in the reusable connector  108 . 
     Disclosed above are embodiments of reusable, environmentally sealed connector assemblies that provide ingress protection. Ingress protection includes reducing or preventing the ingress of environmental constituents into the connector, for example, that would otherwise be harmful to or interfere with the electrical connection of flexible circuits (FCs). In one preferred embodiment, the connector  108  prevents the ingress of water. When used in water, the connector  108  provides an Ingress Protection (IP) rating (as defined by IEC 60529) of at least about IP64, which is IP rated as “dust tight” and protected against water projected from a nozzle up to 60° from vertical. More preferably, the connector  108  provides an IP rating of at least about IP67, which is IP rated as “dust tight” and protected against immersion. Even more preferably, the connector  108  provides an IP rating of at least about IP68, which is IP rated as “dust tight” and protected against complete, continuous submersion in water. In other embodiments, the connector  108  can be manufactured so as to prevent the ingress of other environmental constituents, including, but not limited to, silicone oil, mineral oil, acetone, PGME, PGMEA, gasoline, diesel fuel, aqueous acids having a pH of 1 to 6, aqueous bases having a pH of 7 to 12, NMP, hexanes, ethers, esters, ketones, alcohols, and combinations thereof. 
     EXAMPLES 
     The following examples set forth methods in accordance with the above disclosure. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention. 
     Example 1—Manufacture of Upper and Lower Enclosure 
     The connector cap  112  and the connector base  110  were manufactured by three-dimensional (3D) printing using extrusion material GPFR03 (Formlabs, Inc.). Upon completion of the 3D printing, the connector cap  112  and the connector base  110  were cured by means of exposure to an ultraviolet light source and finished by sanding and/or buffing. Hex nuts, such as the nuts  120 , were pressed into the respective four cavities  168  of the connector base  110  for use in the final mating process. 
     Example 2—Electrical Contact Insertion 
     KK 2759 Molex® terminals were attached to 22 AWG stranded wire with 300 VDC insulation, such as the conductive component  104 , by first stripping the outer insulation from the 22 AWG wire and then attaching the KK 2759 terminals using Molex® crimping tool 64016-0201. The electrical wire/terminal assembly was inserted into the terminal cavity, such as terminal cavities  132  and  134 , of the connector cap  112  until fully seated, as shown in  FIG. 3 . The remaining 22 AWG wire was routed through the cable access hole  130 . This was repeated with a second wire. Potting material (Pacer Technology Corporation Anchor-Tite® waterproof epoxy [15206, 15368]) was injected into the cable access hole  130  until full. 
     Example 3—Final Connector Assembly 
     A 1 mm×7.5 mm outside diameter (OD) Buna-N O-ring was placed into the groove  140  of the connector cap  112 . The connector cap  112  and the connector base  110  were coupled together and four screws, such as fasteners  118 , were routed through the connector cap  112  to the hex nuts, such as nuts  120 , that were previously pressed into the connector base  110 . The screws were tightened until the O-ring was compressed and a seal was formed. 
     Example 4—Pressure Testing for Water Ingress 
     A pressure pot was filled to a depth of 3 inches with water. One gram of salt was added to the water and stirred. A two-electrode resistive printed sensor, such as FC  102 , was inserted into the connector  108  and the connector was tightened. The sensor was inserted upside down so that no contact would be made between the two wires of the connector. Silicone was used to create an airproof seal around the wires leading out of the pressure pot from the connector  108 . The connector  108  and sensor were submerged in the salt water. The resistance of the connector  108  was monitored by a Brewer Science sensor test kit. If any valid resistance was measured, it would indicate that salt water had entered the connector  108  and shorted the connection. 
     A pressure regulator was attached in-line to a compressed air line and a hose was used to connect the regulator to the pressure pot. All other airways on the pressure pot were sealed. The regulator was initially set to 0 psi. Over the course of 3 hours, the pressure setting of the regulator was increased by 10 psi and left to sit for approximately 20 minutes. This simulated a salt water depth of 6.86 meters. Meanwhile, the electrical signal from the connector  108  was monitored in order to detect for conduction caused by water leaks. The maximum pressure that was achievable using the equipment available was 80 psi (simulating 54.9 meters of saltwater depth). There was no evidence of water ingress throughout the entire test. 
     With respect to the above description, it is noted that the optimal dimensional relationships for the components of the embodiments, to include variations in size, materials, shape, form, function, and manner of operation, assembly, and use, are deemed readily apparent to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by an embodiment of the disclosure. 
     Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing. 
     This written description uses examples to disclose the embodiments, including the best mode, and to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.