WO2008020946A1

WO2008020946A1 - Electrical connector with active electronic components

Info

Publication number: WO2008020946A1
Application number: PCT/US2007/016233
Authority: WO
Inventors: Frank H. Slauenwhite, Iii
Original assignee: Hypertronics Corporation
Priority date: 2006-08-11
Filing date: 2007-07-18
Publication date: 2008-02-21

Abstract

An electrical connector (10, 74) is provided having active electronic components with multiple mechanical and electrical configurations. The connector may comprise a base portion (12, 68) having associated pin contacts (14, 70) and a non-rigid electronic circuit (20, 52) attached thereto. The contact pins may be inserted into a rear of the base portion. The non-rigid electronic circuit may be secured to the pins and the base portion. Electrical wires may be terminated directly to the rear of the base portion mating with the contact pins. Alternatively, electrical wires may be attached to the non-rigid electronic circuitry in prescribed areas.

Description

ELECTRICAL CONNECTOR WITH ACTIVE ELECTRONIC COMPONENTS

DESCRIPTION OF THE INVENTION

[001] This application claims priority to provisional U.S. patent application entitled, Connector With Active Electrical Components, filed August 1 1, 2006, having a serial number 60/836,960, the disclosure of which is hereby incorporated by reference in its entirety.

Field of the Invention

[002] The present invention relates to an electrical connector with active electrical components, and more particularly, to a medical device connector utilizing an intelligent on board electrical design.

Background of the Invention

[003] Electronic equipment, such as that utilized in the medical industry, including, for example, defibrillators or centrifuges, may require electrical connectors for providing power. Additionally, or alternatively, a need may exist for coupling the aforementioned electrical equipment to additional equipment or electrical components.

[004] The connector design, found, for example, in many electrical connector types for such equipment may be specialized according to the type of device. Hence, one electrical connector design may be utilized for one type of equipment, and another connector design may be required for another type of equipment. Supplying each kind of equipment with respective electrical connectors can be challenging since various plug types may exist or be required. The design of each electrical connector may also be tedious since, in many cases, electrical components provided on electrical connectors may not be readily adaptable to the constraints of an electrical connector design. This may include, for instance, size requirements, location of the components with respect to the electrical connector, and the ability to properly provide signals to the connector, such as via specialized wire termination. Providing electrical connectors to meet the vast variety of equipment types may not only prove impractical but too expensive to provide the multitude of electrical connector designs for each application. [005] Accordingly, it is desirable to provide an improved electrical connector and methods.

SUMMARY OF THE INVENTION

[006] In accordance with one disclosed exemplary embodiment, an electrical connector may be provided having active electronic components with multiple mechanical and electrical configurations. The connector may comprise a base portion having associated pin contacts and a non-rigid electronic circuit attached thereto. The contact pins may be inserted into a rear of the base portion. The non-rigid electronic circuit may be secured to the pins and the base portion. Electrical wires may be terminated directly to the rear of the base portion mating with the contact pins. Alternatively, electrical wires may be attached to the non-rigid electronic circuitry in prescribed areas.

[007] In accordance with another exemplary embodiment, an electrical connector may be provided having a base member and at least one contact pin. The contact pin may be positioned to engage the base member. A non-rigid circuit board may be configured to engage the at least one contact pin.

[008] In accordance with another exemplary embodiment, an electrical connector may be provided having a base member having receiving portions and a plurality of contact pins. The contact pins may be positioned to engage the base member by contacting the receiving portions of the base member. A non-rigid circuit board may be configured to engage the plurality of contact pins. The non-rigid circuit board may include a first portion adjacent to the plurality of contact pins and a second portion having one or more bending regions. The second portion is capable of changing shape, wherein in an initial state, the second portion is generally configured along a first plane, and, in a second state, the second portion is generally bent along the one or more bending regions to form an altered shape outside the first plane.

[009] In accordance with yet another exemplary embodiment, an electrical connector may be provided having a base member having receiving portions and a plurality of contact pins. The contact pins may be positioned to engage the base member by contacting the receiving portions of the base member. A non-rigid circuit board may be configured to engage the plurality of contact pins. The non-rigid circuit board may include a first portion adjacent to the plurality of contact pins and a second portion having one or more bending regions, wherein the second portion is capable of changing shape. Tn an initial state, the second portion may be generally configured along a first plane, and, in a second state, the second portion may be generally bent along the one or more bending regions to form a generally cylindrical shape outside the first plane. The non-rigid circuit board may further include one or more electronic components attached thereto wherein said one or more electronic components are disposed interior to the cylindrical shape of the non- rigid circuit board in the second state. An enclosure device may also be attached to the base member. The enclosure device may have an interior for receiving and encapsulating the cylindrical shape of the non-rigid circuit board.

[010] In accordance with still another exemplary embodiment, a method of assembling an electrical connector may be provided. The method may include providing a base member having receiving portions and positioning a plurality of contact pins to engage the base member by contacting the receiving portions. The method may also include engaging a non-rigid circuit board with the plurality of contact pins, wherein the non-rigid circuit board includes a first portion adjacent to the plurality of contact pins and a second portion having a first geometric configuration. The second portion may further include one or more bending regions, wherein the second portion is capable of changing shape along the bending regions. The non-rigid circuit board may be bent along the bending regions to produce a second geometric configuration.

[011] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

[012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[013] FIG. 1 provides an exploded view of an electrical connector having active electronic components according to an exemplary disclosed embodiment; [014] FIG. 2 provides a perspective view of the electrical connector of FIG. 1 in a completed connector assembly;

[015] FIG. 3 provides a side view of the electrical connector of FIG. 2;

[016] FIG. 4 provides a rear plan view of the electrical connector of FIG. 2;

[017] FIG. 5 provides a side view of the electrical connector of FIG. 2 in an alternate configuration;

[018] FIG. 6 provides a rear plan view of the electrical connector of FIG. 2 in a revolved state;

[019] FIG. 7 provides a sectional view of the electrical connector of FIG. 2 illustrating a wire termination according to an exemplary disclosed embodiment;

[020] FIG. 8 provides a sectional view of the electrical connector of FIG. 2 illustrating a direct wire termination according to an exemplary disclosed embodiment;

[021] FIG. 9 provides an exploded perspective view of the completed connector assembly of FIG. 5 with an optional cable rear cap configuration;

[022] FIG. 10 provides an assembly view of FIG. 9;

[023] FIG. 11 provides an exploded perspective view of the completed connector assembly of FIG. 5 with a disposable medical device according to an exemplary disclosed embodiment;

[024] FIG. 12 provides an assembly view of FIG. 11 ;

[025] FIG. 13 provides an exploded view of an alternate electrical connector configuration according to an exemplary disclosed embodiment;

[026] FIG. 14 provides a perspective view of the electrical connector of FIG. 13 in a completed connector assembly;

[027] FIG. 15 provides an exploded perspective view of the completed connector assembly of FIG. 14 with an optional cable rear cap configuration;

[028] FIG. 16 provides a reverse exploded perspective view of the completed connector assembly of FIG. 14 with an optional cable rear cap configuration; and

[029] FIG. 17 provides an assembly view of FIG. 15 in connection with an exterior receptacle, with the exterior receptacle being shown in a see-through arrangement. DESCRIPTION OF THE EMBODIMENTS

[030] Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[031] Embodiments of the electrical connector design are illustrated in the attached FIGS. 1-17. The electrical connector 10 may be disposable and designed to mate with an appropriate electrical device such as an electrical plug utilized, for example, in the medical device industry or other industries. The electrical connector 10 may include a base portion 12 comprising, for example, an outer shell. The shell may be of any suitable material such as plastic. Examples of suitable plastics include, but are not limited to, any high temperature thermoplastic such as PBT, polysulfone, or polyetherimide. As shown, the shell is in a generally cylindrical shape although it may be any suitable geometric shape. The shell may be configured to receive one or more low cost industry standard size contacts or pins 14 with optional multiple configurations and pin counts. The base portion 12 may include an industry standard thread 16 that can be used to retain the electrical connector 10 in a medical device or custom enclosure as further described below. As shown, for example, in FIGS. 1-3, the thread 16 is positioned on an outer cylindrical surface of the base portion 12. The base portion 12 may also provide additional features, such as a tab receptacle 18 for receiving a mating tab of a custom enclosure. The tab receptacle 18 may prevent rotation of the electrical connector 10 when it is assembled to additional components such as a corresponding custom enclosure.

[032] The pins 14 may be mounted in the base portion 12 by various methods. In the example shown in FIGS. 1-4, the pins 14 are oriented to mount into respective receiving portions, such as contact holes 15 in the base portion 12. In some configurations, the pins 14 may snap or press into the contact holes of the base portion 12. The pins 14 may also be retained via adhesive means, including, for example soldering. Pins 14 may be made of any suitable electrically conductive material. For example, in one embodiment, the pins 14 may be made of brass including a portion containing a gold or silver flash. The pins 14 may be made by various methods such as via machine rod, stamping, forging, or drawing processes. Any suitable number of contacts or pins 14 may be used in the disclosed embodiment. In the example shown in FIGS. 1-4, fourteen pins 14 are illustrated, however, any suitable number of pins 14 (e.g., one to one thousand) may be used by the present design. The pins may be of any suitable size and shape.

[033] The electrical connector 10 may also include a circuit board 20 . The circuit board 20 may comprise a substrate such as a polyimide film having a suitable thickness (e.g., 0.0005", 0.001", 0.002", 0.003", or 0.005"). The substrate may also include teflon also having an appropriate thickness (e.g., 0.001" or 0.002"). A cover insulation of the circuit board 20 may include similar materials as the substrate. Optionally, a UV-cured liquid cover may be utilized as a cover insulation. Adhesives used by the circuit board 20 may include any suitable adhesive, including, but not limited to, a modified acrylic, epoxy, epoxy prepreg, or phenolic. Conductors utilized by the circuit board 20 may be electrodeposited, rolled, or annealed copper having an appropriate thickness (e.g., 0.5 oz. (0.0007"), 1 oz. (0.0014"), 2 oz. (0.0028"), 3 oz. (0.0042"), or thicker). Additional or optional conductors may include beryllium copper (e.g., 0.003" and thicker), cupronickel, or other suitable metals for specialized applications. Stiffeners for the circuit board 20 may also include various materials such as epoxy-glass (FR-4), polyimide-glass, polyimide, or aluminum. The circuit board 20 may contain a polyimide-glass or epoxy-glass hardboard. In addition, the circuit board 20 may utilize a plating including, for example, copper, solder, nickel, and/or gold.

[034] In the example shown, the circuit board 20 is a non-rigid circuit board. The non-rigid circuit board may be coupled to either one or both of the pins 14 and base portion 12. For example, the non-rigid circuit board may be adhesively secured to a surface portion 28 of the base portion 12. The circuit board 20 may include a contact portion 22 in connection with the pins 14 for securing the circuit board to the base portion. The contact portion 22 may include any suitable geometric configuration. In the embodiment shown, the contact portion 22 is a circular design. A tab member 24 extends from the contact portion 22 to a body portion 26. The body portion 26 may also include any suitable geometric configuration. The body portion 26, shown herein, includes a rectangular configuration.

[035] The body portion 26 may include perforated or fold lines 30. Bending along the perforated or fold lines 30 may allow the body portion 26 of the non-rigid circuit board to be flexed or urged into a predetermined shape. Hence, by bending, folding or flexing along the perforated or fold lines 30, the surface area taken up by the body portion 26 may be altered to fit into prescribed locations of additional components. Alternatively, instead of providing folding lines 30 at which the body portion 26 is bent, the body portion may be bent at any region. For example, instead of being bent at six distinct lines shown in Figs. 2- 4, the surface of the body portion 26 could be generally bent so that it does not form distinct angles. In other words, the body portion could be bent, in one embodiment, into a cylindrical configuration, without producing specific bends at folding lines. The body portion 26 may also be folded with respect to the circular portion 22. For example, the body portion 26 may be folded along a folding line 32, for instance, located at the connection of the tab member 24 and the circular portion 22 as shown in FIGS. 1, 4 and 5. The folding line 32 may be disposed at other suitable locations such as at various positions on the surface of the tab member 24.

[036] The body portion 26 of the non-rigid circuit board may be populated with multiple types of one or more electrical components 80, including, for example, EPROMs, capacitors, resistors, or any other suitable electronic component known in the art. The electrical components 34 and associated circuitry may be configured to attach to the circuit board 20 and remain operably attached when the circuit board 20 is conformed from a flat or un-altered state (such as shown, for example, in FIGS. 1-4) to an alternate configuration (such as a generally, hexagonal, cylindrical or other altered state shown, for example, in FIGS. 5-8). Thus, in the altered state, the body portion 26 is folded along the perforated or fold lines 30 to alter the configuration of the body portion 26. In addition, the body portion 26 may be bent with respect to the contact portion 22 such as along the folding line 32. All or some of the perforated or fold lines 30 may be folded according to a preferred use of the electrical connector 10. Furthermore, any electrical components 34 attached to the body portion 26 of the circuit board 20 may be sized and positioned (such as between the perforated or fold lines 30) in order to allow sufficient folding along the perforated or fold lines 30 in a completed assembly.

[037] In one embodiment, the body portion 26 may be folded to achieve a generally cylindrical configuration as shown, for example, in FIGS. 5-8. A cross section of the body portion 26 in the altered statue may include one of many cross-sectional shapes, including for example, a generally circular shape. However, by designing the body portion 26 to include an appropriate amount of perforated or fold lines 30, a plurality of other cross- sectional shapes, including, for example, a hexagon, an octagon, a tetragon, or a decagon may also be obtained. Alternately, if specific folding lines are not provided, body portion 26 could be bent at bending regions so that there are no specific folds or bends at folding lines but instead more gradual bends to take on a cylindrical or other shape. When the body portion 26 is bent to form an altered configuration, such as a generally cylindrical shape, the body portion 26 may be folded such that any electrical components 34 may be disposed within an interior of the body portion 26 in the altered configuration (e.g., see FIG. 6).

[038] The number of perforated or fold lines 30 and their location upon the body portion 26 may vary in accordance with a preferred design of the body portion 26 in the altered state. Hence, any suitable number of perforated or fold lines 30 may be disposed at any suitable location on the body portion 26 in order to generate a desired final configuration once the body portion 26 is urged into the altered state, for instance, as described above.

[039] The non-rigid circuit board may include solder points 36 to allow for connection to additional electrical wiring 38. Solder points may refer to any appropriate location on the non-rigid circuit board to which electrical components may be attached such as by traditional soldering methods known in the art. Alternatively, wire termination may bypass the non-rigid circuit board altogether and be configured directly to pins 14 as shown, for example, in FIG. 8. For example, FIG. 8 shows the wiring 38 configured to traverse an interior of the body portion 26 of the non-rigid circuit board. Ends of the wiring 38 may be attached to appropriate corresponding pins 14 such as by soldering or other suitable connection methods. Thus, the wiring 38 may be arranged to by pass the body portion 26 altogether and be attached directly to one or more pins 14.

[040] The disclosed embodiment may be utilized in a variety of applications. In one disclosed embodiment, a portion of the electrical connector 10 may be sized to fit inside additional components. For example, FIGS. 9 and 10 illustrate how the electrical connector 10 may be fitted within an enclosure 40. In FIGS. 9 and 10, the enclosure 40 is a customized rear cap cable assembly. The disclosed embodiment of the enclosure 40 includes a customized rear cap cable assembly having a cylindrical interior 42 and a plurality of locking tabs 44. The body portion 26 may be manipulated such as by folding along the perforated or fold lines 30 (or bending regions) to achieve an altered state. In the altered state, the body portion 26 is configured to be received by the interior 42 of the enclosure 40. Thus, the manipulated body portion 26 may be inserted within the interior 42 in a final assembly. In addition, the base portion 12 may be urged towards the interior 42 of the enclosure 40 such that the tabs 44 are inserted into the tab receptacles 18 and are locked therein. In some embodiments, the enclosure 40 may also have mating threads corresponding to the threads 16 of the electrical connector 10. The enclosure 40 may serve to provide a degree of protection to the circuitry along the body portion 26 and prevent exposure to contaminants.

[041] In another embodiment, as shown in FIGS. 11 and 12, a portion of the electrical connector 10 is shown to fit within a receptacle of a medical device 46. Again, the body portion 26 may be folded along the perforated or fold lines 30 (or bending regions) to achieve a configuration which may be received by the interior 48 of the medical device 46. Thus, the body portion 26 may be inserted within the interior 48. In addition, the base portion 12 may be urged toward the interior 48 of the medical device 46 in order to align and position a retaining or anti-rotation device 50 within one of the tab receptacles 18.

[042] As previously discussed, alternative configurations of the circuit board 20 may be provided. The aforementioned alternative configurations may be selected in accordance with a particular application for an electrical plug design. For example, turning to FIGS. 13-14, an alternate configuration of a circuit board 52 is shown. Again, in the example shown, the circuit board 52 may include a non-rigid circuit board of any suitable geometric configuration. As with the previously discussed circuit board, the circuit board 52 may also comprise a substrate such as a polyimide film having a suitable thickness (e.g., 0.0005", 0.001", 0.002", 0.003", or 0.005"). The substrate may also include teflon also having an appropriate thickness (e.g., 0.001" or 0.002"). A cover insulation of the circuit board 52 may include similar materials as the substrate. Optionally, a UV-cured liquid cover may be utilized as a cover insulation. Adhesives used by the circuit board 52 may include any suitable adhesive, including, but not limited to, a modified acrylic, epoxy, epoxy prepreg, or phenolic. Conductors utilized by the circuit board 52 may be electrodeposited, rolled, or annealed copper having an appropriate thickness (e.g., 0.5 oz. (0.0007"), 1 oz. (0.0014"), 2 oz. (0.0028"), 3 oz. (0.0042"), or thicker). Additional or optional conductors may include beryllium copper (e.g., 0.003" and thicker), cupronickel or other suitable metals for specialized applications. Stiffeners for the circuit board 52 may include epoxy-glass (FR-4), polyimide-glass, polyimide, or aluminum. The circuit board 52 may contain a polyimide-glass or epoxy-glass hardboard. In addition, the circuit board 52 may utilize a plating including, for example, copper, solder, nickel, and/or gold.

[043] Circuit board 52 may include any suitable number of tabs. In the example shown in Figs. 13-14, the circuit board includes two tabs 54, 56 extending from a first set of opposite ends of a central portion 58 of the circuit board 52. The central portion 58 may generally include a square or rectangular middle portion 60, or any other suitable shape. The tabs 54, 56 may each include a rectangular configuration, or any other suitable shape. In the example shown, semi-circular portions 62, 64 extend from a second set of opposite ends of the central portion 58.

[044] The tabs 54, 56 may be folded along perforated or fold lines 66. The provision of the number of perforated or fold lines 66 and their location upon the circuit board 52 may vary in accordance with a preferred design. Hence, any suitable number of perforated or fold lines 66 may be disposed at any suitable location on the circuit board 52 in order to generate a desired final configuration once the circuit board 52 is urged into the altered state as described herein.

[045] As with the previous embodiment described above, a base portion 68 may be mated with the non-rigid circuit board 52. Again, the base portion 68 may include one or more pins 70 which may be oriented to mount into respective contact holes 72 in circuit board 52 to form a completed electrical connector 74 assembly. In some configurations, the pins 70 may snap or press into the contact holes of the base portion 68. The pins 70 may also be retained via adhesive means, including, for example, soldering. Pins 14 may be made of any suitable electrically conductive material. For example, in one embodiment, the pins 70 may be made of brass including a portion containing a gold or silver flash. The pins 70 may be made by various methods such as via machine rod, stamping, forging, or drawing processes. Any suitable number of contacts or pins 70 may be used in the disclosed embodiment. The pins may be of any suitable size and shape.

[046] The circuit board 52 may be populated with multiple types of one or more electrical components 80, including, for example, EPROMs, capacitors, resistors, or any other suitable electronic component known in the art. The electrical components 80 and associated circuitry may be configured to attach to the circuit board 52 and remain operably attached when the circuit board 52 is conformed from a flat or un-altered state (such as shown, for example, in FIG. 13) to an alternate configuration (such as the altered state shown, for example, in FIG.14). Thus, in the altered state, the circuit board 52 is folded along the perforated or fold lines 66 to alter the configuration. All or some of the perforated or fold lines 66 may be folded according to a preferred use of the electrical connector 74. Furthermore, any electrical components 80 attached to the circuit board 52 may be sized and positioned in order to allow sufficient folding along the perforated or fold lines 66 in a completed assembly to provide a suitable operation of the electrical connector 74.

[047] As shown in FIGS. 15-16, the electrical connector 74 may be further coupled to additional equipment, such as a rear cable cap assembly 76. The rear cable cap assembly 76 may also include additional electronic components suitable for being connected to components of the electrical connector 74 in order to complete the electrical plug design. Additionally, other suitable electronic components may be provided for connection to the electrical connector 74. For example, FIG. 17 depicts an exterior receptacle 78 assembled to the electrical connector 74 and the cable rear cap assembly 76. For purposes of ease of viewing, the exterior receptacle 78 is drawn so components of the electrical connector 74, such as pins 70, may be viewed. The aforementioned components may be configured to connect with corresponding components of the exterior receptacle 78. Hence, the exterior receptacle 78 may provide an additional electronic configuration which may interact with and/or extend the electronic capabilities of the electrical connector 74. Such exterior receptacles 78 may also serve as an extension to the electrical connector 74 to provide an alternate configuration for coupling to additional electronic devices. Furthermore, the exterior receptacle 78 may provide a degree of protection to the circuitry along the body portion 26 and prevent exposure to contaminants.

[048] Hence, various embodiments may be employed to produce an electrical plug assembly, such as via the disclosed electrical connectors 10 and 74, to satisfy a multitude of electrical applications.

[049] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. An electrical connector comprising: a base member; at least one contact pin, said contact pin being positioned to engage said base member; and a non-rigid circuit board, said non-rigid circuit board configured to engage the at least one contact pin.

2. The connector of claim 1, wherein the non-rigid circuit board includes a contact portion and a body portion, said body portion being integrally connected to said contact portion and said body portion being positioned outside a plane of said contact portion.

3. The connector of claim 1, wherein the non-rigid circuit board comprises one or more materials including a substrate, a cover insulation, one or more adhesives, one or more conductors, and one or more stiffeners.

4. The connector of claim 3, wherein the substrate includes one or both of a polyimide film and teflon, wherein the cover insulation includes one or more of polyimide film, teflon, and a UV-cured liquid, wherein the one or more adhesives comprises one or more of a modified acrylic, epoxy, epoxy prepreg, and phenolic, wherein the one or more conductors comprises one or more of annealed copper, beryllium copper, and cupronickel, and wherein the one or more stiffeners comprises one or more of epoxy-glass (FR-4), polyimide-glass, polyimide, and aluminum.

5. The connector of claim 3, wherein the non-rigid circuit board further comprises a polyimide-glass or epoxy-glass hardboard and a plating including one or more of copper, solder, nickel, and gold.

6. The connector of claim 2, wherein the non-rigid circuit board includes perforations disposed at prescribed areas of the body portion.

7. The connector of claim 2, wherein the contact portion engages the at least one contact pin.

8. The connector of claim 2, further comprising: one or more electronic components attached to the non-rigid circuit board.

9. The connector of claim 8, wherein the connector is configured to receive one or more wire connections at one or more locations including the at least one contact pin, the non-rigid circuit board and the one or more electronic components.

10. The connector of claim 1, wherein the non-rigid circuit board is configurable from a first geometric configuration to at least another geometric configuration different from the first geometric configuration.

11. The connector of claim 10, wherein the at least another geometric configuration includes at least two different configurations each being different from the first geometric configuration.

12. The connector of claim 1, further comprising: an enclosure device removably attached to the base member, said enclosure device having an interior for receiving and encapsulating the non-rigid circuit board.

13. The connector of claim 12, wherein the non-rigid circuit board is configured from a first geometric configuration to a second geometric configuration similar to a geometric configuration of the interior of the enclosure device. r-

14. The connector of claim 13, wherein the enclosure device is a generally cylindrical member that surrounds the non-rigid circuit board and at least a portion of the at least one contact pin and the base member.

15. The connector of claim 14, wherein the second geometric configuration is essentially cylindrical and is configured to be inserted within the interior of the enclosure device.

16. The connector of claim 15, wherein the non-rigid circuit board includes one or more electronic components attached thereto, wherein the one or more electronic components are disposed interior to the surface of the non-rigid circuit board when said non-rigid circuit board is configured in the essentially cylindrical second geometric configuration.

17. The connector of claim 12, wherein the enclosure device is attached to the base member via threaded assembly.

18. The connector of claim 12, wherein the enclosure device is attached to the base member via snap fit.

19. The connector of claim 12, wherein the enclosure device is electrically connected to one or both of the non-rigid circuit board and the at least one contact pin when it is attached to the base member.

20. The connector of claim 1, wherein the base member is attached to and electronically operable with another electronic component.

21. The connector of claim 20, wherein the electronic component is configured to engage the at least one contact pin.

22. An electrical connector comprising: a base member having receiving portions; a plurality of contact pins, said contact pins being positioned to engage said base member by contacting the receiving portions of the base member; and a non-rigid circuit board, said non-rigid circuit board being configured to engage the plurality of contact pins, said non-rigid circuit board including a first portion adjacent to the plurality of contact pins and a second portion having one or more bending regions, wherein the second portion is capable of changing shape, wherein in an initial state the second portion is generally configured along a first plane and in a second state the second portion is generally bent along the one or more bending regions to form an altered shape outside the first plane.

23. The connector of claim 22, wherein the altered shape includes a generally cylindrical shape.

24. The connector of claim 23, further comprising: one or more electronic components attached to the non-rigid circuit board, wherein the one or more electronic components are disposed interior to the cylindrical shape of the non-rigid circuit board.

25. The connector of claim 24, wherein the connector is configured to receive one or more wire connections at one or more locations including the plurality of contact pins, the non-rigid circuit board, and the one or more electronic components.

26. The connector of claim 22, wherein the bending regions are folding lines.

27. The connector of claim 22, further comprising: an enclosure device removably attached to the base member, said enclosure device having an interior for receiving and encapsulating the non-rigid circuit board.

28. An electrical connector comprising: a base member having receiving portions; a plurality of contact pins, said contact pins being positioned to engage said base member by contacting the receiving portions of the base member; a non-rigid circuit board, said non-rigid circuit board being configured to engage the plurality of contact pins, said non-rigid circuit board including a first portion adjacent to the plurality of contact pins and a second portion having one or more bending regions, wherein the second portion is capable of changing shape, wherein in an initial state the second portion is generally configured along a first plane and in a second state the second portion is generally bent along the one or more bending regions to form a generally cylindrical shape outside the first plane, said non-rigid circuit board further including one or more electronic components attached thereto wherein said one or more electronic components are disposed interior to the cylindrical shape of the non-rigid circuit board in the second state; and an enclosure device attached to the base member, said enclosure device having an interior for receiving and encapsulating the cylindrical shape of the non-rigid circuit board.

29. The connector of claim 28, wherein the connector is configured to receive one or more wire connections at one or more locations including the plurality of contact pins, the non-rigid circuit board, and the one or more electronic components.

30. The connector of claim 28, wherein the bending regions are folding lines.

31. A method of assembling an electrical connector: providing a base member having receiving portions; positioning a plurality of contact pins to engage said base member by contacting the receiving portions; engaging a non-rigid circuit board with the plurality of contact pins, wherein said non-rigid circuit board includes a first portion adjacent to the plurality of contact pins and a second portion having a first geometric configuration, said second portion further including one or more bending regions, wherein the second portion is capable of changing shape along said bending regions; and bending the non-rigid circuit board along the bending regions to produce a second geometric configuration.

32. The method of claim 31, wherein the second geometric configuration of the second portion is a generally cylindrical shape.

33. The method of claim 32, wherein the second portion further includes one or more electrical components, said one or more electrical components being disposed interior to the cylindrical shape.

34. The method of claim 33, further comprising: connecting one or more wire connections at one or more locations including the plurality of contact pins, the non-rigid circuit board and the one or more electronic components.

35. The connector of claim 31, wherein the bending regions are folding lines.

36. The method of claim 31, further comprising: providing an enclosure device having an interior region; inserting the second geometric configuration of the non-rigid circuit board into the interior region; and attaching the enclosure device to the base member to completely encapsulate the second geometric configuration of the non-rigid circuit board.

37. The method of claim 33, wherein the second geometric configuration generally includes a cylindrical shape and the interior of the enclosure device is configured to accommodate said cylindrical shape of the non-rigid circuit board.