In-line connector stack with testing capability

1. A method for manufacturing an in-line connector comprising:

encapsulating an in-line connector stack with an encapsulation layer to form an encapsulated in-line stack, wherein:

the encapsulation layer comprises an elongated body defining a bore having a continuous length, a plurality of slots, and a section of the elongated body that is formed as a continuous integral element in a radial direction;

the in-line connector stack comprises a plurality of seal elements, a plurality of conductive contact elements, and a plurality of canted coil springs in contact with the plurality of conductive contact elements;

sliding the in-line connector stack inside the bore so that at least a portion of the in-line connector stack slides past the section that is continuous in the radial direction; wherein a non-conductive end cap comprising an opening is disposed at each end of the in line connector stack; and

aligning the plurality of conductive contact elements with the plurality of slots on the encapsulation layer; and

wherein each of the plurality of canted coil springs is located in a groove comprising a back wall and two side walls formed from a combination of a conductive material and a non-conductive material.

2. The method of claim 1 , wherein the encapsulation layer seals a plurality of seams formed between adjacent pairs of seal elements and conductive contact elements.

3. The method of claim 1 , wherein the snap fit end cap has an entry annular seal for sealing against a lead cable.

4. The method of claim 1 , wherein the in-line connector stack is placed into the bore through one end of the encapsulation layer.

5. The method of claim 1 , further comprising placing the encapsulated in-line stack into a bore of a pre-formed header.

6. The method of claim 5 , wherein the encapsulated in-line stack is pre-tested prior to placing into the bore of the header.

7. The method of claim 5 , further comprising engaging a snap fit end cap against an end opening of the header to retain the encapsulated in-line stack within the bore of the pre-formed header.

8. The method of claim 7 , wherein the snap fit end cap and the bore of the header exert an axial compressive force on the encapsulated in-line stack.

9. The method of claim 5 , wherein the pre-formed header comprises a plurality of slots.

10. The method of claim 9 , wherein the plurality of slots of the pre-formed header are aligned with the plurality of slots on the encapsulation layer.

11. The method of claim 1 , wherein the encapsulation layer comprises a non-conductive continuous cylindrical body forming a cavity for receiving the plurality of seal elements and conductive contact elements.

12. A connector header assembly comprising a header comprising a bore, an in-line connector stack comprising a plurality of alternating seal elements, a plurality of canted coil springs, and conductive contact elements encapsulated by an encapsulation layer to form an encapsulated in-line stack positioned inside the bore of the header, and a snap fit end cap comprising a bore mechanically engaged to the header to retain the encapsulated in-line stack within the bore of the header, the snap fit end cap and the header define a seam therebetween, and wherein the header comprises a plurality of slots aligned with a plurality of slots formed on the encapsulation layer and wherein the encapsulation layer comprises an elongated body that is continuous along a length and continuous in a radial direction without a seam.

13. The connector header assembly of claim 12 , further comprising a first end cap attached to a first end of the encapsulation layer and a second end cap attached to a second end of the encapsulation layer, said first and second end caps each comprising an opening.

14. The connector header assembly of claim 12 , wherein the encapsulated in-line stack is formed before being placed inside the bore of the header.

15. The connector header assembly of claim 14 , wherein the snap fit end cap and the bore of the header exert an axial compressive force on the encapsulated in-line stack.

16. The connector header assembly of claim 12 , wherein the snap fit end cap comprises an opening for accessing a fastener.

17. The connector header assembly of claim 12 , wherein the encapsulation layer seals a plurality of seams formed between adjacent pairs of seal elements and conductive contact elements.

18. The connector header assembly of claim 12 , further comprising a second bore for receiving a second encapsulated in-line stack.

19. The connector header assembly of claim 12 , further comprising an opening on the header for placing a holding ring therethrough.

20. A method for manufacturing an in-line connector comprising:

forming an encapsulated in-line stack by sliding a plurality of seal elements, springs, and conductive contact elements through a firstend opening of a cylindrical housing comprising a bore, a continuous housing section along a radial direction, and the first end opening and a second end opening, said cylindrical housing further comprising a plurality of slots formed laterally of the first opening;

engaging an end cap to the first end opening of the cylindrical housing;

aligning the plurality of conductive contact elements with the plurality of slots on the cylindrical housing; and

testing the encapsulated stack by applying an electrical signal across at least one of the conductive contact elements.

21. The method of claim 20 , further comprising placing the encapsulated stack into a bore of a pre-formed header.