Tight bend-radius cable structures and methods for making the same

A method for making a connector assembly, the connector assembly comprising a connector comprising a connector housing and a plurality of leads extending out from the connector housing and at least one cable coupled to one of the leads, each of the at least one cable comprising a coupling region, a bend region, and a non-bend region, the method comprising:

• encapsulating at least a portion of the coupling region of the cable, at least a first portion of the connector housing, and the plurality of leads with an inner strain-relief member;
• manipulating the cable to create a tight-radius bend in the bend region;
• and
• coupling an outer strain-relief member over the inner strain-relief member, the bend region, at least a second portion of the connector housing, and at least a portion of the non-bend region of the cable.

A connector assembly comprising:

• a connector comprising a plurality of cable connector leads;
• a plurality of individual cables each coupled to a respective one of the connector leads, each of the cables extending from the cable connector leads in a first direction, the plurality of cables comprising first and second sets, wherein each set comprises at least one cable of the plurality of cables, wherein each cable in the first set comprises a coupling region, a bend region, and a non-bend region, and wherein the coupling region extends in the first direction;
• an inner strain-relief member that encapsulates the connector leads and the coupling region of each cable in the first set;
• and
• an outer strain-relief member that encapsulates the inner strain-relief member, the bend region of each cable in the first set, and a portion of the non-bend region of each cable in the first set, the outer strain-relief member operative to secure the bend region of each cable in the first set in a first curved position, and wherein:
• the non-bend region of each cable in the first set extends in a second direction, the second direction being different than the first direction;
• each cable in the second set comprises a coupling region, a bend region, and a non-bend region;
• the inner strain-relief member encapsulates the connector leads and the coupling region of each cable in the first and second sets;
• the outer strain-relief member encapsulates the inner strain-relief member and a portion of the non-bend region of each cable in the first and second sets;
• the outer strain-relief member is operative to secure the bend region of each cable in the second set in a second curved position;
• and
• the non-bend region of each cable in the second set extends in a third direction, the third direction being different than the second direction.