U.S. patent number 3,923,367 [Application Number 05/468,041] was granted by the patent office on 1975-12-02 for simultaneous double crimp coaxial cable contact assembly.
This patent grant is currently assigned to Hughes Aircraft Company. Invention is credited to David P. Carter.
United States Patent |
3,923,367 |
Carter |
December 2, 1975 |
Simultaneous double crimp coaxial cable contact assembly
Abstract
An electrical connector shielded contact assembly allows easy
termination of coaxial cables by simultaneous crimping of coaxial
cable conductors to the contact assembly in a single operation.
Users installation comprises stripping of the cable to bare the
inner and braided outer conductors, sliding of the inner and outer
conductors respectively into and onto the contact assembly,
slipping a ring over the braided outer conductor, and
simultaneously crimping both the outer conductor and the inner
conductor to the contact assembly. This operation is enabled by
constructing the coaxial contact assembly from a stamped and formed
outer contact configured as a housing utilizing dovetails on the
seam for strength, an inner pin or socket contact, and suitable
insulators therebetween. The housing and the inner contact have
reliefs therebetween so that, when assembling an inner plastic
dielectric component together with the inner pin or socket contact
into place within the housing, the dielectric flows into the
reliefs between the inner contact and the housing to form a stable
and strong assembly. Windows in the outer housing permit subsequent
simultaneous crimping of the inner and outer coaxial cable
conductors respectively to the inner contact and the housing, with
the inner crimp being aligned and protected by the dielectric
component which serves the further purpose of controlling the
differential span of electrical characteristics, that is, the
dielectric constant, between the coaxial cable and the coaxial
contact.
Inventors: |
Carter; David P. (Laguna
Niguel, CA) |
Assignee: |
Hughes Aircraft Company (Culver
City, CA)
|
Family
ID: |
23858204 |
Appl.
No.: |
05/468,041 |
Filed: |
May 8, 1974 |
Current U.S.
Class: |
439/585 |
Current CPC
Class: |
H01R
9/0518 (20130101) |
Current International
Class: |
H01R
9/05 (20060101); H01R 011/08 () |
Field of
Search: |
;339/6C,9C,91P,94C,142,143R,276R,177R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lake; Roy
Assistant Examiner: Desmond; E. F.
Attorney, Agent or Firm: MacAllister; W. H. Sternfels; Lewis
B.
Claims
What is claimed is:
1. A simultaneous double crimp coaxial cable and contact assembly
comprising:
a male coaxial contact assembly, a female coaxial contact assembly
capable of being electrically coupled with said male coaxial
contact assembly, and a pair of coaxial cables having an electrical
connection respectively with said male and female coaxial contact
assemblies;
each of said cables comprising an inner conductor, inner insulation
surrounding said inner conductor, a braided conductor surrounding
said inner insulation, and outer insulation surrounding said
braided conductor, with said inner conductor, said inner
insulation, said braided conductor and said outer insulation being
stripped backward at the point of said electrical connection;
said male coaxial contact assembly having an axis and comprising a
socket inner contact of general circular cross-section position on
the axis and having means at one end for defining a pin-receiving
socket and means at its opposite end for defining a wire-receiving
bore for receiving said inner conductor of one of said cables in
crimped connection therewith, insulation means of general circular
cross-section comprising a socket insulator and a socket entry
stabilizer in contact therewith for forming an extension thereof
and positioned on the axis and enclosing said socket inner contact,
a single piece male housing of general circular cross-section on
the axis and enclosing said insulation means in crimped engagement
therewith and with said socket inner contact and having means for
defining diagonally opposite crimp ports radially positioned about
said wire-receiving bore of said socket inner contact for enabling
the crimped connection between said cable inner conductor and said
wire-receiving bore of said socket inner contact, said male housing
further including a front end and a rear end surrounding and
insulated from said stripped inner insulation of said one of said
cables and being surrounded by said stripped braided conductor of
said one of said cables, and a crimp ring surrounding said stripped
braided conductor of said one of said cables in crimped engagement
therewith and with said male housing rear end, said socket entry
stabilizer including a tapered end for defining an opening of said
male coaxial contact for the electrical coupling with said female
coaxial contact and a rearwardly facing shoulder abutting against
said front end of said male housing; and
said female coaxial contact assembly having an axis and comprising
a pin inner contact of general circular cross-section positioned on
the axis and having means at one end for defining a pin received in
said socket of said male coaxial contact assembly and means at its
opposite end for defining a wire-receiving bore receiving said
inner conductor of the second of said cables in crimped connection
therewith, a one piece pin insulator of general circular
cross-section on the axis and enclosing said pin inner contact, a
single piece female housing of general circular cross-section on
the axis in electrical receiving coupling with said male housing of
said male coaxial contact assembly and enclosing said pin insulator
in crimped engagement therewith and with said pin inner contact and
having means for defining diagonally opposite crimp ports radially
positioned about said wire-receiving bore of said pin inner contact
for enabling the crimped connection between said second cable inner
conductor and said wire-receiving bore of said pin inner contact,
said female housing further including a rear end surrounding said
stripped inner insulation of said second of said cables and being
surrounded by said stripped braided conductor of said second of
said cables, and a crimp ring surrounding said stripped braided
conductor of said second of said cables in crimped engagement
therewith and with said female housing rear end.
2. A coaxial electrical contact assembly having an axis comprising
a housing of electrically conductive material having an inner
surface, a contact therein having an outer surface, said inner and
outer surfaces having substantially the same radial spacing
therebetween along the axis, means for defining insulation of
deformable plasticity between said housing and said contact, and
means for imparting a plastic deformation of substantially uniform
wall separation between said inner and outer surfaces, and for
securing said insulation means between said housing and said
contact, thereby for providing a stable, strong and interlocked
assembly of said housing, said contact and said insulation means,
and for establishing a substantially uniform dielectric constant
along the axis.
3. A contact assembly as in claim 2 wherein said housing comprises
a stamped and formed tube.
4. A contact assembly as in claim 2 wherein said housing comprises
means for defining an enclosure formed from flat stock having edges
in contacting relationship for forming a seam, and means for
securing said edges together for preventing separation of said
seam.
5. A contact assembly as in claim 4 wherein said securing means
comprises at least one dovetailed joint.
6. A contact assembly as in claim 1 wherein said plastic
deformation means includes means on said housing and on said
contact for defining at least two substantially annular reliefs
spaced at different radial distances from the axis.
7. A contact assembly as in claim 6 wherein said housing includes
at least one radially inwardly formed portion and at least one
radially outwardly formed portion for defining said annular relief
means.
8. A contact assembly as in claim 7 wherein said contact includes a
major diameter portion and a minor diameter portion of lesser
dimension than said major diameter, said major and minor diameter
portions being axially aligned and radially spaced respectively
from said radially outwardly and inwardly formed housing portions
for defining said annular relief means.
9. A contact assembly as in claim 8 wherein said plastic
deformation means further includes radially inwardly and outwardly
extending annular portions positioned and deformed in a plastic
flow respectively between said major diameter portion and said
radially outwardly formed portion and between said minor diameter
portion and said radially inwardly formed portion.
10. A coaxial electrical contact assembly for terminating a coaxial
cable having a specific dielectric constant including an inner
conductor and an outer conductor surrounding inner conductor,
comprising:
means for defining an inner contact positioned on an axis and
having a wire-receiving end for receipt of the inner conductor;
means for defining an enclosure coaxially surrounding said inner
contact means for use as an outer contact and having an end for
receiving the outer conductor, said end of said outer contact means
overlapping said wire-receiving end of said inner contact
means;
means for electrically insulating said inner contact means from
said outer contact means and for establishing a substantially
uniform dielectric constant between said inner and outer contact
means having substantially the same numerical value as the specific
dielectric constant of the coaxial cable; and
means for defining at least one opening in said end of said outer
contact means for providing access to said wire-receiving end of
said inner contact means and for enabling electrical connection of
the inner conductor with said wire-receiving end.
11. A coaxial electrical contact assembly as in claim 10 further
including a ring positioned over said end of said outer contact
means for electrically and mechanically securing the outer
conductor thereto.
12. A coaxial electrical contact assembly as in claim 11 wherein
said enclosure of said outer contact means includes protuberances
at said end thereof for limiting axial engagement of said ring
thereon.
13. A coaxial electrical contact assembly as in claim 10 wherein
said enclosure of said outer contact means comprises a stamped and
formed tube wherein said opening means comprises stamped out
portions of said tube.
14. A simultaneous double crimp coaxial cable and contact assembly
comprising:
a male coaxial contact assembly, a female coaxial contact assembly
capable of being electrically coupled with said male coaxial
contact assembly, and a pair of coaxial cables having an electrical
connection respectively with said male and female coaxial contact
assemblies;
each of said cables comprising an inner conductor, inner insulation
surrounding said inner conductor, a braided conductor surrounding
said inner insulation, and outer insulation surrounding said
braided conductor, with said inner conductor, said inner
insulation, said braided conductor and said outer insulation being
stripped backward at the point of said electrical connection;
said male coaxial contact assembly having an axis and comprising a
socket inner contact of general circular cross-section positioned
on the axis and having means at one end for defining a
pin-receiving socket and means at its opposite end for defining a
wire-receiving bore for receiving said inner conductor of one of
said cables in crimped connection therewith, insulation means
comprising a socket insulator and a socket entry stabilizer of
general circular cross-section positioned on the axis and
enclosisng said socket inner contact, a male housing of general
circular cross-section on the axis and enclosing said insulation
means in crimped engagement therewith and with said socket inner
contact and having means for defining diagonally opposite crimp
ports radially positioned about said wire-receiving bore of said
socket inner contact for enabling the crimped connection between
said cable inner conductor and said wire-receiving bore of said
socket inner contact, said male housing further including a front
end and a rear end surrounding and insulated from said stripped
inner insulation of said one of said cables and being surrounded by
said stripped braided conductor of said one of said cables, and a
crimp ring surrounding said stripped braided conductor of said one
of said cables in crimped engagement therewith and with said male
housing rear end, said socket entry stabilizer including a tapered
end for defining an opening of said male coaxial contact for the
electrical coupling with said female coaxial contact and a
rearwardly facing shoulder abutting against said front end of said
male housing;
said female coaxial contact assembly having an axis and comprising
a pin inner contact of general circular cross-section positioned on
the axis and having means at one end for defining a pin received in
said socket of said male coaxial contact assembly and means at its
opposite end for defining a wire-receiving bore receiving said
inner conductor of the second of said cables in crimped connection
therewith, a pin insulator of general circular cross-section on the
axis and enclosing said pin inner contact, a female housing of
general circular cross-section on the axis in electrical receiving
coupling with said male housing of said male coaxial contact
assembly and enclosing said pin insulator in crimped engagement
therewith and with said pin inner contact and having means for
defining diagonally opposite crimp ports radially positioned about
said wire-receiving bore of said pin inner contact for enabling the
crimped connection between said second cable inner conductor and
said wire-receiving bore of said pin inner contact, said female
housing further including a rear end surrounding said stripped
inner insulation of said second of said cables and being surrounded
by said stripped braided conductor of said second of said cables,
and a crimp ring surrounding said stripped braided conductor of
said second of said cables in crimped engagement therewith and with
said female housing rear end; and
said housings of both said male and female coaxial contact
assemblies each comprising a single piece stamped and rolled
metallic tube having a seam and dovetail joints at said seam for
preventing separation of said housing at said seam.
15. An assembly as in claim 14 wherein:
each said stamped and formed metallic tube includes at least one
radially inwardly directed formed annular indentation and at least
one radially outwardly directed formed annular protuberance
substantially contiguous with said indentation;
said inner contacts of both said male and female coaxial contact
assemblies include a major diameter portion and a minor diameter
portion of lesser diameter than said major diameter portion, said
major diameter and said minor diameter portions of each of said
inner contacts being axially aligned and radially spaced
respectively from said protuberance and said indentation of each of
said tubes; and
said pin insulator and said socket insulators each having radially
inwardly and outwardly extending annular portions positioned and
deformed in plastic flow respectfully between said major diameter
portion and said protuberance and between said minor diameter
portion and said indentation to provide a stable and strong
interlock between said respective coaxial contacts, inner contacts
and insulators, said dovetail joints maintaining said interlock and
preventing spread of said housing at said seam.
16. An electrical contact assembly comprising:
a housing;
a contact therein;
means for defining insulation of deformable plasticity between said
housing and said contact;
means on said first contact and on said housing including at least
one radially inwardly formed portion and at least one radially
outwardly formed portion for defining at least two substantially
annular reliefs spaced at different radial distances from the axis
of the connector, for imparting a plastic deformation of and
thereby for securing said insulation means between said housing and
said contact and for providing a stable, strong and interlocked
assembly of said housing, said contact and said insulation means;
and
a coaxial cable having a specific dielectric constant electrically
coupled to said housing and said first contact, wherein the spacing
between the inner surface of said housing and the outer surface of
said first contact is substantially the same throughout the axis of
the connector for providing with said insulation means, a
substantially uniform dielectric constant having substantially the
same numerical value as the specific dielectric constant of said
coaxial cable.
17. A coaxial electrical contact assembly for terminating a coaxial
cable including an inner conductor and an outer conductor
surrounding said inner conductor, comprising:
means for defining an inner contact positioned on an axis and
having a wire-receiving end for receipt of the inner conductor;
means for defining an enclosure coaxially surrounding said inner
contact means for use as an outer contact and having an end for
receiving the outer conductor, said end of said outer contact means
overlapping said wire-receiving end of said inner contact
means,
said enclosure of said outer contact means including means for
defining at least one radially inwardly directed indentation and at
least one radially outwardly directed protuberance, and
said inner contact means including at least one portion of major
cross-sectional dimention and at least a portion of minor
cross-sectional dimension of lesser dimension than the major
cross-sectional dimension, said major and minor portions being
axially aligned respectfully with said protuberance and indentation
means;
means for electrically insulating said inner contact means from
said outer contact means and having a deformed and interlocked
engagement between said inner and outer contact means between said
major portion and said protuberance means and between said minor
portion and said indentation means; and
means for defining at least one opening in said end of said outer
contact means for providing access to said wire-receiving end of
said inner contact means and for enabling electrical connection of
the inner conductor with said wire-receiving end.
18. A coaxial electrical contact assembly as in claim 17 wherein
said enclosure of said outer contact means comprises formed flat
stock having edges in contacting relationship to form a seam, and
means for securing said edges together for preventing separation of
said seam under bias of said insulating means and for maintaining
the deformed and interlocked engagement of said insulating
means.
19. A coaxial electrical contact assembly as in claim 17 further
including a retaining clip mounted on said outer contact means and
abuttable against said protuberance means thereof for enabling
retention of said contact assembly within opening means in an
insulation of a connector body.
20. A coaxial electrical assembly for terminating a coaxial cable
including an inner conductor and an outer conductor surrounding
said inner conductor, comprising:
means for defining an inner contact positioned on an axis and
having a wire-receiving end for receipt of the inner conductor, and
including means for defining a socket at an end opposite from said
wire-receiving end;
means for defining an enclosure coaxially surrounding said inner
contact means for use as an outer contact and having an end for
receiving the outer conductor, said end of said outer contact means
overlapping said wire-receiving end of said inner contact
means;
means for electrically insulating said inner contact means from
said outer contact means;
a socket entry stabilizer of dielectric material positioned between
said socket means of said inner contact means and said outer
contact means, said socket entry stabilizer contacting said
insulating means and forming an extension thereof; and
means for defining at least one opening in said end of said outer
means for providing access to said wire-receiving end of said inner
contact means and for enabling electrical connection of the inner
conductor with said wire-receiving end.
21. A coaxial electrical contact assembly as in claim 20 wherein
said insulating means includes a split end and wherein said socket
entry stabilizer extends over said split end for deformation
thereof into a recess in said inner contact means.
22. A coaxial electrical contact assembly as in claim 20 wherein
said socket entry stabilizer includes a tip extending beyond the
end of said outer contact means, said tip including an outwardly
extending flange defining a shoulder abutting against an end
opposite said outer conductor receiving end of said outer contact
means and an internal recess for reception of a pin contact
engageable with said socket means of said inner contact means.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to coaxial contacts for terminating
electrical coaxial cables, and methods of assembly therefor.
2. Description of the Prior Art
Coaxial contact assemblies for terminating coaxial electrical
cables comprise inner and outer contacts and one or more insulators
which are generally fabricated on screw machines in which material
is machined from the inside and outside of solid round stock.
Several problems result from such construction, relating to cost,
contact configuration, and cable-to-contact assembly. Any
transverse holes required in any of those components must be formed
in a machining, milling or drilling operation separate from work by
the screw machine, leading not only to increased costs of capital
equipment but also of the required labor. The configuration of the
contact components, in particular to their internal configurations,
is limited to simple stepped holes or recesses of increasing
diameter within and facing the end openings, unless very expensive
and specialized tooling is utilized.
With respect to assembly operations in terminating coaxial cables
to prior art coaxial contact assemblies, several crimp operations
are generally required, one for each connection of each coaxial
cable conductor to its assigned connecting point in the contact
assembly. Usually several crimp tools or repeated use of a single
tool is required. Furthermore, the prior art coaxial contact
assemblies must be shipped to the user as several loose components
and the user must make a multistage connection of the cable
conductors to the contact components. Thus, use of prior art
coaxial contacts and their assembly to coaxial cables involves
considerable cost in time, labor and assembly techniques.
SUMMARY OF THE INVENTION
The present invention overcomes these and other problems by
utilizing a coaxial contact assembly having a unique progressively
stamped and formed outer housing contact having dovetails on its
seam for strength. The housing is configured in such a manner that
when an inner plastic dielectric component, previously assembled
onto an inner pin or socket contact, is forced within the housing,
the dielectric material flows into reliefs between the housing and
the inner contact to provide a stable and strong assembly.
Specially designed windows or ports in the outer housing enables
crimping of the cable inner conductor to the inner contact of the
coaxial contact. As a result of this design, the coaxial contact
assembly may be shipped to the user fully assembled except for one
separate crimp ring, so that the user need only strip the cable,
slide its conductors into place respectively into the inner contact
and over the housing, slip the crimp ring over the outer cable
conductor, and simultaneously crimp the cable outer and inner
conductors to the coaxial contact assembly in a single
operation.
It is, therefore, an object of the invention to provide a coaxial
contact assembly of inexpensive construction and of low cost.
Another object is to provide such a contact assembly which is
capable of being shipped to a customer as fully assembled as in
practicable.
Another object of the present invention is to provide a stable and
strong contact assembly.
Another object of the present invention is to provide a controlled
dielectric constant between the coaxial electrical components of
the contact assembly.
Another object of the present invention is to provide such a
contact assembly with a dielectric constant which is capable of
matching, as nearly as possible, the dielectric constant of the
coaxial cable to which it is to be coupled.
Other aims and objects as well as a more complete understanding of
the present invention will appear from the following explanation of
exemplary embodiments and the accompanying drawings thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts one embodiment of the present invention in partial
cross-section configured as a male coaxial contact assembly;
FIGS. 1a through 1d depict several components of the male coaxial
contact assembly illustrated in FIG. 1 respectively including its
inner socket contact, its housing contact, its socket insulator,
and its socket entry stabilizer;
FIG. 2 depicts another embodiment of the present invention in
partial cross-section configured as a female coaxial contact
assembly;
FIGS. 2a through 2c respectively depict several components of the
female contact assembly of FIG. 2 including its inner pin contact,
its housing contact, and its pin insulator;
FIGS. 3a through 3g depict several steps for securing a coaxial
cable to either of the coaxial contact assemblies of FIGS. 1 and
2;
FIG. 4 depicts a coaxial cable affixed to a coaxial contact
assembly; and
FIG. 5 is a cross-sectional view of FIG. 4 taken along lines 5--5
thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Accordingly, referring to FIG. 1, a male coaxial contact assembly
10 comprises a socket inner contact 12 coaxially housed within a
male housing 14 with a socket insulator 16 and a socket entry
stabilizer 18 secured between inner contact 12 and housing 14.
Socket inner contact 12, see also FIG. 1a, comprises a bifurcated
socket 20 for reception of an inner pin contact on a female coaxial
contact assembly (shown in FIG. 2) and a wire-receiving end 22 for
receipt of an inner conductor of a coaxial cable. It is to be
understood that socket 20 need not be bifurcated, only that it
incorporate means to enable secure electrical coupling with the
mating pin contact. Between bifurcated socket 20 and wire-receiving
end 22, socket inner contact 12 includes a major diameter portion
24 bounded on either side by a pair of recesses 26 and 28, major
diameter portion 24 having sloping connecting portions 30 adjoining
the recesses.
Housing 14, see also FIG. 1b, comprises an enclosure formed from
flat stock having opposed edges in contacting relationship to form
a seam 32, with dovetail joints 34 locking the edges together for
strength and to prevent the separation of the housing at its seam.
Housing 14 is provided with a pair of diametrically opposed ports
or openings 36, one of which is formed by notching out or otherwise
removing material at the edges of seam 32 from the housing stock.
During forming of the housing, a plurality of protuberances,
indentations and bumps are formed therein, comprising a pair of
annular protuberances 38 and 40, an annular indentation 42, and a
plurality of bumps 44, preferably three in number. The housing
terminates at an end 45.
Socket insulator 16, see also FIG. 1c, comprises a dielectric
plastic material capable of plastic deformation and flow. The
socket insulator includes a through bore 46 of generally constant
diameter from each end for reception of socket inner contact 12,
with an inner annular ring 48 of lesser diameter than that of bores
46. Insulator 16 also is provided with an entry port 51 and with an
outer annular portion 52 of slightly greater dimension than that of
the periphery of the insulator. At its end opposite from its entry
port 51, socket insulator 16 terminates in a preferably bifurcated
lipped portion 54.
Socket entry stabilizer 18, see also FIG. 1d, comprises a
dielectric plastic material of general tubular form having a nose
section 56 of greater diameter than that of the remainder of the
stabilizer so as to form a rearwardly facing shoulder 58. The outer
diameter 59 of nose section 56 is substantially equal to the outer
diameter of end 45 of housing 14. At its other end the stabilizer
is provided with a bevelled opening 60 which is adapted to
cooperate with bifurcated lipped portion 54 of socket insulator 16.
Socket entry stabilizer 18 is also bevelled at opening 62 to serve
as a guide for entry of the inner pin contact 80 of the female
coaxial contact (FIG. 2) into socket 20.
When male coaxial contact 10 is assembled by the manufacturer,
major diameter portion 24 of socket inner contact 12 forces inner
annular ring 48 of socket insulator 16 and the material surrounding
ring 48 into the space formed by protuberance 38 of housing 14. In
a similar manner, indentation 42 of housing 14 forces outer annular
part 50 of socket insulator 16 and the material below part 50
within recess 26 of socket inner contact 12. As a consequence of
these undulating features of both the housing and the socket inner
contact, socket insulator 16 is flowed into place into the reliefs
formed to secure coaxial contact assembly 10 togetheer thus
providing a stable and strong assembly thereof. Furthermore, the
interior of the housing is configured approximately to conform to
that of the socket inner contact, insofar as it is possible, to
maintain an equal spacing between the two electrical pin and
housing contacts so as to maintain, with socket insulator 16, a
particular dielectric constant which is made as nearly equal as
possible to that of the coaxial cable which is to be terminated in
the coaxial contact assembly.
As a further feature of the present invention, the spacing between
protuberances 38 and 40 on housing 14 provides a site for a
retention clip 64, which enables latching of male coaxial contact
assembly 10 within an insulation body of a connector.
Socket entry stabilizer 18 fits within housing 14 so that
rearwardly facing shoulder 58 abuts against end 45 of the housing,
while bevelled opening 60 fits over bifurcated lipped portion 54 of
insulator 16 to force portion 54 within recess 28 of socket inner
contact 12. Socket entry stabilizer 18 may be secured to the
housing by any suitable adhesive.
A female coaxial contact assembly 70, which is adapted to mate with
male coaxial contact assembly 10, is depicted in FIG. 2. It is
formed similar to male contact assembly 10 and includes a pin inner
contact 72 coaxially surrounded by a female housing 74 with a pin
insulator 76 of dielectric material separating and insulating
contact 72 from housing 74. There is no element in the female
coaxial contact assembly comparable to socket entry stabilizer 18
of male coaxial contact assembly 10.
Pin inner contact 72, see also FIG. 2a, includes a pin 80 which is
adapted to slide and reside within bifurcated socket 20 of the male
coaxial contact. The pin inner contact also includes a
wire-receiving end 82 which is adapted to receive an inner
conductor of a coaxial cable. Between pin 80 and end 82 is a major
diameter portion 84 with a pair of connecting stepped recesses 86
and 88 defined by two diameters disposed between portion 84 and
wire-receiving end 82. A sloping connecting portion 90 joins
portion 84 with recess 86.
Female housing 74, see also FIG. 2b, like male housing 14 of male
coaxial contact assembly 10, is formed from stamped and formed
stock to form an enclosure whose edges abut at a seam 92 which is
secured and locked together by a pair of dovetail joints 94. A pair
of diametrically opposed openings or ports 96 stamped from the
stock extend through the housing. A pair of protuberances 98 and
100 with an indentation 102 therebetween and preferably three bumps
104 are also stamped into the stock. Housing 74 is deformed
inwardly at 105 to insure electrical contact with housing 14 of the
male coaxial contact assembly when the male and female coaxial
contact assemblies are engaged.
Pin insulator 76, see also FIG. 2c, comprises dielectric material
capable of being plastically deformed. The pin insulator is
provided with a through bore 106 of substantially uniform diameter,
with an inner annular ring 108 of lesser diameter. An outer annular
portion of two diameters 110 and 111 is formed on the exterior of
the pin insulator and terminates at one end in an entry port
112.
In a manner similar to that described with respect to the male
coaxial contact assembly of FIG. 1, the female coaxial contact
assembly is coupled together in a stable strong assembly by outward
extrusion of inner annular ring 108 and surrounding material of pin
insulator 76 by recess 86 of pin inner contact 72 into protuberance
98 of housing 74. In a similar manner, indentation 102 of housing
74 forces outer annular part 111 and internal material of pin
insulator 76 within recess 88 of pin inner contact 72. The spacing
between protuberances 98 and 100 form a recess for a retention clip
114 to enable latching of the female coaxial contact assembly
within an insulation body of a connector.
Just as with male coaxial contact assembly 10, female coaxial
contact assembly 70 is constructed so that the spacing between the
interior surface of housing 74 and the outer surface of pin inner
contact 72 is as nearly equal as possible to obtain, with pin
insulator 76, as nearly equal a dielectric constant as is
possible.
As shown in FIGS. 1 and 2, both coaxial contact assemblies are
prepared in readiness for connection to a coaxial cable by the
user; therefore, both contacts are provided with separate crimp
rings 116 and 118 respectively on the male and female coaxial
contact assemblies. In addition, both coaxial contact assemblies
are provided with separate dielectric spacers 120 and 122 which are
furnished as optional equipment in the event that the inner
conductor insulation of the coaxial cable needs to be build up in
thickness to provide for proper alignment, support, and other
mechanical and electrical stability. As a consequence, spacers 120
and 122 enable attachment of a variety of coaxial cables to the
contacts.
The assembly of a coaxial cable to either a male or female coaxial
contact assembly is depicted in FIGS. 3a through 3g inclusive. In
FIG. 3a is shown a coaxial cable 124 comprising an inner conductor
126, an inner conductor insulation jacket 128, a braided outer
conductor 130, and an outer conductor insulation jacket 132.
In operation, crimp ring 116 or 118 is slid over the coaxial cable
and in back of the area to be stripped. The cable is then stripped
as shown in FIG. 3b so that inner conductor insulation jacket 128
is stripped back from inner conductor 126, braided conductor 130 is
cut back from inner conductor insulation jacket 128, and outer
insulation jacket 132 is stripped back from braided conductor 130.
Outer braided conductor 130 is then flared as shown in FIGS. 3c and
3d preferably by use of an appropriate flaring tool. Flaring of
conductor 130 must be sufficient to accept an end barrel portion
134 of the respective coaxial contact.
As shown in FIG. 3e, inner conductor 126 of coaxial cable 124 is
aligned with preassembled coaxial contact assembly 10 or 70, and
the prestripped coaxial cable is then slid into position so that
inner conductor 126 is received within wire-receiving end 22 or 82
and outer braided conductor 130 passes over end barrel 134. The
installer may observe that inner conductor 126 of cable 124 is
penetrating wire-receiving end 22 or 82 by viewing through the
inner conductor crimp port or opening 36 or 96. In this operation,
it is important that coaxial cable braid conductor 130 envelop the
outside diameter of end barrel 134 and that individual strands of a
braid not penetrate the inside diameter of the crimp barrel to
avoid electrical short circuitry. Furthermore, of course, it is
important that conductor 126 likewise not make an electrical
short-circuit to housing 14 or 74.
As shown in FIG. 3f, crimp ring 116 or 118 is then slid forwardly
over braid 130 until it abuts bumps 44 or 104. The assembly is now
ready for simultaneous crimp, as shown in FIG. 3g.
As shown in FIG. 3g, a portion of a crimp tool 136 includes a pair
of diametrically opposed inner conductor crimp indentors 138 and a
pair of crimp ring indentors 140. Closure of indentors 138 and 140
in the direction of arrows 142 permits simultaneous crimping of
crimp ring 116 or 118 about outer braided conductor 130 and end
barrel 134 while, at the same time, inner conductor crimp indentors
138 pass through inner conductor crimp ports 36 or 96 to crimp wire
receiving ends 22 or 82 about inner conductor 126. The result of
this simultaneous crimping operation is shown in FIGS. 4 and 5,
wherein the coaxial contact assembly is now in readiness for
insertion within an insulation body of a connector along with other
coaxial contacts.
It is to be understood that, although preferred stamping, forming,
etc., constructions are described, other suitable manufacturing
processes may be employed. Furthermore, although the invention has
been described with reference to particular embodiments thereof, it
should be realized that various changes in modifications may be
made therein without departing from the spirit and scope of the
invention.
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