Coaxial connector and coaxial cable connector assembly and related method

Abstract

A method of making a coaxial cable assembly is disclosed, the assembly comprising a coaxial cable and a connector, or connector termination, at least one end of the cable. A connector, comprised of connector components, is also disclosed. The method comprises placing connector components into contact with the cable before the connector components are assembled into a connector. The connector is assembled simultaneously with securing the connector to the cable to make a coaxial cable assembly. A method of preparing coaxial cable in a manner suitable for making coaxial cable assemblies is also disclosed. The coaxial cable assembly can be a jumper, or a lead.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a partial cutaway view of an end of a known coaxial cable.

FIG. 1B shows the cable of FIG. 1A with outer cable components removed to expose braid and the center conductor.

FIG. 1C shows the cable of FIG. 1B with the braid folded back over the jacket.

FIG. 2 is a side cutaway view along the centerline of a known connector connected to a cable, shown in partial cutaway view, prepared according to a known method.

FIGS. 3A-3C are partial cutaway views along the centerline of a coaxial cable illustrating the cable preparation method for the current invention.

FIG. 4 is a side cutaway view along the center line of the present invention components.

FIG. 5 is a side cutaway view along the centerline of the connector disclosed herein and a partial side cutaway view along the centerline of a cable prepared according to a method disclosed herein.

FIG. 6 is a partial side cutaway view along the centerline of the present invention with an F connector interface fully installed on coaxial cable.

FIG. 7 is a partial side cutaway view along the centerline of the present invention with an RCA connector interface fully installed on coaxial cable.

Claims

1. A method of making a coaxial cable assembly, the method comprising: passing an end of a coaxial cable through an internal bore in a tubular shell, wherein the coaxial cable has a longitudinal axis;inserting a first portion of a tubular post axially into the end of the coaxial cable, wherein a coupler is mounted on the post, and wherein the shell is axially spaced away from the first portion of the post, and the shell does not surround the first portion of the post;moving the shell axially relative to the post and the cable, wherein at least part of the shell surrounds at least part of the post.

2. The method of claim 1 wherein the coupler is rotatably mounted on the post.

3. The method of claim 2 wherein the shell limits axial movement of the coupler.

4. The method of claim 1 wherein, in the moving step, the shell and the post are press fit together.

5. The method of claim 1 wherein, after the moving step, part of the cable is sandwiched between the shell and the post.

6. A method of making a coaxial cable assembly, the method comprising: passing an end of a coaxial cable through an internal bore in a tubular shell;inserting a tubular post into the end of the coaxial cable, wherein the shell is spaced away from the post, and the shell does not surround the post;moving the shell and the post together sufficient to surround at least part of the post with at least part of the shell.

7. The method of claim 6 wherein, after the moving step, the shell limits movement of the coupler.

8. A combination of coaxial cable connector components comprising: a tubular shell having a shell inner diameter defining a internal bore adapted to accept a coaxial cable, and a shell outer diameter; a tubular post adapted to be inserted into the coaxial cable, and a coupler adapted to mount on the post and having a coupler outer diameter, wherein the ratio of the coupler outer diameter divided by the shell outer diameter is greater than 1.10.

9. The method of claim 8 wherein the ratio of the coupler outer diameter divided by the shell outer diameter is greater than 1.30.

10. A method of preparing an end of a coaxial cable, the coaxial cable comprising an inner conductor, a dielectric surrounding the inner conductor, a braid surrounding the dielectric, and a protective layer surrounding the braid, the method comprising: removing a portion of the protective layer, a portion of the braid, and a portion of the dielectric from the end of the coaxial cable to provide a prepared end of the cable, wherein the prepared end comprises: a protective layer cut edge; a protruding portion of the braid that protrudes a length X from the cut edge of the protective layer, a protruding portion of the dielectric that protrudes a length Y from the cut edge of the protective layer, and a protruding portion of the inner conductor that protrudes a length Z from the cut edge of the protective layer, wherein the ratio of X/Y is less than 1.

11. The method of claim 10 wherein the protruding portion of the dielectric terminates in a dielectric cut edge, and the protruding portion of the inner conductor protrudes a length A from the dielectric cut edge.

12. The method of claim 11 wherein the length A is between 0.25 and 0.375 inch.

13. The method of claim 10 wherein the coaxial cable further comprises a foil layer disposed between the braid and the dielectric, wherein the removing step further comprises removing a portion of the foil layer, and wherein the prepared end further comprises a protruding portion of the foil layer that protrudes a length Y′ from the cut edge of the protective layer, wherein the length Y′ is less than or equal to the length Y.

14. The method of claim 10 further comprising lifting at least part of the protruding portion of the braid radially outwardly.

15. A method of making a coaxial cable assembly with the cable prepared according to claim 10, the method comprising: before the removing step, providing a tubular shell having an internal bore and passing the cable through the internal bore.

16. The method of making a coaxial cable assembly of claim 15 further comprising: providing a tubular post;inserting an end of the tubular post into the prepared end of the cable and under the braid;moving the prepared end of the cable and the tubular post axially together with the tubular shell sufficient for the post and the shell to cooperatively apply a radial force to the braid thereby securing the shell and the post onto the cable.

17. The method of making a coaxial cable assembly of claim 16 wherein in the moving step, the protective layer and the braid are sandwiched between the tubular shell and the tubular post.

18. The method of making a coaxial cable assembly of claim 16 wherein, after the moving step, the protruding portion of the braid is disposed in an annular cavity between the post and the shell.

19. The method of making a coaxial cable assembly of claim 16 wherein, in the moving step, the shell contacts the post.

20. The method of making a coaxial cable assembly of claim 19 wherein, in the moving step, the post and the shell are press fit together.