Patent Application
20230253721
This disclosure is directed to an electrical cable terminal with a two piece coaxial crimped outer ferrule.
Automotive electrical connectors are being required to meet new, more stringent, mechanical vibration requirements by automotive manufactures. In electrical connection systems used in motor vehicles, mechanical vibration can be transmitted to an electrical terminal via a wire cable attached to it. In coaxial connection systems, the amplitude of the vibration is too great of if the frequency of the vibration is at or near a resonant frequency of the terminal, the vibration can cause fretting corrosion or wear to the center contacts of the terminal that results in increased electrical resistance and degradation of the signal transmission through the connector.
According to one or more aspects of the present disclosure, a coaxial electrical cable assembly includes a central conductor disposed within a shield conductor of the coaxial cable and a shield terminal having a tubular portion. The central conductor of the coaxial cable is disposed within the tubular portion. The tubular portion is disposed within the shield conductor of the coaxial cable. The coaxial electrical cable assembly also includes a first outer ferrule crimped that is around the shield conductor of the coaxial cable and forms a first seam. The coaxial electrical cable assembly further includes a second outer ferrule that is crimped around the first outer ferrule and forms a second seam.
In one or more embodiments of the coaxial electrical cable assembly according to the previous paragraph, the first seam has a first seam portion longitudinally extending from an end of the first outer ferrule, a second seam portion longitudinally extending from an opposite end of the first outer ferrule and radially offset from the first seam portion, and a third seam portion extending diagonally across the first outer ferrule from the first seam portion to the second seam portion.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, an outer surface of the first outer ferrule defines a knurled pattern.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, an inner surface of the second outer ferrule defines a knurled pattern.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, an inner surface of the first outer ferrule defines a plurality of lateral grooves.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, the first outer ferrule is formed from a first preform and the second outer ferrule is formed from a second preform different from the first preform.
In one or more embodiments of the coaxial electrical cable assembly according to previous paragraph, the first preform is a stainless steel alloy and the second preform is a beryllium-copper alloy.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, the first seam is radially offset from the second seam, preferably by about 180 degrees.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, the second seam defines rectangular alignment features.
In one or more embodiments of the coaxial electrical cable assembly according to any one of the previous paragraphs, the first outer ferrule is arranged over the tubular portion of the shield terminal. The second outer ferrule is arranged over the first outer ferrule and an outer insulative jacket of the coaxial cable.
In one or more embodiments of the coaxial electrical cable assembly according to previous paragraph, a first portion of the second outer ferrule arranged over the first outer ferrule has a larger diameter than a second portion of the second outer ferrule arranged over the outer insulative jacket.
According to one or more aspects of the present disclosure, a method of assembling a coaxial electrical cable assembly includes:
In one or more embodiments of the method according to the previous paragraph, the first seam has a first seam portion longitudinally extending from an end of the first outer ferrule, a second seam portion longitudinally extending from an opposite end of the first outer ferrule and radially offset from the first seam portion, and a third seam portion extending diagonally across the first outer ferrule from the first seam portion to the second seam portion.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes arranging the second outer ferrule such that the second seam is radially offset from the first seam.
In one or more embodiments of the method according to the previous paragraph, the second outer ferrule preform is arranged such that the second seam is radially offset from the first seam by about 180 degrees.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes forming a knurled pattern in an outer surface of the first outer ferrule preform.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes forming a knurled pattern in an inner surface of the second outer ferrule preform.
In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes forming a plurality of lateral grooves in an inner surface of the first outer ferrule preform.
In one or more embodiments of the method according to any one of the previous paragraphs, the first outer ferrule preform is formed from a first material and the second outer ferrule preform is formed from a second material different from the first material.
In one or more embodiments of the method according to any one of the previous paragraphs, the first outer ferrule preform is crimped over the tubular portion of the shield terminal. The second outer ferrule preform is crimped over the first outer ferrule and an outer insulative jacket of the coaxial cable.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
Similar elements in the various illustrated embodiments share the last two digits of the reference numbers.
A non-limiting example of a coaxial electrical cable assembly 100 and a method for producing such an assembly is presented herein.
As illustrated in
A tubular end portion 116 of the shield terminal 114 is disposed between the inner insulation layer 104 and the shield conductor 106 of the coaxial cable 110 and serves as an inner ferrule. The shield terminal 114 is mechanically and electrically connected to the shield conductor 106 of the coaxial cable 110 by a two-piece crimped outer ferrule 118. The two-piece crimped outer ferrule 118 includes an inner portion, hereafter referred to as the first outer ferrule 120, and an outer portion, hereafter referred to as the second outer ferrule 122. The first and second outer ferrules 120, 122 are formed from flat sheet metal, e.g., by a stamping, blanking, or cutting process, and may be attached to a carrier strip 128 as formed to facilitate automated handling of the first and second outer ferrules 120, 122, see
Prior to attachment to the shield terminal 114, the open ends of the first and second outer ferrules 120, 122 are arranged opposite each other as shown in
Due to the arrangement of the first and second outer ferrules 120, 122 prior to crimping, the edges 130A, 130B, 130C, 132 of the first and second outer ferrules 120, 122 form first and second seams 134, 136 where the centers of the seams 134, 136 are radially offset from each other, preferably by about 90 to 270 degrees. As used herein “about X degrees” means X ±10 degrees. The inventors have found that the hoop strength of the two-piece crimped outer ferrule 118 is diminished when there is little to no radial offset between the first and second seams 134, 136 of the first and second outer ferrules 120, 122 and thus negates at least one of the benefits of using the two-piece crimped outer ferrule 118.
As shown in
As illustrated in
The edges of the first outer ferrule 120 have first edge portions 130A longitudinally extending from an end of the first outer ferrule 120, second edge portions 130B longitudinally extending from an opposite end of the first outer ferrule 120 and radially offset from the first edge portions 130A, and third edge portions 130C extending diagonally across the first outer ferrule 120 from an interior end of the first edge portions 130A to an interior end of the second edge portions 130B. These three edge portions 130A, 130B, 130C form wings that overlap and wrap around the shield conductor 106. Other embodiments may be envisioned in which the edge portions of the first outer ferrule have other shapes forming the wings.
These wings are configured to capture any stray strands of the shield conductor 106 when the first outer ferrule 120 is crimped. Different seam shapes, such as a straight longitudinal seam, may allow stray strands of the shield conductor 106 to protrude through and fill the seam since the first seam may form a gap due to spring back of the first outer ferrule after it is crimped. These stray strands would not be compacted when the second outer ferrule 122 is crimped over the first outer ferrule and would prevent the first outer ferrule from reaching it's designed diameter when the second outer ferrule 122 is crimped over it, thus reducing the retention force applied by a two-piece crimped outer ferrule on the shield conductor 106.
One longitudinal edge 132 of the second outer ferrule 122 defines a rectangular tab 148 extending therefrom and the other longitudinal edge 132 of the second outer ferrule 122 defines a corresponding rectangular notch 150. When the second outer ferrule 122 is crimped, the rectangular tab 148 is disposed within the rectangular notch 150, thereby providing an alignment feature for the seam 136 of the second outer ferrule 122. While the illustrated example has rectangular tabs 148 and notches 150 in the second outer ferrule edges 132, alternative embodiments may be envisioned having other shapes for the tabs and notches, e.g., square, semicircular, etc. Additionally, yet other embodiments may also be envisioned in which the edge portions of the first outer ferrule and the tabs and notches of the second outer ferrule have the same shape.
As best illustrated in
As best shown in
In an alternative embodiment of the coaxial electrical cable assembly 200 illustrated in
The edges 230, 232 of the first and second outer ferrules 220, 222 of the coaxial electrical cable assembly 200 form first and second seams 234, 236. Due to the arrangement of the first and second outer ferrules 220, 222 prior to crimping, the centers of the seams 234, 236 are radially offset from each other, preferably by about 180 degrees. The inventors have found that the hoop strength of the two-piece crimped outer ferrule 218 is diminished when there is little to no radial offset between the first and second seams 234, 236 of the first and second outer ferrules 220, 222 and thus negates at least one of the benefits of using the two-piece crimped outer ferrule 218.
In addition, a first portion 252 of the second outer ferrule 222 that is arranged over the first outer ferrule 220 has the same diameter as a second portion 254 of the second outer ferrule 222 that is arranged over the outer insulative jacket 108 of the coaxial cable 110.
A method 300 of assembling a coaxial electrical cable assembly 100, such as the one described above, is shown in
STEP 310, FORM A FIRST OUTER FERRULE PREFORM AND A SECOND OUTER FERRULE PREFORM, includes forming a first outer ferrule preform 124 and a second outer ferrule preform 126 made from flat sheet metal.
STEP 312, DISPOSE A CENTRAL CONDUCTOR OF A COAXIAL CABLE WITHIN A TUBULAR PORTION OF A SHIELD TERMINAL, includes disposing a central conductor 102 of a coaxial cable 110 within a tubular end portion 116 of a shield terminal 114;
STEP 314, DISPOSE THE TUBULAR PORTION WITHIN A SHIELD CONDUCTOR OF THE COAXIAL CABLE, includes disposing the tubular end portion 116 within a shield conductor 106 of the coaxial cable 110;
STEP 316, FORM A FIRST OUTER FERRULE HAVING A FIRST SEAM, includes forming a first outer ferrule 120 having a first seam 134 by crimping the first outer ferrule preform 124 around the shield conductor 106. Due to the offset edges 130A, 130B and diagonal edges 130C of the first outer ferrule 120, the first seam has a shape that may be described as a Z shape, an S shape, or a serpentine shape. The first seam 134 may have first edge portions 130A longitudinally extending from an end of the first outer ferrule 120, second edge portions 130B longitudinally extending from an opposite end of the first outer ferrule 120 and radially offset from the first edge portions 130A, and third edge portions 130C extending diagonally across the first outer ferrule 120 from the first edge portions 130A to the second edge portions 130B. The first outer ferrule preform 124 is crimped over the tubular end portion 116 of the shield terminal 114. The first outer ferrule 120 is crimped such that the edges of the first seam 134 are separated. The first outer ferrule preform 124 may be formed from a first material and the second outer ferrule preform 126 may be formed from a second material different from the first material. The first material may be a stainless steel alloy and the second material may be a beryllium-copper alloy;
STEP 318, FORM A SECOND OUTER FERRULE HAVING A SECOND SEAM, includes forming a second outer ferrule 122 having a second seam 136 by crimping the second outer ferrule preform 126 around the first outer ferrule 120. The second outer ferrule preform 126 is crimped over the first outer ferrule 120 and an outer insulative jacket 108 of the coaxial cable 110. Crimping the second outer ferrule 122 around the first outer ferrule 120 draws the edges 130A, 130B, 130C of the first seam 134 together;
STEP 320, ARRANGE THE SECOND OUTER FERRULE SUCH THAT THE SECOND SEAM IS RADIALLY OFFSET FROM THE FIRST SEAM, includes arranging the second outer ferrule 122 such that the second seam 136 is radially offset from the first seam 134. STEP 320 is preferably performed prior to STEP 318. The second seam 136 is preferably radially offset from the first seam 134 by about 180 degrees;
STEP 322, FORM A KNURLED PATTERN IN AN OUTER SURFACE OF THE FIRST OUTER FERRULE PREFORM, includes forming a knurled pattern 140 in an outer surface 138 of the first outer ferrule preform 124. STEP 322 is preferably performed prior to STEP 316;
STEP 324, FORM A KNURLED PATTERN IN AN INNER SURFACE OF THE SECOND OUTER FERRULE PREFORM, includes forming a knurled pattern 140 in an inner surface 142 of the second outer ferrule preform 126. STEP 324 is preferably performed prior to STEP 318; and
STEP 326, FORM A PLURALITY OF LATERAL GROOVES IN AN INNER SURFACE OF THE FIRST OUTER FERRULE PREFORM, includes forming a plurality of lateral grooves 146 in an inner surface 144 of the first outer ferrule preform 124. STEP 326 is preferably performed prior to STEP 316.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.
