Barrel crimp retention feature for connectors with braided wires

Abstract

A cable assembly includes a coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The inner and outer barrels each include first and second features that cooperate to form a retention feature. The cable assembly comprises a cable having at least one wire surrounded by an inner insulator encased in a metal shield. The metal shield is disposed between the inner and outer barrels. The first feature is disposed below the metal shield, while the second feature is disposed above the metal shield. At least one of the first and second features extends radially relative to the other of the first and second features to capture the metal shield with the retention feature.

Description

Technical Field

[0001] The present disclosure relates to a barrel crimp securing feature for a connector used with a shield, such as a braided wire. Background Art

[0002] Cables such as those used in high-voltage applications or coaxial cables for video often include a braided shield to prevent interference. Customer requirements to meet stringent automotive-grade cable retention requirements challenge typical stamped and formed shield crimp wing designs. That is, under design loads, the electrical connector may pull out of the shield. Current cable designs include formed crimp wing geometries that rely on sustained compression to provide consistent friction during cable use. New customer space constraints are requiring cable designs with thinner materials, making cable design even more challenging. Summary of the Invention

[0003] In an exemplary embodiment, a cable assembly includes a coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The inner and outer barrels each include first and second features that cooperate to form a retention feature. The cable assembly also includes a cable having at least one wire surrounded by an inner insulator encased in a metal shield. The metal shield is disposed between the inner and outer barrels. The first feature is disposed below the metal shield, while the second feature is disposed above the metal shield. At least one of the first and second features extends radially relative to the other of the first and second features to capture the metal shield using the retention feature.

[0004] In any further embodiment of the foregoing, the metal shield is provided by a braided or foil sleeve. One of the inner and outer sleeves is secured to an electrical connector having an outer housing. The metal shield is grounded and secured to the outer housing. The metal shield is encased in a non-conductive sheath, and the other of the inner and outer sleeves is secured to the non-conductive sheath.

[0005] In any further embodiment above, the first feature is provided by a flange at the terminal end of the inner barrel, the flange flaring radially outward.

[0006] In any further embodiment of the foregoing, the second feature is a window, the first feature is disposed within the window, the flange is disposed circumferentially around the terminal end, and the flange is axially aligned with the window.

[0007] In any further embodiment of the foregoing, the second feature is a window, and the first feature is disposed within the window. The first feature is provided by a protrusion in the inner barrel, the protrusion being disposed axially inwardly of the terminal end. The protrusion is aligned axially and circumferentially with the window.

[0008] In a further embodiment, the outer barrel includes a crimping portion provided by a plastically deformed zone and generates a crimping force on the metal shield and the inner barrel.

[0009] In any further embodiment of the foregoing, a portion of the inner barrel includes an irregularly shaped circumferential edge that forms the body. The irregularly shaped circumferential edge has a shearing edge extending inwardly from the circumferential edge. The first feature is provided by the shearing edge extending radially outward relative to the body. The shearing edge is axially blocked by the outer barrel to provide a retention feature.

[0010] In any further embodiment of the foregoing, a portion of the inner barrel includes an irregularly shaped circumferential edge that forms the body. The irregularly shaped circumferential edge has a circumferentially extending portion that provides the edge. The first feature is provided by the edge extending radially outward relative to the body. The edge is axially blocked by the outer barrel to provide a retention feature.

[0011] In a further embodiment of any of the above, the first feature is provided by a window.The second feature is provided by a recess extending radially inwardly to the window.

[0012] In any further embodiment above, a portion of the recess provides a shearing edge.

[0013] In any further embodiment above, the shearing edge is disposed inwardly from the periphery of the outer barrel blank.

[0014] In a further embodiment of any of the above, a shearing edge is provided between opposing sides of the recessed portion, both of the opposing sides extending radially into the window.

[0015] In any further embodiment of the foregoing, the inner cylinder and the outer cylinder are each metal cylindrical or elliptical members.

[0016] In any further embodiment of the foregoing, the inner barrel and the outer barrel are formed from a sheet metal blank, wherein at least one of the first and second features is provided in the blank.

[0017] In another exemplary embodiment, a method of assembling a cable includes the steps of: a) providing first and second features respectively disposed on an inner barrel and an outer barrel, wherein at least one of the first and second features extends in a radial direction relative to the other of the first and second features, b) inserting the cable into the outer barrel, c) inserting one end of the inner barrel under a metal shield, d) aligning the first and second features to provide a retention feature, and e) capturing the metal shield between the first and second features of the inner and outer barrels and preventing the inner and outer barrels from relative axial movement with respect to each other.

[0018] In a further embodiment of any of the above, the second feature is a window. Step e) includes pressing the outer cylinder adjacent the window. The first feature is in the window.

[0019] In any further embodiment of the foregoing, the cable includes at least one wire surrounded by an inner insulator encased in a metal shield. Step c) includes inserting one end of the inner barrel between the inner insulator and the metal shield. Step e) includes securing one of the inner barrel and the outer barrel to a terminal connector having an outer housing. The metal shield is grounded and secured to the outer housing. The cable includes a non-conductive sheath covering the metal shield. The other of the inner barrel and the outer barrel is secured to the non-conductive sheath.

[0020] In any further embodiment above, step d) includes sliding the outer barrel axially over the inner barrel and the metal shield.

[0021] In any further embodiment above, before performing step a), the method includes the step a1) forming a first feature by bending a circumferential flange radially outward on the terminal end of the inner barrel blank.

[0022] In any further embodiment above, before performing step a), the method includes step a1) forming a first feature by deforming the terminal end of the inner barrel blank radially inwardly into a protrusion. Step d) includes circumferentially aligning the protrusion with a window providing a second feature.

[0023] In any of the foregoing further embodiments, step e) includes plastically deforming a portion of the outer barrel to provide an innermost diameter that is smaller than an outermost diameter of the first feature. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure may be further understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0025] Figure 1 A perspective view of a portion of a coaxial cable with a connector.

[0026] Figure 2 It is along Figure 1 A sectional view taken along line 2-2.

[0027] Figure 3A It is a top view of the inner tube blank.

[0028] Figure 3B It is a top view of the outer cylinder blank.

[0029] Figure 4A This is a three-dimensional diagram of the inner cylinder and the outer cylinder arranged coaxially relative to each other. For the sake of clarity, the cables are omitted.

[0030] Figure 4Bis an enlarged view of a portion of the inner and outer barrels showing the flange on the inner barrel that provides a braid retention feature.

[0031] Figure 5 is an enlarged cross-sectional view of a portion of the inner and outer barrels with a metal shield remaining therebetween.

[0032] Figure 6 Additional examples of braid retention features are described.

[0033] Figure 7A An additional inner barrel blank is shown.

[0034] Figure 7B It is along Figure 7C An end view of the inner barrel taken along line BB.

[0035] Figure 7C yes Figure 7A The inner tube and Figure 4A A perspective view of the outer cylinders arranged coaxially relative to each other, with cables omitted for clarity.

[0036] Figure 8A An additional inner barrel blank is shown.

[0037] Figure 8B is with Figure 7B Similar end view, but with the inner barrel made of Figure 8A The blank shown is formed.

[0038] Figure 9A An additional inner barrel blank is shown.

[0039] Figure 9B It is another outer cylinder blank.

[0040] Figure 9C Described Figure 9A and 9B 1 is a partial cross-sectional view of an inner barrel and an outer barrel formed from a blank shown in FIG, which are arranged coaxially with each other and with the cables omitted for clarity.

[0041] Figure 10A An additional inner barrel blank is shown.

[0042] Figure 10B It is another outer cylinder blank.

[0043] Figure 10C Described Figure 10A and 10B A partial cross-sectional view of the inner and outer barrels formed from the blank shown in FIG, which are laid coaxially with each other - with the cables omitted for clarity.

[0044] Figure 11A Yet another inner barrel blank is shown.

[0045] Figure 11B This is another outer tube blank.

[0046] Figure 11C Described Figure 11A and 11B 1 is a partial cross-sectional view of an inner barrel and an outer barrel formed from a blank shown in FIG, which are arranged coaxially with each other and with the cables omitted for clarity.

[0047] The embodiments, examples, and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including their various aspects or corresponding individual features, may be employed independently or in any combination. Features described in conjunction with one embodiment are applicable to all embodiments unless such features are incompatible. In the various drawings, the same reference numerals and names denote the same elements. DETAILED DESCRIPTION

[0048] Figure 1 and Figure 2 . Cable assembly 10 includes a coaxial cable 12 having wires 14 surrounded by an inner insulator 16. The inner insulator is a non-conductive insulating layer. A metallic, conductive shield 18 covers the inner insulator 16. In this example, shield 18 is a braided or foil jacket or wire braid that provides protection against radio frequency (RF) interference.

[0049] A connector 20 is provided at one end of the cable 12. Although the exemplary connector 20 is shown as a female connector, the connector 20 may also be a male connector or a splice connector. The connector 20 includes an outer housing 22 that is grounded to the shield 18. An inner non-conductive housing 26 supports electrical terminals 24 that are electrically connected to the wires 14. A non-conductive jacket 28, such as a polymer material, is disposed over the shield 18.

[0050] Reference Figure 2 The inner and outer barrels 32 and 34 are coaxially arranged relative to each other and are in at least partially axially overlapping relation. The inner and outer barrels 32 and 34 each include first and second features that cooperate to form a retention feature 36 that captures the shield 18 to establish a robust electrical connection and provide reliable shielding, such as against electromagnetic interference (EMI). In the illustrated example, the first feature is positioned below the shield 18, while the second feature is positioned above the shield 18. To securely retain the shield 18 once the cable assembly 10 is assembled, at least one of the first and second features extends radially relative to the other of the first and second features to capture the shield 18. This arrangement effectively clamps the shield 18 while preventing the inner and outer barrels 32 and 34 from being easily pulled apart during use, thereby maintaining good contact with the shield 18.

[0051] In one exemplary retention feature, the inner barrel 32 includes a first feature provided by a circumferential flange 48 that is arranged relative to a second feature provided by a window 38 in the outer barrel 34. The circumferential flange 48, when fully assembled, cooperates with the window 38 to provide a stop that prevents the inner barrel 32 and the outer barrel 34 from sliding or moving axially relative to each other, so that the shield 18 is captured under all designed pull-out forces. Standard crimping operations can be used, and degradation of the connection between the connector 20 and the cable 12 is avoided during use of the cable assembly 10.

[0052] Figure 3A and 3B , examples of inner and outer barrel blanks (semi-finished products) 40 and 50 are shown, respectively. At least one of the first and second features is provided in the blanks 40 and 50. With reference to the inner barrel blank 40, a flat metal stamping is rolled into a cylindrical or oval shape to provide first and second diameter portions 42 and 44; in the illustrated example, the first diameter portion 42 is larger than the second diameter portion 44. A carrier strip 46 is joined to the second diameter portion 44 via a tab 45. During the forming process, the carrier strip 46 is sheared from the remainder of the inner barrel blank 40 at the tab 45 and discarded.

[0053] In an exemplary embodiment, the second diameter portion 44 is provided with an end portion 62. The end portion 62 is provided with a flange 48 that flares radially outward relative to the second diameter portion 44. When fully assembled, the first diameter portion 42 is engaged with the outer housing 22 of the connector 20. It should be understood that the outer barrel 34 can be engaged to the outer housing 22 instead of the inner barrel 32 (as shown), if desired.

[0054] Referring to the outer barrel blank 50, the main body portion 52 is provided in a cylindrical or elliptical shape. The main body portion 52 is joined to the wing portion 58 by a longitudinal portion 56, which is arc-shaped. The longitudinal portion 56 is narrower than the main body portion 52 and the wing portion 58, thereby providing a window portion 54 forming the window 38. Figure 2 and 4A . The wing portion 58 may be provided with a reinforcing indentation or depression 60 to provide more rigidity. The wing portion 58 is secured to the sheath 28 by, for example, crimping.

[0055] Reference Figure 4A-5 , the retention feature 36 is formed by a flange 48 disposed within the window 38. During assembly, as Figure 5As shown, a portion of the outer barrel 34 is plastically deformed under the action of a crimping force 66 to provide a crimping portion 64 adjacent to the flange 48. The crimping portion 64 is provided with an edge 68 having an innermost diameter d that is smaller than an outermost diameter D of the flange 48. In this manner, the shield 18 is securely retained between the edge 68 and the flange 48, preventing the shield 18 from being pulled out under axial loads. The crimping portion 64 generates a clamping force on the shield 18 and the inner barrel 32.

[0056] Figure 6 An example of another configuration is shown. In this example, the retention feature 136 is provided by a protrusion 74 in the inner barrel 32. The edge 68 of the crimp portion 64 is adjacent to the protrusion 74 so that the protrusion 74 and the shield 18 cannot be axially pulled out of the window 38 of the outer barrel 34.

[0057] Figures 7A-7C Another exemplary arrangement is shown in FIG. Inner barrel blank 140 best illustrates the first feature prior to forming inner barrel 132. Portion 143 of inner barrel 132 includes a peripheral edge 142 having an irregular shape (e.g., nonlinear) that forms the body. In this example, peripheral edge 142 is V-shaped. Portion 143 has a shear edge 144 extending from the interior of peripheral edge 142. Figure 7B and 7C As shown, the first feature is provided by a shear edge 144 that extends radially outward relative to the body to a raised portion 146. In this example, one edge 145 of portion 143 is adjacent an opposite edge 147 of portion 143 when formed into inner barrel 132. End 148 of portion 143 does not need to include a flange because end 148 is disposed radially inward relative to raised portion 146. Shear edge 144 is axially blocked by outer shell 34 to provide a retention feature.

[0058] Reference Figures 8A-8B , showing the Figures 7A-7C A similar arrangement is used, but a different inner barrel blank 240 is used to form the inner barrel 232. In this example, a portion 243 of the inner barrel blank 240 includes an irregularly shaped circumferential edge 242, forming the body. In this example, the circumferential edge 242 is Z-shaped. The circumferential edge 242 provides an edge 244 rather than a discrete cutout. When formed into the inner barrel 232, one edge 245 of the portion 243 is adjacent to an opposite edge 247 of the portion 243. Figure 8B As best shown, the first feature is provided by an edge 244 extending radially outward relative to the body to the raised portion 246. Likewise, the end 248 of portion 243 need not include a flange since the end 248 is disposed radially inward relative to the raised portion 246. The edge 244 is axially blocked by the outer housing to provide a retention feature (similar to Figure 7C ).

[0059] Reference Figures 9A-11C The first feature is provided by a corresponding window 349, 449, 549 in portion 343, 443, 543 of the inner barrel blank 340, 440, 540. The inner barrel 332, 432, 532 and its first feature cooperate with a second feature of the outer barrel 334, 434, 534 (formed from the outer barrel blank 350, 450, 550) to provide a retention feature. In addition to the windows 349, 449, 549 formed by cutouts in the inner barrel blank 340, 440, 540 shown in the figures, a recessed feature formed in the inner barrel 332, 432, 532 can also cooperate with the second feature of the outer barrel 334, 434, 534. For clarity, the captured shield 18 is omitted from the figures.

[0060] like Figure 9B and 9C As shown, the second feature is provided by a recess 354 extending radially inwardly to the window 349. Figure 10B and 10C The second feature is provided by a recess 454 having a portion forming a shear edge 456. Figure 10B As shown, the shear edge 456 is disposed inwardly from the periphery of the outer barrel blank 450 . Figures 11B-11C The example shown combines Figure 9B and 9C as well as Figure 10B and 10C In various aspects of the illustrated embodiment, the second feature is provided by a recess 554 having a sheared edge 556 disposed between opposing sides 554a, 554b of the recess 554, both of which extend radially to the window 549.

[0061] In operation, first and second features are provided on the inner barrel 32 and outer barrel 34, respectively. One of the first and second features extends radially outward, while the other of the first and second features extends radially inward. The cable assembly 10 is assembled by inserting the cable 12 into the outer barrel 34. One end of the inner barrel 32 is positioned below the shield 18. In the example, the first and second features are aligned both circumferentially and axially to provide a retention feature. The retention feature prevents relative axial movement of the inner and outer barrels 32, 34, thereby securely retaining the shield 18.

[0062] It should also be understood that although a specific component arrangement is disclosed in the illustrated embodiments, other arrangements may also benefit therefrom. Although a specific order of steps is shown, described, and claimed, it should be understood that unless otherwise indicated, the steps may be performed in any order, separated, or combined, and still benefit from the present invention.

[0063] Although different examples have specific components shown in the drawings, embodiments of the present invention are not limited to these specific combinations. It is possible to use some components or features in one example in combination with features or components in another example.

[0064] Although exemplary embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims.For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims

1. A cable assembly, comprising: An inner cylinder and an outer cylinder are coaxially arranged, wherein the outer cylinder overlaps a portion of the inner cylinder, and the inner cylinder and the outer cylinder respectively include a first feature and a second feature, wherein the first feature and the second feature cooperate with each other to form a retaining feature, wherein the second feature is a window; a cable comprising at least one wire surrounded by an inner insulator covered in a metal shield, wherein the metal shield is disposed between the inner and outer barrels; wherein the metal shield is provided by a braided sleeve or a foil sleeve, wherein one of the inner and outer sleeves is secured to an electrical connector having an outer housing, and the metal shield is grounded and secured to the outer housing, wherein the metal shield is covered in a non-conductive sheath and the outer sleeve is crimped to the non-conductive sheath; and The first feature is arranged below the metal shield and within the window, the second feature is arranged above the metal shield, at least one of the first feature and the second feature extends in a radial direction relative to the other of the first feature and the second feature to capture the metal shield with the retaining feature, wherein the metal shield is within the window of the outer barrel.

2. The cable assembly according to claim 1, wherein: The first feature is provided by a flange at the end of the inner barrel, the flange flaring radially outwardly.

3. The cable assembly according to claim 2, wherein: The flange is disposed around the circumference of the end portion, and the flange is axially aligned with the window.

4. The cable assembly according to claim 1, wherein: The first feature is provided by a protrusion in the inner barrel, the protrusion being arranged axially inwardly of the end portion, the protrusion being axially and circumferentially aligned with the window.

5. The cable assembly according to claim 1, wherein: The outer cylinder includes a press-contact portion provided by a plastic deformation zone, and the press-contact portion generates a press-contact force on the metal shield and the inner cylinder.

6. The cable assembly according to claim 1, wherein: The portion of the inner barrel includes an irregularly shaped circumferential edge forming a main body, the irregularly shaped circumferential edge having a shearing edge extending inwardly from the circumferential edge, the first feature being provided by the shearing edge extending radially outwardly relative to the main body, the shearing edge being axially blocked by the outer barrel to provide the retaining feature.

7. The cable assembly according to claim 1, wherein: The portion of the inner barrel includes an irregularly shaped circumferential edge forming a body, the irregularly shaped circumferential edge having a circumferentially extending portion providing an edge, the first feature being provided by the edge extending radially outwardly relative to the body, the edge being axially blocked by the outer barrel to provide the retention feature.

8. The cable assembly according to claim 1, wherein: The inner cylinder and the outer cylinder are each a metal cylindrical or elliptical member.

9. The cable assembly according to claim 1, wherein: The inner and outer barrels are formed from a sheet metal blank, at least one of the first and second features being provided in the blank.

10. A method for assembling a cable, comprising the following steps: a) providing a first feature and a second feature respectively disposed on the inner barrel and the outer barrel, wherein at least one of the first feature and the second feature extends in a radial direction relative to the other of the first feature and the second feature, wherein the second feature is a window; b) inserting the cable into the outer cylinder; c) inserting the end of the inner cylinder under the metal shield; d) aligning the first feature and the second feature to provide a retention feature; and e) capturing the metal shield between the first and second features of the inner and outer cylinders and preventing relative axial movement of the inner and outer cylinders, wherein the metal shield is provided by a braided sleeve or a foil sleeve, wherein one of the inner and outer sleeves is secured to an electrical connector having an outer housing, and the metal shield is grounded and secured to the outer housing, wherein the metal shield is covered in a non-conductive sheath and the outer sleeve is crimped to the non-conductive sheath; wherein the first feature is arranged within the window, and Wherein, the metal shielding member is inside the window of the outer cylinder.

11. The method according to claim 10, characterized in that Step e) includes crimping the outer barrel adjacent the window.

12. The method according to claim 10, characterized in that The cable includes at least one wire surrounded by an inner insulator covered in the metal shield, and step c) includes inserting the end of the inner barrel between the inner insulator and the metal shield, and step e) includes fixing one of the inner barrel and the outer barrel to a terminal connector having an outer housing.

13. The method according to claim 10, characterized in that Step d) comprises sliding the outer cylinder axially over the inner cylinder and the metal shield.

14. The method according to claim 10, characterized in that Prior to performing step a), the step a1) includes forming a first feature by bending a circumferential flange radially outward on the terminal end of the inner barrel blank.

15. The method according to claim 10, characterized in that Prior to performing step a), the method includes the step a1) forming a first feature by deforming a protrusion axially inwardly of the end portion of the inner barrel blank, and wherein step d) includes circumferentially aligning the protrusion with a window providing the second feature.

16. The method according to claim 11, characterized in that Step e) includes plastically deforming a portion of the outer barrel to provide an innermost diameter that is smaller than an outermost diameter of the first feature.

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