Coaxial cable connector assembly method, coaxial cable connector and crimping tool

Abstract

The invention provides a method for assembling a coaxial cable connector (1), a crimping tool for assembling a coaxial cable connector (1) and a coaxial cable connector (1). The method of the invention comprises crimping an inner ferrule (3) onto an exposed braid (4) of the coaxial cable (2), folding the exposed braid (4) of the coaxial cable (2) back onto the inner ferrule (3), and crimping an outer contact (5) onto the exposed braid (4) folded back wherein the outer contact (5) has different contractions of decreasing diameter in predetermined functional regions (5a, 5b), in this way, the extension of the outer contact (5) and the compression of the cable (2) are reduced. This innovation reduces the need for multiple terminal components, simplifies the assembly process, and ensures reliable mechanical and pneumatic connections for various applications.

Description

Technical Field

[0001] The present invention relates to the field of coaxial cable connector assembly, with a particular focus on improving the assembly process for small-diameter coaxial cables. The invention relates to innovative methods, connectors, and associated crimping tools that are configured to enhance the performance, reliability, and reusability of these connectors in various applications. Background Art

[0002] Coaxial cables are renowned for their ability to transmit high-frequency signals with minimal loss and reduced electromagnetic interference, making them integrated in various industries, including telecommunications, automotive, aerospace, and consumer electronics. The effectiveness and functionality of coaxial cables in these applications critically depend on the quality, integrity, and especially the adaptability of their connectors, particularly when considering the need for compatibility across various cable sizes and the challenges of maintaining signal integrity during connector assembly.

[0003] In traditional coaxial cable connector assemblies, the process typically involves crimping a ferrule onto the cable's shield braid and then attaching an outer contact to establish a secure and conductive connection. However, while this crimping process is effective for its intended purpose, it has historically been limited in its scope and adaptability. For each different cable size, a unique crimp barrel design is necessary, resulting in a wide variety of connector parts and dedicated crimping tools, each suitable for a specific cable diameter. This level of specialization, while necessary to ensure proper connections, leads to significant manufacturing costs, along with the complexities of inventory management and logistics due to the diversity of required parts.

[0004] Furthermore, when components initially designed for larger cable diameters are used with smaller cables, traditional crimping methods often result in material redundancy and excessive elongation of the crimp area due to the excess material intended for larger diameters. This elongation can adversely affect the positional stability of the center contact within the connector assembly. Consequently, this displacement can detrimentally impact the electrical performance of the coaxial cable, particularly manifested as impedance mismatch and signal integrity degradation. These issues are critical in applications where maintaining consistent electrical characteristics is vital for the functionality of coaxial cable systems.

[0005] One of the major limitations of the prior art in coaxial cable connector assemblies is the lack of reusability and adaptability in crimp barrel design. Traditional methods, which customize crimp barrels specifically for a particular cable diameter, limit their use to a limited range of cable sizes. This lack of versatility not only leads to a greater environmental impact due to the need to manufacture an array of single-size-specific parts but also results in increased costs associated with the production and inventory management of cable connectors.

[0006] Accordingly, the industry has been challenged with developing a crimping method that not only accommodates a wide range of cable sizes, including smaller diameter cables, but does so without compromising the basic integrity of the electrical connection. Such a balanced approach is crucial for ensuring consistent and reliable signal transmission in coaxial cables. SUMMARY OF THE INVENTION

[0007] In view of the foregoing, it is an object of the present invention to provide an effective method for assembling a coaxial cable connector that enables the reuse of components across cable sizes, optimizes the crimping of a multi-purpose crimping tool, and ensures a high-performance coaxial cable connector.

[0008] According to the present invention, the above object is achieved by providing a method for assembling a coaxial cable connector as described in independent claim 1, a crimping tool for such assembly as described in independent claim 10, and a coaxial cable connector itself as described in independent claim 15. Advantageous further developments of the invention are set forth in the dependent claims.

[0009] Specifically, the method for assembling a coaxial cable connector according to the present invention includes the following steps:

[0010] a. Providing a coaxial cable;

[0011] b. Crimping an inner ferrule onto the exposed braid of the coaxial cable;

[0012] c. Folding back the exposed braid of the coaxial cable onto the inner ferrule; and

[0013] d. Crimping an outer contact onto the folded-back exposed braid, wherein the outer contact has different constrictions with a reduced diameter in a predetermined functional zone to reduce elongation of the outer contact and compression of the cable.

[0014] The present invention presents a method approach for assembling a coaxial cable connector that includes the key feature of an outer contact with a dedicated constriction. This feature collectively enhances the functionality, usability, and adaptability of the connector to different cable sizes while ensuring the integrity of the electrical connection and signal transmission.

[0015] The process begins with providing a suitable coaxial cable, which is a crucial initial step in the coaxial cable connector assembly process, especially in cases where accommodation of various cable sizes is emphasized. This involves selecting the appropriate cable type and ensuring it meets the specific requirements of the intended application, such as diameter, signal frequency, and environmental resistance.

[0016] Subsequently, pressing the inner ferrule onto the exposed braid of the cable is a critical operation. This step requires precise alignment of the ferrule and attachment to the braid, which is fundamental to the shielding effectiveness of the cable.

[0017] This crimp ensures a secure mechanical and electrical connection between the cable and the ferrule. Proper crimping is necessary to maintain the signal integrity of the cable as it preserves the continuity of the shield and minimizes electromagnetic interference.

[0018] Then, the exposed braid of the cable is folded back over the inner ferrule. This action strengthens the joint and prepares the assembly for the next critical step.

[0019] Pressing the outer contact onto the folded-back exposed braid is a key innovation of the present invention compared to traditional methods. The outer contact is constructed with different constrictions in a predefined functional area.

[0020] This feature significantly reduces the risk of cable elongation and over-compression during crimping. The constrictions in the outer contact are configured to ensure accurate and effective application of the crimping pressure.

[0021] This precise application of pressure maintains the integrity of the mechanical and electrical connection, which is crucial for the performance of coaxial cables.

[0022] The diameter-reducing constrictions in specific areas mitigate the issues of material redundancy and elongation that occur when using a crimp barrel designed for a larger cable diameter during a conventional crimping process. These constrictions are strategically positioned and shaped to minimize unnecessary material deformation during the crimping process.

[0023] By focusing on these functional areas, the method ensures a secure crimp without applying excessive force that could deform the cable or compromise its electrical performance. This precise crimping method is crucial for the integrity of the connection.

[0024] This feature is particularly beneficial in maintaining the characteristic impedance of the coaxial cable, which is essential for high-frequency signal transmission. The controlled crimping process helps maintain the structural and electrical characteristics of the cable, thus ensuring optimal signal quality.

[0025] Overall, this process represents an improved method for coaxial cable connector assembly, ensuring greater reliability, consistency, and adaptability across a range of cable sizes. This meets the industry's need for a versatile and efficient manufacturing process, addresses key challenges in connector assembly, and provides a solution that is both practical and innovative.

[0026] More specifically, a crimping tool for assembling a coaxial cable connector according to the present invention includes at least one of the following:

[0027] a. An interchangeable die set corresponding to a specified cable diameter and an adjustable mechanism for setting the crimp height, the interchangeable die set being configured to be used with a common inner ferrule provided with overlapping crimp side joints to allow adaptation to a range of cable diameters; and

[0028] b. A crimp profile characterized by a constriction portion that is positioned to selectively apply pressure to a predetermined functional area of an outer contact, wherein the constriction portion is configured to prevent over-elongation of the outer contact during crimping.

[0029] The crimping tool has an adjustable mechanism for setting the crimp height, which allows for precise customization according to the specific dimensions of the coaxial cable, thereby overcoming significant limitations associated with traditional crimping tools. Although different crimping tools may be required for specific cable diameters, the components - particularly the inner ferrules - remain standardized for use across a range of cable diameters.

[0030] The die set is specifically configured to have an adjustable crimp height feature to achieve precise adaptation of the overlap between the overlapping side joints of the ferrules for optimal fit, especially in the case of smaller diameter cables. This configuration element provides a versatile crimping process that can be finely adjusted to accommodate the precise requirements of various cable diameters.

[0031] Different crimping tools (each with a specialized die set) are essential for effectively accommodating coaxial cables of different sizes, thus ensuring that reusable inner ferrules can be effectively utilized across a range of cable sizes. This flexibility is particularly beneficial in various applications where the cable diameter can vary, allowing for a wider range of applications.

[0032] By reusing the same connector components across different cable diameters, harness manufacturers can significantly reduce material inventory, even though different crimping tools are required for each cable size. This not only minimizes manufacturing costs but also streamlines the assembly process, resulting in higher efficiency and reduced complexity in the manufacturing setup.

[0033] The crimping tool has a special crimp profile that has constriction portions that selectively apply pressure to a predetermined functional area of an outer contact. These constriction portions are carefully configured to prevent over-elongation of the outer contact during the crimping process.

[0034] This aspect of the outer contact construction directly addresses and mitigates the material redundancy issues and associated elongation problems common to traditional crimp geometries. By effectively controlling elongation, the tool plays a key role in maintaining the positional integrity of the center contact, thereby ensuring the electrical performance of the coaxial cable, particularly in maintaining consistent impedance and optimal signal integrity.

[0035] Overall, the present invention represents a significant advancement in the field of coaxial cable connector assembly. It introduces a versatile and effective solution that not only ensures high-quality connections but also promotes a more sustainable approach by enabling the use of reusable connector components for multiple cable sizes.

[0036] This adaptability, combined with the ability to maintain the integrity of the electrical connection, makes the present invention particularly valuable in industries such as telecommunications, automotive, and aerospace, where the widespread use of coaxial cables demands reliability and versatility.

[0037] Finally, in detail, the coaxial cable connector according to the present invention comprises at least one of the following:

[0038] a. An inner ferrule that is crimped to the exposed braid of the coaxial cable, the ferrule including an adjustable overlapping side connection portion to accommodate coaxial cables of different diameters; and

[0039] b. An outer contact that is crimped to the exposed braid of the coaxial cable, the exposed braid being folded back over the inner ferrule, which is in turn crimped to the exposed braid of the coaxial cable, the outer contact having different constriction portions with a reduced diameter in a predetermined functional area, the constriction portions being configured to minimize elongation of the outer contact during crimping, thereby maintaining the position integrity of the center contact within the connector.

[0040] The described coaxial cable connector incorporates innovative features that significantly enhance its adaptability and performance. The key elements of the present invention (which are effective both as a combination and as individual improved aspects) include the following:

[0041] The adjustable inner ferrule is equipped with overlapping side connection portions, enabling it to accommodate coaxial cables of various diameters. This adaptability is essential for creating a versatile connector compatible with a range of cable sizes. By reducing the need for multiple size-specific ferrules, this feature streamlines the manufacturing process and lowers inventory requirements.

[0042] The outer contact, which is fixed to the folded-back exposed braid of the inner ferrule and the cable, has different constriction portions in specific functional areas. Characterized by their reduced diameter, these constriction portions are strategically positioned to limit elongation of the outer contact during the crimping process. This elongation control is crucial for maintaining the position integrity of the center contact within the connector. In turn, maintaining this position integrity is key to ensuring optimal electrical performance of the connector, as any misalignment of the center contact can lead to impedance mismatch and compromise signal integrity.

[0043] The advantages of the present invention are substantial and diverse. The adaptability of the inner ferrule to accommodate coaxial cables of various diameters greatly expands the utility of the connector in various applications, including telecommunications and automotive systems. The outer contacts are precisely configured to maintain the electrical and mechanical characteristics of the connector throughout the assembly process, ensuring reliable and consistent performance. Additionally, this construction significantly helps to reduce material waste and improve the overall efficiency of the connector assembly process.

[0044] In summary, the present invention represents a significant advancement in coaxial cable connector technology, effectively addressing the industry's common challenges of versatility, reliability, and performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Additional features and benefits of the present invention and details of its preferred embodiments are set forth in the following detailed description with reference to the accompanying drawings. These drawings illustrate:

[0046] Figure 1 : A cross-sectional view of a coaxial cable connector assembly for a large-diameter coaxial cable (RTK031) and a small-diameter coaxial cable (RG174), also including perspective views of the individual components of these assemblies, each component depicted in an uncrimped state;

[0047] Figure 2a 、 Figure 2b 、 Figure 2c and Figure 2d : The step-by-step process (Steps 1 to 14) of a method for assembling a coaxial cable connector, clearly showing the sequence of methods involved in the assembly;

[0048] Figure 3a and Figure 3b : Two different external views of the inner ferrule, shown crimped to the exposed braid of a small-diameter coaxial cable prior to the application of the outer contacts;

[0049] Figure 4 : Figure 3a and Figure 3b External views of the inner ferrule of

[0050] Figure 5a 、 5b and 5c: Three different external views (side view, top view, and bottom view) of a coaxial cable connector according to the present invention, attached to a small-diameter coaxial cable, highlighting the unique shrinkage configuration of the outer contacts;

[0051] Figure 6 : A side external view of a coaxial cable connector attached to a large-diameter coaxial cable, characterized by the Figure 5a 、5b the outer contact of 5c; and

[0052] Figure 7a and 7b : Cross-sectional views (top and side views) of a coaxial cable connector according to the present invention, attached to a small-diameter cable, highlighting constrictions of different diameters located at the functional zones of the connector. DETAILED DESCRIPTION

[0053] In the following detailed description section, preferred embodiments of the coaxial cable connector 1 and the assembly method are explored, as depicted in the accompanying drawings. This section provides a comprehensive overview of the innovative approach of the present invention, detailing the adaptable and effective features that distinguish it from the prior art. The embodiments shown are used to demonstrate the practical application of these novel features and the substantial advantages they confer.

[0054] Figure 1 Two configurations of the coaxial cable connector assembly in the upper part marked with the label "a" are shown. On the left, the assembly is connected to a large-diameter coaxial cable 2 of type RTK031, and on the right, it is paired with a small-diameter coaxial cable 2 of type RG174. These illustrations show the adaptability of the connector 1 to different cable sizes, which is a core feature of the present invention's construction. The cross-sectional depictions reveal how the internal components of the connector 1 are well-suited to cables 2 of different diameters, reflecting an innovative construction centered around the assembly method for the connector 1.

[0055] Each connector configuration includes a center contact 6, visible in the lower part marked with the label "d". These center contacts 6 are configured to form an electrical connection with the inner conductor 8 of the coaxial cable 2. The center contacts 6 are distinguished by their diameters to match the internal specifications of the RTK031 and RG174 cables 2, thus facilitating adaptability to these two different cable types.

[0056] In Figure 1 the central part marked with "b", the sub-assembly 7 is depicted in its original uncrimped state. This sub-assembly 7 includes an outer contact 5, which is configured to mechanically and electrically secure to the braid 4 of the cable 2. The standardization of the sub-assembly 7 for use with varying cable diameters represents a key innovation, substantially reducing the need for a wide range of parts specifically designed for different cable sizes. This consistent design approach for the sub-assembly 7 is applicable to various connector types, representing a leap in connector component standardization and indicating a departure from traditional manufacturing methods.

[0057] Additionally, in Figure 1In the central part marked "c.", the inner ferrule 3 is shown in its initial uncrimped state. The inner ferrule 3 is positioned between the outer contact member 5 on the outside and the folded-back braid 4 and the non-folded braid 4 and the dielectric layer of the cable 2 on the inside, playing a key role in ensuring a stable and consistent assembly process. The inner ferrule 3 is constructed to be compatible with both large-diameter cables 2 and small-diameter cables 2, thus meeting the purpose of the assembly process of the streamlined connector 1 of the present invention. This method further improves manufacturing efficiency by further reducing the variety of required components.

[0058] Therefore, the coaxial cable connector 1 significantly reduces production and logistics costs by restricting the variation of the central contact member 6, which is the only component constructed for a specific cable diameter. The originality of this design supports the ability of the present invention to produce a streamlined and economical coaxial cable connector 1, highlighting the practical and cost-effective benefits of this technological advancement.

[0059] Figures 2a to 2d Systematically outlines the sequence of steps numbered 1 to 14 required to attach the coaxial cable connector 1 to the end of the coaxial cable 2. These steps are as follows:

[0060] In step 1 ( Figure 2a ), the coaxial cable 2 is precisely cut to a specified length, which is the necessary first step to establish a consistent starting point for the connector assembly process.

[0061] In step 2 ( Figure 2a ), an accurate initial cutting action is performed to remove a portion of the outer sheath from one end of the cable 2, including the underlying braid 4 and foil. This action exposes the necessary layers required to attach the connector to this end.

[0062] Step 3 ( Figure 2a ) involves a secondary cutting (stripping) action on the same end of the coaxial cable 2, which is carefully configured to remove a section of the outer sheath and expose a specific longitudinal section of the braid 4, while keeping the insulation intact at the very end of the cable 2 to prevent the braid 4 from wearing or unraveling. This operation is essential for the subsequent attachment of the inner ferrule 3 of the coaxial cable connector 1, which will be attached to this end of the cable 2.

[0063] In Figure 2a step 4, the assembly process of the coaxial cable connector 1 onto the coaxial cable 2 begins with carefully crimping the inner ferrule 3 (marked with the label "c" in Figure 1 ) onto the exposed braid 4 of the coaxial cable 2. After crimping, a quality inspection is performed to verify the secure attachment and structural integrity of the ferrule 3.

[0064] Step 5 of the Cable Handling Procedure ( Figure 2b ) Remove any remaining half-strip on the cable end section between the crimped inner ferrule 3 and the distal end of the cable 2. This step ensures that the braid 4 within this longitudinal end section of the cable is fully exposed.

[0065] After removing the half strip in step 5, Figure 2b As shown in step 6, the exposed braid 4 at the end of the cable 2 is carefully folded back 180 degrees over the crimped inner ferrule 3. This action is critical to increase mechanical stability and optimize electrical grounding of the assembly.

[0066] After folding back the exposed braid 4 in step 6, step 7 ( Figure 2b ) involves precisely trimming the inner foil from the cable end at the point where the braid 4 has been folded back. This process ensures that the additional shielding layer is properly shaped to complement the assembly.

[0067] In step 8 ( Figure 2b ), the dielectric insulator is carefully trimmed from the end of the cable 2 to expose the inner conductor 8. Special care is taken to ensure that no remnants of foil are left, which could compromise signal integrity.

[0068] Step 9 Figure 2c ) is to place the center contact 6 (in Figure 1 The inner conductor 8 of the coaxial cable 2 is crimped onto the now exposed inner conductor 8 of the coaxial cable 2. This critical step establishes the electrical path required for signal transmission.

[0069] exist Figure 2c In step 10, the end of the coaxial cable 2 (now with the newly crimped center contact 6) is inserted into the subassembly 7, which includes the outer contact 5 and is marked with the label "b". Figure 1 This process positions the components for final assembly.

[0070] Step 11 Figure 2c ) involves verifying the precise longitudinal position of the center contact 6 by tactile inspection. This ensures that the contact 6 is correctly aligned within the connector 1 to achieve an optimal electrical connection.

[0071] The outer contact 5 of the subassembly 7 is then crimped onto the exposed braid 4 folded back over the inner ferrule 3 . Figure 2d This step 12 in strengthens the mechanical connection and forms a consistent electrical shield around the cable 2.

[0072] exist Figure 2d In step 13, electrical testing is performed to confirm the correct assembly of the connector 1, with particular attention paid to the length and precise positioning of the center contact 6 to ensure a reliable electrical connection.

[0073] After the electrical tests, step 14( Figure 2d ) involves labeling or marking the cable 2 to provide identification and facilitate traceability. This is an essential practice for maintaining quality control and streamlining future maintenance or repair activities.

[0074] The final step 15 (not shown) prepares the fully assembled coaxial cable connector 1 for installation in its designated housing, which can include telecommunications equipment, automotive systems (especially automotive data connection applications), aerospace instruments, or other advanced applications.

[0075] Adopting the Figures 2a to 2d assembly process outlined in helps create a reliable and durable coaxial cable connector assembly that is specifically constructed to maintain signal integrity in high-frequency applications, reflecting the emphasis of this innovation on precision and versatility in connector manufacturing. This assembly process maintains strict precision standards and minimizes dependence on a wide range of specialized tools and components. This increased efficiency is particularly advantageous in high-volume manufacturing environments where consistency, reliability, and cost-effectiveness are key factors.

[0076] Figure 3a and Figure 3b shows the inner ferrule 3 being crimped onto the exposed braid 4 of a small-diameter RG174 type coaxial cable 2 using a crimping tool set to a width of 2.25 mm, achieving a crimp height (CH) of 2.50. This particular ferrule 3 is the same as the ferrule for a larger-diameter RTK 031 type coaxial cable 2 (see Figure 4 ) indicating that the present invention is capable of accommodating various cable sizes while reducing the number of different components required.

[0077] The ferrule 3 has uniquely designed overlapping side joints 3a, 3b (clearly visible in the Figure 3b side view) that allow for an adjustable fit, which can be customized for the smaller diameter of the RG174 cable 2. This adaptability is achieved by increasing the overlap of the side joints 3a, 3b to conform to the inner diameter of the cable 2, ensuring a secure and consistent crimp. This implementation of the overlapping side joints 3a, 3b is a key aspect of the present invention, facilitating component reuse and enabling a streamlined manufacturing process across different cable sizes. Thus, Figure 3a and 3b highlight the method of the present invention to maintain connection integrity while optimizing logistics efficiency through component standardization.

[0078] When preparing to apply the outer contact 5, the inner ferrule 3 is evenly crimped along the length of the braid 4 that has been exposed through the cable preparation steps, particularly as outlined in step 3 of Figure 2a AsFigure 3a and Figure 3b As shown in Figure 3b , this consistent crimping technique is integral to the component standardization method of the present invention, which helps streamline the assembly process and reduce the complexity of manufacturing and logistics. This method of crimping innovation ensures the compatibility of the same ferrule components across different cable diameters, which not only simplifies the manufacturing workflow but also contributes to overall cost efficiency.

[0079] In the depicted connector assembly method, the inner ferrule 3 is initially crimped onto the exposed braid 4 of the coaxial cable 2. After the process outlined in steps 5 and 6 in Figure 2b , a half-strip is removed from the longitudinal section of the cable 2, which extends from the crimped inner ferrule 3 towards the distal end of the cable 2. Then the exposed braid 4 is carefully folded back 180 degrees over the ferrule 3. This action not only enhances the mechanical stability of the assembly but also ensures consistent electrical grounding. As shown in the subsequent steps 10 to 13 in Figure 2c and 2d , the precise application of the outer contact 5 is crucial for maintaining the electrical integrity and performance of the connector 1 according to the present invention. Figure 2b After the process outlined in steps 5 and 6 in Figure 2b , a half-strip is removed from the longitudinal section of the cable 2, which extends from the crimped inner ferrule 3 towards the distal end of the cable 2. Then the exposed braid 4 is carefully folded back 180 degrees over the ferrule 3. This action not only enhances the mechanical stability of the assembly but also ensures consistent electrical grounding. As shown in the subsequent steps 10 to 13 in Figure 2c and 2d , the precise application of the outer contact 5 is crucial for maintaining the electrical integrity and performance of the connector 1 according to the present invention. Figure 2c and 2d As shown in the subsequent steps 10 to 13 in Figure 2c and 2d , the precise application of the outer contact 5 is crucial for maintaining the electrical integrity and performance of the connector 1 according to the present invention.

[0080] Figure 4 Complemented by the method shown in Figure 3a and 3b , a side view of the inner ferrule 3 is shown, where the inner ferrule 3 is crimped onto the braid 4 of the RTK031 type coaxial cable 2 using a crimping tool set to a width of 2.75 mm and achieving a crimp height (CH) of 2.90. This illustration again shows the intermediate stage detailed in step 4 of Figure 2a , where the braid 4 is exposed by stripping the outer sheath of the cable 2. Then the ferrule 3 is crimped onto this exposed braid 4, accommodating the larger diameter of the RTK031 cable 2 by correspondingly adjusting the overlap of the crimp side joints 3a, 3b. Figure 3a and 3b Complemented by the method shown in Figure 3a and 3b , a side view of the inner ferrule 3 is shown, where the inner ferrule 3 is crimped onto the braid 4 of the RTK031 type coaxial cable 2 using a crimping tool set to a width of 2.75 mm and achieving a crimp height (CH) of 2.90. This illustration again shows the intermediate stage detailed in step 4 of Figure 2a , where the braid 4 is exposed by stripping the outer sheath of the cable 2. Then the ferrule 3 is crimped onto this exposed braid 4, accommodating the larger diameter of the RTK031 cable 2 by correspondingly adjusting the overlap of the crimp side joints 3a, 3b. Figure 2a Complemented by the method shown in Figure 3a and 3b , a side view of the inner ferrule 3 is shown, where the inner ferrule 3 is crimped onto the braid 4 of the RTK031 type coaxial cable 2 using a crimping tool set to a width of 2.75 mm and achieving a crimp height (CH) of 2.90. This illustration again shows the intermediate stage detailed in step 4 of Figure 2a , where the braid 4 is exposed by stripping the outer sheath of the cable 2. Then the ferrule 3 is crimped onto this exposed braid 4, accommodating the larger diameter of the RTK031 cable 2 by correspondingly adjusting the overlap of the crimp side joints 3a, 3b.

[0081] This illustration confirms the principle of the adaptable component construction of the present invention, allowing the same ferrule 3 to be used for cables 2 of different diameters, thus streamlining the manufacturing process and reducing inventory complexity. This method exemplifies the contribution of the present invention to efficient manufacturing by limiting the diversity of required components, which is consistent with the primary goal of reducing production and logistics costs.

[0082] The crimping tool includes an adjustable mechanism specifically for setting the crimp height, which is a key feature in this assembly process. This adjustability allows the crimp height to be precisely matched to the unique dimensions of each coaxial cable 2, enabling the universal ferrule 3 to be used for multiple purposes across a range of cable sizes. This innovative method contributes to standardization in the assembly process and improves the economic and efficient production of coaxial cable connectors 1 by streamlining the use of standardized components (especially the ferrule 3) for various cable diameters.

[0083] Figure 5a 、 Figure 5b and Figure 5c present different external views (side view, top view, and bottom view) of the coaxial cable connector 1 assembled with the small-diameter RG174 coaxial cable 2. These illustrations capture the connector 1 in its final assembled state, highlighting the shrinkage areas on the outer contact 5. These diameter-reduced shrinkage portions are strategically implemented to enhance the mechanical and electrical functions of the connector 1. In Figure 5b the mechanical functional area 5a indicated in the top view provides structural stability and a firm grip, while the electrical functional area 5b also evident in the Figure 5b top view ensures the maintenance of consistent impedance and electrical continuity, which is crucial for the signal integrity of the coaxial cable 2. The improved crimping method that focuses the diameter-reducing pressure only on these critical areas allows for minimal distortion and maintains the RF signal quality of the coaxial cable 2.

[0084] Figure 5a 、 Figure 5b and Figure 5c show the coaxial cable connector 1 in its final assembled form, where the center contact 6 connected to the inner conductor 8 of the coaxial cable 2 has been incorporated into the subassembly 7. Then, the outer contact 5 of the subassembly 7 is precisely crimped onto the exposed braid 4, which has been folded back over the inner ferrule 3.

[0085] This crimping is performed using a dedicated crimping tool that has a crimping profile configured to selectively apply diameter-reducing pressure only on the predetermined functional areas 5a, 5b of the outer contact 5: the mechanical functional area 5a and the electrical functional area 5b. This crimping tool configuration ensures that the crimping process avoids excessive elongation of the outer contact 5, thereby maintaining the structural and electrical integrity of the coaxial cable connector assembly, particularly the structural and electrical integrity of the center contact 6. The correct positioning of the center contact 6 is critical because any longitudinal displacement can lead to impedance mismatch and compromise the electrical performance of the connector 1.

[0086] The construction of the outer contact 5 includes targeted shrinkage portions with reduced diameters that are used for specific purposes within the assembly of the connector 1. The mechanical functional area 5a is designed to enhance structural stability and ensure a firm grip within the crimped contact, thus contributing to the robustness of the connector 1. At the same time, the electrical functional area 5b is optimized to maintain consistent impedance and ensure uninterrupted electrical continuity, which is crucial for the signal transmission performance of the connector 1.

[0087] This strategic crimping method allows the outer contact 5 (usually associated with a coaxial cable 2 of larger diameter) to be adapted for use with a coaxial cable 2 of smaller diameter. By concentrating the crimping action on these key functional areas 5a, 5b, the connector 1 avoids applying unnecessary pressure on the intermediate material. Carefully maintaining the original state of the material between the regions contributes to the overall flexibility of the cable 2 and the preservation of signal integrity, demonstrating the refined approach of the present invention to enhance the functionality of coaxial cable connectors.

[0088] As Figure 5a shown, the outer contact 5 has a flat top surface 5c and a bottom surface 5d, enabling precise measurement of the crimp height. This construction detail ensures that the crimp is applied consistently on the connector 1, which is crucial for maintaining the mechanical and electrical integrity of the connection. The crimping process itself is finely tuned to minimize capacitance distortion, which is a key factor in maintaining the quality of RF signal transmission through the coaxial cable 2. This attention to detail underscores the commitment of the present invention to ensuring the effectiveness of the coaxial cable connector 1 in various applications where signal fidelity is critical.

[0089] As Figure 5a 、 Figure 5b and Figure 5c depicted in, the coaxial cable connector 1 embodies the inventive concept of configuring reusable and multi-purpose components, capable of docking with various cable diameters. This method streamlines the manufacturing process by reducing the need for multiple size-specific components and enhances the functional adaptability of the connector 1, facilitating its application across coaxial cable types and sizes. The strategic placement of the constrictions in the outer contact 5 visible in these Figure 5a 、 5b and 5c is central to this adaptability, allowing for effective assembly while maintaining the essential mechanical and electrical characteristics required for reliable high-frequency signal transmission.

[0090] Figure 6 shows a subassembly 7 connected to a coaxial cable 2 of large diameter (RTK031 type). The present invention facilitates the use of the same subassembly 7 for coaxial cables 2 of large diameter (RTK 031 type) and small diameter (RG 174 type), thus exemplifying the multi-purpose nature of the connector construction. Different from the dedicated constrictions employed in the small diameter cable 2 depicted in Figure 5a 、 5b and 5c, the outer contact 5 seen here in Figure 6 follows a standard crimp geometry. This method involves uniform crimping along the entire length of the outer contact 5, without the targeted diameter constriction present in the assemblies for small diameter cables 2. The standardization of the subassembly 7 across different cable diameters emphasizes the innovative aspect of the present invention, which allows for component reuse and efficient manufacturing without compromising the functionality of the connector 1.

[0091] Figure 6 Shows a conventional crimping method applied to a large - diameter coaxial cable 2 of type RTK 031. This conventional crimping technique involves applying uniform pressure over the entire length of the outer contact 5, ensuring that it firmly grips the braid 4, which is folded backward over the ferrule 3. Historically, this uniform crimping method was the standard practice for coaxial cables of all diameters, based on the belief that a consistent design of the entire contact is essential for maintaining mechanical and electrical integrity.

[0092] The present invention introduces a novel method, transitioning from the conventional uniform crimping method to a more advanced technique that utilizes local crimping in predetermined functional zones 5a, 5b. This innovation shows that a dedicated crimping design can effectively maintain the mechanical and electrical reliability of a small - diameter cable 2, similar to the results achieved for larger diameters. By employing a dedicated crimping tool that performs a targeted circular crimping process, the present invention ensures consistent and firm contact without the risk of over - expanding (over - stretching) the outer contact 5. This precise crimping method is crucial for maintaining the stability of the center contact 6 and the overall electrical integrity of the coaxial cable connector 1, thus combining the benefits of versatility with technical efficiency.

[0093] The accompanying drawings highlight the innovative aspects of the present invention, which harmonize economic efficiency with advanced technical capabilities. Figure 5a 、 5b and 5c, together with Figure 6 show that the same sub - assembly 7 can be effectively used for varying cable diameters without compromising the performance of the connector 1. As shown in Figure 5a 、 5b and 5c, the technique of the present invention that employs different constrictions for small - diameter cables 2 in the outer contact 5 maintains the mechanical and electrical integrity of the connector 1. This is in contrast to the standard uniform crimping applied to larger - diameter cables 2 as visible in Figure 6 , demonstrating the versatility of the present invention and its successful challenge to the conventional crimping method. The different constrictions with reduced diameters allow the use of consistent sub - assembly components across a range of cable sizes, streamlining the manufacturing process while ensuring reliable connector functionality.

[0094] Figure 7a and Figure 7b depict longitudinal cross - sectional views of a coaxial cable connector assembly, showing a top view ( Figure 7a ) and a side view ( Figure 7b ). These figures detail the assembly of an RG174 - type coaxial cable 2 and a connector 1 involving small diameters. The assembly is presented in its final state, where the center contact 6 is fixed within the sub - assembly 7 and the outer contact 5 of the sub - assembly 7 is crimped to the backward - folded braid 4 of the coaxial cable 2.

[0095] Figure 7a The top sectional view in [reference] shows the innovative crimp geometry of the connector 1, where different constriction parts with decreasing diameters are located in the mechanical functional area 5a and the electrical functional area 5b respectively. These areas are precisely formed by a dedicated crimping tool that selectively narrows the diameter at the point where the outer contact 5 abuts the folded-back braid 4 of the coaxial cable 2. The mechanical functional area 5a is designed to support the structural stability and grip of the connection, while the electrical functional area 5b is crucial for ensuring the operational electrical continuity and impedance matching of the coaxial cable 2.

[0096] Figure 7b A side sectional view showing the flat top surface 5c and the flat bottom surface 5d of the outer contact 5 is provided. These planar reference parts are crucial for precisely measuring the crimp height, thus contributing to a consistent crimping process across components. This design detail is testament to the engineering precision of the connector 1 and contributes to its reliable and uniform functionality.

[0097] The inner ferrule 3, which is assembled onto the braid 4 of the cable before the sub-assembly step, has adjustable overlapping side joints 3a, 3b that are configured to accommodate coaxial cables 2 of various diameters, thus demonstrating the versatility of the connector 1 for multi-purpose applications. This feature allows for seamless accommodation of cables 2 with measured diameters between 1.5 mm and 3.5 mm, exemplifying the ability of the present invention to meet a wide range of specifications while streamlining the manufacturing process by reducing the need for multiple size-specific ferrules 3.

[0098] Figure 7a and Figure 7b shows the novel construction of the coaxial cable connector 1, characterized by dedicated crimping areas (mechanical functional area 5a and electrical functional area 5b) that ensure the mechanical robustness and electrical continuity of the connection. Additionally, the versatility of the inner ferrule 3, which can be adjusted according to various cable diameters, and the flat surfaces 5c, 5d of the outer contact 5 that facilitate precise crimp height measurement represent further significant enhancements to coaxial cable connector assembly technology.

[0099] The present invention represents a significant advancement in coaxial cable connector assemblies, characterized by innovative crimping methods and component construction. This method enables the use of a unified sub-assembly 7 across a range of cable diameters, thus significantly simplifying the manufacturing process and reducing costs. The introduction of different constriction parts with decreasing diameters in the functional areas 5a, 5b ensures mechanical stability and electrical reliability without compromising signal integrity. This adaptable approach not only streamlines production but also enhances the versatility of the coaxial cable connector 1, thus meeting the evolving needs of the telecommunications, automotive, and aerospace industries.

[0100] List of reference numerals

[0101] 1 Coaxial cable connector

[0102] 2 Coaxial cable

[0103] 3 (Inner) ferrule

[0104] 3a, 3b (Overlapping) crimped side connection parts

[0105] 4 (Exposed) braid

[0106] 5 Outer contact

[0107] 5a Mechanical functional area

[0108] 5b Electrical functional area

[0109] 5c Top flat surface

[0110] 5d Bottom flat surface

[0111] 6 Center contact

[0112] 7 Sub-assembly

[0113] 8 Inner conductor

Claims

1. A method for assembling a coaxial cable connector (1), the method comprising the following steps: a. Provide a coaxial cable (2); b. crimping the inner ferrule (3) onto the exposed braid (4) of the coaxial cable (2); c. folding the exposed braid (4) of the coaxial cable (2) back onto the inner ferrule (3); and d. crimping an external contact (5) onto the exposed braid (4) folded back, wherein the external contact (5) has different constrictions with reduced diameter in predetermined functional areas (5a, 5b) to reduce the elongation of the external contact (5) and the compression of the cable (2).

2. The method according to claim 1, wherein: The functional areas (5a, 5b) include at least one mechanical functional area (5a) and at least one electrical functional area (5b), wherein the at least one mechanical functional area (5a) is mainly constructed to provide structural stability and grip within the crimped external contact (5), and the at least one electrical functional area (5b) is mainly constructed to ensure consistent impedance and electrical continuity.

3. The method according to claim 1 or 2, wherein: The inner ferrule (3) has overlapping crimping side portions (3a, 3b), which are configured to accommodate different cable sizes, and the overlapping crimping side portions (3a, 3b) of the inner ferrule (3) are crimped using crimping tools with different crimping widths, each crimping width is selected based on a specific cable size, and these crimping tools also have adjustable crimping height settings to ensure the increased overlapping overlapping side portions (3a, 3b) required for smaller diameter cables (2).

4. The method according to any one of claims 1 to 3, further comprising the following steps: e. Using the top flat surface (5c) and the bottom flat surface (5d) of the outer contact (5) as reference points to measure the crimp height of the outer contact (5) to ensure consistent crimping throughout the process of assembling the coaxial cable connector (1).

5. The method according to any one of claims 1 to 4, wherein: The coaxial cable (2) is of RG174 type.

6. The method according to any one of claims 1 to 5, wherein: Crimping of the outer contact (5) is performed to minimize capacitive distortion, thereby maintaining the RF signal integrity of the coaxial cable (2).

7. A coaxial cable connector (1), the coaxial cable connector (1) being assembled according to the method according to any one of claims 1 to 6.

8. The coaxial cable connector (1) according to claim 7, wherein: The connector (1) is configured for automotive data connection applications.

9. The coaxial cable connector (1) according to claim 7 or 8, wherein: At least one of the inner ferrule (3) and the outer contact (5) is configured to be reusable and adaptable to accommodate coaxial cables (2) of different diameters.

10. A crimping tool for assembling a coaxial cable connector (1), the crimping tool comprising at least one of the following: a. An interchangeable die set corresponding to a specified cable diameter and an adjustable mechanism for setting the crimp height, the interchangeable die set being configured for use with a universal inner ferrule (3) provided with overlapping crimp side contacts (3a, 3b) to allow accommodation of a range of cable diameters; and b. Crimp profile, characterized by A constriction is positioned to selectively apply pressure to predetermined functional areas (5a, 5b) of an external contact (5), wherein the constriction is configured to prevent the external contact (5) from over-stretching during crimping.

11. The crimping tool according to claim 10, wherein: The crimp height is adjustable to optimize the overlap and secure crimping of the overlapping crimp side portions (3a, 3b) of the inner ferrule (3) for the range of cable diameters, thereby ensuring consistent mechanical and electrical performance across the range of cable diameters.

12. The crimping tool according to claim 10 or 11, wherein: The constriction is differently defined for the mechanical functional area (5a) and the electrical functional area (5b) of the external contact (5).

13. The crimping tool according to any one of claims 10 to 12, wherein: The crimp profile is specifically tailored to prevent over-compression of the coaxial cable (2), thereby maintaining RF signal integrity.

14. The crimping tool according to any one of claims 10 to 13, further comprising a measuring instrument for determining the crimping height on the external contact (5), the measuring instrument being configured to perform precise measurements using a top flat surface reference portion and a bottom flat surface reference portion of the external contact (5).

15. A coaxial cable connector (1), comprising at least one of the following: a. an inner ferrule (3) crimped onto the exposed braid (4) of the coaxial cable (2), the ferrule (3) comprising overlapping side portions (3a, 3b) adjustable to accommodate coaxial cables (2) of different diameters; and b. An outer contact (5) crimped onto an exposed braid (4) of a coaxial cable (4), the exposed braid (4) being folded back onto an inner ferrule (3), the inner ferrule (3) in turn being crimped onto the exposed braid (4) of the coaxial cable (2), the outer contact (5) having different constrictions with reduced diameters in predetermined functional areas (5a, 5b), the constrictions being configured to minimize the elongation of the outer contact (5) during crimping, thereby maintaining the positional integrity of the center contact (6) within the connector (1).

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