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

Abstract

To provide a method for assembling a coaxial cable connector, a crimping tool for assembling a coaxial cable connector, and a coaxial cable connector, which reduce the need for multiple terminal components, streamline an assembly process, and ensure reliable mechanical and electrical connections for diverse applications.SOLUTION: The method includes: crimping an inner ferrule (3) onto an exposed braid (4) of a coaxial cable (2); folding back the exposed braid (4) of the coaxial cable (2) over the inner ferrule (3); and crimping an outer contact (5) onto the folded-back exposed braid (4), where the outer contact (5) has multiple distinct constrictions of reduced diameter in predetermined functional zones (5a, 5b) to reduce elongation of the outer contact (5) and compression of the cable (2).SELECTED DRAWING: Figure 7a

Description

Technical Field

[0001] The present invention relates to the field of coaxial cable connector assembly and places particular emphasis on improving the assembly process for small-diameter coaxial cables. This relates to innovative methods, connectors, and associated crimping tools, which are configured to improve the performance, reliability, and reusability of these connectors in various applications.

Background Art

[0002] Coaxial cables are well known for their ability to transmit high-frequency signals with minimal loss and reduced electromagnetic interference, and are thus essential in a variety of industries including telecommunications, automotive, aerospace, and consumer electronics. The effectiveness and functionality of coaxial cables in these applications depend extremely heavily on the quality, integrity, and especially the compatibility of their connectors, particularly considering the need for compatibility between various cable sizes and the challenges in maintaining signal quality during connector assembly.

[0003] In conventional coaxial cable connector assembly, the process typically involves crimping a ferrule onto the cable's shield braid, followed by attaching an external contact to establish a stable and conductive connection. However, while this crimping process is effective for its intended purpose, its scope and compatibility have thus far been limited. Due to the need for a unique crimp barrel design for each different cable size, a wide variety of connector parts and dedicated crimping tools, each adapted to a specific cable diameter, have emerged. This level of specialization, while necessary to ensure proper connections, results in significant manufacturing costs, which are further exacerbated by the inventory management and logistics complexities arising from the diversity of required parts.

[0004] In addition, when components originally designed for larger cable diameters are used with smaller cables, conventional crimping methods often result in excess material and excessive elongation of the crimp area during the crimping process due to the extra material intended for the larger diameter. This elongation can sometimes negatively affect the positional stability of the central contact in the connector assembly. As a result, such misalignment can sometimes have a detrimental effect on the electrical performance of the coaxial cable, particularly manifesting as impedance mismatches and signal quality degradation. These issues are important in applications where maintaining consistent electrical characteristics is of utmost importance for the functionality of the coaxial cable system.

[0005] One of the main limitations of the current technology in coaxial cable connector assembly is the lack of reusability and compatibility in the crimp barrel design. The conventional approach of specially adjusting the crimp barrel to a specific cable diameter restricts their use to a limited range of cable sizes. This lack of versatility not only leads to greater environmental impact due to the need to manufacture a large number of single-size-specific parts, but also results in increased costs associated with the production and inventory management of cable connectors.

[0006] As a result, the industry has constantly faced the challenge of developing a crimping methodology that can accommodate a wide range of cable sizes, including smaller diameter cables, without compromising the essential integrity of the electrical connection. This balanced approach is extremely important to ensure consistent and reliable signal transmission in coaxial cables. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] In view of the above, an object of the present invention is to provide an efficient method for assembling a coaxial cable connector that enables the reuse of components between cable sizes, optimizes crimping with a general-purpose crimping tool, and ensures high-performance coaxial cable connectors. MEANS FOR SOLVING THE PROBLEMS

[0008] The above object is achieved according to the invention by providing a method for assembling a coaxial cable connector as claimed in independent claim 1, a crimping tool for this assembly as claimed in independent claim 10, and the coaxial cable connector itself as claimed in independent claim 15. Further advantageous developments of the invention are described in the dependent claims.

[0009] Specifically, a method for assembling a coaxial cable connector according to the invention comprises a. providing a coaxial cable; b. crimping an inner ferrule onto the exposed braid of the coaxial cable; c. folding back the exposed braid of the coaxial cable so as to cover the inner ferrule; d. crimping an outer contact onto the folded-back exposed braid, the outer contact having a plurality of separate constrictions of reduced diameter in a predetermined functional area in order to reduce the elongation of the outer contact and the compression of the cable, the crimping step; and includes.

[0010] The invention introduces an ordered approach to the assembly of a coaxial cable connector incorporating an important feature of an outer contact having special constrictions. This feature collectively improves the functionality, usability, and compatibility of the connector for different cable sizes while ensuring the integrity of the electrical connection and signal transmission.

[0011] The process starts with the provision of a suitable coaxial cable, which is a very important first step in the coaxial cable connector assembly process, especially considering the emphasis on accommodating various cable sizes. This involves selecting a suitable cable type and ensuring that it meets the specific requirements of the intended application, such as diameter, signal frequency, and environmental resistance.

[0012] Subsequent crimping of the inner ferrule to the exposed braid of the cable is an important operation. This step requires accurate alignment and attachment of the ferrule to the braid, which is the basis of the cable's shielding effect.

[0013] This crimping ensures a stable mechanical and electrical connection between the cable and the ferrule. Proper crimping is essential for maintaining the signal quality of the cable as it preserves the continuity of the shield and minimizes electromagnetic interference.

[0014] Next, the exposed braid of the cable is folded back to cover the inner ferrule. This operation strengthens the joint and prepares the assembly for the next important step.

[0015] Crimping of the external contact to the folded-back exposed braid is an important innovation of the present invention compared to conventional methods. The external contact is configured to have a plurality of distinct constrictions in a predetermined functional area.

[0016] This feature significantly reduces the risk of cable elongation and over-compression during crimping. The constrictions in the external contact are configured to ensure that the crimping pressure is applied accurately and effectively.

[0017] This accurate application of pressure maintains the integrity of the mechanical and electrical connection, which is important for the performance of the coaxial cable.

[0018] The reduced-diameter constrictions in specific areas mitigate the issues of material surplus and elongation that occur when reusing crimp barrels intended for larger cable diameters in conventional crimping techniques. These constrictions are strategically placed and shaped to minimize unnecessary material deformation during the crimping process.

[0019] By focusing on these functional areas, the method ensures stable crimping without deforming the cable or applying excessive force that could impair its electrical performance. This precise crimping approach is important for the integrity of the connection.

[0020] This feature is particularly beneficial in maintaining the characteristic impedance of coaxial cables, which is essential for high-frequency signal transmission. The controlled crimping process helps maintain the structural and electrical properties of the cable, ensuring optimal signal quality.

[0021] Overall, the process presents a sophisticated approach to coaxial cable connector assembly, ensuring higher reliability, consistency, and compatibility across a range of cable sizes. This meets the industry's requirements for a versatile and efficient manufacturing process, addresses important issues in connector assembly, and provides a practical and innovative solution.

[0022] More specifically, the crimping tool for assembling a coaxial cable connector according to the present invention comprises a. An adjustable mechanism for setting the crimping height, accompanied by a replaceable die set corresponding to a specified cable diameter, configured for use with a common inner ferrule provided with overlapping crimping flanks to enable adaptation to a range of cable diameters; b. A crimping profile characterized by a constriction arranged to selectively apply pressure to a predetermined functional area of the external contact, the constriction being configured to prevent excessive elongation of the external contact during crimping; at least one of the above.

[0023] The crimping tool features an adjustable mechanism for setting the crimping height, which enables precise customization to specific dimensions of coaxial cables, thereby overcoming significant constraints associated with conventional crimping tools. While specific cable diameters may require the use of different crimping tools, the components, particularly the inner ferrule, maintain commonality for use across a range of cable diameters.

[0024] The die set is specially configured to have an adjustable crimping height mechanism to enable precise fitting between overlapping flanks of the ferrule for optimal fitting, particularly in the case of smaller diameter cables. This component provides a versatile crimping process that can be precisely adjusted to conform to the exact requirements of various cable diameters.

[0025] Different crimping tools, each having a dedicated die set, are essential for efficiently accommodating coaxial cables of various sizes, thereby ensuring that reusable inner ferrules can be effectively utilized across a range of cable dimensions. This flexibility is particularly beneficial in various applications where cable diameters can vary, enabling a wider range of applications.

[0026] By reusing the same connector components across different cable diameters, harness manufacturers can significantly reduce material stock, despite the need for separate crimping tools for each cable size. This not only minimizes manufacturing costs but also streamlines the assembly process, resulting in higher efficiency and reduced complexity of manufacturing equipment.

[0027] The crimping tool has a special crimping profile with constrictions that selectively apply pressure to a predetermined functional area of the external contact. These constrictions are meticulously configured to prevent excessive elongation of the external contact during the crimping process.

[0028] This aspect of the external contact configuration directly addresses and mitigates the issues of material surplus and attendant elongation problems common to conventional crimp geometries. By effectively controlling elongation, the tool plays an important role in maintaining the positional integrity of the central contact, thereby ensuring the electrical performance of the coaxial cable, particularly with regard to maintaining consistent impedance and optimal signal quality.

[0029] Overall, the present invention represents a significant advancement in the field of coaxial cable connector assemblies. It 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, introducing a versatile and efficient solution that also facilitates the use of a more sustainable approach.

[0030] This compatibility, combined with the ability to maintain the integrity of the electrical connection, makes the present invention particularly useful in industries such as telecommunications, automotive, and aerospace, where the widespread use of coaxial cables requires both reliability and versatility.

[0031] Finally, in detail, the coaxial cable connector according to the present invention comprises a. an internal ferrule crimped to the exposed braid of the coaxial cable, the ferrule including adjustable overlapping flanks for accommodating coaxial cables of various diameters; b. an external contact crimped to the exposed braid of the coaxial cable, folded back to cover the internal ferrule crimped to the exposed braid of the coaxial cable, the external contact having a plurality of discrete constrictions of reduced diameter in a predetermined functional area, the constrictions being configured to minimize elongation of the external contact during crimping, thereby maintaining the positional integrity of the central contact within the connector; and at least one of the foregoing.

[0032] The described coaxial cable connector incorporates innovative features that substantially improve its compatibility and performance. The key elements of the present invention, which are effective either in combination or as individual improvements, include the following.

[0033] The adjustable inner ferrule has overlapping flanks that enable it to fit coaxial cables of various diameters. This compatibility is essential for creating a versatile connector that is compatible with a range of cable sizes. By reducing the need for multiple size-specific ferrules, this feature streamlines the manufacturing process and eases inventory requirements.

[0034] The external contacts, which are fixed to the inner ferrule and the folded-back exposed braid of the cable, have multiple distinct constrictions in specific functional areas. These constrictions, characterized by their reduced diameter, are strategically placed to limit the elongation of the external contacts during the crimping process. This control of elongation is important for maintaining the positional integrity of the central contact within the connector. Also, since any misalignment of the central contact can result in impedance mismatch and degrade signal quality, maintaining this positional integrity is important for ensuring optimal electrical performance of the connector.

[0035] The advantages of the present invention are significant and diverse. The compatibility of the inner ferrule to coaxial cables of various diameters greatly extends the usefulness of the connector in a variety of applications, including telecommunications and automotive systems. The external contacts are precisely configured to maintain the electrical and mechanical characteristics of the connector throughout the assembly process, thereby ensuring high reliability and consistent performance. Furthermore, this configuration significantly contributes to reducing material waste and improving the overall efficiency of the connector assembly process.

[0036] In summary, the present invention represents a notable advancement in coaxial cable connector technology that effectively addresses the general challenges in the industry regarding versatility, reliability, and performance.

[0037] Further features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which show:

Brief Description of the Drawings

[0038]

Figure 1

Figure 2a

Figure 2b

Figure 2c

Figure 2d

Figure 3a

Figure 3b

Figure 4

Figure 5a

Figure 5b

Figure 5c

Figure 6

Figure 7a

Figure 7b

[0039] In the following detailed description section, as shown in the accompanying drawings, preferred embodiments of the coaxial cable connector 1 and the assembly method are considered. This section comprehensively outlines the innovative approach of the present invention and details the adaptable and efficient features that distinguish it from the prior art. The illustrated embodiments serve to demonstrate the practical application of these novel features and the significant advantages they provide.

[0040] FIG. 1 presents two configurations of the coaxial cable connector assembly at the top labeled "a.". On the left side, the assembly is connected to a large-diameter coaxial cable 2 of type RTK031, and on the right side, it is combined 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 central feature of the configuration of the present invention. The cross-sectional views present how the internal components of the connector 1 fit neatly to coaxial cables 2 of various diameters, representing an innovative configuration that forms the core of the methodology for assembling the connector 1.

[0041] Each connector configuration incorporates a central contact 6 that is visualized at the lower part marked with the label "d.". These central contacts 6 are configured to form an electrical junction with the inner conductor 8 of the coaxial cable 2. These central contacts 6 are distinguished by their diameters to match the internal specifications of the RTK031 and RG174 cables 2, thereby facilitating compatibility with these two distinct cable types.

[0042] In the central part of FIG. 1 labeled "b.", the subassembly 7 is shown in its original uncrimped state. This subassembly 7 incorporates external contacts 5 that are configured to be mechanically and electrically fixed to the braid 4 of the cable 2. The commonization of the subassembly 7 for use with various cable diameters represents an important innovation, substantially reducing the need for an extensive range of parts specially designed for different cable sizes. This consistent design approach for the subassembly 7 applicable to various connector types represents a quantum leap in the commonization of connector components, indicating a departure from conventional manufacturing methods.

[0043] In addition, in the central part of FIG. 1 labeled "c.", the inner ferrule 3 is shown in its initial uncrimped state. The inner ferrule 3, which is disposed between the external contact 5 on the outside and the folded braid 4, and the unfolded braid 4 and the dielectric layer of the cable 2 on the inside, plays a crucial role in ensuring a stable and consistent assembly process. The inner ferrule 3 is configured to be compatible with both large-diameter and small-diameter cables 2, reflecting the object of the present invention to rationalize the assembly process of the connector 1. This approach further improves manufacturing efficiency by further reducing the variety of components required.

[0044] As a result, the coaxial cable connector 1 significantly reduces production and logistics costs by limiting variability in the central contact 6, which is the only component configured for a specific cable diameter. The originality of this design supports the potential of the present invention to rationalize and economize the production of the coaxial cable connector 1, highlighting the practical and cost-effective advantages of this technological advancement.

[0045] Figures 2a to 2d schematically outline, in order, a series of numbered steps 1 to 14 necessary for attaching the coaxial cable connector 1 to the end of the coaxial cable 2. These steps are as follows.

[0046] In step 1 (Figure 2a), the coaxial cable 2 is cut to the precisely specified length. That is, it is an essential first step to establish a consistent starting point for the connector assembly process.

[0047] In step 2 (Figure 2a), an exact primary cutting operation is performed to remove a portion of the outer jacket including the lower braid 4 and the foil from one end of the cable 2. This operation exposes the essential layers necessary for attaching the connector to that end.

[0048] Step 3 (Figure 2a) involves a secondary cutting (stripping) operation at the same end of the coaxial cable 2 and is carefully configured to remove a portion of the outer jacket while leaving the insulator intact at the very end of the cable 2 to prevent the braid 4 from fraying or loosening, and to expose a specific longitudinal portion of the braid 4. This operation is essential for the subsequent attachment of the inner ferrule 3 of the coaxial cable connector 1, which is to be attached to this end of the cable 2.

[0049] In step 4 of FIG. 2a, the assembly process of the coaxial cable connector 1 to the coaxial cable 2 is started by carefully crimping the inner ferrule 3 labeled with the label "c." in FIG. 1 to the exposed braid 4 of the coaxial cable 2. After crimping, a quality inspection is performed to verify the stable attachment and structural integrity of the ferrule 3.

[0050] Step 5 of the cable processing procedure (FIG. 2b) removes all remaining semi-strips at the cable end 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 of the cable is completely exposed.

[0051] After removing the semi-strip in step 5, as shown in step 6 of FIG. 2b, the exposed braid 4 at the end of the cable 2 is carefully folded back 180 degrees to cover the crimped inner ferrule 3. This operation is important for increasing the mechanical stability of the assembly and optimizing the electrical grounding.

[0052] After folding back the exposed braid 4 in step 6, step 7 (FIG. 2b) involves accurately cutting the inner foil from the cable end at the location where the braid 4 is folded back. This procedure ensures that the additional shield layer has the appropriate shape to complement the assembly.

[0053] In step 8 (FIG. 2b), the dielectric insulator is carefully cut off from the end of the cable 2 to expose the inner conductor 8. Great care is taken to ensure that no remnants of the foil remain that could degrade the signal quality.

[0054] Step 9 (FIG. 2c) crimps the central contact 6 labeled with the label "d." in the lower part of FIG. 1 to the now-exposed inner conductor 8 of the coaxial cable 2. This important step establishes the electrical path necessary for signal transmission.

[0055] In step 10 of FIG. 2c, the end of the coaxial cable 2, which now has the newly crimped central contact 6, is inserted into the subassembly 7 having the outer contact 5 and labeled "b." in the central part of FIG. 1. This process positions each component for final assembly.

[0056] Step 11 (FIG. 2c) involves verifying the exact longitudinal position of the central contact 6 by a tactile inspection. This ensures that the central contact 6 is correctly aligned within the connector 1 for optimal electrical connectivity.

[0057] Thereafter, the outer contact 5 of the subassembly 7 is crimped to the folded-back exposed braid 4 that overlaps the inner ferrule 3. This step 12 in FIG. 2d strengthens the mechanical connection and forms a consistent electrical shield surrounding the cable 2.

[0058] In step 13 of FIG. 2d, an electrical test is performed to confirm the proper assembly of the connector 1 while paying particular attention to the length and exact placement of the central contact 6 to ensure a highly reliable electrical connection.

[0059] Following the electrical test, step 14 (FIG. 2d) involves labeling or marking the cable 2 to provide identification and facilitate traceability. This is an essential technique for maintaining quality control and simplifying future maintenance or repair operations.

[0060] The final step 15 (not shown) prepares the fully assembled coaxial cable connector 1 for installation into its designated housing, which may include telecommunications equipment, automotive systems (especially for automotive data connection applications), space instruments, or other advanced applications.

[0061] By using the assembly process outlined in FIGS. 2a - 2d, it becomes easier to create a highly reliable and durable coaxial cable connector assembly that is specially configured to maintain signal quality in high - frequency applications, reflecting the innovation focus on accuracy and versatility in connector manufacturing. This assembly process adheres to strict accuracy standards and minimizes reliance on a wide range of dedicated tools and components. This improved efficiency is particularly advantageous in high - volume manufacturing situations where consistency, reliability, and cost - effectiveness are important factors.

[0062] FIGS. 3a and 3b show the crimping of an inner ferrule 3 onto the exposed braid 4 of a small - diameter RG174 - type coaxial cable 2 using a crimping tool set at a width of 2.25 mm to achieve a crimp height (CH) of 2.50. This particular ferrule 3 is the same as that used for a larger - diameter RTK031 - type coaxial cable 2 (see FIG. 4), presenting the possibility of the present invention to adapt to various cable sizes while reducing the number of separate components required.

[0063] The ferrule 3 features uniquely designed overlapping flanges 3a, 3b that are clearly visible in the side view of FIG. 3b, allowing for an adjustable fit that can be adjusted to the smaller diameter of the RG174 cable 2. This adaptability is achieved by increasing the overlap of the flanges 3a, 3b to fit the inner diameter of the cable 2, thereby ensuring stable and consistent crimping. The implementation of such overlapping flanges 3a, 3b is an important aspect of the present invention, facilitating the reuse of components and rationalizing the manufacturing process between different cable sizes. Thus, FIGS. 3a and 3b emphasize the approach of the present invention to maintain connection integrity while optimizing logistics efficiency through component commonality.

[0064] As preparation for the application of the outer contact 5, the inner ferrule 3 is evenly crimped along the length of the braid 4 exposed by the second cut outlined in the cable preparation step, specifically step 3 of FIG. 2a. This consistent crimping technique shown in FIGS. 3a and 3b is essential to the inventive approach of component commonalization, thereby facilitating the rationalization of the assembly process and reducing manufacturing and logistics complexity. This methodological crimping innovation ensures the interchangeability of the same ferrule between different cable diameters, which not only simplifies the manufacturing workflow but also contributes to overall cost efficiency.

[0065] In the illustrated connector assembly method, the inner ferrule 3 is first crimped to the exposed braid 4 of the coaxial cable 2. In accordance with the process outlined in steps 5 and 6 of FIG. 2b, the semi-stripping is removed from the longitudinal portion of the cable 2 extending from the crimped inner ferrule 3 towards the distal end of the cable 2. The exposed braid 4 is then carefully folded back 180 degrees to cover the ferrule 3. This operation not only improves the mechanical stability of the assembly but also ensures consistent electrical grounding. The exact application of the outer contact 5, as specified in subsequent steps 10 - 13 of FIGS. 2c and 2d, is important for maintaining the electrical integrity and performance of the connector 1 according to the present invention.

[0066] FIG. 4, which complements the approach shown in FIGS. 3a and 3b, presents a side view of the inner ferrule 3 crimped to 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 step detailed in step 4 of FIG. 2a where the braid 4 is exposed by stripping the outer jacket of the cable 2. The ferrule 3 is then crimped to this exposed braid 4 and adjusted for the larger diameter of the RTK031 cable 2 by appropriately adjusting the overlap of the crimp flanks 3a, 3b.

[0067] This illustration demonstrates the principle of the invention of a configurable component configuration that enables the same ferrule 3 to be used with cables 2 of different diameters, thereby streamlining the manufacturing process and reducing inventory complexity. This approach exemplifies the contribution of the invention to efficient manufacturing by limiting the variety of components required, which is consistent with the overriding objective of reducing production and logistics costs.

[0068] The crimping tool is a central feature in this assembly process and incorporates an adjustable mechanism, particularly for setting the crimping height. This adjustability enables the precise adaptation of the crimping height to the specific dimensions of each coaxial cable 2, thereby allowing for the universal use of a common ferrule 3 across a wide range of cable sizes. This innovative approach promotes standardization in the assembly process by rationalizing the use of standardized components, particularly the ferrule 3, at various cable diameters, improving the economic and efficient production of coaxial cable connectors 1.

[0069] Figures 5a, 5b, and 5c present different external views of the side, top, and bottom of a coaxial cable connector 1 assembled with a small-diameter RG174 coaxial cable 2. These illustrations capture the connector 1 in its final assembled state and highlight the constricted areas in the external contacts 5. These constrictions with reduced diameters are strategically implemented to improve both the mechanical and electrical functionality of the connector 1. The mechanical function area 5a shown in the top view of Figure 5b provides structural stability and secure grip, while the electrical function area 5b, also evident in the top view of Figure 5b, ensures the maintenance of consistent impedance and electrical continuity, which is crucial for the signal quality of the coaxial cable 2. The refined crimping approach that focuses the pressure to reduce the diameter only in these critical areas allows for minimal distortion and preserves the RF signal quality of the coaxial cable 2.

[0070] Figures 5a, 5b, and 5c show the coaxial cable connector 1 in its final assembled form, with the central contact 6 connected to the inner conductor 8 of the coaxial cable 2 incorporated into the sub-assembly 7. The outer contact 5 of the sub-assembly 7 is then precisely crimped onto the exposed braid 4 folded back to cover the inner ferrule 3.

[0071] This crimping is performed using a dedicated crimping tool having a crimping profile configured to exert pressure selectively reducing the diameter only in predetermined functional regions 5a, 5b of the outer contact 5, namely the mechanical functional region 5a and the electrical functional region 5b. The configuration of this crimping tool 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 central contact 6. Since any longitudinal displacement can cause impedance mismatch and impair the electrical performance of the connector 1, the proper placement of the central contact 6 is extremely important.

[0072] The configuration of the outer contact 5 incorporates a reduced-diameter targeted constriction that serves a specific purpose within the assembly of the connector 1. The mechanical functional region 5a is designed to improve structural stability and ensure secure gripping within the crimped contact, contributing to the robustness of the connector 1. At the same time, the electrical functional region 5b is optimized to maintain a consistent impedance and ensure continuous electrical connectivity, which is important for the signal transmission performance of the connector 1.

[0073] This strategic crimping methodology enables the adaptation of the outer contact 5, normally combined with a larger-diameter coaxial cable 2, for use with a smaller-diameter coaxial cable 2. By concentrating the crimping action on these extremely important functional regions 5a, 5b, the connector 1 avoids exerting unnecessary pressure on the intervening material. This careful preservation of the original state of the material between regions contributes to maintaining the overall flexibility and signal quality of the cable 2, presenting the delicate approach of the present invention to improving the functionality of coaxial cable connectors.

[0074] As observed in Figure 5a, the external contact 5 features an upper flat surface 5c and a bottom flat surface 5d that enable accurate measurement of the crimp height. The details of this configuration ensure that the crimp is applied consistently across the connector 1, which is important for maintaining the mechanical and electrical integrity of the connection. The crimping process itself is precisely adjusted to minimize capacitive distortion, an important factor in maintaining the quality of RF signal transmission through the coaxial cable 2. Attention to such details emphasizes the invention's approach to ensuring the effectiveness of the coaxial cable connector 1 in various applications where signal fidelity is of utmost importance.

[0075] As shown in Figures 5a, 5b, and 5c, the coaxial cable connector 1 embodies the inventive concept of being a reusable and versatile component that can be adapted to various cable diameters. This approach streamlines the manufacturing process by reducing the need for multiple size-specific components and improves the functional compatibility of the connector 1, facilitating its application across a range of coaxial cable types and sizes. The strategic placement of the constrictions in the external contact 5, visible in these Figures 5a, 5b, and 5c, forms the center of this compatibility and enables efficient assembly while maintaining the essential mechanical and electrical properties required for reliable high-frequency signal transmission.

[0076] Figure 6 shows a sub - assembly 7 connected to a large - diameter (RTK031 type) coaxial cable 2. The present invention illustrates the versatility of the connector configuration by facilitating the use of the same sub - assembly 7 for both large - diameter (RTK031 type) and small - diameter (RG174 type) cables 2. Unlike the special constrictions used in the small - diameter cable 2 shown in FIGS. 5a, 5b, and 5c, the external contacts 5 seen here in FIG. 6 conform to a standard crimp geometry. This approach involves uniform crimping over the entire length of the external contact 5 without the targeted diameter constrictions present in the assembly of the small - diameter cable 2. The commonality of the sub - assembly 7 between different cable diameters emphasizes the innovative aspect of the present invention that enables the reuse of components and efficient manufacturing without compromising the functionality of the connector 1.

[0077] Figure 6 shows a conventional crimping method applied to a large - diameter coaxial cable 2 of type RTK031. The conventional crimping technique involves applying uniform pressure over the entire length of the external contact 5, thereby ensuring that the external contact 5 stably grips the braid 4 folded back to cover the ferrule 3. So far, such a uniform crimping approach has been the standard method for coaxial cables of all diameters, assuming that a consistent design throughout the contact is essential for maintaining mechanical and electrical integrity.

[0078] The present invention introduces a novel approach that departs from conventional uniform crimping methods to a more advanced technique that utilizes local crimping in predetermined functional regions 5a, 5b. This innovation demonstrates a special crimping design that can effectively maintain the mechanical and electrical reliability for small-diameter cables 2, similar to the results achieved with larger diameters. By using a dedicated crimping tool that executes a focused circular crimping process, the present invention ensures consistent and stable contact without the risk of over-expanding (over-stretching) the external contact 5. This precise crimping method is crucial for maintaining the stability (positional integrity) of the central contact 6 and the overall electrical integrity of the coaxial cable connector 1, thus combining the advantage of versatility with technical efficiency.

[0079] Each of the figures presented emphasizes the innovative aspects of the present invention that reconcile economic efficiency with advanced technical possibilities. Figures 5a, 5b, and 5c, together with Figure 6, show that the same sub-assembly 7 can be effectively utilized for various cable diameters without compromising the performance of the connector 1. The technique of the present invention, which uses multiple distinct constrictions in the external contact 5 as shown in Figures 5a, 5b, and 5c for small-diameter cables 2, 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 seen in Figure 6, demonstrating the versatility of the present invention and the solution to the problems with its conventional crimping methods. The multiple distinct constrictions of reduced diameter enable the use of consistent sub-assembly components across a range of cable sizes, rationalizing the manufacturing process while ensuring the functionality of a highly reliable connector.

[0080] Figures 7a and 7b show longitudinal cross-sectional views of a coaxial cable connector assembly, presenting viewpoints of both the top surface (Figure 7a) and the side surface (Figure 7b). These figures show in detail an assembly with a small-diameter RG174 type coaxial cable 2 and a connector 1. The assembly is presented in its final state where the central contact 6 is fixed within the sub-assembly 7 and the outer contact 5 of the sub-assembly 7 is crimped to the folded braid 4 of the coaxial cable 2.

[0081] The top cross-sectional view in Figure 7a emphasizes the innovative crimp geometry of the connector 1 where a plurality of separate constrictions of reduced diameter are localized in the mechanical functional region 5a and the electrical functional region 5b respectively. These regions are precisely formed by a dedicated crimping tool that selectively reduces the diameter at the location where the outer contact 5 interacts with the folded braid 4 of the coaxial cable 2. The mechanical functional region 5a is designed to support the structural stability and grip of the connection, while the electrical functional region 5b is extremely important for ensuring the electrical continuity and impedance matching of the operation of the coaxial cable 2.

[0082] Figure 7b provides a side cross-sectional view presenting the flat top surface 5c and bottom surface 5d of the outer contact 5. These planar references are extremely important for accurately measuring the crimp height, thereby facilitating a consistent crimping process across the assembly. This design detail is evidence of the intended accuracy of the connector 1 that contributes to the high reliability and uniform functionality of the connector 1.

[0083] The internal ferrule 3 that is fitted onto the braid 4 of the cable before the sub-assembly step is characterized by adjustable overlapping flanges 3a, 3b configured to accommodate coaxial cables 2 of various diameters, demonstrating the ability of the connector 1 for general-purpose applications. This feature enables seamless accommodation of cables 2 with dimensions between 1.5 mm and 3.5 mm in diameter, rationalizing the manufacturing process by reducing the need for multiple size-specific ferrules 3 and exemplifying the ability of the present invention to meet diverse specifications.

[0084] Figures 7a and 7b present a novel configuration of the coaxial cable connector 1, which features special crimping regions (mechanical function region 5a and electrical function region 5b) that ensure both mechanical robustness and electrical continuity of the connection. Additionally, the versatility of the internal ferrule 3, which can be adjusted to various cable diameters, presents a further significant improvement in the technology of coaxial cable connector assembly, together with the flat surfaces 5c, 5d of the external contact 5 that facilitate the measurement of the exact crimping height.

[0085] The present invention shows a significant advancement in coaxial cable connector assembly, characterized by an innovative crimping methodology and component configuration. This approach enables the use of a uniform sub-assembly 7 across a range of cable diameters, thereby significantly simplifying the manufacturing process and reducing costs. The introduction of a plurality of distinct constrictions with reduced diameters in the functional regions 5a, 5b ensures mechanical stability and electrical reliability without compromising signal quality. This adaptable methodology not only rationalizes production but also improves the versatility of the coaxial cable connector 1, meeting the evolving requirements of the telecommunications, automotive, and aerospace industries.

Explanation of Reference Numerals

[0086] 1 Coaxial cable connector 2 Coaxial cable 3 (Internal) ferrule 3a, 3b (Overlapping) crimping flanges 4 (Exposed) braid 5 External contact 5a Mechanical function region 5b Electrical function region 5c Upper flat surface 5d Bottom flat surface 6 Central contact 7 Sub-assembly 8 Internal conductor

Claims

1. A method for assembling a coaxial cable connector (1), the method comprising: a. providing a coaxial cable (2); b. crimping an inner ferrule (3) onto the exposed braid (4) of the coaxial cable (2); c. Folding the exposed braid (4) of the coaxial cable (2) over the inner ferrule (3); d. crimping an outer contact (5) onto the folded exposed braid (4), the outer contact (5) having a plurality of discrete constrictions of reduced diameter in predetermined functional areas (5a, 5b) to reduce elongation of the outer contact (5) and compression of the coaxial cable (2); A coaxial cable connector assembly method comprising:

2. 2. The coaxial cable connector assembly method of claim 1, wherein the functional areas (5a, 5b) comprise at least one mechanical functional area (5a) primarily configured to provide structural stability and grip within the crimped outer contact (5) and at least one electrical functional area (5b) primarily configured to ensure consistent impedance and electrical continuity.

3. 3. The method of assembling a coaxial cable connector according to claim 1 or 2, wherein the inner ferrule (3) has overlapping crimp flanks (3 a, 3 b) configured to accommodate different cable sizes, the overlapping crimp flanks (3 a, 3 b) of the inner ferrule (3) being crimped using a crimping tool having various crimp widths each selected based on a particular cable size, the crimping tool also having an adjustable crimp height setting to ensure increased overlap of the overlapping flanks (3 a, 3 b) required for smaller diameter cables (2).

4. e. measuring the crimp height of the outer contacts (5) using the top (5c) and bottom (5d) flat surfaces of the outer contacts (5) as reference points to ensure consistent crimping throughout the method of assembling the coaxial cable connector (1); 4. The coaxial cable connector assembly method of claim 1, further comprising:

5. A method for assembling a coaxial cable connector according to any one of claims 1 to 4, wherein the coaxial cable (2) is of the RG174 type.

6. 6. A method of assembling a coaxial cable connector as claimed in any one of claims 1 to 5, wherein crimping of the outer contacts (5) is performed to minimize capacitive distortion, thereby preserving RF signal integrity of the coaxial cable (2).

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

8. The coaxial cable connector (1) of claim 7, wherein the coaxial cable connector (1) is configured for use in an automotive data connection application.

9. 9. The coaxial cable connector (1) of 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 various diameters.

10. A crimping tool for assembling a coaxial cable connector (1), comprising: a. Interchangeable die sets corresponding to specified cable diameters with an adjustable mechanism for setting the crimp height, configured for use with a common inner ferrule (3) with overlapping crimp flanks (3a, 3b) to allow for fitting to a range of cable diameters; b. a crimping profile characterized by a constriction arranged to selectively apply pressure to a predetermined functional area (5a, 5b) of an external contact (5), said constriction being configured to prevent excessive stretching of said external contact (5) during crimping; A crimping tool comprising at least one of:

11. 11. The crimping tool of claim 10, wherein the crimp height is adjustable to optimize overlap and stable crimping of the overlapping crimp flanks (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. Crimping tool according to claim 10 or 11, wherein the constriction is defined separately for the mechanical functional area (5a) and for the electrical functional area (5b) of the external contact (5).

13. A crimping tool according to any one of claims 10 to 12, wherein the crimping profile is specially tailored to prevent over-compression of the coaxial cable (2), thereby preserving RF signal integrity.

14. 14. The crimping tool of any one of claims 10 to 13, further comprising a measurement gauge for determining the crimp height at the external contact (5), the measurement gauge being configured to use references on the top and bottom flat surfaces of the external contact (5) for accurate measurements.

15. A coaxial cable connector (1), a. an inner ferrule (3) crimped onto the exposed braid (4) of a coaxial cable (2), said inner ferrule (3) including adjustable overlapping flanks (3a, 3b) to accommodate various diameters of coaxial cables (2); an outer contact (5) crimped onto the exposed braid (4) of the coaxial cable (2) folded over an inner ferrule (3) crimped onto the exposed braid (4) of the coaxial cable (2), the outer contact (5) having a plurality of distinct constrictions of reduced diameter in predetermined functional areas (5a, 5b), the constrictions configured to minimize elongation of the outer contact (5) during crimping, thereby maintaining positional integrity of a central contact (6) within the coaxial cable connector (1); A coaxial cable connector (1) comprising at least one of the following:

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