CN103222125A - 摩擦焊接同轴连接器和互连方法 - Google Patents
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Abstract
一种用于借助于摩擦焊接与具有实心外导体同轴电缆互连的同轴连接器,该同轴连接器设置有带有孔的单体式连接器本体。孔的侧壁设置有向内环形凸起,该向内环形凸起朝着孔的电缆端部倾斜。向内环形凸起的侧壁和孔的侧壁形成向孔的电缆端部敞开的环形摩擦沟槽。环形摩擦沟槽的尺寸设计成在摩擦沟槽的连接器端部处具有小于外导体的前端的厚度的锥体。当外导体就位于摩擦沟槽中时,锥体在外导体的前端和摩擦沟槽的连接器端部之间提供环形材料腔室。
Description
技术领域
本发明涉及电缆连接器。更具体地,本发明涉及可通过摩擦焊接互连的同轴电缆连接器。
背景技术
同轴电缆连接器例如用在要求高水平精度和可靠性的通信系统中。
为了在电缆和连接器之间形成可靠的机械互连和最优的电互连,期望的是在同轴电缆外导体的前缘和连接器本体之间具有大体上均匀的周向接触。外导体的张开端部可以经由联接本体抵靠连接器本体的环形楔形表面夹紧。该技术的代表是2004年9月21日授予给Buenz的共同拥有US专利No.6793529。虽然该类型的连接器是典型地可移除的/可再使用的,但是通过所需的多个分离的内部元件、互连螺纹和相关环境密封,因而制造和安装复杂。
构造用于经由焊料和/或粘合互连的永久互连的连接器在本领域中也是公知的。该技术的代表是1998年9月8日授予给Bufanda等人的共同拥有US专利No.5802710。然而,焊料和/或粘合互连对于应用高水平的质量控制来说可能是困难的,从而例如在随着时间的推移暴露给振动和/或腐蚀时导致不太令人满意的互连。
在同轴电缆连接器市场中的竞争将集中于改善电缆对连接器互连的电性能和长期可靠性。而且,包括材料、培训和安装成本的总体成本的减小是商业成功的重要因素。
因此,本发明的一个目的是提供一种同轴连接器和克服现有技术中缺陷的互连的方法。
附图说明
被结合在本说明书中并且构成本说明书一部分的随附附图示出本发明的实施例,其中附图中相同的附图标记指的是相同的特征或元件,并且不必对于出现这些附图标记的每个附图进行详细描述,并且与上面给出的本发明的总体说明以及下面给出的实施例的详细描述一起用于解释本发明的原理。
图1是沿着用于连接器至电缆的互连的电缆且利用远离连接器的联接螺母安装在同轴电缆上的同轴连接器的示例性实施例的示意性外等轴测视图;
图2是利用安置在同轴连接器上的联接螺母安装在同轴电缆上的图1的同轴连接器的示意性等轴测视图;
图3是图1的同轴连接器的示意性等轴测视图;
图4是图2的示意性截面视图;
图5是图4的区域A的放大视图;
图6是图1的连接器和电缆的示意性分解局部切开的等轴测视图;
图7是图5的连接器本体的示意性局部切开的等轴测视图;
图8是在连接器本体的凸缘上具有凹口的可替换连接器本体的示意性等轴测视图;
图9是在连接器本体的外径上具有纵向滚花的可替换连接器本体的示意性等轴测视图;
图10是图5的包覆体(overbody)的示意性切开等轴测视图;
图11是图4的区域B的放大视图;
图12是在电缆端部的内径上具有沟纹的可替换包覆体的示意性截面侧视图;
图13是在电缆端部的内径上具有台肩形表面的可替换包覆体的示意性截面侧视图;
图14是具有内导体端部帽的同轴连接器实施例的示意性截面侧视图。
具体实施方式
铝已经被作为铜的节约成本的替代物应用于同轴电缆中的导体。然而,铝氧化表面涂层快速地形成在暴露于空气的铝表面上。这些铝氧化表面涂层会使传统的机械、焊料和/或传导粘合互连劣变。
发明人已经认识到,对具有铝和/或铝合金制成的实心外导体的同轴电缆的越来越多接受使得连接器能够构造成在外导体和连接器本体之间经由摩擦焊接互连,其中,连接器本体也可以节省成本地设置,例如由铝和/或铝合金形成。
可摩擦焊接的同轴连接器2的示例性实施例在图1-4中示出。如图4最好示出的,单体式连接器本体4设置有尺寸设计成在其中接收同轴电缆9的外导体8的孔6。朝着连接器本体4的电缆端部12倾斜的向内突出台肩10形成向电缆端部12敞开的环形摩擦沟槽14。如图5中最好示出,摩擦沟槽14的尺寸设计成在其中接收外导体8的前缘,外导体8的厚度阻止外导体8初始地到达摩擦沟槽14底部,从而当外导体8初始地就位于摩擦沟槽14内时在外导体8的前缘和摩擦沟槽14的底部之间形成环形材料腔室16。
本领域技术人员将理解的是,连接器端部18和电缆端部12在此作为识别器被施加,用于连接器以及在此描述的同轴连接器的分立元件的相应端部,以便根据它们沿着连接器端部18和电缆端部12之间的连接器的纵向轴线的对准来识别自身和它们相应的互连表面。
孔侧壁20的沿径向的尺寸设计成邻近摩擦沟槽14形成摩擦部22。摩擦部22在孔侧壁20和外导体8的外径之间形成附加过盈,以便在摩擦焊接期间增加摩擦。
在通过摩擦焊接(也已知为旋转焊接)的互连之前,如图6最好示出的,可以通过切割电缆9从而使内导体24从外导体8伸出而制备电缆端部12。而且,在内导体24和外导体8之间的电介质材料26可以向回剥离并且一段外罩28被移除以暴露内导体和外导体的所需长度,包括外导体8在摩擦焊接工艺期间消耗的耗费部分。
为了开始摩擦焊接,在外导体8的前缘在纵向压力下安置在摩擦部分22内并且进入摩擦沟槽14内期间,连接器本体4相对于外导体8旋转。在旋转期间,例如在每分钟250-500转的速度下,在外导体8的前缘和/或外径和孔6的摩擦部分22和/或摩擦沟槽14之间的摩擦产生足够的热量来软化前缘和/或外导体8和连接器本体4的局部相邻部分,从而当外导体8的耗费部分形成流入材料腔室16内的塑性焊缝以便将外导体8和连接器本体4熔接在一起时将它们铸造在一起。
因为摩擦焊接工艺的局部腐蚀可以在紧接焊接区域中破坏任何氧化铝表面涂层,因而不需要移除或以其它方式管理存在于互连表面上的氧化铝的附加处理。
如例如图10示出的,包覆体30可以作为聚合体材料制成的包覆成型层被施加到连接器本体4。包覆体30使电缆相对于连接器的扭转和拉伸抗力增大。包覆体30也可以在连接器端部18处提供连接接口结构,并且进一步增强在电缆端部12处的支撑,从而实现连接器本体4的尺寸的相当大的减小,籍此减小总体材料成本。
取决于在本文中的示例性实施例中举例说明的被施加的连接接口31作为标准7/16DIN接口,包覆体30可以设置有用于联接螺母36的包覆体凸缘32和纵向支撑脊34。联接螺母36通过包覆体凸缘32保持在连接器端部18处的支撑脊34上并且通过设置在支撑脊34的至少之一上的保持凸部38保持在电缆端部12处。保持凸部38可以朝着连接器端部18倾斜,允许互连期间联接螺母36被放置在电缆9上,初始地远离同轴连接器2(参见图1),然后允许联接螺母36从电缆端部12穿过保持凸部38并且置于支撑脊34上,以便此后借助于保持凸部(多个保持凸部)38紧邻用于连接器与连接器的匹配的连接器接口31保持在支撑脊上(参见图2)。支撑脊34减小了包覆体30的聚合体材料需求,同时对连接器/互连2提供了横向强度以及联接螺母36的对准和保持。
包覆体30还可以从连接器本体4的连接器端部18延伸,以便设置已选连接器接口31的各部分,例如7/16DIN接口的对准柱体39,以便进一步减小连接器本体4的金属材料需求。
包覆体凸缘32可以经由设置在连接器本体凸缘40和/或连接器本体4的外径中的一个或更多个互锁开口42,例如孔、纵向滚花43、沟槽、凹口45等等牢固地键接合到连接器本体4的连接器本体凸缘40并且由此与连接器本体4牢固地键接合,如图7-9中举例示出的。籍此,由于包覆体30的聚合体材料在包覆成型期间流入互锁开口42内,因而在固化时,包覆体30被永久地联接到连接器本体4并且与连接器本体4可旋转地互锁,如在图10中举例示出的。
如图11最好示出,包覆体30的电缆端部12的尺寸可以设计成具有邻近同轴电缆外罩28的内径的内径摩擦表面44,从而允许在连接器本体4的包覆体30和外导体8的外罩28之间的聚合体摩擦焊接,籍此消除在连接器/电缆互连的电缆端部12处的环境密封的需求。在摩擦焊接期间,同轴连接器2相对于电缆9旋转。在摩擦表面44和外罩28的外径之间的摩擦将相应表面加热至相应表面开始软化并且混合的点,从而使相应表面抵靠彼此密封。为了提供增强的摩擦、允许由于摩擦位移而用于过多流动的空隙并且为了增加用于附加强度的键锁定,外罩28和/或包覆体30的内径可以设置有一系列间隔开的环形峰状轮廓图案,如例如图12中示出的沟纹46或如例如图13中示出的台阶形表面48。可替换地,包覆体30可以利用粘合剂/密封剂密封抵靠外罩28,或者可以利用将包覆体30与外罩28结合和/或密封抵靠外罩28的被注射的聚合体材料的热量而在与外导体8互连之后包覆成型在连接器本体4上。
从同轴电缆9的已制备端部延伸的内导体24可以选择成穿过至连接器端部18作为已选连接接口31的一部分,例如如图4所示。如果已选同轴电缆9的内导体24具有比已选连接器接口31的内导体部分大的直径,则内导体24可以在连接器18处磨削至所需直径。
尽管直接穿过的内导体24例如使用传统同轴连接器内触头的弹簧垫圈有利地消除了互连,但是这种直接穿过会引来例如PIM的电性能劣变。在内导体24也为铝材料情况下,一些应用可以在连接器接口31的内触头/内导体处需要非铝材料连接点。如例如图14中所示,例如由诸如黄铜或其他期望金属形成的中心帽50也可以通过激光或摩擦焊接施加到内导体24的端部。为了施加中心帽50,内导体24的端部被磨削以提供对应于中心帽50的已选凹窝几何尺寸的销。为了允许在焊接附接期间的材料内部流动,中心帽50的凹窝几何尺寸和/或内导体24的端部可以形成为提供如相对于如上描述的材料腔室16描述的材料间隙。
本领域技术人员将理解的是,公开的连接器和互连方法具有显著的材料成本有效性并且提供具有减小尺寸和/或减小重量需求的永久密封互连。
部件目录
2 | 同轴连接器 |
4 | 连接器本体 |
6 | 孔 |
8 | 外导体 |
9 | 电缆 |
10 | 台肩 |
12 | 电缆端部 |
14 | 摩擦沟槽 |
16 | 材料腔室 |
18 | 连接器端部 |
20 | 孔侧壁 |
22 | 摩擦部分 |
24 | 内导体 |
26 | 电介质材料 |
28 | 外罩 |
30 | 包覆体 |
31 | 连接接口 |
32 | 包覆体凸缘 |
34 | 支撑脊 |
36 | 联接螺母 |
38 | 保持凸部 |
39 | 对准柱体 |
40 | 连接器本体凸缘 |
42 | 互锁开口 |
43 | 纵向滚花 |
44 | 摩擦表面 |
45 | 凹口 |
46 | 沟纹 |
48 | 台肩形表面 |
50 | 中心帽 |
在前述描述中,已经提及的材料、比例、整数或部件具有已知等同物,这种等同物结合在此,就好像单独阐述一样。
虽然已经通过对实施例的描述举例说明了本发明,并且虽然已经对实施例进行了相当详细的描述,但是申请人的意图不是限定本发明或者以任何方式将随附权利要求书的范围限定到这种细节。附加优点和改进对于本领域技术人员将变得显而易见。因此,本发明在其更广义方面不被限定到特定细节、代表装置、方法和被示出和描述的示例性实施例。因此,可以对这些细节进行改变,但是不会偏离申请人的总体发明概念的精神或范围。而且,将理解的是,可以对其进行改进和/或修改,而不会背离本发明的如随附权利要求书限定的范围或精神。
Claims (20)
1.一种用于与具有实心外导体同轴电缆互连的同轴连接器,包括:
具有孔的单体式连接器本体;
所述孔的侧壁设置有朝着所述孔的电缆端部倾斜的向内环形凸起;所述向内环形凸起的侧壁和所述孔的侧壁形成向所述孔的电缆端部敞开的环形摩擦沟槽,所述环形摩擦沟槽的尺寸设计成在所述环形摩擦沟槽的连接器端部处具有小于所述外导体的前端的厚度的锥体;当所述外导体就位于所述摩擦沟槽中时,所述锥体在所述外导体的前端和所述摩擦沟槽的连接器端部之间提供环形材料腔室。
2.如权利要求1所述的连接器,所述向内环形凸起布置成邻近所述孔的连接器端部。
3.如权利要求1所述的连接器,其中,所述孔的、邻近所述向内环形凸起的直径减小以与所述外导体的外径过盈配合。
4.如权利要求1所述的连接器,还包括位于所述连接器本体的外径上的、由聚合体材料制成的包覆体。
5.如权利要求4所述的连接器,所述包覆体包括在所述连接器的连接器端部处的连接器接口的对准柱体。
6.如权利要求4所述的连接器,所述包覆体包括多个纵向支撑脊,所述多个纵向支撑脊从所述包覆体的外径延伸为小于联接螺母的内径,所述联接螺母的尺寸设计成能够安装在所述支撑脊上。
7.如权利要求6所述的连接器,所述联接螺母被保持在位于所述包覆体的凸缘和向外延伸的保持凸部之间的所述支撑脊上,所述保持凸部邻近所述支撑脊中的至少一个支撑脊的电缆端部。
8.如权利要求4所述的连接器,其中,所述包覆体从所述连接器本体的所述电缆端部延伸,从所述连接器本体的所述电缆端部延伸的所述包覆体的内径设置为摩擦表面,所述摩擦表面与所述同轴电缆的外罩的外径形成过盈配合。
9.如权利要求8所述的连接器,其中,所述摩擦表面设置为所述包覆体的所述内径的一系列间隔开的环形峰状轮廓图案。
10.如权利要求4所述的连接器,还包括在所述包覆体和所述连接器本体之间的可旋转互锁件。
11.如权利要求10所述的连接器,其中,所述可旋转互锁件是设置在从所述连接器本体的外径突出的连接器本体凸缘中的多个互锁开口。
12.一种用于将同轴连接器与实心外导体同轴电缆互连的方法,包括以下步骤:
提供具有孔的单体式连接器本体;
使所述孔的侧壁设置有朝着所述孔的电缆端部倾斜的向内环形凸起,所述向内环形凸起的侧壁和所述孔的侧壁形成向所述孔的电缆端部敞开的环形摩擦沟槽;
将所述同轴电缆的前端插入所述孔内,直到所述实心外导体的前端安置于所述摩擦沟槽内;
在施加纵向作用力以驱动所述摩擦沟槽抵靠所述外导体的所述前端的同时,使所述连接器本体围绕所述同轴电缆的所述前端的纵向轴线旋转。
13.如权利要求12所述的方法,其中,所述外导体和所述连接器本体均由铝和铝合金材料之一制成。
14.如权利要求12所述的方法,其中,所述摩擦沟槽在所述摩擦沟槽的连接器端部处设置有环形材料腔室。
15.如权利要求12所述的方法,其中,施加所述旋转和所述纵向作用力,直到产生足以熔化所述外导体的所述前端的热量。
16.如权利要求12所述的方法,其中,所述旋转和所述纵向作用力在所述外导体和所述连接器本体之间产生摩擦焊接。
17.如权利要求12所述的方法,还包括采用聚合体制成的包覆体使附接到所述同轴电缆的端部的所述连接器本体包覆成型的步骤。
18.如权利要求12所述的方法,还包括以下步骤:
通过移除所述外导体的一部分使得内导体从所述外导体伸出而在插入到所述孔内之前制备所述电缆端部的所述前端,移除所述内导体和所述外导体之间的电介质材料的一部分,使得当所述外导体的所述前缘接触所述向内环形凸起时,所述摩擦沟槽不接触所述电介质材料;和
从所述外导体向回剥离外罩的一部分。
19.如权利要求12所述的方法,还包括在所述连接器本体的外径上提供聚合体材料制成的包覆体,所述包覆体从所述连接器本体的所述电缆端部延伸,所述包覆体的内径从所述连接器本体的所述电缆端部延伸,所述包覆体的内径设置成摩擦表面,其中所述摩擦表面的尺寸设计成与所述同轴电缆的外罩的外径形成过盈配合。
20.如权利要求19所述的方法,其中,所述旋转和所述纵向作用力使得在所述外导体和所述连接器本体之间以及在所述包覆体和所述同轴电缆的所述外罩之间形成摩擦焊接。
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US12/951,558 US8826525B2 (en) | 2010-11-22 | 2010-11-22 | Laser weld coaxial connector and interconnection method |
US12/962,943 | 2010-12-08 | ||
US12/962,943 US8302296B2 (en) | 2010-11-22 | 2010-12-08 | Friction weld coaxial connector and interconnection method |
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CN103222125B CN103222125B (zh) | 2016-05-18 |
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CN110401066A (zh) * | 2018-04-20 | 2019-11-01 | 通用电气照明解决方案有限公司 | 一种连接器、连接器组件和照明系统 |
CN110401066B (zh) * | 2018-04-20 | 2021-06-18 | 卡任特照明解决方案有限公司 | 一种连接器、连接器组件和照明系统 |
CN113689990A (zh) * | 2021-08-27 | 2021-11-23 | 深圳供电局有限公司 | 高温超导带材连接环形电极装置 |
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US8302296B2 (en) | 2012-11-06 |
EP2643896A4 (en) | 2014-04-16 |
US8556655B2 (en) | 2013-10-15 |
US20120129389A1 (en) | 2012-05-24 |
WO2012071080A1 (en) | 2012-05-31 |
CN103222125B (zh) | 2016-05-18 |
US20130029521A1 (en) | 2013-01-31 |
US8887379B2 (en) | 2014-11-18 |
US20130252463A1 (en) | 2013-09-26 |
EP2643896A1 (en) | 2013-10-02 |
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