US3652758A - Method of manufacturing an electrical connector - Google Patents

Method of manufacturing an electrical connector Download PDF

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Publication number
US3652758A
US3652758A US95746A US3652758DA US3652758A US 3652758 A US3652758 A US 3652758A US 95746 A US95746 A US 95746A US 3652758D A US3652758D A US 3652758DA US 3652758 A US3652758 A US 3652758A
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United States
Prior art keywords
sleeve
dielectric
dielectric sleeve
tube
core
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Expired - Lifetime
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US95746A
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Henri De Saint Pierre
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TE Connectivity Corp
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AMP Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/38—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure having concentrically or coaxially arranged contacts
    • H01R24/40—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure having concentrically or coaxially arranged contacts specially adapted for high frequency
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2103/00—Two poles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
    • Y10T29/49211—Contact or terminal manufacturing by assembling plural parts with bonding of fused material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49938—Radially expanding part in cavity, aperture, or hollow body

Definitions

  • Known coaxial electrical connectors include an inner contact member, normally in the form of a pin, which is surrounded by a dielectric member of electrically insulating material, the dielectric member serving to locate the inner contact member within an outer contact member which surrounds the dielectric member.
  • the dielectric member is usually secured within the outer contact member, and it is known so to secure the dielectric member by crimping the outer contact member onto the dielectric member.
  • Coaxial connectors tend to be bulky in relation to the conductor and also expensive to manufacture and it is an object of the invention to simplify the manufacture of an assembly of a dielectric member within a metal tube for use in a coaxial connector and so to facilitate and economise in the cost of manufacture and allow easier assembly of the connector to a coaxial conductor.
  • a method of manufacturing an electrical connector in which a sleeve of dielectric material is secured within a metal tube, is characterised by the steps of inserting a dielectric sleeve of thermo-plastics material into an open-ended metal tube having an internal recess, inserting a core member into the dielectric sleeve axially compressing the dielectric sleeve under heat to mould the dielectric sleeve between the inside surface of the metal tube and the core member, and force dielectric sleeve material into the recess, allowing the dielectric sleeve to set, and removing the core member from the assembly.
  • FIG. 1 is an axial sectional view of an outer contact member for a coaxial electrical connector
  • FIG. 2 is a section on the line II--II of FIG. 1;
  • FIG. 3 is a section on the line IIIIII of FIG. 2, but with a dielectric sleeve and a core member in position within the outer contact member;
  • FIG. 4 is a section on the line IVIV of FIG. 2, but with a dielectric sleeve and an inner contact member in position within the outer contact member, and a spring member in position around the outer contact member.
  • the outer contact member shown in FIGS. 1 and 2 is in the form of a circular cross-section metal tube 1 of substantially uniform wall thickness, having two integrally formed parts 2 and 3 of mutually different diameter.
  • the larger diameter part 2 of the tube 1 has a portion of its wall cut away to provide a window 4.
  • the small diameter part 3 of the tube 1 has a circumferential rib 5 formed in it to provide an annular recess 6 within the part 3.
  • the dielectric sleeve 7 of FIGS. 3 and 4 is secured within the tube 1.
  • the circular cross-section sleeve 7 of dielectric material the outer diameter of which is substantially equal to the inside diameter of the part 3 of the tube 1, is slidably inserted into the part 3.
  • a circular cross-sectional metal core member 8, FIG. 3, is then slidably inserted into the dielectric sleeve 7, the core 8 having three portions 9, 10 and 11 of mutually different diameter.
  • the diameter of the largest diameter portion 11 of the core 8 is substantially equal to the inside diameter of the part 3 of the tube 1, and this portion 11 provides a shoulder 12 at its junction with the portion 10 of the core 8, which engages an end face of the dielectric sleeve 7.
  • the intermediate core portion 10 of intermediate diameter and the end core portion 8 of smallest diameter extend within the sleeve 7 and the end portion 8 projects from the sleeve end.
  • a circular cross-section pressure member (FIG. 3) is then inserted into the part 2 of the metal sleeve 1, the pressure member having a main body 13 of a diameter substantially equal to the inside diameter of the part 2 of the tube 1 and a boss 14 at one end of the body 13, the boss 14 having a diameter substantially equal to the inside diameter of the part 3 of the tube 1.
  • the junction between the parts 13 and 14 of the pressure member forms a shoulder 15 which engages the inner end face 16 of the part 3 of the tube 1, the free end of the boss 14 forming a stop which serves to position the dielectric sleeve 7 within the tube 1.
  • An axial blind bore 17 extends into the pressure member 13, 14 from the free end of the boss 14, the bore 17 having a diameter slightly greater than the diameter of the portion 9 of the core 8 which is slidably received within the bore 17.
  • the tube 1 containing the dielectric sleeve 7, the core 8 and the pressure member 13, 14 is then positioned within a heating jacket, not shown, and the core 8 and the pressure member 13, 14 urged axially towards each other by means not shown.
  • the heat from the heating jacket softens the material of the dielectric sleeve 7, and as the core 8 moves toward the pressure member 13, 14 the portion 9 of the core 8 entering the bore 17 in the pressure member 13, 14, the dielectric sleeve 7 is compressed axially and moulded between the inside surface of the part 3 of the tube 1 and the core 8.
  • Material of the dielectric sleeve 7 is forced into the annular recess 6 in the part 3 of the tube 1, and the shoulder 15 of the pressure member engages the face 16 of the part 3 of the tube 1 precisely to locate the dielectric sleeve axially within the tube 1.
  • the assembly is then removed from the heating jacket, and the core 8 and pressure member 13, 14 removed from within the tube 1.
  • the dielectric sleeve 7 remains secured within the tube 1 against axial movement as a result of the material of the dielectric sleeve 7 positioned within the recess 6 and the tight engagement of the sleeve 7 within the tube portion 3.
  • the inner surface of the dielectric sleeve 7 is profiled by the core member to receive an inner contact member 18, FIG. 4, inserted at the free end of the part 3 of the tube 1.
  • the contact member 18 is suitably of tubular form having a leading plug portion extending from a rear wire connecting portion of enlarged diameter. The leading plug portion extends through the reduced diameter leading end of the sleeve 7, which was formed by the core portion 8, and projects from the sleeve 7 within the forward tube portion 2.
  • the rear wire connecting portion of member 18 is disposed within the larger diameter rear end of the sleeve 7 defined by core portion 10 with the transition between the different portions of the contact member 18 engaging a complementary shoulder defined between the different diameter bores of the sleeve 7.
  • the wire connecting portion of contact member 18 is secured to a core conductor by crimping and then inserted into the sleeve 7 to the position of FIG. 4.
  • the rear end of the tube portion 3, the right hand end in FIG. 4 is inserted between the dielectric and the outer conductor of the coaxial conductor and suitably secured in known manner by a surrounding crimping ferrule not shown.
  • a spring member 19 (FIG. 4), is secured around the part 3 of the tube 1 adjacent the inner end of the part 2 of the tube 1.
  • the member 19 has three outwardly directed arms 20 which, in use, serve to secure the connector in a housing.
  • the arms 20 are angularly spaced by 90, and the centre one has a further arm 21 extending in line therewith over the window 4 in the part 2 of the tube 1.
  • the arm 21 is bent at its free end to form an inwardly extending rib 22 which in use engages a male terminal inserted into the part 2 of the tube 1, to secure the male terminal to the tube 1.
  • a method of manufacturing an electrical connector in which a sleeve of dielectric material is secured within a metal tube comprising the steps of inserting a dielectrio sleeve of thermo-plastics material into an open ended metal tube having an internal recess, inserting a core member into the dielectric sleeve, axially compressing the dielectric sleeve under heat to mould the dielectric sleeve between the inside surface of the metal tube and the core member, and force dielectric sleeve material into the recess, allowing the dielectric sleeve to set, and removing the core member from within the dielectric sleeve.

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  • Coupling Device And Connection With Printed Circuit (AREA)

Abstract

A method of manufacturing an electrical connector in which a sleeve of dielectric material is secured within a metal tube, comprising the steps of inserting a dielectric sleeve of thermo-plastics material into an open ended metal tube having an internal recess, inserting a core member into the dielectric sleeve, axially compressing the dielectric sleeve under heat to mold the dielectric sleeve between the inside surface of the metal tube and the core member, and force dielectric sleeve material into the recess, allowing the dielectric sleeve to set, and removing the core member from within the dielectric sleeve.

Description

METHOD OF MANUFACTURING AN FLECTRICAL CONNECTOR March 28, 197 H. DE SAINT PIERRE Filed Dec. 7, 1970 ll'll'l r Patented Mar. 28, 1972 3,652,758 METHOD OF MANUFACTURING AN ELECTRICAL CONNECTOR Henri de Saint Pierre, Paris, France, assignor to AMP Incorporated, Harrisburg, Pa. Filed Dec. 7, 1970, Ser. No. 95,746 Int. Cl. 1329c 27/12; H01r 17/08 US. Cl. 264249 3 Claims ABSTRACT OF THE DISCLOSURE This invention relates to a method of manufacturing an electrical connector, particularly a coaxial electrical connector, and to a connector manufactured by the method.
Known coaxial electrical connectors include an inner contact member, normally in the form of a pin, which is surrounded by a dielectric member of electrically insulating material, the dielectric member serving to locate the inner contact member within an outer contact member which surrounds the dielectric member. The dielectric member is usually secured within the outer contact member, and it is known so to secure the dielectric member by crimping the outer contact member onto the dielectric member.
Ditiiculty is presented, particularly with coxial connectors of small sizes in holding all of the connector parts in appropriate relative positions during assembly of the connector to a coaxial conductor. Coaxial connectors tend to be bulky in relation to the conductor and also expensive to manufacture and it is an object of the invention to simplify the manufacture of an assembly of a dielectric member within a metal tube for use in a coaxial connector and so to facilitate and economise in the cost of manufacture and allow easier assembly of the connector to a coaxial conductor.
According to the present invention, a method of manufacturing an electrical connector, in which a sleeve of dielectric material is secured within a metal tube, is characterised by the steps of inserting a dielectric sleeve of thermo-plastics material into an open-ended metal tube having an internal recess, inserting a core member into the dielectric sleeve axially compressing the dielectric sleeve under heat to mould the dielectric sleeve between the inside surface of the metal tube and the core member, and force dielectric sleeve material into the recess, allowing the dielectric sleeve to set, and removing the core member from the assembly.
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an axial sectional view of an outer contact member for a coaxial electrical connector;
FIG. 2 is a section on the line II--II of FIG. 1;
FIG. 3 is a section on the line IIIIII of FIG. 2, but with a dielectric sleeve and a core member in position within the outer contact member; and
FIG. 4 is a section on the line IVIV of FIG. 2, but with a dielectric sleeve and an inner contact member in position within the outer contact member, and a spring member in position around the outer contact member.
The outer contact member shown in FIGS. 1 and 2 is in the form of a circular cross-section metal tube 1 of substantially uniform wall thickness, having two integrally formed parts 2 and 3 of mutually different diameter. The larger diameter part 2 of the tube 1 has a portion of its wall cut away to provide a window 4. The small diameter part 3 of the tube 1 has a circumferential rib 5 formed in it to provide an annular recess 6 within the part 3.
For use of the outer contact member in a coaxial connector, as shown in FIG. 4, the dielectric sleeve 7 of FIGS. 3 and 4 is secured within the tube 1. The circular cross-section sleeve 7 of dielectric material, the outer diameter of which is substantially equal to the inside diameter of the part 3 of the tube 1, is slidably inserted into the part 3. A circular cross-sectional metal core member 8, FIG. 3, is then slidably inserted into the dielectric sleeve 7, the core 8 having three portions 9, 10 and 11 of mutually different diameter. The diameter of the largest diameter portion 11 of the core 8 is substantially equal to the inside diameter of the part 3 of the tube 1, and this portion 11 provides a shoulder 12 at its junction with the portion 10 of the core 8, which engages an end face of the dielectric sleeve 7. The intermediate core portion 10 of intermediate diameter and the end core portion 8 of smallest diameter extend within the sleeve 7 and the end portion 8 projects from the sleeve end.
A circular cross-section pressure member (FIG. 3) is then inserted into the part 2 of the metal sleeve 1, the pressure member having a main body 13 of a diameter substantially equal to the inside diameter of the part 2 of the tube 1 and a boss 14 at one end of the body 13, the boss 14 having a diameter substantially equal to the inside diameter of the part 3 of the tube 1. The junction between the parts 13 and 14 of the pressure member forms a shoulder 15 which engages the inner end face 16 of the part 3 of the tube 1, the free end of the boss 14 forming a stop which serves to position the dielectric sleeve 7 within the tube 1. An axial blind bore 17 extends into the pressure member 13, 14 from the free end of the boss 14, the bore 17 having a diameter slightly greater than the diameter of the portion 9 of the core 8 which is slidably received within the bore 17.
The tube 1 containing the dielectric sleeve 7, the core 8 and the pressure member 13, 14 is then positioned within a heating jacket, not shown, and the core 8 and the pressure member 13, 14 urged axially towards each other by means not shown. The heat from the heating jacket softens the material of the dielectric sleeve 7, and as the core 8 moves toward the pressure member 13, 14 the portion 9 of the core 8 entering the bore 17 in the pressure member 13, 14, the dielectric sleeve 7 is compressed axially and moulded between the inside surface of the part 3 of the tube 1 and the core 8. Material of the dielectric sleeve 7 is forced into the annular recess 6 in the part 3 of the tube 1, and the shoulder 15 of the pressure member engages the face 16 of the part 3 of the tube 1 precisely to locate the dielectric sleeve axially within the tube 1.
The assembly is then removed from the heating jacket, and the core 8 and pressure member 13, 14 removed from within the tube 1.
The dielectric sleeve 7 remains secured within the tube 1 against axial movement as a result of the material of the dielectric sleeve 7 positioned within the recess 6 and the tight engagement of the sleeve 7 within the tube portion 3. The inner surface of the dielectric sleeve 7 is profiled by the core member to receive an inner contact member 18, FIG. 4, inserted at the free end of the part 3 of the tube 1. The contact member 18 is suitably of tubular form having a leading plug portion extending from a rear wire connecting portion of enlarged diameter. The leading plug portion extends through the reduced diameter leading end of the sleeve 7, which was formed by the core portion 8, and projects from the sleeve 7 within the forward tube portion 2. The rear wire connecting portion of member 18 is disposed within the larger diameter rear end of the sleeve 7 defined by core portion 10 with the transition between the different portions of the contact member 18 engaging a complementary shoulder defined between the different diameter bores of the sleeve 7. In assembling the connector to a coaxial conductor, not shown, the wire connecting portion of contact member 18 is secured to a core conductor by crimping and then inserted into the sleeve 7 to the position of FIG. 4. The rear end of the tube portion 3, the right hand end in FIG. 4, is inserted between the dielectric and the outer conductor of the coaxial conductor and suitably secured in known manner by a surrounding crimping ferrule not shown.
A spring member 19 (FIG. 4), is secured around the part 3 of the tube 1 adjacent the inner end of the part 2 of the tube 1. The member 19 has three outwardly directed arms 20 which, in use, serve to secure the connector in a housing. The arms 20 are angularly spaced by 90, and the centre one has a further arm 21 extending in line therewith over the window 4 in the part 2 of the tube 1. The arm 21 is bent at its free end to form an inwardly extending rib 22 which in use engages a male terminal inserted into the part 2 of the tube 1, to secure the male terminal to the tube 1.
Although the invention has been described above in relation to a female coaxial electrical connector, it is equally applicable to a male coaxial electrical connector.
I claim: 1. A method of manufacturing an electrical connector in which a sleeve of dielectric material is secured within a metal tube, comprising the steps of inserting a dielectrio sleeve of thermo-plastics material into an open ended metal tube having an internal recess, inserting a core member into the dielectric sleeve, axially compressing the dielectric sleeve under heat to mould the dielectric sleeve between the inside surface of the metal tube and the core member, and force dielectric sleeve material into the recess, allowing the dielectric sleeve to set, and removing the core member from within the dielectric sleeve.
2. A method according to claim 1, in which the dielectric sleeve is compressed between a shoulder on the core member intermediate its ends, and a pressure member inserted into the metal tube from the opposite end to and about the core member.
3. A method according to claim 2, in which the dielectric sleeve is precisely located within the metal tube while being compressed, by a shoulder on the pressure member engaging an internal shoulder of the metal tube.
References Cited UNITED STATES PATENTS 1,968,314 7/1934 Rohde 29-522 2,421,105 5/1947 Warren 264249 2,804,679 9/1957 Tracy 29-522 2,059,867 11/1936 Hinds 264249 2,135,380 11/1938 Benge Q64262 FOREIGN PATENTS 122,320 10/1946 Australia 264262 MARVIN A. CHAMPION, Primary Examiner L. I. STAAB, Assistant Examiner V U.S. Cl. X.R.
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3947959A (en) * 1973-12-03 1976-04-06 Essex International, Inc. Method of making an electrical connector
US4209896A (en) * 1976-04-02 1980-07-01 Texas Instruments Incorporated Method of assembly of an anti-corrosion anode connector system
FR2451647A2 (en) * 1979-03-12 1980-10-10 Souriau & Cie Terminal for connection to coaxial cable - has two u=shaped parts for cable inner and outer conductors, open on same side
WO1986000679A1 (en) * 1984-07-13 1986-01-30 Vassallo Research & Development Corporation Plastic-encased gasket
US20040219835A1 (en) * 2003-04-09 2004-11-04 Hirschmann Electronics Gmbh & Co. Kg Plug for a coaxial plug connection
US20050150097A1 (en) * 2004-01-09 2005-07-14 Jones Ronald E. Cold process for joining metal
US20200061902A1 (en) * 2017-07-28 2020-02-27 Sanoh Industrial Co., Ltd. Pipe end processing device

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3947959A (en) * 1973-12-03 1976-04-06 Essex International, Inc. Method of making an electrical connector
US4209896A (en) * 1976-04-02 1980-07-01 Texas Instruments Incorporated Method of assembly of an anti-corrosion anode connector system
FR2451647A2 (en) * 1979-03-12 1980-10-10 Souriau & Cie Terminal for connection to coaxial cable - has two u=shaped parts for cable inner and outer conductors, open on same side
WO1986000679A1 (en) * 1984-07-13 1986-01-30 Vassallo Research & Development Corporation Plastic-encased gasket
US20040219835A1 (en) * 2003-04-09 2004-11-04 Hirschmann Electronics Gmbh & Co. Kg Plug for a coaxial plug connection
US20050150097A1 (en) * 2004-01-09 2005-07-14 Jones Ronald E. Cold process for joining metal
US20200061902A1 (en) * 2017-07-28 2020-02-27 Sanoh Industrial Co., Ltd. Pipe end processing device
US10821656B2 (en) * 2017-07-28 2020-11-03 Sanoh Industrial Co., Ltd. Pipe end processing device

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