Conductive polymer cable assembly

• US 5,317,109 A
• Filed: 06/19/1992
• Issued: 05/31/1994
• Est. Priority Date: 06/19/1992
• Status: Expired due to Fees

• Current Assignee: Champlain Cable Corporation (Brown & Brown Inc.)
• Original Assignee: Champlain Cable Corporation (Brown & Brown Inc.)
• Inventors: Aldissi, Mahmoud
• Primary Examiner(s): NIMMO, MORRIS
• Application Number:
  US07/901,634
• Time in Patent Office: 711 Days
• Field of Search: 174/84 C, 174/94 R, 174/82, 439/874, 439/877, 439/879, 29/862, 29/863
• US Class Current: 174/84.00C
• CPC Class Codes: H01R 4/18 by crimping H01R4/01, H01R4/2495 take precedence; for coaxial cables H01R9/0518
• CPC Class Codes: H01R 4/187 combined with soldering or welding
• CPC Class Codes: Y10T 29/49183 of ferrule about conductor and terminal
• CPC Class Codes: Y10T 29/49185 of terminal

Abstract

This invention features an assembly that creates a strong bond connection between a conductive polymeric element of a cable, such as a polymeric conductive core or polymeric conductive shield layer, and an electrical connector. The invention features two components: a newly styled connector, and an intermediate sleeve. The newly styled connector is made of an inner, concave, bullet-shaped recess that fits within an outer, deformable shell. The intermediate sleeve joins the polymeric element of the cable and the electrical connector. The sleeve consists of two sections. The first section has a solid, convex, bullet-shaped nose portion that fits into the concave, bullet-shaped recess located in the connector. The two bullet-shaped male and female surfaces mate with each other; they are metallic, so that they are easily solderable. The second section of the sleeve is made of a hollow tube-like portion that fits over the polymeric element; this hollow tube-like portion is deformably crimped over the polymeric element, providing a strong mechanical bond. The first section of the sleeve is solderable to the connector after the outer shell of the connector has been fitted over the sleeve and crimped onto it. The double crimp between the connector and the sleeve, and between the sleeve and the polymeric element, provides a double mechanical bond between the polymeric element, the sleeve and the connector. Such double crimping, in combination with the soldered connection, provides a very strong mechanical bond.

Claims

1. A cable connection construction for a cable having a conductive polymeric element such as a conductive polymeric core or shield layer, comprising;

a first component comprising a first deformable portion for attachment to a conductive polymeric element of a cable such as a core or shield layer by means of crimping said first deformable portion about said conductive polymeric core or shield layer, said first component additionally having a male element contiguously joined to said first deformable portion for mating with a female recess disposed in an electrical connector; and

a second component comprising an electrical connector having a second deformable portion and a solid portion defining a female recess for receipt of, and mating with, said male element of said first component, said second deformable portion of said second component being securable about said first deformable portion of said first component by crimping said second deformable portion about said first deformable portion, whereby said electrical connector is attached to the conductive polymeric element by means of a double crimp that provides a connection of improved mechanical strength.

2. The cable connection construction in accordance with claim 1, further comprising a solder connection between said male element of said first component and said female recess defined by said solid portion of said second component.

3. The cable connection construction in accordance with claim 1, wherein said male element and said female recess comprise bullet-shaped mating surfaces.

4. The cable connection construction in accordance with claim 1, wherein said first component defines an intermediate sleeve disposed between said electrical connector and said conductive polymeric element.

5. A cable connection construction for a cable having a conductive polymeric element such as a polymeric core or polymeric shield layer, said cable construction including an electrical connector and an intermediate sleeve that fits within and attaches to said electrical connector, and attaches to said conductive polymeric element of said cable, said cable connection comprising;

an electrical connector having a second deformable portion and a solid portion defining a female recess for receipt of, and mating with, a male element of an intermediate sleeve, said second deformable portion of said electrical connector being securable about said deformable portion of said intermediate sleeve by means of a crimping securement of said second deformable portion about a first deformable portion of said intermediate sleeve; and

an intermediate sleeve comprising a first deformable portion for attachment to a conductive polymeric element of a cable by means of a crimping securement of said first deformable portion about said conductive polymeric element, said intermediate sleeve additionally having a male element contiguously joined to said first deformable portion for mating with said female recess disposed in an electrical connector;

whereby said electrical connector is attached to the conductive polymeric element via said intermediate sleeve by means of a double crimp that provides a connection of improved mechanical strength.

6. The cable connection construction in accordance with claim 5, further comprising a solder connection between said male element of said intermediate sleeve and said female recess defined by said solid portion of said electrical connector.

7. The cable connection construction in accordance with claim 5, wherein said male element and said female recess comprise bullet-shaped mating surfaces.

8. A cable connection construction for a cable having a conductive polymeric element such as a polymeric core or polymeric shield layer, said cable construction including an electrical connector and an intermediate sleeve that fits within and attaches to said electrical connector, and attaches to said conductive polymeric element of said cable, said cable connection comprising;

an electrical connector having a second deformable portion and a solid portion contiguously joined thereto, defining a female recess for receipt of, and mating with, a male element of an intermediate sleeve, said second deformable portion of said electrical connector being securable about said deformable portion of said intermediate sleeve by means of a crimping securement of said second deformable portion about a first deformable portion of said intermediate sleeve;

an intermediate sleeve comprising a first deformable portion for attachment to a conductive polymeric element of a cable by means of a crimping securement of said first deformable portion about said conductive polymeric element, said intermediate sleeve additionally having a male element contiguously joined to said first deformable portion for mating with said female recess disposed in an electrical connector;

whereby said electrical connector is attached to the conductive polymeric element via said intermediate sleeve by means of a double crimp that provides a connection of improved mechanical strength; and

means defining a solder connection between said male element of said intermediate sleeve and said female recess defined by said solid portion of said electrical connector.

9. A method of attaching an electrical connector to a conductive polymeric element of a cable, such as a polymeric conductive core or polymeric conductive shield layer, comprising the steps of;

a) attaching an intermediate sleeve to a conductive polymeric element of a cable and securing said intermediate sleeve to said conductive polymeric element by means of crimping said intermediate sleeve about said conductive polymeric element; and

b) attaching an electrical connector having a crimpable portion and an adjacent female mating surface to said intermediate sleeve and securing said electrical connector to said intermediate sleeve by means of crimping said electrical connector about said intermediate sleeve, said intermediate sleeve mating with said electrical connector via respective male and female mating surfaces disposed thereupon.

10. The method of claim 9, further comprising the step of;

c) forming a solder connection between said male and female mating surfaces.