Multi-shot coaxial connector and method of manufacture

• US 7,607,942 B1
• Filed: 08/14/2008
• Issued: 10/27/2009
• Est. Priority Date: 08/14/2008
• Status: Active Grant

• Current Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Original Assignee: Andrew LLC (CommScope Holding Company, Inc.)
• Inventors: Van Swearingen, Kendrick
• Primary Examiner(s): Gushi; Ross N
• Application Number:
  US12/191,922
• Time in Patent Office: 439 Days
• Field of Search: 439/578, 298/28, 298/58, 298/60, 298/56, 298/83
• US Class Current: 439/578
• CPC Class Codes: B29C 2045/1696 injecting metallic layers and plastic material layers
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/16 Making multilayered or multicoloured articles B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816
• CPC Class Codes: H01R 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 13/5219 Sealing means between coupling parts, e.g. interfacial seal
• CPC Class Codes: H01R 13/622 Screw-ring or screw-casing H01R13/623 takes precedence
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/40 specially adapted for high frequency
• CPC Class Codes: H01R 43/18 for manufacturing bases or cases for contact members
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: H01R 9/0521 Connection to outer conductor by action of a nut
• CPC Class Codes: Y10T 29/49123 Co-axial cable
• CPC Class Codes: Y10T 29/49172 by molding of insulating material

Abstract

A coaxial cable connector formed via multi-shot injection molding has a body formed by multiple injection molding layers of different injection moldable materials about a central inner contact to form an integral connector body. The connector body is provided with a coaxial dielectric spacer of dielectric polymer surrounding the inner contact; a coaxial inner body of injectable molded metal composition surrounding an outer diameter of the dielectric spacer; and an outer body of polymer surrounding the inner body. A range of different coupling bodies compatible with the connector body may also be formed via injection molding to provide connectors compatible with a range of different coaxial cable configurations.

Claims

1. A coaxial cable connector, comprising:

a connector body multi-shot injection molded about an inner contact;

the connector body comprising;

a dielectric insulator of dielectric polymer molded upon an outer diameter of the inner contact;

a coaxial inner body of injectable molded metal composition molded upon an outer diameter of the dielectric spacer; and

an outer body of polymer injection molded upon an outer diameter of the inner body.

2. The coaxial cable connector of claim 1, further including:

a polymeric coupling body threadably coupled to the outer body.

3. The coaxial cable connector of claim 1, further including:

an annular ramp surface formed on an end face of the inner body,

a generally cylindrical slip ring positioned within a bore of the connector body,

a clamp spring positioned between the annular ramp surface and the slip ring, and

a polymeric coupling body threadably coupled to the outer body operative to drive the slip ring against the clamp spring.

4. The coaxial connector of claim 1, further including:

an annular ramp surface formed on an end face of the inner body,

a clamp spring positioned between the annular ramp surface; and

a polymeric coupling body threadably coupled to the outer body operative to drive the clamp spring towards the annular ramp surface.

5. The coaxial connector of claim 1, further including:

an annular ramp surface on an end face of the inner body;

a retaining lip on an inner diameter sidewall of the outer body proximate the annular ramp surface; and

a polymeric coupling body threadably coupled to the outer body;

the polymeric coupling body molded upon a spring finger portion of injectable molded metal composition;

a plurality of spring fingers of the spring finger portion projecting towards the annular ramp surface;

wherein threading of the polymeric coupling body into the connector body drives a distal end of the spring fingers towards the annular ramp surface.

6. The coaxial connector of claim 1, wherein the injectable molded metal composition is an alloy comprising zinc and aluminum.

7. A method for manufacturing a multi-shot injection molded coaxial cable connector, comprising the steps of:

injection molding an inner body of injectable molded metal composition;

positioning an inner contact coaxial within a bore of the inner body,

injection molding a dielectric insulator between the inner body and the inner contact, and

injection molding an outer body of polymer upon an outer diameter surface of the inner body.

8. The method of claim 7, further comprising injection molding a slip ring comprising:

a slip ring mating surface of injectable molded metal composition;

injection molding a polymer slip ring body onto the slip ring mating surface;

injection molding a coupling body; and

threadably coupling the coupling body to the outer body, retaining the slip ring between the inner body and the coupling body.

9. The method of claim 7, further comprising injection molding a polymer coupling body;

and

threadably coupling the coupling body to the outer body.

10. The method of claim 7, wherein the coupling body comprises a spring finger portion injection molded of an injectable molded metal composition;

and wherein the method further comprises injection molding a polymer about the spring finger portion.

11. The method of claim 7, further including injection molding a coupling nut provided with a clamp ring surface;

and wherein

the inner body is provided with an annular ramp surface at an end face;

the coupling nut threadable into the outer body and drives the clamp ring surface towards the annular ramp surface.

12. The method of claim 7, wherein the injection molded metal composition is an alloy comprising aluminum and zinc.

13. The method of claim 7, wherein the injection molding is performed at a temperature of 1100 degrees Fahrenheit or less.

14. A method for manufacturing a multi-shot injection molded coaxial cable connector, comprising the steps of:

inserting an inner contact into a mold;

injection molding an inner body of injectable molded metal composition;

injection molding a dielectric insulator between the inner contact and the inner body;

injection molding an outer body of polymer upon an outer diameter surface of the inner body.

15. The method of claim 14, further comprising injection molding a slip ring comprising:

a slip ring mating surface of injectable molded metal composition;

injection molding a polymer slip ring body onto the slip ring mating surface;

injection molding a coupling body; and

threading the coupling body into the connector body, retaining the slip ring between the coupling body and the connector body.

16. The method of claim 14, further comprising injection molding a polymer coupling body;

and

threadably coupling the coupling body to the outer body.

17. The method of claim 16, wherein the coupling body comprises a spring finger portion injection molded of an injectable molded metal composition;

and

the method further comprises injection molding a polymer about the spring finger portion.

18. The method of claim 14, further including injection molding a coupling nut provided with a clamp ring surface;

and

the inner body is provided with an annular ramp surface at an end face;

the coupling nut threadable into the outer body, to drive the clamp ring surface towards the annular ramp surface.

19. The method of claim 14, wherein the injection molded metal composition is an alloy comprising aluminum and zinc.

20. The method of claim 14, wherein the injection molding is performed at a temperature of 1100 degrees Fahrenheit or less.