Connector for an audio cable, a combination connector and cable, and a method of securing said connector to said cable

• US 7,686,663 B1
• Filed: 12/30/2008
• Issued: 03/30/2010
• Est. Priority Date: 12/30/2008
• Status: Active Grant

• Current Assignee: Benjamin Zapolsky
• Original Assignee: Benjamin Zapolsky
• Inventors: Zapolsky, Benjamin
• Primary Examiner(s): Hammond; Briggitte R
• Application Number:
  US12/317,841
• Time in Patent Office: 455 Days
• Field of Search: 439/879, 439/888, 439/883, 174/89
• US Class Current: 439/879
• CPC Class Codes: H01R 11/12 End pieces terminating in an eye, hook, or fork
• CPC Class Codes: H01R 13/03 characterised by the material, e.g. plating, or coating materials
• CPC Class Codes: H01R 4/726 Making a non-soldered electrical connection simultaneously with the heat shrinking
• CPC Class Codes: H01R 43/00 Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28

Abstract

A connector for an audio cable, a combination connector and cable, and a method of securing the connector to the cable are disclosed. The connector includes a connector body formed from an electrically conductive material and having a first end sized to abut an end of an audio speaker cable, a second end shaped to be securely attached to a connecting post formed on a piece of audio equipment, and an exterior surface located therebetween. The exterior surface has a first portion, a second portion and a third portion. The first portion is sized to receive the exposed terminal surface of each of a plurality of wires present in the cable. An insulating layer extends over the exposed terminal surface of each of said wires and a band surrounds the insulating layer to provide a positive electrical interface between the exposed terminal surfaces and the first portion.

Claims

1. A connector for an audio cable which contains a plurality of wires each having an exposed terminal surface, comprising:

a) a connector body formed from an electrically conductive material and having a longitudinal central axis, said connector body having a first end sized to abut an end of an audio cable, a second end shaped to be securely attached to a connecting post formed on a piece of audio equipment, and an exterior surface which extends between said first and second ends, said exterior surface having a first portion, a second portion and a third portion, said first portion having a circular outer periphery with a length measured parallel to said longitudinal central axis, said first portion being located adjacent to said first end, said first portion is sized to receive said exposed terminal surface of each of said wires, said second portion being relatively flat and located adjacent to said second end, and said third portion converges downward from said first portion to said second portion;

b) an insulating layer extending over at least the length of said first portion and surrounding said exposed terminal surface of each of said wires; and

c) a band surrounding said insulating layer and extending over said first portion, said band being formed from a pliable material which is capable of being reduced in circumference to provide a positive electrical interface between said exposed terminal surface of each of said wires and said first portion.

2. The connector of claim 1 wherein said first portion has a plurality of cavities formed therein, each of said cavities has a dimension measured at said exterior surface of said first portion, and each of said wires has a diameter approximately equal to said dimension of each of said cavities, and each of said wires when positioned in one of said cavities is located at an equal distance from said longitudinal central axis.

3. The connector of claim 2 wherein each of said cavities has a semi-circular configuration and each of said cavities is spaced an equal distance from an adjacent semi-circular cavity.

4. The connector of claim 3 wherein each of said semi-circular cavities has a length that is at least 50% of said length of said first portion.

5. The connector of claim 4 wherein each of said semi-circular cavities has a length that is equal to said length of said first portion.

6. The connector of claim 5 wherein there are at least twelve semi-circular cavities equally spaced about said outer periphery of said first portion.

7. The connector of claim 5 wherein said outer periphery is plated with rhodium to increase electrical conductivity and make it resistant to corrosion.

8. The connector of claim 2 wherein said cavities are irregularly spaced about said outer periphery of said first portion.

9. The connector of claim 2 wherein there are at least thirty-two cavities equally spaced about said outer periphery of said first portion.

10. A combination connector and audio cable comprising:

a) a connector body formed from an electrically conductive material and having a longitudinal central axis, said connector body having a first end sized to abut an end of an audio cable, a second end shaped to be securely attached to a connecting post formed on a piece of audio equipment, and an exterior surface which extends between said first and second ends, said exterior surface having a first portion, a second portion and a third portion, said first portion having a circular outer periphery with a length measured parallel to said longitudinal central axis, said first portion being located adjacent to said first end and having a plurality of cavities formed therein, each of said cavities is sized to receive an exposed terminal surface of a wire, said second portion being relatively flat and located adjacent to said second end, and said third portion converges downward from said first portion to said second portion;

b) an audio cable having a flexible tubular core formed from a non-electrically conductive material, said core having a longitudinal central axis, a first end, and a circumferential surface spaced at a constant radius from said longitudinal central axis, a plurality of spaced apart metallic wires extending along and positioned outward of said circumferential surface, each of said wires having an exposed terminal surface which extends beyond said first end of said tubular core, each of said wires being positioned at an equal distance from said longitudinal central axis, and a cover layer surrounding at least a portion of said tubular core and said plurality of wires, and when said connector body is abutted against said first end of said cable said exposed terminal surface of each of said wires will contact said first portion;

c) an insulating layer extending over at least the length of said first portion and surrounding said exposed terminal surface of each of said wires; and

d) a band surrounding said insulating layer and extending over said first portion, said band being formed from a pliable material which is capable of being reduced in circumference to provide a positive electrical interface between said exposed terminal surfaces of each of said wires and said first portion.

11. The combination of claim 10 wherein said tubular core is hollow having a wall thickness of less than about 0.1 inches, and said tubular core is formed from Teflon.

12. The combination of claim 10 wherein said tubular core and said first portion have an identical outside diameter, said length of said first portion ranges from between about 10 millimeters to about 20 millimeters, each of said cavities has a semi-circular configuration and each of said semi-circular cavities has a length equal to said length of said first portion.

13. The combination of claim 10 wherein each of said wires is formed from silver, copper or brass, and said outer periphery of said first portion is plated with rhodium to increase its electrical conductivity and make it resistant to corrosion.

14. The combination of claim 10 wherein each of said exposed terminal surfaces has an outer periphery and at least 45% of said outer periphery is in contact with said first portion.

15. The combination of claim 10 wherein said second end of said connector has a spade configuration with a U-shaped cutout which is angled at least 10 degrees relative to said longitudinal central axis of said connector body.

16. A method of securing a connector to an audio cable, comprising the steps of:

a) forming a connector body from an electrically conductive material, said connector body having a longitudinal central axis, a first end sized to abut an end of an audio cable, a second end shaped to be securely attached to a connecting post formed on a piece of audio equipment, and an exterior surface which extends between said first and second ends, said exterior surface having a first portion, a second portion and a third portion, said first portion having a circular outer periphery with a length measured parallel to said longitudinal central axis, said first portion being located adjacent to said first end and having a plurality of cavities formed therein each being sized to receive an exposed terminal surface of a wire, said second portion being relatively flat and located adjacent to said second end, and said third portion converges downward from said first portion to said second portion;

b) forming an audio cable having a flexible tubular core formed from a non-electrically conductive material, said core having a longitudinal central axis, a first end, and a circumferential surface spaced at a constant radius from said longitudinal central axis, a plurality of spaced apart metallic wires extending along and positioned outward of said circumferential surface, each of said wires having an exposed terminal surface which extends beyond said first end of said tubular core, each of said wires being positioned at an equal distance from said longitudinal central axis, and a cover layer surrounding at least a portion of said tubular core and said plurality of wires;

c) abutting said first end of said connector against said first end of said cable such that said exposed terminal surface of each of said wires will be positioned in one of said cavities;

d) positioning an insulating layer over at least the length of said first portion such that it surrounds said exposed terminal surface of each of said wires;

e) positioning a pliable band about said insulating layer such that it extends over said first portion; and

f) reducing the circumference of said pliable band to provide a positive electrical interface between said exposed terminal surface of each of said wires and said first portion.

17. The method of claim 16 further comprising forming each of said cavities with a semi-circular configuration having a diameter approximately equal to a diameter of each of said wires, and each of said wires when positioned in one of said semi-circular cavities is located at an equal distance from said longitudinal central axis of said connector.

18. The method of claim 17 further comprising forming at least 20 semi-circular cavities in said outer periphery of said first portion and each of said semi-circular cavities being equally spaced from one another.

19. The method of claim 18 further comprising forming each of said wires from silver into a circular cross-section with a predetermined diameter and positioned said exposed terminal surface of each of said wires into one of said semi-circular cavities such that approximately 50% of said diameter of each wire is in direct contact with said first portion.

20. The method of claim 16 further comprising plating said outer periphery of said first portion with rhodium to increase its electrical conductivity and make it resistant to corrosion.