# Patent

## Title
Method for crimping a coaxial cable to a connector

## Abstract

A method and crimping tool for creating a crimp connection between a coaxial cable having an inner conductor, an outer conductor, a dielectric between the outer conductor and inner conductor, a jacket made of an electrically insulating material surrounding the outer conductor, and a coaxial connector having an outer conductor part. A hollow cylindrical supporting sleeve is arranged on the jacket. A section of the outer conductor from which the jacket has been stripped is pulled over the supporting sleeve, so that this section of the outer conductor is at least in part arranged radially on the outside of the supporting sleeve, with the outer conductor part enclosing the supporting sleeve and lying on the outside, wherein a radial force is applied from outside on the outer conductor part over at least a part of the circumference of the outer conductor part, such that a cold weld is achieved.

## Background
This application claims priority to German Patent Application No. DE 10 2010 051 775.5, filed Nov. 18, 2010.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for creating a crimp connection between a coaxial cable which comprises, arranged coaxially in relation to one another, an inner conductor, an outer conductor, a dielectric arranged between the outer conductor and inner conductor, and a jacket made of an electrically insulating material surrounding the outer conductor, and a coaxial connector, which possesses an outer conductor part. The invention also relates to a crimping tool for performing the method, wherein the crimping tool possesses an anvil to hold the outer conductor part which is to be crimped as well as a die to apply the crimping force.
2. Description of Related Art
Crimp connections, in which two components are connected together through plastic deformations, represent a proven mechanical connection technique and are widely known.
Usually, the cross section of such known crimp connections represents a so-called hexagonal crimp, in which a supporting sleeve is hexagonal in cross section and is pressed, i.e. crimped, onto the inner conductor or onto a shield braid or an outer conductor arranged between the two. However, this only results in a pointwise connection being formed between the supporting sleeve and the outer conductor part. This means that approximately 60% of the shielding strands of the outer conductor of the coaxial cable remain loose, so that both the positive fit and the force locking of such a connection is only serviceable to a limited extent.
SUMMARY OF THE INVENTION
The invention is therefore based on the problem of developing a method of the aforementioned type in order to eliminate the described disadvantages such that both the positive fit and the force locking of such a connection are significantly improved and it is also made possible for other materials than those previously used to be used for the crimp sleeve or the outer conductor part serving as a crimp sleeve. Also, the invention is intended to provide a crimping tool suitable for creating such a crimp connection.
According to the invention, this problem is solved through a method of the aforementioned type with the features identified in the claims and through a crimping tool of the aforementioned type. Advantageous embodiments of the invention are described in the other claims.
Bearing in mind the problems and deficiencies of the prior art, an object underlying the invention is to a method for creating a crimp connection between a coaxial cable which possesses, arranged coaxially in relation to one another, an inner conductor, an outer conductor, a dielectric arranged between the outer conductor and inner conductor, and a jacket made of an electrically insulating material surrounding the outer conductor, and a coaxial connector which possesses an outer conductor part, the method comprising: arranging a hollow cylindrical supporting sleeve on the jacket; pulling a predetermined section of the outer conductor, from which the jacket has been stripped, over the supporting sleeve, so that this section of the outer conductor is at least in part arranged radially on the outside of the supporting sleeve; arranging the outer conductor part to at least partially enclose the supporting sleeve with the outer conductor lying on the outside, radially from the outside, wherein a radial force is applied from outside on the outer conductor part over at least a part of the circumference of the outer conductor part, seen in a circumferential direction and an axial direction; and forming a cold weld between the supporting sleeve, the outer conductor part, and the outer conductor.
The method further includes forming at least one accumulation of material due to the displaced material, the at least one accumulation of material rising radially outwards on the outer conductor part at the height of a closing gap of a crimping tool.
The method may also include forming at least one accumulation of material due to the displaced material, rising radially inwards on the outer conductor part at the height of a closing gap of a crimping tool.
In a second aspect, the present invention is directed to a crimping tool for forming a cold weld between a supporting sleeve, an outer conductor part, and an outer conductor of a coaxial cable, wherein the crimping tool comprises: an anvil to hold the outer conductor part which is to be crimped; and a die to apply the crimping force; wherein the anvil and die each possess a part-cylindrical recess, the diameter d2 of which substantially corresponds to or is slightly less than the diameter of the conductor part which is to be crimped.
The crimping tool may include the part-cylindrical recess of the die extending over an internal angle of approximately 180° and terminating in two parallel arms, having an internal distance d1 between which corresponds to the diameter d2 of the die recess.
The crimping tool may also include the part-cylindrical recess of the anvil extending over an internal angle of less than 180° and terminating in two arm points which, together with inner surfaces of the die arms, form a closing gap of the crimping tool.



BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:
FIG. 1 shows a diagrammatic cross-sectional view of a crimp connection with a coaxial connector made using the method according to the invention;
FIG. 2 shows a longitudinal section of said crimp connection;
FIG. 3 shows an end view of the crimping tool with die and anvil used to perform the crimping method according to the invention in open position; and
FIG. 4 shows an end view of the crimping tool with die and anvil used to perform the crimping method according to the invention in closed position.



DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
According to the invention, in a method of the aforementioned type, a hollow cylindrical supporting sleeve is arranged on the jacket, a predetermined section of the outer conductor, from which the jacket has been stripped, is pulled over the supporting sleeve, so that this section of the outer conductor is at least in part arranged radially on the outside of the supporting sleeve, and the outer conductor part is so arranged that this at least partially encloses the supporting sleeve with the outer conductor lying on the outside, radially from the outside, wherein a radial force is applied from outside on the outer conductor part over at least a part of the circumference of the outer conductor part, seen in a circumferential direction and an axial direction, in such a way that a cold weld is achieved between the supporting sleeve, the outer conductor part and the outer conductor.
This has the advantage that the outer conductor part itself serves as crimp sleeve and a force- and form-locked connection, seen in a circumferential direction, is achieved over the entire circumference and not only at separate points. The crimp connection is substantially circular in cross section.
A particularly firm crimp connection is achieved in that, due to the displaced material, at least one accumulation of material, which rises radially outwards, is formed on the outer conductor part at the height of a closing gap of a crimping tool.
An improved positive fit between the supporting sleeve and the outer conductor part as well as with the outer conductor arranged between them is achieved in that, due to the displaced material, at least one accumulation of material, which rises radially inwards, is formed on the outer conductor part at the height of a closing gap of a crimping tool.
According to the invention, in a crimping tool of the aforementioned type, the anvil and die each possess a part-cylindrical recess with a diameter d2 which substantially corresponds to, or is slightly less than, the diameter of outer conductor part which is to be crimped.
This has the advantage that the crimping process can be performed in a reliably repeatable manner and at the same time a crimp connection is achieved which is radially circumferential and circular in cross section.
A particularly secure holding of the outer conductor part in the crimping tool is achieved in that the part-cylindrical recess of the die extends over an internal angle of around 180° and terminates in two parallel arms, the internal distance d1 between which corresponds to the diameter d2 of the die recess.
A complete contact of the crimping tool in a radial direction with an outer surface of the outer conductor part which is to be crimped is achieved in that the part-cylindrical recess of the anvil extends over an internal angle of less than 180° and terminates in two arm points which, together with inner surfaces of the die arms, form a closing gap of the crimping tool.
The crimp connection created according to the invention is based on the essential principle that the outer conductor part serving as crimp sleeve is crimped in a largely annular form onto the supporting sleeve or onto a shield braid arranged between the two, forming both a form-locked and a force-locked crimp connection.
Due to the method and crimping tool according to the invention, a crimp connection is created which is virtually 100% form-locking and at the same time almost completely force-locking.
Another advantage of such a design is that other materials than those previously used, for example brass, can be used for the crimp connection, i.e. for the crimp sleeve or the outer conductor part, since it is no longer necessary, as previously, to use only copper as material due to the limited connecting forces.
As can be seen from FIGS. 1 and 2, the crimp connection shown is made on a coaxial connector. This has an inner conductor 1 which is usually enclosed by an inner insulation 2 as well as an outer conductor 3. This arrangement is enclosed by a supporting sleeve 4, around the outer surface of which the outer conductor 3 in the form of a shield braid is wrapped. This shield braid 3 is crimped onto the supporting sleeve 4 by means of the crimp connection. For this purpose, an outer conductor part 5 of the coaxial connector surrounding the supporting sleeve 4 and the wrapped shield braid 3, which is not shown in greater detail, is pressed together radially by means of a corresponding crimping tool in such a way that a plastic lateral deformation takes place, such that the outer conductor part 5 serving as crimp sleeve is crimped in a largely annular form onto the supporting sleeve 4 or onto a shield braid 3 arranged between the two.
As can clearly be seen from FIG. 1, due to the annular displacement of the material, small accumulations of material 6 are formed on both sides of the crimped outer conductor part 5 at the height of a closing gap of the crimping tool. These project radially both outwards and inwards, so that a strengthened positive fit with the supporting sleeve 4 or with the interposed shield braid 3 is formed.
The crimping tool designed to create the described crimp connection, as shown in FIGS. 3 and 4, possesses an anvil 7 to hold the outer conductor part 5 which is to be crimped as well as a die 8 for applying the crimping force.
As can be seen, both the anvil 7 and the die 8 each have a part-circular or part-cylindrical recess 9 or 10, the diameter d2 of which corresponds to or is slightly less than the diameter of the conductor part 5 which is to be crimped.
The part-cylindrical recess 10 of the die 8 extends over an internal angle of around 180° and terminates in two parallel arms 11, the internal distance d1 between which corresponds to the diameter d2 of the die recess 10.
As can also be seen from FIG. 3, the part-cylindrical recess 9 of the anvil 7 only extends over an internal angle of less than 180°. Also, this anvil recess 9 terminates in two arm points 12, the outer surfaces 13 of which, starting out from a distance corresponding to the internal distance d1 between the die arms 11, are spaced an increasing distance apart and which, together with the inner surfaces of the die surfaces 11, form the closing gap of the crimping tool.
If the crimp connection shown in FIGS. 1 and 2 are to be created using the described crimping tool, the arrangement which is to be crimped is laid in the part-circular recess 9 of the anvil 7, whereupon the die 8, with its part-circular recess 10 is pressed downwards from above until the arm points 12 of the anvil 7 penetrate between the inner surfaces of the die arms 11, where their obliquely outwardly sloping outer surfaces 13 come to rest in a clamping action. As explained, the closing gap of the crimping tool is formed at this point, with the accumulations of material 6 of the annularly distorted outer conductor part 5 which project radially outwards and inwards also being formed at this point.
The term “hollow cylindrical” here describes a body with an outer surface and inner surface which are circular in cross section. In other words, this refers to a hollow cylinder which is rotationally symmetrical around its central longitudinal axis.
While the present invention has been particularly described, in conjunction with the specific preferred embodiment(s), it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art, in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications, and variations as falling within the true scope and spirit of the present invention.

## Claims

1. A method for creating a crimp connection between a coaxial cable which possesses, arranged coaxially in relation to one another, an inner conductor, an outer conductor, a dielectric arranged between the outer conductor and inner conductor, and a jacket made of an electrically insulating material surrounding the outer conductor, and a coaxial connector which possesses an outer conductor part, said method comprising:
arranging a hollow cylindrical supporting sleeve on the jacket;
pulling a predetermined section of the outer conductor, from which the jacket has been stripped, over the supporting sleeve, so that this section of the outer conductor is at least in part arranged radially on the outside of the supporting sleeve;
arranging the outer conductor part to at least partially enclose the supporting sleeve with the outer conductor lying on the outside, radially from the outside, wherein a radial force is applied from outside on the outer conductor part over at least a part of the circumference of the outer conductor part, seen in a circumferential direction and an axial direction, such that the outer conductor part is crimped in an annular form onto the supporting sleeve, the crimp connection being substantially circular in cross section;
forming a cold weld between the supporting sleeve, the outer conductor part, and the outer conductor; and
forming at least one accumulation of material due to the displaced material, said at least one accumulation of material rising radially outwards on the outer conductor part at a height of a closing gap of a crimping tool.

2. The method of claim 1 including forming at least one accumulation of material due to the displaced material, rising radially inwards on the outer conductor part at the height of a closing gap of a crimping tool.