Abstract:
A coaxial cable side tap assembly of a coaxial cable with pins separately attached to the cable center conductor and braided sheath for connecting to a branch cable or an integrated circuit or transducer microchip and processes for manufacture thereof.

Description:
RELATED APPLICATION 
     This application is a continuation-in-part of an application Ser. No. 07/833,687, filed Feb. 11, 1992, now U.S. Pat. No. 5,163,852. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to side tap connector assemblies for tapping into a coaxial electric signal cable at any point for attachment of integrated circuit chips and to processes for assembling the connector, coaxial cable, and chip. 
     BACKGROUND OF THE INVENTION 
     In the provision of wiring systems carrying voice, electronic data, and/or electrical power between separate buildings, communication or data equipment and networks, or work stations within a building, it is frequently needed to splice or branch coaxial electric cables. Splicing is usually done by tapping into a coaxial cable along its length at a convenient point for branching. This can become tedious, complicated, and time consuming where the tap connectors are complicated and/or bulky and require special tools and skills for installation. 
     Several methods are currently used to tap a coaxial cable. One method is to cut the coaxial cable, terminate each end with a connector, and connect each connector to a tee connector. This method often gives a bulky and labor intensive connection. In a second method, the jacket, shield, and insulation are stripped from a short section of coaxial cable. The exposed center conductor is soldered to the exposed center conductor of a second coaxial cable, the shields connected by jumper wire, and the splice covered with insulation. This method is usually labor intensive, and the mechanical integrity of the coaxial cable is reduced since the braided shield, a primary strength member, has been cut. 
     A third method utilizes coaxial solder sleeves to tie in a third coaxial cable after the coaxial cable has been cut in two. Poor electrical characteristics and poor mechanical strength usually characterize the product of this method. 
     One may also cut and strip a coaxial cable and solder each center conductor to a pin on a small printed circuit (PC) board. The braids are soldered to pads on the board and onto a metal cover. The inside of the cover is incapsulated in insulation. The two pins protruding from the rear side of the PC board may connect to a branch coaxial cable. This product has good electrical properties, but only fair mechanical properties, and is usually a bit bulky. 
     A frequently used method is a saddle clamp device attached to a coaxial cable from which pointed contacts pierce the cable to contact the shield and the center conductor. Unreliable contact is often a problem with this method. 
     SUMMARY OF THE INVENTION 
     The invention comprises a coaxial cable side tap assembly with an integrated circuit chip. 
     The coaxial cable comprises an electrically-conductive center conductor surrounded by insulation (dielectric), which is preferably expanded polytetrafluoroethylene (ePTFE). The insulation is surrounded by a braided electrically-conductive sheath and optionally a protective polymer jacket around the shield. 
     The assembly of the invention is manufactured by removing the jacket from a short section of cable at a point where a tap is desired and tinning or soldering the conductive braid, preferably of a metal strand, wire, or strips of copper, copper alloy, aluminum, or steel, for example, to hold all strands of braid in place. Conductive epoxy resin may also be used in place of solder to hold the strands of braid in place. A small notch is cut from opposing sides of the tinned braid leaving intact the center conductor. The insulation (dielectric) is removed from the center conductor in the area of the two notches in the braid, such as by laser beam cutter. A notched insulated conductive pin is soldered at the notch to the center conductor, extending outwardly therefrom. The insulation of the pin extends at least to the outer surface level of the jacket. The cavity around the pin and center conductor is filled with insulation. A cylindrically-curved conductive top cap, having optionally already soldered in place a conductive pin or a formed raised pad for contacting the conductive braid of the cable and an adjacent hole for passage through the top cap of the insulated pin soldered to the center conductor, is placed over said insulated pin soldered to the center conductor in the opening in the braid of the cable and the cap soldered or adhered with conductive epoxy resin to the braid. A cylindrically-curved conductive bottom cap is placed on the opposite side of the cable from the top cap and soldered or adhered with conductive epoxy resin to the braid. The exposed area may then be covered with insulating protective polymer, such as by injection molding or shrink tubing. 
     Alternatively, the tap may be applied to the coaxial cable before application of a protective polymer outer jacket. 
     In this invention, the above described side tap is connected to a small integrated circuit microchip or transducer to form an integral part of a cable side tap microchip assembly under a plastic outer protective jacket covering the entire assembly. Optionally, the microchip under the jacket may have means provided for connection outside the assembly and may have a thin layer of insulation inserted between the microchip or transducer and the conductive braid surrounding the insulation and top and/or bottom portions of a conductive cap. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1a is a side view of a coaxial cable 1 with a section of jacket 2 removed and the braid tinned at 4. The alternative form 1B has no jacket. 
     FIG. 2A is a side view of a coaxial cable with notches 6 cut through the tinned braid 4 to expose insulation 5. FIG. 2B depicts the cable of FIG. 2B rotated 90° to give a better view of the notches 6. 
     FIGS. 3A and 3B are side views of a cable showing the insulation removed from around the center conductor 2 in two 90° rotated views (E &amp; F). 
     FIG. 4 is a side view of a cable having an insulated notched pin 9 soldered to the center conductor and passing through a top cap 8 fitted to the tinned braid, the top cap having a pin 10 soldered to it adjacent the exit of the notched pin through the top cap. 
     FIG. 5 is a side view of the partial assembly wherein insulation has been filled into the cavity formed by notch 6 surrounding the notched pin and center conductor. 
     FIG. 6 is a side view of the assembly with top cap and bottom cap in place on the tinned portion of the cable. 
     FIG. 7 is a blown up perspective view of the top cap, bottom cap, and insulated notched pin in spatial relationship to each other. 
     FIG. 8 is a side view of a top half and a bottom half of a cylindrically-shaped conductive cap with contact pins extending from the top cap to bring the outer conductor and the conductive braid of the shielded cable into contact with an integrated circuit chip or transducer affixed to the contact pins. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The assembly of the invention and the processes for its manufacture are now described with reference to the drawings to more fully and carefully delineate the components of the assembly and how they are assembled together by the processes of the invention. 
     FIG. 1 shows jacketed A and unjacketed B forms of a coaxial cable 1 in which jacket 2 has been removed from a section of cable 1. A section of exposed conductive braid 3 is tinned 4 to hold the strands comprising the braid firmly in place. 
     In FIG. 2, notches 6 have been cut partially through the tinned braid 4 opposite each other to expose the main cable dielectric 5. Views 2A and 2B are rotated 90° apart for better viewing of the exposed cross-section. 
     In FIG. 3, dielectric 5 has been removed from around center conductor 7, by laser beam, for example. Other removal methods may be used. Views 3A and 3B are rotated 90° apart. 
     FIG. 4 shows a cylindrically-curved top cap 8 fitted to and soldered to the tinned braid 4 over notch 6. Insulated notched pin 9 has been fitted over center conductor 7 and soldered in place and passed through a hole for housing the insulated pin in the top cap 8. Pin 10 for contacting the braid 3 has been soldered to top cap 8 adjacent pin 9. Notch 6 lies beneath pin 9 soldered to center conductor 7. 
     In FIG. 5, the cavity surrounding pin 9 has been filled with insulation. 
     FIG. 6 shows bottom cap 12 fitted over filled lower notch 6. It is soldered to braid 3 to complete the assembly. 
     At this point, protective polymeric jacket material may be applied to the assembly around the top and bottom caps in the area where it has been removed at the start of the manufacturing process. If the cable has no jacket, a jacket may now be applied over the cable and side tap assembly, such as by extrusion, to protect the cable and assembly while leaving the ends of the top contacts 9 and 10 exposed for connection to a cable branch. 
     FIG. 7 shows a blown up perspective diagram of the spatial relationship of the top cap 8 to the bottom cap 12, and that of the insulator sleeve 13 to notched pin 9 and the hole for its passage through top cap 8. The relation of pin 10 to top cap 8 is also shown. The pins may be level with or extend above a protective jacket applied to the top and bottom caps or may lie below the jacket to be later located, opened and the ends of the pins placed in contact with outside terminals. Notched pin 9 is soldered to the center conductor 7 of the cable being tapped. 
     FIG. 8 shows a side view of a cable with side tap in place, such as depicted in FIG. 6, with an integrated circuit chip 19 affixed in place on the contact pins of the side cap in electrical contact with the circuits of the cable upon which the side tap is assembled. 
     The integrated circuit chip 19 may be a central processor wafer of about 0.2 inch by about 0.2 inch or less in dimensions. Such a chip contains the interconnected components: the clock; a control unit comprising the program counter, the instruction register, process status word, and stack pointer; a control memory; a bus control; a working register; an arithmetic/logic unit; and an internal memory or stack. Chip 19 may be a transducer. 
     The conductive metals known to be useful in coaxial signal cables are useful in this invention. The insulation of the cable may be any useful insulation (dielectric), but a foamed or expanded insulation, especially of ePTFE, is preferred for the cable used in this invention. The jacket may be of a material common in wire and cable manufacture, such as a thermoplastic fluorocarbon resin, polyethylene, polypropylene, polyurethane, or rubber, for example. 
     The assemblies of the invention are easily manufactured by the processes of the invention, are very light in weight, have a minimum cross-section, virtually the same as that of the coaxial cable used to make the assemblies, are very strong, and provide a minimum of protruding parts outside the surface contours of the coaxial cable. Easy and rapid connection and termination to a branch coaxial cable, tranducers, or microchips are provided. The assembly is useful in towed underwater sensors, such as those used in sonar arrays, and other areas of application include industrial sequence controllers, machine tool controllers, point-of-sale terminals, intelligent terminals, instrument processors, traffic light controllers, weather and seismic data collection systems, and process controllers.