Abstract:
A flairing device having a handle and a body connected to the handle. The body includes an inner wall forming an open ended chamber in the body. The open ended chamber has an opening at one end of the body. An outer wall forms an edge with the inner wall at the one end of the body.

Description:
PRIORITY  
       [0001]    This application claims priority to U.S. Patent Application entitled, Automated Connection of Connectors to Cables, filed Jul. 26, 2002, having Ser. No. 10/202,893, and Positioning a Connector for Crimping a Ferrule Onto a Cable, filed Jul. 26, 2002, having Ser. No. 10/202,894 the disclosures of which are incorporated herein by reference. 
     
    
     GOVERNMENT RIGHTS IN THIS INVENTION  
       [0002] This invention was made with U.S. government support under contract number 8942184. The U.S. government has certain rights in this invention. 
     
    
     
       FIELD OF THE INVENTION  
         [0003]    The present invention relates generally to separating layers of a cable. More particularly, the present invention relates to separating shielding from a dielectric core of a coaxial cable.  
         BACKGROUND OF THE INVENTION  
         [0004]    Connectors are typically manually connected to cables, such as coaxial cables or RF cables. This involves repetitive motion by a worker by first stripping the cable and placing a ferrule over the stripped end of the cable. A connector is then placed onto the cable and the ferrule pushed up over top of the cable into or onto the connector. The ferrule can then be crimped to secure the ferrule onto the cable.  
           [0005]    There are many deficiencies to manually installing connectors onto a cable such as a coaxial cable or RF cable. One major deficiency is repetitive motion by a worker which may cause fatigue and result in improperly connected connectors. For example, most cables have a metal braid within the outer sheath of the cable. When manually placing the connector onto the cable, this braid can many times be damaged or pushed back too far. This will result in improper shielding and could cause negative effects especially when using high frequency cables.  
           [0006]    Another deficiency is not achieving proper contact depth. When attaching a connector to a cable the conductor or center part of the cable must be properly positioned on the center part or contact portion of the connector. When the conductor is properly positioned or seated onto the connector at the proper depth, proper contact depth has been achieved. Improper contact depth is caused through manual installation of connectors onto cables. Although some connectors include features that will indicate when proper contact depth is achieved, these features are usually inadequate and do not work well. Also the use of these features can be time consuming.  
           [0007]    When creating cables such as coaxial cables with connectors, it is important to keep the cables uniform so that uniform results can be obtained. However, during manual installation and because of fatigue which may be introduced through manual installation, the cables may not be uniformly manufactured. Thus, the installation could also become very time consuming. Accordingly, a way to install connectors and to crimp ferrules onto the cable that will provide uniform consistent results giving proper contact depth and efficient processing time is desired.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention includes an apparatus for effectively separating the shielding of a coaxial cable from the cable so that a connector can be easily connected to the end of the cable. One embodiment of the invention includes a flairing device having a handle and a body connected to the handle. The body includes an inner wall forming an open ended chamber in the body. The open ended chamber has an opening at one end of the body. An outer wall forms an edge with the inner wall at the one end of the body.  
           [0009]    In another embodiment of the invention, a method for separating an outer member of an object from an inner member of the object includes the steps of placing an end of a flair device onto the object so that a chamber formed by an inner wall of the flair device having an opening at the end of the flair device that can be pushed onto the inner member of the object, and pushing the end of the flair device into the object so that an edge at the end of the flair device separates the inner member from the outer member allowing the inner member to enter the chamber.  
           [0010]    There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
           [0011]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract included below, are for the purpose of description and should not be regarded as limiting.  
           [0012]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1A is an illustration of a stripped cable.  
         [0014]    [0014]FIG. 1B is a front view of the stripped cable illustrated in FIG. 1A.  
         [0015]    [0015]FIG. 2A is an illustration of a connector.  
         [0016]    [0016]FIG. 2B is a front view of the connector illustrated in FIG. 2A.  
         [0017]    [0017]FIG. 3 is an illustration of a flair device.  
         [0018]    [0018]FIG. 4 is an illustration of a connection device.  
         [0019]    [0019]FIG. 5 is an illustration showing a ferrule being pushed up against a stop by a connector.  
         [0020]    [0020]FIG. 6 is an illustration of a connection device with a indicator attachment.  
         [0021]    [0021]FIG. 7 is an illustration of method steps for connecting a connector to a cable.  
         [0022]    [0022]FIG. 8A is a side view of a connector positioner.  
         [0023]    [0023]FIG. 8B is a top view of a connector positioner.  
         [0024]    [0024]FIG. 9 is a flow chart showing the steps taken in crimping a ferrule. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]    The present invention provides a way of connecting a connector onto a cable at a proper contact depth without gauging and properly and uniformly crimping a ferrule onto a cable without damaging the center contact or shielding. The present invention also provides a way of positioning the shielding of the cable over the connector body without disturbing the shielding of the cable. The present invention further provides a way of connecting a connector onto a cable precisely and efficiently.  
         [0026]    [0026]FIG. 1A is an illustration of a coaxial cable  100  having a core  101 , a place covering or dielectric  102  and an outer jacket  104 . FIG. 1B is a front view of the coaxial cable  100  depicted in FIG. 1A. The coaxial cable depicted in FIG. 1B has a core  101  and a dielectric  102  surrounding core  101 . An inner flat braid  106  surrounds the dielectric  102 . A center foil  108  surrounds inner flat braid  106  and an outer braid  110  surrounds center foil  108 . Outer braid  110  is surround by outer jacket  104 .  
         [0027]    [0027]FIG. 2A is an illustration of a connector  200  having a first end  202  and a second end  204 . FIG. 2B is a front view of the first end  202  of connector  200  having a contact  206 . When manually connecting connector  200  to a coaxial cable  100 , the coaxial cable  100  must be stripped to expose core  101 . As depicted in FIG. 1A, core  101  can be exposed by cutting away dielectric  102 , outer jacket  104  and all other layers located therebetween. Connector  200  is connected to the coaxial cable via end  204 . This may involve separating the braiding such as the outer braid  110 , the foil or wrap mylar film  108  and the inner braid  106  away from dielectric  102 . This can be accomplished by working connector end  204  slowly onto the coaxial cable to ensure that these layers are pushed back properly.  
         [0028]    In one embodiment of the invention, a flair device  300  can be used as depicted in FIG. 3. Flair device  300  has an opening  302 , which is of a sufficient width to separate the braiding such as the outer braid  110 , the foil or wrap mylar film  108  and the inner braid  106  away from dielectric  102 . Once cable  100  is stripped, opening  302  is pushed onto the stripped end of cable  100 . Since opening  302  is of a sufficient width to separate dielectric  102  from the outer layer such as the outer braid  110 , the foil or wrap mylar film  108  and the inner braid  106 , the outer layers are separated from dielectric  102  without causing any damage to any of the outer layers. By using flair device  300  the problem of damaging the shielding wall when sliding the connector onto the coaxial cable is obviated.  
         [0029]    Once the outer layers have been pushed back sufficiently, second end  203  of connector  200  is pushed onto the stripped end of cable  100  until core  101  connects with contact  206  at a sufficient contact depth. In some instances good contact may not be made because a good contact between core  101  and contact  206  is not made. This can, in some instances, be overcome by including features such as small inspection holes in contact  206  to determine whether proper contact has been made or providing a means on contact  206  in which a audible click can be heard when the center pin or core  101  is properly seated onto the connector. However, in some instances, this can be time consuming. Furthermore, once the connector is properly placed onto the coaxial cable the ferrule must be slid onto to coaxial cable up against the connector  102 . Once the braiding has been expanded and the connector is pushed onto the cable it can be very difficult to jam the ferrule up against connector  200  without damaging the braiding.  
         [0030]    [0030]FIG. 4 is an illustration of a connection device  400  for accurately connecting a connector onto a cable. FIG. 4 includes a securing device  402  and a stop  404 , which is attached to securing device  402 . Stop  404  can be integrally attached to securing device  402 . Securing device  402  also includes a passage  406  for receiving a cable such as a coaxial cable and a handle  408  which when engaged secures a cable in passage  406 . In one embodiment of the invention handle  408  can be locked in the engaged position allowing for one hand operation.  
         [0031]    A connector installer  410  is spaced from securing device  402 . The connector installer  410  includes a handle  412  and a connector engagement device  414 . Handle  412  like handle  408  can be locked in an engaged position allowing for one hand operation. When handle  412  is engaged, the engagement device  414  will operate to force fit connector  200  onto a cable pushing a ferrule  416  against the stop  404  and simultaneously against connector  200 . In one embodiment of the invention, connector engagement device  414  moves to the right to push or force fit the connector  200  onto cable  100 . In another embodiment of the invention, the connector  200  is attached to the engagement device  414 . As engagement device  414  moves to the right, the connector  200  is pushed or force fit onto the cable  100 .  
         [0032]    [0032]FIG. 5 is an illustration of the connector forced fitted onto the cable  100  having a ferrule  416  pushed up against stop  404 . As is illustrated in FIG. 5, the apparatus as illustrated in FIG. 4 provides an efficient way to connect connector  200  to cable  100  and at the same time move ferrule  416  into the appropriate position using stop  404 . This provides a quick efficient way of uniformly attaching multiple connectors to a cable with less repetitive motion stress and also avoiding damaging the braiding. This also provides a way of getting the core  101  to be seated properly onto contact  206  of connector  200  and also ensures that the assembly of the connector is tight and prevents the connector from spinning or twisting on the cable (loose connectors cause cable failures, especially at high frequencies).  
         [0033]    As illustrated in FIG. 6, the connection device  400  can also include an indicator  610  which will help determine the appropriate length of the cable to obtain uniform results and ensure proper seating of core  101  onto contact  206  of connector  200 . The cable  100  can be placed in passage  406  of securing device  402 . Using markings  612  located on indicator  610 , the cable  100  can be placed in the passage  406  of securing device  402  until the end of cable  100  reaches the appropriate marking  612 . Thus, the correct contact depth will be achieved easily and uniformly. Markings  612  can also have retractable extensions  614  that extend outwards so that the cable  100  can be accurately measured. Once the cable  100  is measured, the retractable extensions  614  can be retracted so that connector  200  can be connected to the cable. Once the connector  200  is appropriately connected to the cable  100 , the handles  408  and  412  can be released to disengage the cable  100  and connector  200 .  
         [0034]    [0034]FIG. 7 is an illustration of the method steps used to connect the connector  200  to cable  100 . In step  700  the cable is secured using securing device  402 . In one embodiment of the invention the cable is secured by being placed in passage  406 . The cable can then be aligned to alignment member  610  to determine the proper length of the cable. Measuring the proper cable length will ensure that core  101  is properly seated onto connector  200 . When the proper length of the cable has been measured, securing handle  408  can be engaged to secure the cable  100 . A ferrule is then slid onto the end of the cable where connector  200  is to be connected. Connector  200  can then be placed on the cable  100  or the connector engagement device  414 . Once handle  412  is pressed down the engagement device moves toward the cable  100  so that connector  200  is force fitted onto the cable as illustrated in step  720 . Once the engagement device  414  engages the connector  200  and force fits connector  200  onto the cable, the ferrule  416  is pushed against the stop  404  thereby properly engaging ferrule  416  to the connector  100  such that the braiding is not damaged. The braiding bunches up underneath ferrule  416  to make a tight connection.  
         [0035]    Once the connector  200  and ferrule  416  are in proper position, the ferrule  416  can be crimped to the cable  100 . FIG. 8A is a side view of a connector positioner  800  having a base  802  and a cable stop  804 . An adjustment member  806  is attached to cable stop  804 . Adjustment member  806  moves cable stop  804  so that when the connector  200  of cable  100  rests against outer surface  808  of cable stop  804 , ferrule  416  of cable  100  is properly positioned to be crimped. Base  802  can include a depression  810  to accommodate the size of a connector at the end of a cable. FIG. 7B is a top view of connector positioner  800 .  
         [0036]    The connector positioner  800  can be used to properly position cable  100 , connector  200  and ferrule  416  to be crimped. As illustrated in FIG. 9, in step  902  the cable stop  804  is positioned using adjustment member  806 . Cable stop  804  can be positioned so that the ferrule  416  lies on the base  802  and the connector  200  is in the center of depression  810 . Depression  810  can have a depth that will accommodate connector  200  without miss-aligning the connector  200  with cable  100 .  
         [0037]    In step  904  the connector  200  of cable  100  is placed against outer surface  808  of cable stop  804 . Once the cable  100  is in place, a clamp can be used to secure cable  100 , preventing cable  100  from moving when ferrule  416  is being crimped.  
         [0038]    In step  906  ferrule  416  is crimped using a crimping machine located above the base  802 . When ferrule  416  is crimped, inner flat braid  106 , center foil  108 , outer braid  110  and outer jacket  104  are all compressed pushing connector  200  outward. If outer surface  808  of cable stop  804  is vertical, connector  200  will be pushed up against outer surface  808  miss-aligning connector  200  and possibly damaging the connector  200  or cable  100 .  
         [0039]    In one embodiment of the invention, outer surface  808  can be slanted downward and away from connector  200  as illustrated in FIG. 8A. In one embodiment of the invention, outer surface  808  can be slanted 3-5 degrees from vertical (the dotted line depicted in FIG. 8A is vertical). By slanting outer surface  808  downward and away from the connector  200 , when the ferrule  416  is crimped, the cable  100  will be pushed downward and the connector  200  will be pushed toward outer surface  808 . Since the outer surface  808  is slanted downward and away from the connector, when the connector is forced toward the outer surface  808  there will be a space provided for this expansion without damaging the connector  200  or cable  100 .  
         [0040]    Thus, the present invention provides a way to connect a connector and crimp a ferrule onto a cable quickly and efficiently reducing assembly time from approximately 2 minutes for each cable end to approximately 15 second per cable end. The present invention also provides consistent test results at frequencies above 7.0 GHz, resulting in repetitive-quality cables. The present invention also allows an operator to achieve proper contact depth without gauging and allows an operator to position shielding over the connector body without disturbing the shielding of the cable. This is important to maintain mechanical and electrical integrity. The present invention, thus, ensures that the interface between the cable and connector is as specified by the connector&#39;s manufacturing instructions and also ensures that the assembly of the connector is tight and prevents the connector from spinning or twisting on the cable (loose connectors cause cable failures, especially at high frequencies). The present invention also ensures proper connector orientation relative to the cable and prevents the connector or cable from being damaged when the ferrule is crimped.  
         [0041]    The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirits and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.