Method of terminating a coaxial cable
Passive intermodulation (PIM) and impedance management in coaxial cable terminations. In one example embodiment, a method for terminating a coaxial cable is provided. The coaxial cable includes an inner conductor, an insulating layer, an outer conductor, and a jacket. First, a diameter of the outer conductor that surrounds a cored-out section of the insulating layer is increased so as to create an increased-diameter cylindrical section of the outer conductor. Next, an internal connector structure is inserted into the cored-out section so as to be surrounded by the increased-diameter cylindrical section. Finally, an external connector structure is clamped around the increased-diameter cylindrical section so as to radially compress the increased-diameter cylindrical section between the external connector structure and the internal connector structure, and via a single action, a contact force between the inner conductor and a conductive pin is increased.
1. A method for terminating a coaxial cable, the coaxial cable comprising an inner conductor, an insulating layer surrounding the inner conductor, an outer conductor surrounding the insulating layer, and a jacket surrounding the outer conductor, the method comprising the following steps:
removing a section of the insulating layer between the outer conductor and the inner conductor so as to create a cored-out section therebetween;
increasing a diameter of at least a portion of the outer conductor that overlays a cored-out section of the insulating layer so as to create an increased-diameter cylindrical section of the outer conductor, the increased-diameter cylindrical section having a length that is at least two times a thickness of the outer conductor;
inserting at least a portion of an internal connector structure into the cored-out section so as to be surrounded by the increased-diameter cylindrical section;
inserting at least a portion of the inner conductor within a conductive pin resulting in an initial contact force between the inner conductor and the conductive pin; and via a single action:
clamping an external connector structure around the increased-diameter cylindrical section so as to radially compress the increased-diameter cylindrical section between the external connector structure and the internal connector structure; and increasing a contact force between the inner conductor and the conductive pin.
2. The method as recited in claim 1 , wherein: the outer conductor comprises a corrugated outer conductor having peaks and valleys; and the step of increasing the diameter of at least a portion of the outer conductor that surrounds the cored-out section comprises the step of:
increasing a diameter of one or more of the valleys of the corrugated outer conductor that surround the cored-out section so as to create an increased-diameter cylindrical section of the corrugated outer conductor.
3. The method as recited in claim 2 , wherein the increased-diameter cylindrical section of the corrugated outer conductor has a diameter that is greater than a diameter of the peaks of the corrugated outer conductor.
4. The method as recited in claim 2 , wherein the increased-diameter cylindrical section of the outer conductor diameter has a diameter that is about equal to a diameter of unmodified peaks of the corrugated outer conductor.
5. The method as recited in claim 2 , wherein the inserted portion of the internal connector structure comprises a metal inserted portion of the internal connector structure.
6. The method as recited in claim 5 , wherein the thickness of the metal inserted portion of the internal connector structure is greater than the difference between an inside diameter of the peaks of the corrugated outer conductor and an inside diameter of the valleys of the corrugated outer conductor.
7. The method as recited in claim 5 , wherein the metal inserted portion of the internal connector structure has an inside diameter that is about equal to an average diameter of the valleys and the peaks of the corrugated outer conductor.
8. The method as recited in claim 1 , wherein the outer conductor comprises a smooth-wailed outer conductor having a substantially uniform diameter along the length of the outer conductor.
9. The method as recited in claim 8 , wherein the inserted portion of the internal connector structure comprises a metal inserted portion of the internal connector structure.
10. The method as recited in claim 9 , wherein the metal inserted portion of the internal connector structure has an inside diameter that is less than the substantially uniform inside diameter of the smooth-walled outer conductor.
11. The method as recited in claim 1 , wherein the inserted portion of the internal connector structure comprises a cylindrical internal connector structure portion having a substantially uniform outside diameter along the length of the inserted portion of the internal connector structure.