Coaxial electrical terminal with crimped outer ferrule
A coaxial electrical cable assembly includes a coaxial electrical terminal having an inner ferrule disposed between an insulator surrounding a central conductor of a coaxial cable and a shield conductor of the coaxial cable and an outer ferrule crimped to the shield conductor and in compressive contact therewith. The outer ferrule defines a pair of crimp wings extending from a first side of a base portion of the outer ferrule and a single crimp wing extending from a second side of the base portion opposite the first side. The single crimp wing is disposed within a gap between the pair of crimp wings.
1 . An electrical cable assembly, comprising:
an electrical terminal having an inner ferrule disposed between an insulator surrounding a central conductor of an electrical cable and a shield conductor of the electrical cable; and
an outer ferrule crimped to the shield conductor and in compressive contact therewith, the outer ferrule defining a pair of crimp wings, both having a trapezoidal shape, extending from a first side of a base portion of the outer ferrule and a single crimp wing having a trapezoidal shape and extending from a second side of the base portion opposite the first side, the single crimp wing, the pair of crimp wings, and the base portion being bent to form a generally cylindrical tubular shape and each of the pair of crimp wings and the single crimp wing having a length equal to at least half of a circumference of the outer ferrule, each crimp wing narrowing continuously from the base portion to its tip, the single crimp wing being wider than a trapezoidal gap between the pair of crimp wings which widens continuously from the base portion to its end, the single crimp wing being disposed within the gap such that mesial edges of the pair of crimp wings are in compressive contact with distal edges of the single crimp wing.
2 . The electrical cable assembly in accordance with claim 1 , wherein the outer ferrule has a consistent thickness.
3 . The electrical cable assembly in accordance with claim 1 , wherein each of the pair of crimp wings has a right trapezoidal shape.
4 . The electrical cable assembly in accordance with claim 1 , wherein an inner surface of the outer ferrule defines a plurality of rhombus-shaped indentations.
5 . The electrical cable assembly in accordance with claim 1 , wherein the outer ferrule is also crimped to an outer insulator surrounding a portion of the shield conductor and is in compressive contact therewith.
6 . The electrical cable assembly in accordance with claim 5 , wherein the single crimp wing and one crimp wing of the pair of crimp wings are in compressive contact with the outer insulator.
7 . A method of forming an outer ferrule configured to secure an electrical terminal to an electrical cable, the method comprising:
forming an outer ferrule preform from sheet metal of generally uniform thickness, wherein the outer ferrule preform has a central base portion, defining a pair of crimp wings, both having a trapezoidal shape, extending from a first side of a base portion of the outer ferrule and a single crimp wing having a trapezoidal shape and extending from a second side of the base portion, each crimp wing narrowing continuously from the base portion to its tip, the pair of crimp wings defining a trapezoidal gap therebetween which widens continuously from the base portion to its end, and a width of the single crimp wing being greater than a width of the gap; and
bending the single crimp wing, the pair of crimp wings, and the base portion to form a generally cylindrical tubular shape, each of the pair of crimp wings and the single crimp wing having a length equal to at least half of a circumference of the outer ferrule.
8 . The method in accordance with claim 7 , further comprising:
forming a plurality of rhombus-shaped indentations in an inner surface of the outer ferrule preform.
9 . The method in accordance with claim 7 , wherein the single crimp wing has a trapezoidal wing shape, wherein the gap between the pair of crimp wings has a trapezoidal gap shape.
10 . The method in accordance with claim 9 , wherein the width of the trapezoidal crimp wing is 0.5 to 1.0 mm greater than the width of the trapezoidal gap.
11 . The method in accordance with claim 9 , wherein each of the pair of crimp wings has a right trapezoidal shape.
12 . The method in accordance with claim 9 , further comprising:
placing an exposed shield conductor of the electrical cable on the base portion of the outer ferrule preform; and
crimping the pair of crimp wings and the single crimp wing of the outer ferrule preform over the exposed shield conductor to form an outer ferrule having a tubular shape, wherein the single crimp wing is disposed within the trapezoidal gap, thereby pushing the pair of crimp wings apart and causing mesial edges of the pair of crimp wings to be in compressive contact with distal edges of the single crimp wing.
13 . The method in accordance with claim 12 , wherein the single crimp wing, the pair of crimp wings, and the base portion of the outer ferrule form a generally cylindrical tubular shape.
14 . The method in accordance with claim 12 , wherein the outer ferrule has a consistent thickness.
15 . The method in accordance with claim 12 , further comprising:
crimping the single crimp wing and one crimp wing of the pair of crimp wings such that they are in compressive contact with an outer insulator of the electrical cable.
16 . An electrical cable assembly, comprising:
an electrical terminal having an attachment portion having a pair of crimp wings, both having a trapezoidal shape, extending from a first side of a base portion of the attachment portion and a single crimp wing having a trapezoidal shape and extending from a second side of the attachment portion opposite the first side, the single crimp wing, the pair of crimp wings, and the base portion being bent to form a generally cylindrical tubular shape and each of the pair of crimp wings and the single crimp wing having a length equal to at least half of a circumference of an outer ferrule, each crimp wing narrowing continuously from the base portion to its tip, the single crimp wing being wider than a trapezoidal gap between the pair of crimp wings which widens continuously from the base portion to its end, the single crimp wing configured to be disposed within the gap such that mesial edges of the pair of crimp wings are in compressive contact with distal edges of the single crimp wing.
17 . The electrical cable assembly in accordance with claim 1 , wherein the entirety of the mesial edges of the pair of crimp wings are in compressive contact with the entirety of the distal edges of the single crimp wing.