Multi-shot Connector Assembly and Method of Manufacture
A coaxial cable connector formed via multi-shot injection molding has a body formed by multiple injection molding layers of different injection moldable materials about a central inner contact to form an integral connector body. The connector body is provided with a coaxial dielectric spacer of dielectric polymer surrounding the inner contact; a coaxial inner body of injection molded metal composition surrounding an outer diameter of the dielectric spacer; and an outer body of polymer surrounding the inner body. Interlock features provide axial and/or rotational interlock between the layers of the connector.
1 . A multi-connector assembly, comprising:
a monolithic outer body of metal composition; the outer body provided with a flange portion;
the flange portion provided with a female connector portion and a male connector portion;
the female connector portion provided with a female bore;
the male connector portion provided with a male bore;
a plurality of female pins;
a plurality of male pins;
a female insulator of dielectric polymer molded about the female pins, within the female bore;
a male insulator of dielectric polymer molded about the male pins, within the male bore;
an outer diameter of the female insulator sealing against an inner diameter of the female bore; and
an outer diameter of the male insulator sealing against an inner diameter of the male bore.
2 . The dual connector assembly of claim 1 , wherein the female connector portion is provided with an interior thread on the inner diameter of the female bore;
the plurality of female pins open to a connector end;
the female insulator provided with a key slot extending inward from an outer diameter of the female insulator;
the male connector portion protruding from the flange portion towards the connector end;
an exterior thread provided around an outer diameter of the male connector portion; and
a key protruding inward from the inner diameter of the male bore.
3 . The dual connector assembly of claim 1 , further including at least one interlock feature between the inner diameter of the female bore and an outer diameter of the female insulator.
4 . The dual connector assembly of claim 1 , further including at least one interlock feature between the inner diameter of the male bore and an outer diameter of the male insulator.
5 . The dual connector assembly of claim 3 , wherein the at least one interlock feature is an annular protrusion projecting radially inward from the inner diameter of the female bore.
6 . The dual connector assembly of claim 4 , wherein the at least one interlock feature is an annular protrusion projecting radially inward from the inner diameter of the male bore.
7 . The dual connector assembly of claim 1 , wherein a base portion extends from the flange portion towards a device end of the outer body; and
the base portion is dimensioned to couple as an exterior surface of a cellular base station antenna.
8 . The dual connector assembly of claim 1 , wherein the metal composition is an alloy comprising zinc and aluminum.
9 . A method for manufacturing a multi-shot injection molded dual connector assembly, comprising the steps of:
injection molding a monolithic outer body from an injection moldable metal composition;
the outer body having a flange portion provided with a female connector portion and a male connector portion;
the female connector portion provided with a female bore;
the male connector portion provided with a male bore;
injection molding a female insulator about a plurality of female pins, within the female bore;
injection molding a male insulator about a plurality of male pins within the male bore;
an outer diameter of the female insulator sealing against an inner diameter of the female bore; and
an outer diameter of the male insulator sealing against an inner diameter of the male bore.
10 . The method of claim 9 , wherein the female connector portion is provided with an interior thread on the inner diameter of the female bore;
the plurality of female pins provided with interconnection cavities open to a connector end;
the female insulator provided with a key slot extending inward from an outer diameter of the female insulator;
the male connector portion protruding from the flange portion towards the connector end;
an exterior thread provided around an outer diameter of the connector portion; and
a key protruding inward from the inner diameter of the bore.
11 . The method of claim 9 , further including at least one interlock feature between the inner diameter of the female bore and an outer diameter of the female insulator.
12 . The method of claim 9 , further including at least one interlock feature between the inner diameter of the male bore and an outer diameter of the male insulator.
13 . The method of claim 11 , wherein the at least one interlock feature is an annular protrusion projecting radially inward from the inner diameter of the female bore.
14 . The method of claim 12 , wherein the at least one interlock feature is an annular protrusion projecting radially inward from the inner diameter of the male bore.
15 . The method of claim 9 , wherein a base portion extends from the flange portion towards a device end of the outer body; and
the flange portion is dimensioned to close a bottom end of a cellular base station antenna.
16 . The method of claim 9 , wherein the injection moldable metal composition is an alloy comprising aluminum and zinc.
17 . The method of claim 9 , wherein the injection molding is performed at a temperature of 1100 degrees Fahrenheit or less.
18 . A method for manufacturing a multi-shot injection molded dual connector assembly, comprising the steps of:
injection molding a female insulator about a plurality of female pins;
injection molding a male insulator about a plurality of male pins;
injection molding a monolithic outer body from an injection moldable metal composition around the female insulator and the male insulator;
the outer body having a flange portion and a base portion;
the flange portion provided with a female connector portion and a male connector portion;
the female connector portion provided with a female bore;
the male connector portion provided with a male bore;
an outer diameter of the female insulator sealing against an inner diameter of the female bore; and
an outer diameter of the male insulator sealing against an inner diameter of the male bore.
19 . The method of claim 18 , wherein a base portion extends from the flange portion towards a device end of the outer body; and
the flange portion is dimensioned to close a bottom end of a cellular base station antenna.
20 . The method of claim 18 , wherein the injection moldable metal composition is an alloy comprising aluminum and zinc.