Corrugated Solder Pre-form and Method of Use

Abstract

A solder pre-form for soldering a coaxial cable to a connector body is provided with a plurality of flux grooves on a cable side and a connector side. The solder pre-form may also have a plurality of holes between the cable and connector sides. In a method of use, flux is applied to the flux grooves and the solder pre-form applied to encircle the outer conductor which is then inserted into the connector body and the solder pre-form melted to complete the solder interconnection. Where holes are present, flux may be applied to the connector side, passing through the holes also to the cable side.

1 . A solder pre-form with a cable side and a connector side for soldering a coaxial cable to a connector body, comprising:
 a solder pre-form provided with a plurality of flux grooves on the cable side and the connector side;   the flux grooves provided as corrugations of the solder pre-form, wherein a trough of the cable side is a crest of the connector side.   
     
     
         2 . The solder pre-form of  claim 1 , wherein the flux grooves extend along a longitudinal axis of the solder pre-form. 
     
     
         3 . The solder pre-form of  claim 1 , wherein the flux grooves extend perpendicular to a longitudinal axis of the solder pre-form. 
     
     
         4 . (canceled) 
     
     
         5 . The solder pre-form of  claim 1 , further including a plurality of holes in the solder pre-form; the holes communicating between the cable side and the connector side. 
     
     
         6 . The solder pre-form of  claim 5 , wherein the holes are slots perpendicular to a longitudinal axis of the solder pre-form. 
     
     
         7 . The solder pre-form of  claim 1 , wherein the solder pre-form is U-shaped. 
     
     
         8 . The solder pre-form of  claim 7 , wherein a bend radius of the solder pre-form is dimensioned to seat upon an outer diameter of an outer conductor of the coaxial cable. 
     
     
         9 . The solder pre-form of  claim 7 , wherein a bend radius of the solder pre-form is dimensioned for an interference fit upon an outer diameter of an outer conductor of the coaxial cable. 
     
     
         10 . A method for soldering a coaxial cable with a coaxial connector, comprising the steps of:
 applying a flux to a plurality of flux grooves of a cable side of a solder pre-form;   the flux grooves provided as corrugations of the solder pre-form, wherein a trough of the cable side is a crest of a connector side;   applying the solder pre-form around an outer conductor of the coaxial cable,   whereby the solder pre-form at least partially encircles the outer conductor;   applying flux to a plurality of flux grooves of the connector side of the solder pre-form;   inserting the coaxial cable with the solder pre-form thereon into a connector body bore of the coaxial connector; and   melting the solder pre-form.   
     
     
         11 . The method of  claim 10 , wherein the solder pre-form is U-shaped; the solder pre-form applied to encircle the outer conductor by bending first and second ends of the solder pre-form towards one another around the outer conductor. 
     
     
         12 . The method of  claim 11 , wherein the bending is performed with a hand tool. 
     
     
         13 . The method of  claim 10 , wherein the outer conductor and the coaxial connector are one of aluminum and aluminum alloy. 
     
     
         14 . The method of  claim 10 , further including the step of installing an inner contact upon an inner conductor of the coaxial cable. 
     
     
         15 . The method of  claim 14 , further including the step of installing an insulator onto the inner contact. 
     
     
         16 . A method for soldering a coaxial cable with a coaxial connector, comprising the steps of:
 applying a solder pre-form to at least partially enclose an outer conductor of a prepared end of the coaxial cable;   applying flux on a connector side of the solder perform, covering a plurality of holes of the pre-form body with the flux such that the flux flows to a cable side of the solder pre-form therethrough;   inserting the coaxial cable into a connector body bore of the coaxial connector;   melting the solder pre-form.   
     
     
         17 . The method of  claim 16 , wherein the solder pre-form is U-shaped; the solder pre-form applied to encircle the outer conductor by bending first and second ends of the solder pre-form towards one another around the outer conductor. 
     
     
         18 . The method of  claim 16 , wherein the outer conductor and the coaxial connector are one of aluminum and aluminum alloy. 
     
     
         19 . The method of  claim 16 , further including the step of installing an inner contact on an inner conductor of the coaxial cable. 
     
     
         20 . The method of  claim 16 , further including the step of installing an insulator upon the inner contact.