Friction weld inner conductor cap interconnection method

Abstract

An inner conductor cap, with a connector end and a cable end, is provided with an inner conductor socket at the cable end and an inner conductor interface at the connector end. The inner conductor socket may be dimensioned to mate with a prepared end of an inner conductor of a coaxial cable. At least one material gap may be provided between a sidewall of the inner conductor socket and an outer diameter surface of the prepared end when the inner conductor cap is mated with the prepared end. A rotation key may be provided for rotating the inner conductor cap.

We claim: 
     
         1 . A method for interconnecting an inner conductor cap, with a connector end and a cable end, to a prepared end of an inner conductor of a coaxial cable, comprising the steps of:
 providing an inner conductor cap with an inner conductor interface at the connector end, an inner conductor socket open to the cable end, the inner conductor socket dimensioned to mate with the prepared end, at least one material gap between a sidewall of the inner conductor socket and an outer diameter surface of the prepared end when the inner conductor cap is mated with the prepared end, and a rotation key for rotating the inner conductor cap;   inserting the prepared end into the inner conductor socket; and   rotating the inner conductor cap about a longitudinal axis of the prepared end, while applying longitudinal force to drive the inner conductor cap against the prepared end.   
     
     
         2 . The method of  claim 1 , wherein the inner conductor is one of aluminum and aluminum alloy material. 
     
     
         3 . The method of  claim 1 , wherein the rotation and longitudinal force are applied until heat sufficient to plasticize the prepared end of the inner conductor is generated. 
     
     
         4 . The method of  claim 1 , wherein the rotation and longitudinal force is maintained until a friction weld is created between the inner conductor and the inner conductor cap. 
     
     
         5 . The method of  claim 1 , further including the steps of:
 preparing the prepared end by removing a portion of an outer conductor of the coaxial cable so that the inner conductor extends therefrom;   removing a portion of a dielectric material between the inner conductor and the outer conductor;   stripping back a portion of a jacket from the outer conductor; and   grinding a leading end of the inner conductor to form a conical portion.   
     
     
         6 . The method of  claim 1 , further including the step of grinding a cylindrical portion at a base of the conical portion. 
     
     
         7 . A method for interconnecting an inner conductor cap, with a connector end and a cable end, to a prepared end of an inner conductor of a coaxial cable, comprising the steps of:
 providing an inner conductor cap with an inner conductor interface at the connector end, an inner conductor socket open to the cable end, the inner conductor socket dimensioned to mate with the prepared end, at least one material gap between a sidewall of the inner conductor socket and an outer diameter surface of the prepared end when the inner conductor cap is mated with the prepared end;   inserting the prepared end into the inner conductor socket; and   applying torsional vibration to the inner conductor cap, while applying longitudinal force to drive the inner conductor cap against the prepared end.