Wire assembly with welded contact

Abstract

A wire assembly includes a cable and a contact. The wire includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end. The contact is welded to the tip of the inner conductor at the first end.

1 . A coaxial cable assembly, comprising:
 an inner conductor and an insulator surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end, wherein the tip is in a plane substantially perpendicular to a longitudinal axis of the inner conductor; and   a contact welded to the tip of the inner conductor at the first end, wherein no portion of the contact is in contact with an outer circumference of the inner conductor.   
     
     
         2 . The coaxial cable assembly of  claim 1 , wherein the inner conductor and the insulator are coextensive in length. 
     
     
         3 . The coaxial cable assembly of  claim 1 , wherein the insulator is stripped from the inner conductor to expose a length of the inner conductor. 
     
     
         4 . The coaxial cable assembly of  claim 3 , wherein the length is less than 1.0 mm. 
     
     
         5 . The coaxial cable assembly of  claim 3 , wherein the length is less than 0.7 mm. 
     
     
         6 . The coaxial cable assembly of  claim 1 , wherein at least a surface of the welded contact is conductive. 
     
     
         7 . The coaxial cable assembly of  claim 1 , wherein the welded contact is spherical in shape, wherein any surface of the welded contact is welded to the tip of the inner conductor. 
     
     
         8 . The coaxial cable assembly of  claim 7 , wherein a diameter of the welded contact is greater than or equal to a diameter of the inner conductor. 
     
     
         9 . The coaxial cable assembly of  claim 7 , wherein a diameter of the welded contact is less than or equal to a diameter of the inner conductor. 
     
     
         10 . The coaxial cable assembly of  claim 1 , wherein the welded contact is conical in shape, with a base of the conical welded contact is welded to the tip of the inner conductor. 
     
     
         11 . The coaxial cable assembly of  claim 1 , wherein the contact is percussion welded to the tip of the inner conductor. 
     
     
         12 . A coaxial connection assembly comprising:
 a coaxial cable assembly comprising a contact, an inner conductor, and a dielectric insulator, wherein a tip of the inner conductor is exposed at a first end, wherein the tip is in a plane substantially perpendicular to a longitudinal axis of the inner conductor, and wherein the contact is welded to the tip of the inner conductor at the first end; and   an outer terminal assembly having a first opening for receiving the first end of the coaxial cable assembly.   
     
     
         13 . The coaxial connection assembly of  claim 12 , wherein the outer terminal assembly includes a first insulator located within the outer terminal assembly configured to receive the welded contact of the coaxial cable assembly, wherein the first insulator includes an insulator lock edge that detents in response to the welded contact being seated within the first insulator. 
     
     
         14 . The coaxial connection assembly of  claim 13 , wherein the outer terminal assembly further includes a terminal, wherein the terminal is movable between a stage position and a seated position in which the terminal is in contact with the welded contact. 
     
     
         15 . The coaxial connection assembly of  claim 14 , wherein the outer terminal assembly further includes a second insulator at least partially surrounding the terminal, wherein the second insulator is movable with the terminal between the stage position and the seated position. 
     
     
         16 . The coaxial connection assembly of  claim 12 , wherein the outer terminal assembly further includes an inner ferrule, wherein at least the welded contact, the inner conductor and the dielectric insulator are received within the inner ferrule, and wherein the outer conductor is placed over an outer ferrule, wherein the outer ferrule is crimped to the outer conductor and the inner ferrule to secure the coaxial cable assembly to the outer terminal assembly. 
     
     
         17 . The coaxial connection assembly of  claim 12 , wherein the inner conductor and the dielectric insulator are coextensive in length. 
     
     
         18 . The coaxial connection assembly of  claim 12 , wherein the dielectric insulator is stripped at the first end to expose a length of the inner conductor and wherein the length of the exposed inner conductor is less than or equal to 1.0 mm. 
     
     
         19 . The coaxial connection assembly of  claim 12 , wherein the welded contact is a spherical, non-oriented contact. 
     
     
         20 . The coaxial connection assembly of  claim 12 , wherein a diameter of the welded contact is greater than or equal to a diameter of the inner conductor.