Connector with Outer Conductor Axial Compression Connection and Method of Manufacture

A method for manufacturing an electrical connector for a coaxial cable in combination with a solid outer conductor coaxial cable, comprising the steps of:

• forming a connector body from a first material with a bore between a connector end and a cable end;
• the bore having an inner diameter shoulder at the cable end;
• positioning a cylindrical sleeve formed from a second material within the inner diameter shoulder;
• the cylindrical sleeve and the connector body together forming an annular groove open to the cable end;
• the first material having a greater rigidity characteristic than the second material;
• inserting an end of the solid outer conductor into the annular groove;
• and
• inwardly deforming the cable end of the connector body.

A method for manufacturing an electrical connector for a coaxial cable with a solid outer conductor, comprising the steps of:

• forming a connector body by thixotropic metal injection molding from a first material;
• the connector body provided with a bore between a connector end and a cable end;
• the bore having an inner diameter shoulder at the cable end;
• positioning a cylindrical sleeve formed from a second material within the inner diameter shoulder in an interference fit;
• the cylindrical sleeve and the connector body together forming an annular groove open to the cable end;
• the annular groove dimensioned to receive an end of the solid outer conductor;
• the connector body extends toward the cable end farther than the cylindrical sleeve by greater than twice a thickness of the solid outer conductor.