# US 7,610,676 B2 · Bundle cable connector assembly, components, tooling and manufacturing method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,610,676 B2 - Document ID: US7610676B2 - Status: Granted - Kind: B2 - Application number: 11/676,467 - Filed: 2007-02-19 - Published: 2008-08-21 - Granted: 2009-11-03 - Earliest claimed: 2007-02-19 - Assignees: Northrop Grumman Space & Missions Systems Corp. - Inventors: Dean Tran; Alan Hirschberg; Melissa Fuller; Phillip Hayes; Greg Keller - Web page: https://patentgrep.com/patent/US7610676B2 ## CPC - H01R 43/048: Crimping apparatus or processes (H01R43/042 takes precedence) - H01R 4/20: using a crimping sleeve {(H01R4/01 takes precedence)} - Y10T 29/4914: with deforming of lead or terminal - Y10T 29/49181: by deforming - Y10T 29/49192: with insulation removal - Y10T 29/49194: Assembling elongated conductors, e.g., splicing, etc. - Y10T 29/49213: Metal - Y10T 29/49218: with deforming - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method for assembling a bundle cable connector assembly that eliminates bird caging, wire threads extruding through a connector pin, loose wire threads, dielectric shield shrinking, etc. The method includes stripping the wire to create a birdcage preventative zone and an exposed tip with a crimping zone therebetween, and tinning the exposed wire at the birdcage preventative zone and the tip. The method then includes inserting the wire into a connector pin, and crimping the pin to the wire at the crimping zone using heat so that the tinning solder melts. The method then includes mounting the pin to a connector body and mounting a wire-locking device to the connector body to lock the pin to the connector body. ## Claims ### Claim 1 A method for assembling a bundle cable connector assembly, said method comprising: providing a least one electrical wire including an inner conductor and an outer dielectric shield; stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion, an exposed bird cage preventative zone and a crimping zone therebetween that includes the dielectric shield; tinning the electrical wire by depositing a solder coating on the inner conductor at the bird cage preventative zone and the tip portion; removing the dielectric shield around the crimping zone; positioning the end of the wire including the tip portion, the crimping zone and the bird cage preventative zone within an internal bore of a connector pin; crimping the connector pin proximate to the bird cage preventative zone and the crimping zone so as to electrically connect the inner conductor to the pin; and mounting the pin to a connector body. ### Claim 2 (depends on 1) The method according to claim 1 further comprising mounting a wire-locking device to the wire and the connector body. ### Claim 3 (depends on 2) The method according to claim 2 wherein mounting a wire-locking device to the wire and the connector body includes securing a holding ferrule to the wire and positioning a locking ring around the holding ferrule and between annular rims on the connector body. ### Claim 4 (depends on 2) The method according to claim 2 further comprising depositing a potting material over the wire-locking device. ### Claim 5 (depends on 1) The method according to claim 1 wherein crimping the connector pin proximate to the bird cage preventative zone and the crimping zone includes heating the inner conductor so as to melt the solder at the bird cage preventative zone. ### Claim 6 (depends on 5) The method according to claim 5 wherein crimping the connector pin proximate to the bird cage preventative zone and the crimping zone includes using a four probe crimping tool where each probe is spaced about 90° apart and where the probes receive an electrical current to provide the heating. ### Claim 7 (depends on 1) The method according to claim 1 wherein stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion and an exposed bird cage preventative zone includes stripping a tip of the at least one wire, cutting the dielectric shield some distance from the tip and sliding the cut dielectric shield towards the tip to provide the exposed bird cage preventative zone. ### Claim 8 (depends on 1) The method according to claim 1 wherein providing a least one electrical wire including an inner conductor and an outer dielectric shield includes providing a plurality of electrical wires each crimped to separate pins and all mounted to the same at least one connector body. ### Claim 9 (depends on 1) The method according to claim 1 wherein the inner conductor includes a plurality of wound wire threads. ### Claim 10 A method for assembling a bundle cable connector assembly, said method comprising: providing a least one electrical wire including an inner conductor and an outer dielectric shield; stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion; positioning the end of the wire including the tip portion within an internal bore of a connector pin; crimping the connector pin so as to electrically connect the inner conductor to the pin; mounting the pin to a connector body; and mounting a wire-locking device to the wire and the connector body where the wire-locking device holds the wire within the connector body. ### Claim 11 (depends on 10) The method according to claim 10 wherein mounting a wire-locking device to the wire and the connector body includes securing a holding ferrule to the wire and positioning a locking ring around the holding ferrule and between annular rims on the connector body. ### Claim 12 (depends on 10) The method according to claim 10 further comprising depositing a potting material over the wire-locking device. ### Claim 13 (depends on 10) The method according to claim 10 wherein crimping the connector pin includes using a crimping tool having a plurality of probes and heating the probes. ### Claim 14 (depends on 13) The method according to claim 13 wherein crimping the connector pin includes using a four probe crimping tool where each probe is spaced about 90° apart. ### Claim 15 (depends on 10) The method according to claim 10 wherein providing a least one electrical wire including an inner conductor and an outer dielectric shield includes providing a plurality of electrical wires each crimped to separate pins and all mounted to the connector body. ### Claim 16 A method for assembling a bundle cable connector assembly, said method comprising: providing a least one electrical wire including an inner conductor and an outer dielectric shield; stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion, an exposed bird cage preventative zone and a crimping zone therebetween that includes the dielectric shield; tinning the electrical wire by depositing a solder coating on the inner conductor at the bird cage preventative zone and the tip portion; removing the dielectric shield around the crimping zone; positioning the end of the wire including the tip portion, the crimping zone and the bird cage preventative zone within an internal bore of a connector pin; crimping the connector pin proximate to the bird cage preventative zone and the crimping zone so as to electrically connect the inner conductor to the pin, wherein crimping the connector pin proximate to the bird cage preventative zone and the crimping zone includes using a crimping tool having a plurality of probes where the probes receive an electrical current to heat the solder at the birdcage preventative zone; mounting the pin to a connector body; and mounting a wire-locking device to the wire and the connector body where the wire-locking device holds the wire within the connector body and where mounting a wire-locking device to the wire and the connector body includes securing a holding ferrule to the wire and positioning a locking ring around the holding ferrule and between annular rims on the connector body. ### Claim 17 (depends on 16) The method according to claim 16 further comprising depositing a potting material over the wire-locking device. ### Claim 18 (depends on 16) The method according to claim 16 wherein stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion and an exposed bird cage preventative zone includes stripping a tip of the at least one wire, cutting the dielectric shield some distance from the tip and sliding the cut dielectric shield towards the tip to provide the exposed bird cage preventative zone. ### Claim 19 (depends on 18) The method according to claim 18 wherein providing a least one electrical wire including an inner conductor and an outer dielectric shield includes providing a plurality of electrical wires each crimped to separate pins and all mounted to the connector body. ### Claim 20 (depends on 16) The method according to claim 16 wherein using a crimping tool having a plurality of probes includes using a crimping tool having four probes spaced about 90° apart.