A coaxial connector assembly for interconnection with a coaxial cable with a solid outer conductor is provided with a monolithic connector body with a bore. A mating surface with a decreasing diameter toward a connector end is provided on an outer diameter of the connector body proximate the connector end. An overbody may be provided overmolded upon a cable end of the connector body. An interface end may be seated upon the mating surface, the interface end provided with a desired connection interface. The interface end may be permanently coupled to the mating surface by a molecular bond interconnection. In a method of interconnection, the interface end is coupled to the mating surface by application of radial ultrasonic welding.

The present invention relates to electrical conductors for electrical transmission and distribution with pre-stress conditioning of the strength member so that the conductive materials of aluminum, aluminum alloys, copper, copper alloys, or copper micro-alloys are mostly tension free or under compressive stress in the conductor, while the strength member is under tensile stress prior to conductor stringing, resulting in a lower thermal knee point in the conductor.

A frame assembly for a compression tool, including a fitting configured to mount to the compression tool and receive a ram member thereof through a bore of the fitting; and a pair of interlocking jaws pivotally mounted to the fitting about a pair of non-coincident axes. The interlocking jaws are configured to at least partially envelop an annular compression ring while aligning the conductors of a coaxial cable with an axis of the cable connector. The ram member of the compression tool is activated to translate axially along the axis of the cable connector thereby mitigating misalignment of the compression ring as the ring engages the connector body.

An assembly and a method for manufacturing an insulation layer of an electrical conductor are presented. The electrical conductor is enclosed in a cavity of a mold. Spacers embedded into holes of the mold are movable into the cavity for holding the electrical conductor in the cavity to maintain a gap between the electrical conductor and surface of the cavity. Distance of the gap is defined by thickness of the insulation layer. Spacers are movable into the holes of the mold from the cavity to maintain even surface of the cavity. Insulation compound fills entire gap and is cured to form the insulation layer having homogenous thickness.

A method for a down-hole cable is provided. The down-hole cable includes an insulated conductor portion. A filler layer abuts and encapsulates the insulated conductor portion, wherein the filler layer is substantially formed with a foamed fluoropolymer. An armor shell is applied to the exterior of the foamed fluoropolymer filler layer.

A wire includes an elongate conductive core wire, an elongate insulating layer disposed on and surrounding the elongate conductive core wire, an elongate conductive shield wire disposed adjacent to the insulating layer and the elongate conductive core wire, an elongate conductive shield layer disposed on the insulating layer and on the conductive shield wire such that the elongate insulating layer, the elongate conductive core wire, and the elongate conductive shield wire are embedded in the elongate conductive shield layer, the elongate conductive shield wire being electrically connected to the elongate conductive shield layer.

A wire includes an elongate conductive core wire, an elongate insulating layer disposed on and surrounding the elongate conductive core wire, an elongate conductive shield wire disposed adjacent to the insulating layer and the elongate conductive core wire, an elongate conductive shield layer disposed on the insulating layer and on the conductive shield wire such that the elongate insulating layer, the elongate conductive core wire, and the elongate conductive shield wire are embedded in the elongate conductive shield layer, the elongate conductive shield wire being electrically connected to the elongate conductive shield layer.

A method of forming a coaxial wire that includes providing a sacrificial trace structure using an additive forming method, the sacrificial trace structure having a geometry for the coaxial wire, and forming a continuous seed metal layer on the sacrificial trace structure. The sacrificial trace structure may be removed and a first interconnect metal layer may be formed on the continuous seed layer. An electrically insulative layer may then be formed on the first interconnect metal layer, and a second interconnect metal layer is formed on the electrically insulative layer. Thereafter, a dielectric material is formed on the second interconnect metal layer to encapsulate a majority of an assembly of the first interconnect metal layer, electrically insulative layer and second interconnect metal layer that provides said coaxial wire. Ends of the coaxial wire may be exposed through opposing surfaces of the dielectric material to provide that the coaxial wire extends through that dielectric material.

An assembly and a method for manufacturing an insulation layer of an electrical conductor are presented. The electrical conductor is enclosed in a cavity of a mold. Spacers embedded into holes of the mold are movable into the cavity for holding the electrical conductor in the cavity to maintain a gap between the electrical conductor and surface of the cavity. Distance of the gap is defined by thickness of the insulation layer. Spacers are movable into the holes of the mold from the cavity to maintain even surface of the cavity. Insulation compound fills entire gap and is cured to form the insulation layer having homogenous thickness.

A coaxial cable includes: a center conductor; a dielectric layer circumferentially surrounding the center conductor; and an outer conductor circumferentially surrounding the dielectric layer. The dielectric layer comprises an inner sleeve that circumferentially overlies the center conductor and an outer sleeve that circumferentially overlies the inner conductor. The outer sleeve contacts the inner sleeve to form a plurality of longitudinally-spaced seams to create a plurality of sealed segments along a longitudinal axis of the cable.