Dielectric Insert Repair Tool

Most electrical connectors consist of a dielectric insert supported by a metallic shell. The dielectric, electrically insulates the individual leads of the connector. During the life of a connector, it is common for the dielectric to become chipped or damaged in some manner. Typically, the whole connector is replaced. It would be more economical to reuse the existing metal shell, while replacing just the dielectric insert. Therefore, what is needed is a method and tool that replaces the dielectric insert of an electrical connector.

This invention is a method and tool for removing the dielectric insert of a metal shell electrical connector. The tool holds the shell and has a threaded press that pushes the dielectric insert out of the shell. The tool is then used to push a new dielectric insert into the shell. The tool is adjustable, such that it can be used on various sized connectors.

Therefore, it is an object of this invention to provide a method and tool to replace the dielectric insert of a metal shell electrical connector.

It is also an object of this invention to provide a tool to replace a dielectric insert, that is adjustable to various connector sizes, inexpensive and easy to use.

The objectives and advantages of this invention will become more apparent to those skilled in the art, after reviewing the following specification and drawings, wherein:

FIG. 1 is a perspective view of a dielectric insert repair tool;

FIG. 2 is a side view of a dielectric insert repair tool;

FIG. 3 is a cross sectional view of a dielectric insert repair tool taken at line 3-3 of FIG. 1.

Referring to the drawings more particularly by reference numbers, number 2 in FIGS. 1, 2 and 3 is a tool 2 for replacing a dielectric insert 4 in the metal shell 6 of an electrical connector 8. The tool 2 comprises a first rod 10 having a first threaded aperture 12 and a pair of faced surfaces 14. Extending through the first threaded aperture 12 is a second rod 16, with an externally threaded shank 18 that screws into the rod 10. At one end of the second rod 16 is a pad 20 that engages the dielectric insert 4. The pad 20 is attached to the shank 18 in such a manner that the shank 18 is allowed to rotate in the direction indicated by the arrow, when the pad 20 is pressed against the dielectric 4. The other end of the second rod 16 may have a handle 22, of such size and shape to allow a human hand to grasp and rotate the second rod 16. The second rod 16 could also be adapted for use with a power tool to rotate the rod 16.

The tool 2 has a pair of arms 24 that hold the shell 6. The arms 24 can have collars 26 on one end, that fit around the first rod 10, see FIG. 3. Each collar 26 has a second threaded aperture 28. Extending through the second apertures 28 are set screws 30 that engage the faced surfaces 14. The arms 24 are attached to the first rod 10, by rotating the set screws 30 until they press against the faced surfaces 14. Disengaging a screw 30 from a faced surface 14, allows an arm 24 to slide along and become attached at various points of the first rod 10. This allows the tool 2 to be used on various sized connectors 8. At the other end of the arms 24 are grooves 32 that fit onto flanges 34 extending from the connector 8, allowing the arms 24 to hold onto the shell 6. The arms 24 may be constructed such that the height of the grooves 32 are variable, allowing the arms 24 to hold flanges 34 of varying thickness. The collars 26 may have a key 36 that rides within a second groove 38 in the first rod 10, see FIG. 3. The key 36 prevents the arm 26 from rotating about the first rod 10.

As shown in FIG. 2, the tool 2 is used by holding the shell 6 with the arms 24, rotating the second rod 18 until the pad 20 engages and pushes the dielectric insert 4 out of the shell 6. A new dielectric insert (not shown) can then be pushed into the shell 4 using the same method.

While certain exemplary embodiments have been described above and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention. The invention is not to be limited by the specific constructions or arrangements shown and described, since various other modifications may occur to persons having ordinary skill in the art.