Right angle coaxial connector

A connector is provided. The connector can include a coaxial cable segment. The connector can also include a first housing defining a first cavity and a second cavity that intersects the first cavity. The coaxial cable segment can be received into the first cavity through the second cavity and can exit the first housing through the second cavity. The connector can include a second housing having a conductive sleeve. The second housing can be received into the first housing such that the conductive sleeve exits the first housing through the second cavity and electrically engages the coaxial cable. The coaxial cable can be received within the conductive sleeve and the conductive sleeve of the second housing can be disposed concentrically about the coaxial cable.

FIELD

The present invention relates to connector systems, and more particularly to a right angle coaxial connector.

BACKGROUND

Coaxial cables can be used in various applications, such as cellular phone technologies or other communications applications that involve the transmission of high frequency signals. Generally, coaxial cables are coated with a jacket or shielding that prevents interference with the high frequency signals transmitted therein from exterior noise, such as radio frequencies. The shielding, however, can be relatively inflexible, making it somewhat difficult to position the cable in tight spaces. As such, it can be difficult to couple the coaxial cable to devices that, due to size or space limitations, require the coaxial cable to bend or form right angles to make a connection.

Various connectors can enable the coaxial connector to bend; however, most of these connectors require a soldered joint to form the bend. The use of a soldered joint can be time consuming and may also reduce the quality of the transmission through the soldered joint since it can be difficult to control the impedance of this soldered joint. Accordingly, it may be desirable to provide a right angle connector for a coaxial cable that does not require a soldered joint.

SUMMARY

The teachings of the present invention can provide a connector with a coaxial cable segment for transmitting energy therethrough. The coaxial cable segment can include a center conductor, an outer conductor disposed about the center conductor, an inner insulator disposed between the center conductor and the outer conductor, and an outer insulator disposed about the outer conductor. The coaxial cable segment can also have an end portion wherein at least a portion of the outer insulator is stripped from the outer conductor and wherein the center conductor extends outwardly away from a point at which inner insulator terminates. The connector can also include a first housing defining a first cavity and a second cavity that intersects the first cavity. The end portion of the coaxial cable segment can be received into the first cavity through the second cavity and can exit the first housing through the second cavity. The connector can include a second housing having a conductive sleeve. The second housing can be received into the first housing such that the conductive sleeve exits the first housing through the second cavity and electrically engages the outer conductor of the end portion of the coaxial cable. The inner insulator of the end portion of the coaxial cable can be received within the conductive sleeve and the conductive sleeve of the second housing can be disposed concentrically about the central conductor of the end portion of the coaxial cable.

The present teachings can also provide a method of forming an angled connection with a coaxial cable. The method can include providing a first housing defining a first cavity and a second cavity, a second housing defining a sleeve, and a central conductor disposed in the first housing. The method can include inserting the central conductor into the first cavity. Next, the method can provide for removing a portion of an outer insulator of the coaxial cable to expose an outer conductive layer, an inner insulator layer and a central conductive layer, and positioning the central conductive layer of the coaxial cable within the central conductor. Then, the method can include positioning the central conductive layer of the coaxial cable within the central conductor. The method can include bending the portion of the outer conductive layer extending beyond the central conductor to a desired angle and inserting the second housing into the second cavity so that the sleeve of the second housing is disposed between the outer conductive layer and an inner insulator layer of the coaxial cable. Then, the method can include mechanically coupling the outer conductive layer to the second housing.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

The following description of the various embodiments is merely exemplary in nature and is in no way intended to limit the teachings of the various embodiments, their application, or uses. Although the following description is related generally to a right angle connector that can be used to facilitate the transmission of high frequency signals through, for example, a coaxial cable, it will be understood that the right angle connector, as described and claimed herein, can be used with any appropriate application. Therefore, it will be understood that the following discussions are not intended to limit the scope of the appended claims.

With reference toFIG. 1, an exemplary right angle coaxial connector10is shown in operative association with a coaxial cable12. The right angle coaxial connector10can include a main or first housing14and a secondary or second housing16for receipt of the coaxial cable12.

With additional reference toFIG. 2, the first housing14can define a first cavity18and a second cavity20. The first housing14can be composed of any appropriate conductive material, such as zinc, and can be formed by die-casting; however, any appropriate forming technique could be used, such as machining. The first cavity18and second cavity20can generally be cast with the first housing14; however, the first cavity18and second cavity20could be formed in the first housing14by any appropriate technique, such as machining. The first cavity18can be generally cylindrical, and the second cavity20can be generally rectangular. Typically, the second cavity20can intersect the first cavity18at a generally right angle.

With continuing reference toFIGS. 1 and 2, and with additional reference toFIGS. 3 and 4, the first cavity18can include a reduced diameter D1at about a midpoint M of the first cavity18to create a stepped portion22within the first cavity18(FIG. 4). The stepped portion22can act as a guide to ensure the right angle coaxial connector10is properly assembled, as will be discussed in greater detail herein. The first cavity18can also include a second reduced diameter D2adjacent to the second cavity20(FIG. 4). The second reduced diameter D2can be configured to enable the receipt of a selected coupler21from device23to enable communication between the device23and the coaxial cable12(FIG. 5). The first cavity18can generally be configured to receive a portion of the coaxial cable12to couple the coaxial cable12to the second cavity20.

In order to electrically couple the coaxial cable12to the second cavity20, an outer conductive tube24, an inner insulative member26, and a center contact or central conductor28can be disposed in the first cavity18. The outer conductive tube24can be generally cylindrical, and can include a first end30and a second end32. The first end30can include a plurality of slots34that can define a plurality of flexible members36. Each of the flexible members36can include a curved tip38that forms an opening (generally indicated by40) with a reduced diameter (FIG. 2). The reduced diameter opening40can provide for alignment and retention of the coupler21within the outer conductive tube24as the slots34can enable the plurality of flexible members36to deflect outwardly for receipt of the coupler21. The deflection of the flexible members36can provide a holding force H to retain the coupler21within the outer conductive tube24(FIG. 3). It should be noted that the amount of deflection of the flexible members36can be dictated by the type of material used to form the outer conductive tube24. Generally, the outer conductive tube24can be formed of a conductive material, such as zinc or copper; however, any suitable conductive material could be used. The outer conductive tube24can be positioned within the first cavity18such that the outer conductive tube24rests on the stepped portion22, adjacent to the inner insulative member26.

The inner insulative member26can be generally cylindrical and can define a first end42, a second end44and a throughbore46. Generally, the inner insulative member26can be retained within the stepped portion22of the first cavity18such that the first end42can be positioned adjacent to the outer conductive tube24, and the second end44can be adjacent to the second reduced diameter D2so that the throughbore46can be aligned with an opening48defined by the second reduced diameter D2(FIG. 3). The inner insulative member26can be formed of any non-conductive material, either polymeric or metallic, such as polypropylene.

The first end42of the inner insulative member26can include a projection50. The projection50can extend from the first end42into the first cavity18. The projection50generally has a length L, which can be any length appropriate to support the central conductor28, as will be discussed in greater detail herein (FIG. 2). The second end44of the inner insulative member26can include a countersunk surface53surrounding the throughbore46(FIG. 3). The countersunk surface53can be used to couple the central conductor28to the inner insulative member26. The throughbore46can extend through the projection50to the countersunk surface53for receipt of the central conductor28therethrough.

The central conductor28can be generally cylindrical, with a central projection flange54. The central conductor28can further include a first end56and a second end58disposed adjacent to the central projection flange54and a throughbore60. Typically, the central conductor28can be formed from a conductive material, such as zinc or copper; however, any appropriate conductive material could be used. The central projection flange54can have an enlarged width W, which can be larger than the diameter of the throughbore46of the inner insulative member26to provide a locating feature for the assembly of the central conductor28to the inner insulative member26(FIG. 3). The first end56can include at least one slot62to form at least one or a plurality of flexible members64(FIG. 2). The flexible members64can serve to guide the coupler21of the device23into the throughbore60. The first end56generally has a diameter D4, which can be slightly larger than a diameter D5of the coaxial cable12, as will be discussed further herein (FIG. 3).

The second end58of the central conductor28can include a main portion66that has a diameter D6, which can be larger than the diameter D5of the coaxial cable12, but smaller than a diameter D7of the throughbore46of the inner insulative member26to enable the main portion66of the second end58of the central conductor28to be retained within the inner insulative member26. An annular flange68can be formed at an end69of the main portion66. The annular flange68can have a diameter D8, which is greater than the diameter D7of the throughbore46of the inner insulative member26, but smaller than a diameter D9defined by the countersunk surface53of the inner insulative member26. Thus, the diameter D8of the annular flange68can serve to retain the central conductor28to the inner insulative member26and provide a locating feature during the assembly of the central conductor28to the inner insulative member26. The annular flange68, once assembled to the inner insulative member26, can also provide a locator for the assembly of the coaxial cable12within the first cavity18, as will be discussed in greater detail herein.

The second cavity20of the first housing14can be generally rectangular, and can include a curved groove70formed on a first surface72(FIG. 2). The curved groove70can generally be sized to mate with the second housing16, as will be described in greater detail herein. On a second surface74of the second cavity20, a curved lip76can be formed (FIG. 3). The curved lip76can extend from the second surface74to form a bottom section of a passageway for the coaxial cable12. The curved lip76can be generally positioned adjacent to the first cavity18to enable the coaxial cable12to contact the curved lip76to assist in forming the coaxial cable12into a right angle. The second cavity20may also include an opening73formed on the first surface72to enable the coaxial cable12to enter the first housing14. The second cavity20can also generally define a first opening80and a second opening82. The first opening80can be sized to enable the receipt of the second housing16therethrough, and the second opening82can be sized to enable the second housing16and the coaxial cable12to pass therethrough.

The second housing16can generally slidably engage the second cavity20of the first housing14. The second housing16can be formed of a conductive material, such as zinc; however, any appropriate conductive material could be used. The second housing16can include a cap86coupled to a sleeve88. The cap86can be integrally formed with the sleeve88, through die-casting for example; however, the cap86could also be coupled to the sleeve88through any appropriate technique, such as welding, bonding, press-fitting or mechanical fasteners. The cap86can be rectangular, and can have a width W2, which is larger than a width W3of the first opening80of the second cavity20to enclose the second cavity20(FIG. 2). The cap86can also have a thickness T, which can be equivalent to a thickness T2of the second cavity20of the first housing14above the opening48defined by the second reduced diameter D2to secure the cap86within the second cavity20(FIG. 3). Generally, the sleeve88can be formed on the second housing16so that once the cap86is against the first opening80of the second cavity20of the first housing14the sleeve88can be aligned with the opening48of the first cavity for receipt of the coaxial cable12.

The sleeve88can have a curved channel90for receipt of the coaxial cable12. The sleeve88and the curved channel90can generally be formed so that the coaxial cable12can form a 90 degree or right angle. However, it will be understood that although the second housing16is shown generally to enable the coaxial cable12to form a right angle with respect to the first housing14, the second housing16could be modified to enable the coaxial cable12to form any desired angle with respect to the first housing14.

The sleeve88can also include a rectangular mating portion92formed on an exterior surface94of the sleeve88. The rectangular mating portion92can generally be sized to slidably engage the second cavity20of the first housing14to ensure that the second housing16is located and properly retained in the second cavity20. The sleeve88can also include at least one or a plurality of grooves96on the exterior surface94of the sleeve88. The grooves96are generally configured to engage a portion of the coaxial cable12, as will be discussed further herein. The sleeve88may also include a tip98. The tip98can facilitate the engagement of the second housing16with the coaxial cable12, as will be discussed herein.

Prior to coupling the coaxial cable12to the right angle coaxial connector10, a portion of a jacket or outer insulator layer100of the coaxial cable12can be removed or stripped from the coaxial cable12to reveal an outer conductor layer102(FIG. 3). The outer insulator layer100can be formed of a non-conductive polymeric material, such as Fluorinated Ethylene Propylene (FEP) Teflon®, and the outer conductor layer102can be formed of a conductive material, such as a copper wire coil or screen for example. Next, a portion of the outer conductor layer102can be stripped to reveal an inner insulator layer104, which can be formed of a non-conductive material. Lastly, a portion of the inner insulator layer104can be stripped to reveal a center conductor layer106. The center conductor layer106can be formed of a conductive material, such as copper.

After the coaxial cable12has been stripped to reveal the outer conductor layer102, inner insulator layer104and center conductor layer106, the coaxial cable12can be coupled to the right angle coaxial connector10. In order to prepare the right angle coaxial connector10for receipt of the coaxial cable12, the inner insulative member26can be positioned within the first cavity18of the first housing14on the stepped portion22so that the projection50on the inner insulative member26can extend into the first cavity18. Next, the outer conductive tube24can be positioned within the first cavity18of the first housing14on the stepped portion22until the outer conductive tube24abuts the first end42of the inner insulative member26.

In order to couple the coaxial cable12to the assembled right angle coaxial connector10, the coaxial cable12can be fed into the opening73formed in the second cavity20of the first housing14(FIG. 3). First, the central conductor28can be crimped to the central conductive layer106of the coaxial cable12and inserted through the opening73of the second cavity20and the throughbore46of the inner insulative member26until the projection50of the inner insulative member26abuts the central projection flange54and the annular flange68is retained in the countersunk surface53. Typically, the center connector layer106of the coaxial cable12can be inserted into the central conductor28until an end112of the center conductor layer106abuts the central projection flange54. The inner insulator layer104of the coaxial cable12can generally abut the annular flange68of the central conductor28when the center conductor layer106is fully assembled within the central conductor28.

Next, after the coaxial cable12is crimped into the central conductor28and the central conductor28is secured within the inner insulative member, a force F can be applied to the coaxial cable12within the second cavity20to bend the coaxial cable12downward, so that the coaxial cable12can exit the second opening82of the second cavity20. Then, the tip98of the sleeve88of the second housing16can be inserted between the outer conductive layer102and the inner insulator layer104so that the sleeve88of the second housing16can be slid between the outer conductive layer102and the inner insulator layer104. Generally, the outer conductive layer102can be flared outward so that the outer conductive layer102is retained in the grooves96of the sleeve88.

Once the sleeve88is positioned between the outer conductive layer102and the inner insulator layer104of the coaxial cable12, the second housing16can be inserted until the cap86seals the first opening80of the second cavity20of the first housing14, as best shown inFIG. 5. Once the second housing16is against the first opening80of the second cavity20, the crimp tube52can be positioned over the second housing16and over to an edge108of the outer insulator layer100. The crimp tube52can have a diameter D10, which can be greater than a diameter D11of the assembled second housing16and outer conductive layer102of the coaxial cable12, to enable the crimp tube52to fit around the second housing16, and thus the coaxial cable12(FIG. 5). The crimp tube52can be composed of any appropriate conductive polymeric or metallic material that is capable of deformation before failure of the material, such as aluminum.

Generally, once the crimp tube52is positioned over the second housing16, a tool (not shown) can be used to deform the crimp tube52to lock the coaxial cable12within the right angle coaxial connector10. The crimp tube52, when crimped, retains the coaxial cable12via the outer conductive layer102to the second housing16. The close fit and length of the crimp tube52and second opening82can provide lateral support if the coaxial cable12is pulled in any direction. There can also be at least one or three tapered flats89defined in the second opening82to maintain good electrical contact between the crimp tube52and the first housing14. Generally, as the crimp tube52is inserted, the three tapered flats89can contact the crimp tube52and slightly deform it, which generates a contact force to maintain electrical contact even through environmental changes. Good electrical contact can improve radio frequency (RF) performance of the right angle coaxial connector10, and through the tapered flats89, the crimp tube52can be electrically connected to first housing14.

With the right angle coaxial connector10fully assembled, the opening40defined by the flexible members36or the outer connective tube24can be slid into position with the coupler21of the device23to couple the coaxial cable12to the device23. Generally, the coaxial cable12can be configured such that the outer insulator layer100ends approximately adjacent to the tip98of the sleeve88of the second housing16, as best shown inFIG. 4.

The description of these teachings is merely exemplary in nature and, thus, variations that do not depart from the gist of the teachings are intended to be within the scope of the teachings. Such variations are not to be regarded as a departure from the spirit and scope of the teachings.