COAXIAL CABLE AND CONNECTOR WITH ADAPTER TO FACILITATE ASSEMBLY

A coaxial cable-connector assembly includes:   (a) a coaxial cable comprising an inner conductor, a dielectric layer circumferentially overlying the inner conductor, an outer conductor circumferentially overlying the inner conductor, and a polymeric jacket circumferentially overlying the outer conductor;   (b) a connector adapter, comprising an inner contact that is electrically connected to the inner conductor, an outer sleeve that is in electrical contact with the outer conductor, and a dielectric spacer interposed between the inner contact and the outer sleeve, and   (c) a coaxial connector having an outer connector body, the outer connector body having a mating end configured to mate with a mating connector and an adapter ring, the adapter ring configured to engage and electrically connect to the outer sleeve.

FIELD OF THE INVENTION

The present invention is directed generally to electrical cable connectors, and more particularly to coaxial connectors for electrical cable.

BACKGROUND OF THE INVENTION

Coaxial cables are commonly utilized in RF communications systems. A typical coaxial cable includes an inner conductor, an outer conductor, a dielectric layer that separates the inner and outer conductors, and a jacket that covers the outer conductor. Coaxial cable connectors may be applied to terminate coaxial cables, for example, in communication systems requiring a high level of precision and reliability.

Coaxial connector interfaces provide a connect/disconnect functionality between (a) a cable terminated with a connector bearing the desired connector interface and (b) a corresponding connector with a mating connector interface mounted on an electronic apparatus or on another cable. Typically, one connector will include a structure such as a pin or post connected to an inner conductor of the coaxial cable and an outer conductor connector body connected to the outer conductor of the coaxial cable these are mated with a mating sleeve (for the pin or post of the inner conductor) and another outer conductor connector body of a second connector. Coaxial connector interfaces often utilize a threaded coupling nut or other retainer that draws the connector interface pair into secure electro-mechanical engagement when the coupling nut (which is captured by one of the connectors) is threaded onto the other connector. Typically, the processes of joining the connector with coaxial cable vary for different connector designs and development efforts are needed to optimize the process to meet the electrical and mechanical requirement.

There exist many different types of radio frequency (RF) coaxial connectors in the market today. This number continues to grow as requirements change and higher performance is needed over a broader range of frequencies. As demand for coaxial cable assemblies with increasingly different permutations of these connector types grows and may vary from region to region or from customer to customer, fulfilling customer demand can at times be challenging.

SUMMARY OF THE INVENTION

As a first aspect, embodiments of the invention are directed to a coaxial cable-connector assembly. The assembly comprises:(a) a coaxial cable comprising an inner conductor, a dielectric layer circumferentially overlying the inner conductor, an outer conductor circumferentially overlying the inner conductor, and a polymeric jacket circumferentially overlying the outer conductor;(b) a connector adapter, comprising an inner contact that is electrically connected to the inner conductor, an outer sleeve that is in electrical contact with the outer conductor, and a dielectric spacer interposed between the inner contact and the outer sleeve, and(c) a coaxial connector having an outer connector body, the outer connector body having a mating end configured to mate with a mating connector and an adapter ring, the adapter ring configured to engage and electrically connect to the outer sleeve.

As a second aspect, embodiments of the invention are directed to a method of constructing a coaxial cable-connector assembly, comprising:(a) providing a coaxial cable comprising an inner conductor, a dielectric layer circumferentially overlying the inner conductor, an outer conductor circumferentially overlying the inner conductor, and a polymeric jacket circumferentially overlying the outer conductor;(b) attaching a connector adapter to the coaxial cable, the connector adapter including an inner contact that is electrically connected to the inner conductor, an outer sleeve that is in electrical contact with the outer conductor, and a dielectric spacer interposed between the inner contact and the outer sleeve; then(c) attaching a coaxial connector to the connector adapter, the coaxial connector having an outer connector body with a mating end configured to mate with a mating connector and an adapter ring, the adapter ring engaging and electrically connecting to the outer sleeve.

As a third aspect, embodiments of the invention are directed to a coaxial cable subassembly comprising:(a) a coaxial cable comprising an inner conductor, a dielectric layer circumferentially overlying the inner conductor, an outer conductor circumferentially overlying the inner conductor, and a polymeric jacket circumferentially overlying the outer conductor;(b) a connector adapter, comprising an inner contact that is electrically connected to the inner conductor, an outer sleeve that is in electrical contact with the outer conductor, and a dielectric spacer interposed between the inner contact and the outer sleeve, wherein the outer sleeve includes a wider portion that encircles the outer conductor and a narrower portion configured to be received in an outer connector body of a coaxial connector.

DETAILED DESCRIPTION OF THE INVENTION

In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Referring now to the drawings, an adapter for facilitating the attachment of a coaxial cable to a coaxial connector, designated broadly at20, is shown inFIGS.1,2A and2B. The adapter20includes an inner contact22, a dielectric spacer24, and an outer sleeve26. These components are discussed in detail below.

The inner contact22includes a cylindrical base30and three sequentially narrower sections32,34,36that lead to a frustoconical tip38. A circumferential ridge35is present in the section34. As can be seen inFIGS.2A and2B, the interior of the inner contact22is hollow in the base30. The dielectric spacer24is generally disc-shaped, with an interior hole42that receives the inner contact22.

The outer sleeve26has a wider portion50and a narrower portion52. As can be seen inFIG.2A, the dielectric spacer24fits within the wider portion50and abuts a shoulder54between the wider and narrower portions50,52. The outer surface of the wider portion50has circumferential grooves56; however, the outer surface of the narrower portion52is smooth.

The inner and outer contacts22,26are typically formed from a metallic material, such as brass. The dielectric spacer24is typically formed of a dielectric material, such as a polymeric material.

FIGS.3and4illustrate a coaxial cable110. The cable110includes an inner conductor112, a dielectric layer114that circumferentially overlies the inner conductor112, an annularly corrugated outer conductor116that circumferentially overlies the dielectric layer114, and a polymeric cable jacket120that circumferentially overlies the outer conductor116. These components will be well-known to those of skill in this art and need not be described in detail herein.

FIGS.5A and5Bshow the coaxial cable110connected with the adapter20. The forward end of the inner conductor112is received in the base30of the inner contact22. The forward ends of the dielectric layer114and the outer conductor116abut the rear surface of the dielectric spacer24. The wider portion50of the outer contact26is positioned radially outwardly of the outer conductor116. A boot102(typically formed of a flexible material, and in some instances a shrinkable material) fits over the end portion of the jacket120, the exposed portion of the outer conductor116, and the wider portion50of the outer contact26. The boot102has a shoulder104between the forward end of the jacket120and the rear end of the outer contact26, and ridges106on its inner surface.

The inner contact22of the adapter20may be attached to the inner conductor112via a press fit joint, soldering, or the like. The outer contact26of the adapter20may be attached to the outer conductor116via soldering, welding, crimping or the like. Once the adapter20has been attached to the coaxial cable110, the boot102can be slid into place as shown inFIG.5A. The shoulder104of the boot102may abut the rear end of the wider portion50, and the ridges106may fit within the grooves56of the wider portion50.

The adapter20, cable110and boot102form an intermediate subassembly140that can then be employed to construct a coaxial cable-connector assembly150that includes one of any number of coaxial connector varieties. Two examples of connectors are shown inFIGS.6and7; an inline connector150and a right-angle connector150′. The ensuing discussion will reference the inline connector150, but is equally applicable to the right angle connector150′ or other coaxial connectors.

The connector150includes an outer connector body152. The outer connector body152has a mating end154that enables it to mate with the outer connector body of a mating connector, and an adapter ring156. The mating end154can have any configuration known to be suitable for RF coaxial cables, such as DIN 7/16, 4.3/10, N-type, and the like. Typically, the mating end154will include a coupling member or apparatus (such as the coupling nut158shown herein, or a “push-pull” mechanism) to enable the connector150to be mated and secured to a mating connector.

As can be envisioned inFIGS.6,7A and7B, the adapter ring156is sized to receive therewithin the wider portion50of the outer contact26of the adapter20. The wider portion50may be coupled to the adapter ring156via a mechanical joint (e.g., a press-fit or interference-fit joint, a threaded joint, or a crimped joint), or a metallurgical joint (e.g., a soldered or welded joint).

In some embodiments, the connector150may include an inner contact that is coupled to the inner contact22of the adapter20. The inner contact may be mechanically or metallurgically coupled to the inner contact22. In other embodiments (such as the embodiment ofFIGS.7A and7B), the connector150may have no separate inner contact, such that the inner contact22serves as the inner contact that directly mates with the inner contact of a mating connector.

In embodiments in which the connector150includes an inner contact, a dielectric spacer may be present between the inner contact of the connector150and the outer connector body152. In such embodiments, the connector150may be provided as a unitary component that can be coupled quickly to the adapter20.

It will be understood that the adapter20can enable connectors150of virtually any configuration to be attached quickly and easily to the cable110. Thus, a manufacturer may produce only a few sizes of coaxial cables110, each with an accompanying adapter20of appropriate size. These relatively few coaxial cables may then be connected with a much larger number of connector types. Thus, manufacturing advantages may be realized by reducing the number of different processes to produce many different cable-connector combinations, and by providing what is essentially a “made-to-order” technique to provide virtually any cable-connector combination to a customer or user.