A female connector assembly for an electrically conductive coaxial cable, comprises an electrically conductive barrel shaped body having a top end with a centrally located hole forming an input port, and a bottom end configured for connecting with a portion of a housing of an electrical device. An electrically insulative hollow sleeve consisting of two interlocking cap members encloses an electrically conductive clip pin, and is contained within the body of the connector. The sleeve and clip pin are securely held within the body via connection of the body to a housing of an electrical device, and rigid attachment of an elongated pin extending from the sleeve, through a hole in the housing, to electrical circuitry within the housing.

FIELD OF THE INVENTION
 The present invention relates generally to F-connector assemblies for
 coaxial cables, and more particularly to improved ground shielding contact
 F-connector assemblies for coaxial cables.
 BACKGROUND OF THE INVENTION
 In cable television systems a standard connector configuration,
 particularly with regard to the outer shell and mounting threads, is known
 as an F-connector, for connection to a 75 ohm coaxial cable, for example.
 The F-connector comes in many configurations, depending upon the
 application at hand. Typically, the main body or outer shell of the
 F-connector is in the form of a barrel with a hollow throughhole
 connecting the opposed openings at each end thereof, and is typically
 composed of an electrically conducting material such as brass. The
 F-connector outer shell includes an input end, a mounting end and a set of
 external threads extending therearound. The threads of the F-connector are
 standard UNF threads. The mounting end of the outer shell is generally
 configured for attachment to an electrical device housing or a coverplate
 of the electrical device housing through solid casting or threaded
 engagement, for example. In certain applications the exterior portion of
 the outer shell near the mounting end may not be threaded, but configured
 for press fitting into a hole in the electrical device housing. The
 threads further permit the cap of a mating male coaxial cable connector to
 be securely threaded onto the top of the outer shell over the input end of
 the connector for a secure connection therebetween
 The F-connector further includes an inner housing composed of an insulating
 material located within the throughhole of the outer shell. The inner
 housing comprises an upper cap and a lower cap. The top of the lower cap
 is configured for sliding engagement into the bottom of the upper cap to
 form a chamber therein with opposed openings at each end coaxial with the
 openings of the outer shell. A female connector pin is disposed within the
 inner housing chamber and is electrically isolated from the F-connector
 outer shell. To retain the upper and lower caps and the female connector
 pin within the F-connector outer shell, an edge portion of the outer shell
 at the input end is effectively peened or rolled radially inward under
 pressure against the associated components contained therein.
 To provide effective electrical connection, one end of the female pin is
 configured for receiving and electrically linking with a center pin of a
 coupled male connector extending into the chamber through the opening at
 the input end. The other end of the female pin includes an end prong
 protruding from the mounting end of the F-connector. The end prong of the
 female pin is electrically connected to an internal circuit housed within
 the electrical device housing and conducts RF signals, and also AC power
 in certain applications between the coupled male coaxial cable connector
 and the internal circuit. Additionally, the coupling of the F-connector
 and the male coaxial cable connector further foils a ground connection
 between the F-connector outer shell and the shielding sleeve of the
 coaxial cable to minimize undesirable signal leakage and radio frequency
 interference from the outside.
 Recent industry-wide standards have required the fabrication and use of a
 wider and flatter edge portion at the input end of the outer shell to
 achieve the best flush contact with the male coaxial cable connector for
 purposes of gaining the most optimal electrical ground connection. The
 peening or rolling technique used currently produces an undesirable narrow
 curvilinear surface along the edge portion at the input end. Although it
 is possible to produce peened edge portions with substantially flat and
 wide ries, F-connectors having such substantially flat peened edge
 portions are more expensive to fabricate, and experience greater
 structural failure rates due in part to increased occurrences of metal
 fractures and fatigue introduced by the peening process. Another approach
 in fabricating the flat edge surface is to slightly compress radially the
 input end opening without rounding the edge surface. To minimize metal
 fracture and fatigue, the amount of compression forged is very limited and
 slight. Such F-connectors possess limited retainment capacity of the
 internal components. At elevated temperatures, the outer shell and the
 input end opening has a tendency to expand in a manner to permit the
 internal components of the F-connector to exit the outer shell.
 For the foregoing reasons, there is a need for an improved F-connector
 assembly which can provide a substantially flat top edge portion along an
 input end opening thereof while in a cost efficient manner, maintaining
 reliable retaimnent of the associated internal components therein for
 effective long term operation.
 SUMMARY OF THE INVENTION
 With the prior art problems in mind, the present invention is generally
 directed to an F-connector assembly for coaxial cables which is cost
 efficient, easy to fabricate and implement, and adaptable for connection
 with a coaxial cable in a mamer providing reliable long term operation.
 In particular, one aspect of the present invention is directed to an
 F-connector assembly which comprises:
 a) a barrel shaped casing having a top end with a centrally located hole
 forming an input port, and a bottom end configured fbr connecting with a
 portion of a housing of an electrical device, said casing being configured
 for mechanical retainment and electrical connection with a coaxial cable
 connecting element;
 b) a top cap and a bottom cap each configured for locking engagement to
 form a hollow enclosed sleeve, said sleeve being disposed within said
 casing, said hollow enclosed sleeve including a first opening coaxially
 positioned with said top end hole, a second opening on the opposing end in
 communication with an interior volume of said housing and a hollow core
 therebetween; and
 c) a clip pin securely retained within the hollow core of said hollow
 enclosed sleeve, said clip pin including a contact mechanism at one end
 for receiving and retaining a coaxial cable center conductor passing
 through the open end of said port, and a conducting pin at an opposing
 end, extending from the hollow core through the second opening of the
 hollow sleeve into said housing interior volume and rigidly being anchored
 therein for electrical connection to internal electric circuit.

DETAILED DESCRIPTION OF THE INVENTION
 The present invention is generally directed to an F-connector assembly
 constructed in a manner that provides over the prior art improved
 electrical ground contact with a mating male connector and its associated
 ground shield of a coaxial cable attached thereon. The present F-connector
 assembly is constricted with the advantage of reliable retainment and
 operation of the internal components over time and over repeated use, and
 ease of fabrication using known available manufacturing methods In
 addition, the present F-connector assembly may be constructed in a manner
 which allows easy ready replacement of internal components of one
 F-connector assembly unit without disrupting undamaged F-connector units.
 The cost efficient and effective manner by which the F-connector assembly
 is constructed and by which the present F-connector assembly meets the
 requirements of an improved ground contact with coaxial cables as set
 forth by industry-wide standards makes such F-connector assemblies
 especially suitable for telecommunication use.
 FIG. 1 shows a typical prior art configuration of an electrical device 10
 (i.e. signal splitter without its cover) upon which a plurality of
 F-connector assemblies 12 of the prior art are mounted. The electrical
 device 10 includes an electrically conductive metal housing 14 with
 interior volume 16, internal electrical circuitry on a printed circuit
 board 18, and the plurality of F-connector assemblies 12 utilized as
 input/output connections, respectively, for coupling with coaxial cables
 via male coaxial cable connector (not shown).
 The F-connector assembly 12 generally comprises a barrel-shaped or
 cylindrical electrically conductive metal body 20 with a set of eternal
 threads 22 extending therearound, a through hole 24 in communication with
 the interior volume 16 of the electrical device housing 14, and an
 internal connection assembly 26. The body 20 includes a free end
 approximate 28 opening for coupling with a male coaxial cable connector
 with the opposing end of body 20 being mechanically and electrically
 connected to the housing 14 via, for example, as a unitary casting with
 housing 14, or by threaded engagement or press fitting, or welding
 techniques, and so forth as known in the art. The threads 22 are standard
 UNF threads, in this example. The threads 22 permit the cap of a mating
 male connector to be securely screwed onto the top of the body 20 over the
 coupling end thereof. It is noted that although the body 20 typically
 consists of alloy material, or any other suitable, such as aluminum alloy
 or brass, and must be electrically conductive for providing the ground
 termination for the coaxial cable secured thereto, materials other dim
 brass can be used.
 The internal connection assembly 26 provides electrical connection between
 the center conductor of a coaxial cable (not shown) via the associated
 mating male connector (not shown), and the internal circuitry 18 within
 the housing 14 for conducting RF signals, and AC power (if any)
 therebetweem The internal connection assembly 26 is located in the through
 hole 24 of the body 20, and includes a bottom cap 30, a top cap 32, and a
 clip pin 34. The bottom cap 30 is configured to slip fit into the top cap
 32, to form an electrically insulating enclosure for the clip pin 34. The
 clip pin 34 includes a tail portion 36 at one end and a pair of opposing
 spring contacts 38 for clasping the center conductor of a coaxial cable
 associated with a mating male connector at the other end. The tail portion
 36 of the clip pin 34 is adapted to extend through an opening (not shown)
 of the bottom cap 30. A centrally located opening 33 is provided in the
 top cap 32 for permitting insertion of the center conductor of a coaxial
 cable therethrough during connection of the male connector.
 To assemble the F-connector assembly 12, the various components as
 described are slid into the body 20 through the opening 28 thereof with
 the tail portion 36 introduced first into the internal volume 16 of the
 chassis 14. The tail portion 36 of the clip pin 34 is rigidly mechanical
 and electrically connected to the internal circuitry 18 preferably by
 soldering directly to a terminal 42, or through a soldered wire 40. An
 edge portion 44 around the opening 28 is bent or peened radially inward
 for securing the various component elements of the F-connector assembly 12
 in place.
 With reference to the pictorial view of FIG. 2 for the F-connector assembly
 12, note the peened edge portion 44 extending around the opening 28 in an
 attempt to prevent the various internal components from being released
 from the body 20, has a facial surface that is narrow and blunt, providing
 a negligible ground connection between the body 20 and the ground shield
 of the connecting coaxial cable via mechanical connection to a mating male
 connector. Industry-accepted standards now require the use of a wide, flat
 edge portion 44 to provide an improved electrical ground contact between
 the F-connector assembly, and male coaxial cable connector. However,
 fabricating an F-connector assembly with such a flat edge portion is
 difficult and expensive. Peening techniques are limited and may cause
 metal fatigue and deformation.
 With reference to FIG. 3, a wider edge portion 44 is provided by very
 slightly compressing the edge portion 44 radially inward for sufficiently
 retaining the components therein. However, such F-connector assemblies 12
 suffer from retainment failure. During elevated temperatures, the thermal
 expansion gradient of the body 20 may be such that the opening 28 expands
 and a gap or spacing between the edge portion 44 and the outer edge of the
 top cap 32 is created, thus resulting in the loss of retention of the
 internal components, such as top cap 32.
 FIGS. 4 and 5 illustrate two embodiments, respectively, of an F-connector
 assembly in accordance with the present invention, that overcomes the
 problems in the prior art. The F-connector assembly is generally denoted
 by the reference numeral 60, and includes a hollow outer shell or body 62
 with a through hole 64 disposed between an input opening 66 at an input
 end 68 and a base opening 70 proximate a base end 72 thereof, and a set of
 external threads 74 extending around the exterior portion thereof. The
 outer shell 62 is preferably composed of an electrically conductive
 material such as zinc alloy, aluminum alloy, or brass, for example. It is
 noted that a given electrical device typically includes at least a
 plurality of F-connector assemblies 60 for multiple inputs and/or outputs,
 respectively, as may be required for a given application.
 The hollow outer body 62 is part of or mechanically and electrically
 attached to the metal wall of a chassis or housing 76 or some other
 housing of an electrical device having circuitry which is to be connected
 to a coaxial cable. The body 62 is preferably grounded for providing
 continuous shielding of the RF signals and any AC power transmitted
 between the coaxial cable and the associated electrical/electronic
 components housed within the electrical device. The length and size of the
 outer shell 62 and the internal components contained therein may vary, as
 desired, depending on the application and the specification required for
 installation and implementation of the invention as well as the
 configuration of the coaxial cable and/or the male connector for coupling
 therewith.
 The term "electrical device" includes, but is not limited to multi-taps,
 signal conditioners, receivers, encoders/decoders, amplifiers, splitters,
 junction boxes and the like which may be located at either end of a run of
 a coaxial cable or at any other location therebetween.
 The input end 68 of the outer shell 62 is configured for coupling with the
 coaxial cable/male connector (not shown) through the input opening 66 by
 threaded engagement therebetweem The means of engagement is not limited to
 those involving screwthreads, and may include other forms as known to one
 of ordinary skill in the art The base end 72 of the outer shell 62 is
 configured for attachment to the electrical device chassis 76. In this
 example, the shell or body 62 and chassis 76 are formed from a single
 unitary metal casting. It is also understood that the attachment means is
 not limited to this firm only, and may include other forms which provide
 mechanical and electrical connection therebetween such as threaded means,
 press fitted means, welded means and the like as known to one of ordinary
 skill in the art. The through hole 64 of the outer shell 62 is in
 communication with a interior volume 78 of the electrical device chassis
 76 including electrical circuitry 80 housed therein, in this example.
 The F-connector assembly 60 further includes an electrically insulated
 inner housing 82, and a clip pin 84 securely retained therein. The inner
 housing 82 comprises an upper cap member 86 with a centrally located
 beveled hole 88 proximate the input end 68 of the outer shell 62, and a
 lower cap member 90 being configured for fitting partially within and
 slidably engaging an interior lower portion of the upper cap member 86 to
 form an electrically insulated chamber 92 for retaining the electrically
 conductive clip pin 84. Clip pin 84 is typically fabricated from
 phosphorbronze, or beryllium copper, of other suitable material. The lower
 cap member 90 includes a centrally located slot 94 proximate the base end
 72 of the outer shell 62. The inner housing 82 is preferably composed of a
 durable electrically insulating material including, but not limited to,
 plastic, polypropylene, Duron.RTM., and so forth. A ledge portion 96
 extending around the base opening 70 is provided for retaining the inner
 housing and clip pin assembly within the through hole or cavity 64, as
 shown. In a preferred embodiment, the lodge portion 96 is annular.
 The clip pin 84 includes a pair of opposable spring contacts 98 at one end,
 located proximate the hole 88 of the upper cap member 86 for grasping a
 portion of a center conductor of the coaxial cable during coupling, and a
 tail or elongated tab portion 100 at an opposing end thereof. The lower
 cap member 90 includes downwardly converging side portions 102 extending
 to the slot 94 hereof for assisting in assembly by facilitating passing of
 the tail portion 100 through the slot 94 into the interior volume 78 of
 the chassis 76. The internal circuitry 80 includes in the embodiment of
 FIG. 4, a terminal lead in the form of a narrow slot 104 which receives
 the projecting tail portion 100 of the clip pin, whereby a weld or solder
 106 is employed to provide an electrical connection and a secure
 mechanical retainment therebetween.
 With reference to FIG. 4, the upper cap member 86 further includes an outer
 annular top portion 108 extending around the centrally located beveled
 hole 88. A flat top face annular surface 112 is provided for forming the
 most optimal ground contact with the inside face of a mated male coaxial
 cable connector (not shown).
 Referring now to FIGS. 5 and 6, the upper cap member 86 and the lower cap
 member 90 each include a stepped portion 114 and 116, respectively. The
 stepped portions 114 and 116 cooperate with a pair of opposing tabs 118
 located approximately at a mid-portion of the clip pin 84 for securely
 retaining clip pin 84 within the chamber 92 of the cap assembly forming an
 inner housing 82. The bottom of the stepped portion 114 of the upper cap
 member 86 abuts against a top edge 120 of the tabs 118 and the top of the
 stepped portion 116 of the lower cap member 90 abuts against a bottom edge
 122 of the tabs 118. The opposing tabs 118 prevent the clip pin 84 from
 moving downward relative to the input opening 88 when a downward force is
 applied by the entering center conductor of a coaxial cable, in that the
 tabs 118 are abutted against the stepped portion 116 of the lower cap
 member 90. Also the clip pin 84 is prevented from moving upward due to a
 force applied by the exiting center conductor, in a similar manner, in
 that the tabs 118 are abutted against the stepped portion 114 of the upper
 cap member 86.
 To overcome the problems encountered by the prior ant F-connector assembly,
 the F-connector assembly 60 of the present invention further includes a
 pair of opposing locking tabs 124 located on each side of the lower cap
 member 90 and a pair of corresponding locking slots 126 located on each
 side of the upper cap member 86. The locking tabs 124 are each configured
 for securely snapping into and being retained by the respective slots 126.
 In this manner, the coupled slots 126 and tabs 124 locks the upper and
 lower cap members 86 and 90 together for forming a unitary electrically
 insulated inner housing 82. With this configuration, the various
 components are internally secured within the outer shell 62 after the tail
 portion 100 of the clip pin 84 is soldered via solder 106 either into the
 terminal slot 104 for the embodiment of FIG. 4, or via a soldered
 electrical wire conductor 105 between tail portion 100 and a terminal tab
 42 on printed circuit board 80 for the embodiment of FIG. 5.
 With reference to FIG. 6, a pictorial assembly view of the components of
 the inner housing 82 and the clip pin 84 is shown. The lower cap member 90
 includes a pair of guide ears 128 extending away from the side portions
 102 each on opposite sides of the slot 94 (see FIG. 7C). The tail portion
 100 of the clip pin 84 is introduced through the slot 94. The clip pin 84
 is oriented in a manner wherein each of the guide ears 128 contacts a rear
 extended portion 130 of the clip pin spring contacts 98 (see FIG. 4). The
 upper and lower cap members 86 and 90, respectively, are oriented so that
 the locking tabs 124 are in line with the locking slots 126, and the
 guides ears 128 of the lower cap member 90 are inserted into channels 144
 (see FIGS. 8B, 8C, and 8D) of the upper cap member 86 until the bottom of
 the upper cap member 86 contacts a base flange 132 of the lower cap member
 90. The locking tab 124 and locking slots 126 are engaged for a secure
 attachment therebetween.
 With reference to FIGS. 7A through 7E, the design of the lower cap member
 90 is shown in detail. The lower cap member 90 includes a circular base
 134 and a circumferential side wall 136 with a pair of opposing locking
 tabs 124 disposed thereon. The pair of opposing guide ears 128 extend
 upwardly from the sidewall 136. The base flange 132 projects substantially
 along the periphery of the base 134 for preventing the lower cap member 90
 from being inserted into the upper cap member 86. As shown in FIG. 7C
 (cross section from FIG. 7A), the interior lower side portions 102
 converge downwardly toward the slot 94 for guiding and thereby permitting
 entry of the clip pin 84 end prong 100 therethrough (FIG. 9A).
 FIGS. 8A through 8D, show design details for the upper cap member 86. The
 upper cap member 86 includes an upper circular top face 138 with the
 centrally located beveled hole 88 for permitting entry of the center pin
 of the male coaxial cable connector. The beveled hole 88 is concentric
 with an outer flat top portion 108. The upper cap member 86 further
 includes a cylindrical outer sidewall 140 extending from the periphery of
 the top face 138, and a pair of opposing and parallel inside wall portions
 142. The parallel inside wall portions 142 form a pair of opposing
 channels 144 which are configured for sliding engagement with the guide
 ears 128 of the lower cap member 90 (See FIG. 7C), thereby preventing
 rotation therebetween. The guide ears 128 and the wall portions 142 also
 provide indexing for the correct manner of orientation of the cap members
 86 and 90, respectively. A peripheral band 146 extends along the base 148
 of the upper cap member 86. Once the locking tabs 128 are engaged with the
 slots 126, the cap members 86 and 90, respectively are rigidly and
 securely held together to form the inner housing 82 (as shown in FIGS. 4
 and 5) as a single unitary piece with the clip pin 84 securely housed
 therein.
 A preferred embodiment for clip pin 84 is shown in FIGS. 9A through 9D. As
 shown, the front of clip pin 84 includes L-shaped outwardly bent ears 99
 for guiding a coaxial cable center conductor end into engagement between
 contacts 98. The inside surfaces 101 of contacts 98 are curved inward (see
 FIG. 10) to maximize mechanical and electrical contact with the center
 conductor 150. The clip pin 84 is formed via appropriate bending of the
 single piece clip pin metal stamping shown in FIG. 9D. Note that the
 length of the tab 100 can be varied for the requirements of different
 applications.
 Although various embodiments of the invention have been shown and
 described, they are not meant to be limiting. Those of skill in the art
 may recognize various modifications to these embodiments, which
 modifications are meant to be covered by the spirit and scope of the
 appended claims.