Coaxial cable Y-splitter assembly with an integral splitter body and method

A coaxial cable signal splitter with first, second and third connector ends, each adapted to mate with a coaxial cable connector. The first connector end is integral with a splitter body. The second and third connector ends are connected to the body by a pair of coaxial cables. Each connector end includes a center conductor mounted within a coaxially arranged conductive outer shell conductor. The splitter body includes the first connector end and an opposing arrangement for connecting the pair of cables to the body. The splitter body includes a transverse opening between the first connector end and the cable mounting arrangement, the opening extending through the body and having opposing open sides. Within the opening, the center conductor of the first connector end is electrically connected with the center conductors of the second and third connector ends. The center conductor of the first connector end extends within the conductive outer shell of the first connector end and within the opening of the body. The center conductor of each of the pair of coaxial cables extend within the opening of the body and are electrically connected to the center conductor of the first connector end, and each of the conductive outer shell connectors electrically connected to the other conductive outer shells.

TECHNICAL FIELD

The present invention generally relates to telecommunications cable assemblies and more specifically to a Y-splitter assembly and method for use with a coaxial cable.

BACKGROUND

Coaxial cables are often used for the transmission of telecommunications signals. At times, it is desirable to divide these signals. When such a signal is divided to permit a monitor function, only a small fraction of the signal is divided at a monitor tap. The bulk of the signal is transmitted without interruption and the small fraction is directed to a monitoring device or circuit to monitor the quality, quantity or content of the signal being transmitted. However, sometimes it is desirable to break the signal into two approximately equal portions. A Y-splitter is used to divide the signal from a first telecommunications cable into two second telecommunications cables and may provide a desired equal split of the signal or may direct more of the signal from the first cable into one of the two second cables and less of the signal to the other of the two second cables.

Improvements to current Y-splitters are desirable. Improvements to splitting of signals from a first cable into the second cables are desirable.

SUMMARY

The present invention relates generally to a coaxial cable signal splitter with first, second and third connector ends, each adapted to mate with a coaxial cable connector. The first connector end is integral with a splitter body. The second and third connector ends are connected to the body by a pair of coaxial cables. Each connector end includes a center conductor mounted within a coaxially arranged conductive outer shell conductor. The splitter body includes the first connector end and an opposing arrangement for connecting the pair of cables to the body. The splitter body includes a transverse opening between the first connector end and the cable mounting arrangement, the opening extending through the body and having opposing open sides. Within the opening, the center conductor of the first connector end is electrically connected with the center conductors of the second and third connector ends. The center conductor of the first connector end extends within the conductive outer shell of the first connector end and within the opening of the body. The center conductor of each of the pair of coaxial cables extend within the opening of the body and are electrically connected to the center conductor of the first connector end, and each of the conductive outer shell connectors electrically connected to the other conductive outer shells.

A splitter body including a first end including an integral electrically conductive outer shell of a coaxial cable connector and a opposite second end with a pair of electrically conductive crimp extensions for mounting a pair of coaxial cables. The body includes a central opening extending transversely through the body between the first and second ends. The first and second ends are connected by a pair of side walls on either side of the central opening, and the side walls electrically connect the outer shell and the crimp extensions. The first end includes an opening extending from the outer shell into the central opening and sized to receive a center conductor mounted within a center conductor insulator. Each of the crimp extensions includes an opening extending through the crimp extensions into the central opening, the openings sized to receive a center conductor of one of the coaxial cable electrically isolated from the body. Each crimp extension also includes a textured outer surface. The central opening provides space for the center conductor of the first end to be electrically connected with the center conductors of the coaxial cables without electrically contacting the side walls.

The present invention further relates to a method of assembling a coaxial cable splitter including providing a splitter body with a first end defining a first cable connector end, and a second opposing end. The second end includes a first cable mounting arrangement and a second cable mounting arrangement. The splitter body defines a transverse opening extending through the body between the first and second ends of the splitter body. The first end and the cable mounting arrangements electrically connected to each other. A first center conductor is inserted within a first insulator and the first insulator and the first center conductor are positioned within the first end of the splitter body, with a rear end of the first center conductor extending within the transverse opening. A center conductor and a center conductor insulative jacket sheath of a first coaxial cable are inserted through the first cable mounting arrangement and into the transverse opening. A center conductor and a center conductor insulative jacket sheath of a second coaxial cable are inserted through the second cable mounting arrangement and into the transverse opening. A portion of each of the center conductors of the coaxial cables extending from the insulative jacket sheaths. The extended portion of each of the center conductors of the coaxial cables within the transverse opening are intertwined. The intertwined portions of the center conductors of the coaxial cables are positioned within a notch formed in the rear end of the center conductor of the first end to electrically connect the center conductors. An outer conductor of the first coaxial cable is electrically connected to first cable mounting arrangement and the first coaxial cable is crimped to the first cable mounting arrangement. An outer conductor of the second coaxial cable is electrically connected to the second cable mounting arrangement and crimping the second coaxial cable is crimped to the second cable mounting arrangement.

The present invention relates still further to a coaxial cable signal splitter with first, second and third coaxial connectors. The first coaxial connector includes a first conductive body. The first conductive body includes a hollow first end defining a coaxial connector end for mating with a first mating coaxial connector. The first conductive body also includes an opposite end defining two parallel hollow crimp extensions, the opposite end spaced from the first end along a longitudinal axis of the first conductive body. The first conductive body further includes an intermediate portion defining a transverse opening extending through the first conductive body transverse to the longitudinal axis. The intermediate portion includes first and second side walls on opposite sides of the transverse opening and spaced on opposite sides of the longitudinal axis. The intermediate portion also includes first and second end walls on opposite ends of the traverse opening and spaced from each other along the longitudinal axis.

The first conductive body further includes two conductive crimp sleeves, each one mounted over one of the crimp extensions. A first center conductor is positioned within the first end of the first conductive body. A first insulator electrically isolates the first center conductor from the first conductive body. A conductive bushing is positioned over the first conductive body and encloses the transverse opening.

The second coaxial connector includes a second conductive body, a second center conductor disposed within the second conductive body, and a second insulator electrically isolating the second center conductor from the second conductive body. The second coaxial connector defines a distal end for mating with a second mating coaxial connector. The third coaxial connector includes a third conductive body, a third center conductor disposed within the third conductive body, and a third insulator electrically isolating the third center conductor from the third conductive body. The third coaxial connector defines a distal end for mating with a third mating coaxial connector.

Two flexible coaxial cables extend between first and second opposite ends. Each coaxial cable includes an outer jacket, a ground shield inside the outer jacket, an inner jacket inside the ground shield, and a main signal center conductor inside the inner jacket. The ground shield and the main signal center conductor of each coaxial cable are connected at the first ends to the second and third coaxial connectors. The ground shields of the coaxial cables are each connected to one of the respective second and third conductive bodies. The main signal center conductors are each connected to one of the respective second and third center conductors. The ground shields of the coaxial cables at the second ends are each connected to one of the crimp extensions under one of the crimp sleeves. The main signal center conductors of the coaxial cables at the second ends extend through the crimp extensions and into the transverse opening. The main signal center conductors connect to the first center conductor within the transverse opening.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary aspects of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Referring toFIG. 1, a coaxial cable Y-splitter or splitter10is shown, including an input coaxial connector end12, a first output coaxial connector14and a second output coaxial connector end16. Input end12is part of a splitter housing assembly18and the output ends14and16are connected to splitter housing assembly18by cables20and22, respectively. As shown, input end12is a female coaxial connector and a pair of output ends14and16are male coaxial connectors. Ends12,14and16are of the same format and end12could be mated to either of ends14or16. Alternatively, ends12,14and16could be of different combinations of genders and may also conform to incompatible coaxial connectors styles, formats or standards for coaxial cable connectors. The gender, style, format or standards to which the ends conform may be chosen as required for a particular installation or use requirement. Cables20and22are flexible coaxial electrical cables with coaxially arranged conductors. Other types and styles of flexible cables may be used so long as such alternative cables may be terminated using coaxial cable connectors.

FIG. 2shows an electrical schematic diagram of splitter10. Input end12and output ends14and16share a common ground24. Common ground24is electrically connected to a conductive outer shell26,28and30, respectively, of each of the ends. If mating ends are connected to ends12,14and16, and these mating ends terminate coaxial cables, common ground24would provide electrical continuity for the shield conductor within the different coaxial cables. A center conductor32of end12is electrically connected to a center conductor34of end14and a center conductor36of end16by a circuit38. Circuit38includes an electrical split40to separate portions of any electrical signals or impulses transmitted to center conductor32to center conductors34and36. In the preferred embodiment, no other electrical devices or features are provided within splitter10which might serve to deliberately direct a greater or lesser portion of such a signal from end12to either end14or16. Barring differences in internal resistance within wires and joints of circuit38, any signal from center conductor32should be split evenly between center conductor34and36. Alternatively, splitter10may be configured with some degree of resistance in circuit38between split40and either of center conductors34or36. Such an alternative configuration would serve to direct more of the electrical signal from end12to one of the ends14or16. The structure and elements of each of the ends will be described in further detail below.

FIGS. 3 and 26show a closer view of splitter housing assembly18of splitter10adjacent end12, with a protective bushing46of housing assembly18removed to show electrical split40of center conductor circuit38. Center conductors34and36extend from cables20and22into a body44. Center conductors34and36of cables20and22, respectively, are intertwined with each other. The intertwined center conductors34and36are positioned within a second end54of center conductor32of first end12and are soldered to form split40. Second end52and split40are described in further detail below with regard toFIG. 26.

FIG. 4shows an exploded view of housing assembly18, including body44, protective bushing46, a center conductor insulator48and a pair of crimp sleeves50. Center conductor32is mounted within center conductor insulator48, which is in turn mounted within housing42. A first end52of center conductor32extends within conductive outer shell26to form coaxial connector end12. Opposite second end54of center conductor32extends within an opening56of housing44extends within an opening56of housing44and provides a location for electrical split40to be formed.

FIGS. 5 to 10show body44in further detail, with opening56extending through body44and providing access to second end54of center conductor32to form electrical split40. Conductive outer shell26includes a pair of opposing bayonets58to permit a mating coaxial connector to be releasably locked to first end12. Conductive outer shell26also defines an opening60from an outer lip64into opening56through an first inner wall66. Within opening60is an area62sized to receive and retain center conductor insulator48and position center conductor32with first end52positioned within conductive outer shell26and second end54within opening56.

Extending through a second opposing inner wall68of opening56is a pair of openings70. A pair of crimp extensions72extend from an outer wall76, opposite second inner wall68, and extend each opening70from opening56to an outer lip74. Openings70provide a path for cables20and22to connect to body44and extend into opening56to electrical split44. Crimp extensions72may include spiral threads78, as shown, on an outer surface80to provide greater mechanical strength to the connection of cables20and22to body44, as shown inFIG. 10. Alternatively, other surface treatments or textures may be used on the outer surface of extensions72, including, but not limited to, circumferential grooves or raised rings, molded or formed surface textures, applied surface treatments, or other roughening techniques. As a further alternative, no special surface treatment or structure may be provided on the outer surface of extensions72.

Body44may be cast as a blank without openings56,60, and70, and then the blank machined or otherwise configured to include the features shown and described above. Alternatively, body44could be machined from as a complete body from a piece of appropriate raw material, such as aluminum, brass, or other suitable, electrically conductive material. To provide access into opening56to form or repair electrical split44, it is desirable that opening56extend through the width of body44with access provided into opening56through a pair of opposing sides82. As shown, opening56is formed by milling or machining through an intermediate portion84of body44. This creates a side wall86with a maximum thickness87along a centerline perpendicular to the direction of insertion of the milling or machining device and tapering in thickness to opposing edges88adjacent opposite sides82. Other methods or techniques of forming body44may be used to create opening56and sides82.

Within area62is an inner ledge90and an inner wall92which locate and position center conductor insulator48within body44. Inner ledge90limits the depth to which center conductor insulator48may be inserted within opening60through conductive outer shell26.

Center conductor insulator48, shown in greater detail inFIGS. 11 to 14, includes a center shaft portion94defining a central opening96sized to receive center conductor32. Extending from shaft portion96are a plurality of wings98, each having an outer surface100which cooperate to define the outer diameter of center conductor insulator48. Center conductor insulator48also includes a base102with a bottom surface108opposite wings98and transitioning through a taper104to a maximum diameter106, which coincides with the outer diameter defined by outer surfaces100of wings98. Taper104aids insertion of center conductor insulator48within opening60and into portion62so that bottom surface108is proximate inner ledge90and ledge90prevent further insertion within body44. Center conductor32positioned within opening96would have first end52extending beyond a top surface110within conductive outer shell26and second end54extending from bottom surface108into opening56through first inner wall66of body44, when center conductor insulator48is positioned within area62of opening60. A taper112is provided from top surface110into opening96to aid the insertion of center conductor32within opening center conductor insulator48. Adjacent taper112of opening96is an outer surface99of shaft portion94.

Referring now toFIGS. 15 to 19, center conductor32is shown in greater detail. Center conductor32includes an axial opening114in first end52to engage a mating center conductor pin of a mating coaxial connector. Adjacent opening114is a tab116which is shown inFIGS. 15 and 16deflected inward to more positively engage the mating center conductor pin and deflect outward when the mating pin is inserted within opening114. A cylindrical housing115defines substantially the remainder of opening114.

Extending away from opening114is a shaft118extending toward second end54. In a portion of shaft118adjacent housing115is a seating ring122defining a seating ledge124. A taper130provides a transition between seating ledge124and shaft118. When center conductor32is inserted within opening96of center conductor insulator48, seating ledge124engages outer surface99of central shaft portion94and taper130is positioned within taper112. A pair of reverse tapered ledges120are positioned along shaft118between seating ledge124and second end54, and are located so that they will be within opening96of center conductor insulator48when ledge124engages outer surface99. The reverse taper of ledges120permits insertion of center conductor32within opening94of center conductor insulator48through taper112while resisting extraction in the opposite direction.

Second end54includes an axial opening126and a pair of opposing extensions128forming a slot132. Slot132and opening126provide a secure location for forming electrical split44and structure to aid the physical and electrical connection of center conductor wires from cables20and22with center conductor32.

Center conductor32may be constructed without the several features noted above for engaging center conductor insulator48. A friction fit or other method or structure for securely holding the center conductor within center conductor insulator may be utilized.

FIGS. 20 to 25show protective bushing46, which fits about body44and closes sides82of opening56. Bushing46includes a cylindrical body134within a first end136and a second end138, and defines a central cavity140. First end136includes an opening142into cavity140and second end138includes an opening146into cavity140. To position bushing46about body44, as shown inFIG. 1, above, conductive outer shell26is inserted through opening146into cavity140and out opening142. A pair of opposing lobes144of opening142permit passage of bayonets58through bushing46. Alternatively, opening142may be made large enough for passage of bayonets58. Second end138is then positioned about a crimp ring132(shown inFIGS. 5 to 9, above), adjacent second wall68of opening56. Second end138includes a pair of opposing crimp wings148, separated by a pair of notches150, to permit attaching by crimping to crimp ring132to secure bushing46to body44.

When bushing46is inserted about body44, an inner wall152within cavity140adjacent opening142through first end136is positioned adjacent a ledge133(shown inFIGS. 5 to 8, above), with conductive outer shell26extending through opening142. With bushing46secured about crimp ring132, inner wall152and ledge133cooperate to prevent entry into opening56of undesired objects or debris. Notches150are provided to permit easier crimping of bushing46about crimp ring132and permit extension of outer wall76beyond the limits of crimp ring132without adversely affected connection of bushing46to body44. In addition, body44includes a pair of tabs145(shown inFIGS. 5 to 8, above) extending transversely from outer wall76adjacent crimp extensions72. Tabs145engage notches150to orient bushing46prior to crimping to body44. As shown, bayonets58and tabs145of outer wall76are centered approximately ninety degrees from each other about body44. Notches150and lobes144are similarly positioned with respect to each other on bushing46. Other orientations and positions of these features may be used within the bounds of the splitter herein described.

FIG. 26shows a closer side view of opening56of splitter10with bushing46removed. Cable center conductors34and36, each within an insulative jacket sheath156, extend into opening56through an opening70for each of cables20and22. Note that an outer coaxial or shield conductor of each cable20and22is terminated at crimp extension72and held to crimp extension72by crimp sleeve50. The outer coaxial conductor of each cable20and22is electrically connected to crimp extension72and through body44to conductive outer shell26of first end12. These outer coaxial conductors of cables20and22form a portion of common ground24, as shown in the schematic diagram ofFIG. 2. An outer jacket sheath155surrounds the outer coaxial conductor of cable20and22and is indicated inFIG. 1.

Within opening56, cable center conductors34and36are entwined with each other to electrically connect to each other and positioned within slot126between extensions128of second end54of center conductor32. This forms electrical split40. Cable center conductors34and36can be held together by physical means or may also be soldered together to enhance the electrical connection as well as the physical connection. Alternative methods of physically and electrically joining cable center conductors34and36with second end54are within the bounds of the splitter described herein.

FIGS. 27 to 31show a coaxial cable connector160such as used for output coaxial connectors14and16. Connector160is mounted to and terminates cables20and22at an end opposite from crimp extension70. Connector160includes a rotating outer sleeve162for releasably locking connector160to a mating coaxial connector. Rotating sleeve162is rotatably mounted about a conductive connector housing164within which is a center conductor166. Center conductor166is mounted within and electrically isolated from housing164by a center conductor insulator168. Center conductor insulator168is mounted within an opening182of housing164and positions a first end186of center conductor166within a first open end183of housing164. A second end188of center conductor166is positioned within opening182adjacent a second end184of housing164.

Rotating sleeve162is mounted to housing164about a shoulder174. A washer176is positioned against an inner wall190within sleeve162and sleeve162is placed about shoulder174. A wave washer178is positioned on an opposite side of shoulder174from washer176and a crimp washer180is positioned on the opposite side of wave washer178. Crimp washer180is positioned within a second end172of sleeve162and second end172is crimped about crimp washer180to hold sleeve162and washers176,178and180to housing164. When so assembled, first end183of housing164, a first end170of sleeve162and first end186of center conductor166are positioned adjacent one another to physically and electrically connect with a mating coaxial connector.

A second end184of housing164is configured to receive a crimp sleeve to allow a coaxial cable to be terminated and connected to connector160. Such termination and mounting of connectors such as connector160to a coaxial cable are well known in the telecommunications industry. A crimp sleeve187is sized and configured to be placed about second end184and an outer insulative sheath and an outer coaxial conductor of a coaxial cable. The outer coaxial conductor is placed in electrical contact with housing162and thus to first end183of housing162. Crimp sleeve187is crimped about the outer conductor and second end184to secure connector160to the coaxial cable.

FIGS. 32 to 35show center conductor166of connector160including a shaft192extending between first end186and second end188. Intermediate between the first and second ends is an annular recess194which cooperates with a first end200of center conductor insulator168to securely hold center conductor166within housing164. Proximate second end188is a shoulder196which engages a rear surface198of insulator168(seeFIG. 29. The engagement of shoulder196with rear surface198and the engagement of first end200with recess194. Extending axially partially through center conductor166into second end188is an opening202. Opening202permits a center coaxial conductor from the coaxial cable to be inserted to make electrical contact with center conductor of connector160during termination of the cable and mounting of connector160to the cable.

Coaxial cable and coaxial cable connectors are well known in the telecommunications industry. It is to be understood that different styles, formats and genders of such connectors can be substituted for the connectors and ends of connectors described and shown above, with straying from the bounds of the present invention.