# Patent

## Title
Connector assembly for corrugated coaxial cable

## Abstract

A compression connector for connecting to a coaxial cable is provided. The compression connector is provided in a first state for fitting onto an end of the cable, after which it may be compressed to a second state, thereby joining the connector to the cable to make a coaxial cable assembly. The connector is comprised of a tubular connector body and a compression cap structured to slidably engage the second end of the tubular body. The connector is further internally configured with means for collapsing the first exposed corrugation of the outer conductor of the coaxial cable in the axial direction when the compression cap is compressed onto the tubular connector body.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and is a continuation-in-part of U.S. application Ser. No. 13/077,582, filed on Mar. 31, 2011, and entitled “CONNECTOR ASSEMBLY FOR CORRUGATED COAXIAL CABLE,” which claimed priority to U.S. Provisional Application Ser. No. 61/391,290, filed on Oct. 8, 2010.


BACKGROUND
1. Technical Field
This invention relates generally to the field of coaxial cable connectors and more particularly to a contact connector assembly for use with coaxial cables having a center conductor.
2. State of the Art
Corrugated coaxial cables are electrical cables that are used as transmission lines for radio frequency signals. Coaxial cables are composed of an inner conductor surrounded by a flexible insulating layer, which in turn is surrounded by a corrugated outer conductor that acts as a conducting shield. An outer protective sheath or jacket surrounds the corrugated outer conductor.
A corrugated coaxial cable in an operational state typically has a connector affixed on either end of the cable. The quality of the electrical connection between the coaxial cable and the respective connectors is of utmost importance. Indeed, the quality of the electrical connection can either positively or negatively impact the resulting electric signal as well as the performance of the connector. One issue that negatively impacts the electric signal between the cable and the connector is the size of the connector in relation to the size of the cable. Currently, specifically-sized connectors must be chosen for each size of cable that they are to be connected to. Improperly-sized connectors, or even improperly-selected connectors for a certain-sized cable, will negatively impact the electric signal between the cable and the connector, resulting in extremely low performance. Moreover, even when the properly-sized connector is chosen for the designated cable, variations in the actual dimensions of the manufactured cable can lead to improper installation of the connector on the cable. Improper installation could lead to poor electrical and mechanical connection between the compression connector and the cable.
Thus, there is a need in the field of corrugated coaxial cables for a universal connector that addresses the aforementioned problems.
SUMMARY
The present invention relates generally to the field of coaxial cable connectors and more particularly to a contact connector assembly for use with coaxial cables having a center conductor.
An aspect of the coaxial cable connector includes a coaxial cable having an inner conductor, an exposed outer corrugated conductor, an insulator positioned between the inner and outer conductors, and a protective jacket disposed over the corrugated outer conductor, a connector body comprising a first end, a second end, and an inner bore defined between the first and second ends of the body, a compression cap comprising a first end, a second end, and an inner bore defined between the first and second ends of the cap, the first end of the compression cap being structured to engage the second end of the connector body, a clamp ring comprising a first end, a second end, an inner bore defined between the first and second ends of the clamp ring for allowing the coaxial cable to axially pass therethrough, the clamp ring being structured to functionally engage the inner bore of the compression cap, a clamp comprising a first end, a second end, an inner bore defined between the first and second ends of the clamp for allowing the coaxial cable to axially pass therethrough, and an annular recess on the inner bore, the annular recess being structured to engage the outer corrugated conductor of the coaxial cable, the first end of the clamp ring being structured to functionally engage the second end of the clamp, and a compression surface positioned within the connector body, wherein the compression surface and the first end of the clamp are structured to crumple therebetween a corrugation of the outer conductor of the coaxial cable under the condition that the clamp is axially advanced into proximity of the compression surface.
Another aspect of the coaxial cable connector includes the compression surface being integral to the connector body and protruding radially inward from the inner bore of the connector body, the compression surface further comprising an oblique surface, and wherein the clamp further comprises an oblique surface, the oblique surface of the clamp being configured to compliment the oblique surface of the compression surface; wherein under the condition that the clamp is axially advanced toward the compression surface the oblique surface of the clamp and the oblique surface of the compression surface crumple therebetween the corrugation of the outer conductor of the cable.
Another aspect of the coaxial cable connector includes a notch positioned radially outward of the oblique surface, and wherein the first end of the clamp further comprises a protrusion positioned radially outward of the oblique surface of the clamp and extending axially from the first end of the clamp, wherein the notch and the protrusion are structurally configured to functionally engage therebetween a portion of the corrugation of the outer conductor under the condition that the oblique surface of the clamp and the oblique surface of the compression surface crumple therebetween the corrugation of the outer conductor.
Another aspect of the coaxial cable connector includes a compression ring having a first end, a second end, and an inner bored defined between the first and second ends of the compression ring, wherein the compression ring is structured to functionally engage the inner bore of the connector body and wherein the second end of the compression ring functions as the compression surface.
Another aspect of the coaxial cable connector includes the second end of the compression ring including an annular indentation, wherein under the condition that the clamp is axially advanced toward the compression surface the annular indentation engages a leading edge of the corrugation of the outer conductor of the cable, and wherein a portion of the corrugation deforms within the annular indentation and a remaining portion of the corrugation collapses between the compression surface and the clamp.
Another aspect of the coaxial cable connector includes the second end of the compression ring including an oblique surface and an opposing oblique surface that are structurally configured to form a v-shaped indention in the second end of the compression ring, and wherein the first end of the clamp comprises an outer beveled edge and an inner beveled edge, the beveled edges being configured to form a v-shape in the first end of the clamp that fits within the v-shaped indention of the compression surface, such that under the condition that the clamp is axially advanced toward the compression surface a corrugation of an outer conductor of the cable collapses between the v-shaped indention of the compression surface and the v-shape in the first end of the clamp.
Another aspect of the coaxial cable connector includes the clamp being comprised of a plurality of radially displaceable sectors, each sector being structured to independently radially displace under the condition that the coaxial cable passes through the clamp; and an elastic member positioned on an outer surface of the clamp, the elastic member being configured to maintain the relative position of the individual sectors with respect to one another during radial displacement of the individual sectors.
Another aspect of the coaxial cable connector assembly includes a deformable washer having a first end, a second end, and an inner bore defined between the first end and the second end, the deformable washer being positioned between the first end of the clamp and the second end of the connector body and being structured to slidably engage the inner bore of the compression cap.
Another aspect of the coaxial cable connector includes the deformable washer being structured to resist the axial advancement of the clamp under a first force and to deform under a second force greater than the first force to allow the clamp to axial advance through the deformed washer.
Another aspect of the coaxial cable connector includes an insulator having a first end, a second end, and an inner bore defined between the first and second ends of the insulator, the insulator positioned within the inner bore of the connector body and structured to slidably engage the inner bore of the connector body; and a conductive pin having a first end, a second end, and a flange extending radially outward from the pin in a central region of the pin, wherein the pin is positioned within and slidably engages the inner bore of the insulator, the flange is structured to engage the second end of the insulator, and the second end of the pin is structured to functionally engage a center conductor of the coaxial cable.
Another aspect of the coaxial cable connector includes the compression cap functionally engaging the clamp ring to axially advance the clamp ring, the clamp ring functionally engaging the clamp to axially advance the clamp toward the compression surface, the clamp functionally engaging the coaxial cable to axially advance the coaxial cable toward the conductive pin, the connector body functionally engaging the insulator to axially advance the insulator, the insulator functionally engaging the conductive pin to axially advance the conductive pin toward the coaxial cable, wherein the axial advancement of the compression cap and the connector body toward one another results in the corrugation of the outer conductor of the coaxial cable collapsing between the clamp and the compression surface, and the second end of the conductive pin functionally engaging the center conductor of the coaxial cable.
Another aspect of the coaxial cable connector includes a first insulator having a first end, a second end, a tubular cavity extending axially from the second end, and an inner bore defined between the first and second ends of the first insulator, the first insulator being positioned within the inner bore of the connector body and structured to slidably engage the inner bore of the connector body, and wherein the second end of the first insulator functionally engages the first end of the compression ring, a second insulator having a first end, a second end, and an inner bore defined between the first and second ends of the second insulator, the second insulator positioned within the inner bore of the connector body and structured to slidably engage the inner bore of the connector body, and a conductive pin having a first end and a second end, the second end defining an axial socket therein, wherein the pin is positioned within and slidably engages the inner bore of the second insulator, and wherein the second end of the pin is structured to functionally engage the first end of the first conductor and the axial socket is structured to functionally engage a center conductor of the coaxial cable.
Another aspect of the coaxial cable connector includes the second end of the first insulator including a tubular mandrel extending axially from the second end, wherein the tubular mandrel is structured to slidably engage the through hole of the compression ring such that the compression ring is positioned on and functionally engages the tubular mandrel of the first insulator.
Another aspect of the coaxial cable connector includes the deformable member having an inner bore and being positioned within the compression cap between the second end of the compression cap and the second end of the clamp ring.
Another aspect of the coaxial cable connector includes a shoulder on the inner bore of the connector body, a shoulder on the inner bore of the compression cap, a flange on the clamp ring, and a lip on the second end of the compression cap that is structured to functionally engage the deformable member.
Another aspect of the coaxial cable connector includes, under the condition that one of the compression cap and connector body are axially advanced toward the other, the compression cap functionally engaging the clamp ring to axially advance the clamp ring, the clamp ring functionally engaging the clamp to axially advance the clamp toward the compression surface, the clamp functionally engaging the coaxial cable to axially advance the coaxial cable toward the conductive pin, the connector body functionally engaging the second insulator to axially advance the second insulator, the second insulator functionally engaging the conductive pin to axially advance the conductive pin toward the coaxial cable, the conductive pin functionally engaging the first insulator to axially advance the first insulator, the first insulator functionally engages the compression ring to axially advance the compression ring toward the clamp, wherein the axial advancement of the compression cap and the connector body toward one another results in the corrugation of the outer conductor of the coaxial cable collapsing between the clamp and the compression surface, the socket of the conductive pin functionally engaging the center conductor of the coaxial cable, and the first insulator axially displacing the conductive pin through the bore of the second insulator such that the socket of the conductive pin functionally engages the inner bore of the second insulator and the second end of the second insulator functionally engages the first end of the first insulator.
Another aspect includes a coaxial cable assembly, the assembly comprising: a coaxial cable having an inner conductor, an outer corrugated conductor, and an insulator disposed between the inner and outer conductors; a connector body comprising a first end, a second end, and an inner bore defined between the first and second ends of the body; a compression cap comprising a first end, a second end, and an inner bore defined between the first and second ends of the cap, the compression cap being axially movable with respect to the connector body; a clamp movable with the compression cap and structured to engage the outer corrugated conductor of the coaxial cable; a compression surface disposed within the connector body; and a conductor displacement guiding member positioned to engage and act upon the outer conductor as movably engaged with the clamp; wherein axial advancement of one of the connector body and the compression cap toward the other facilitates the clamp being axially advanced into proximity with the compression surface such that a corrugation of the outer conductor of the coaxial cable is collapsed between the clamp and the compression surface; and further wherein structure and positioning of the conductor displacement guiding member helps guide a leading portion of the outer conductor to a location folded near the collapsed corrugation portion, as the outer conductor is collapsed.
Another aspect includes a compression connector, the connector comprising: a connector body comprising a first end, a second end, and an inner bore defined between the first and second ends of the body; a compression cap comprising a first end, a second end, and an inner bore defined between the first and second ends of the cap, the compression cap being axially movable with respect to the connector body; a clamp comprising a first end, a second end, an inner bore defined between the first and second ends of the clamp, wherein the clamp is movable with the compression cap; a compression surface disposed within the connector body, wherein axial advancement of one of the connector body and the compression cap toward the other facilitates the clamp being axially advanced into proximity with the compression surface such that the clamp and the compression surface transmit force between one another; and a conductor displacement guiding member located within the connector in a manner permitting prescribed contact with a conductive member of a coaxial cable to guide displacement of the conductive member, as the cable is compressively attached to the connector.
Another aspect includes a method of facilitating impedance matching between a coaxial cable and a coaxial cable connector, the method comprising: providing a connector body comprising a first end, a second end, and an inner bore defined between the first and second ends of the body; providing a compression cap comprising a first end, a second end, and an inner bore defined between the first and second ends of the cap, the compression cap being axially movable with respect to the connector body; providing a clamp comprising a first end, a second end, an inner bore defined between the first and second ends of the clamp, wherein the clamp is movable with the compression cap; providing a compression surface disposed within the connector body, wherein axial advancement of one of the connector body and the compression cap toward the other facilitates the clamp being axially advanced into proximity with the compression surface such that the clamp and the compression surface transmit force between one another; providing a conductor displacement guiding member located within the connector in a manner permitting prescribed contact with a conductive member of a coaxial cable to guide displacement of the conductive member, as the cable is compressively attached to the connector; axially advancing the compression cap and the connector body toward one another such that the clamp axially advances into proximity of a compression surface disposed within the connector cap and a portion of an outer conductor of the coaxial cable collapses between the clamp and the compression surface; and guiding a leading portion of the outer conductor to a location folded near the collapsed corrugation portion, by engagement with the conductor displacement guiding member as the outer conductor is collapsed, to minimize passive intermodulation and return loss associated with the leading portion of the outer conductor.
The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
The features described herein can be better understood with reference to the drawings described below. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
FIG. 1 is a side view of an embodiment of the connector in a first state, and a coaxial cable having a corrugated outer conductor, and an end prepared for insertion into the connector;
FIG. 2 is a side cross-sectional view of an embodiment of the connector in a first state, and a partial cut-away view of the prepared end of the coaxial cable;
FIG. 3 is a side cross-sectional view of an embodiment of the connector in a first state, with the prepared end of the coaxial cable inserted therein;
FIG. 4 is a side cross-sectional view of an embodiment of the connector in a first state, with the prepared end of the coaxial cable inserted therein;
FIG. 5 is a side cross-sectional view of an embodiment of the connector;
FIG. 6 is a side cross-sectional view of an embodiment of the connector; and
FIG. 7 is a side cross-sectional view of an embodiment of the connector.
FIG. 8 is a cross sectional view of an embodiment of the connector, with the prepared end of the coaxial cable inserted therein;
FIG. 9 is a cross sectional view of an embodiment of the connector;
FIG. 10 is an enlarged view of an embodiment of the connector of FIG. 9;
FIG. 11 is an enlarged view of an embodiment of the connector;
FIG. 12 is a cross sectional view of an embodiment of the connector;
FIG. 13 is an embodiment of the connector of FIG. 12 after compression of the outer conductor of the cable;
FIG. 14 is a cross sectional view of an embodiment of the connector;
FIG. 15 is a cross sectional view of an embodiment of the connector;
FIG. 16 is a blown-up cross-section view of a portion of an embodiment of a connector as attached to a coaxial cable; and
FIG. 17 is a blown-up cross-section view of a portion of another embodiment of a connector as attached to a coaxial cable.



DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring first to FIGS. 1 and 2, one embodiment of the connector 10 and an annularly corrugated coaxial cable 200 with a prepared end 210 are shown aligned on a common central axis 2. Since the connector 10 and the annularly corrugated coaxial cable 200 are generally axially symmetric about their central axis 2, the “radially outward” direction in the following description is considered to be outwardly away from the central axis 2. Conversely, “radially inward” with respect to connector component motion is considered to be inwardly toward the central axis 2. Moreover, “axial advancement” of the cable 200 with respect to the connector 10 and “axial advancement” of components of the connector 10 with respect to one another is considered to be along the length of the axis 2.
The coaxial cable 200 that may be coupled to the connector of the one embodiment is comprised of a solid center conductor 202 surrounded by an insulator 204, a corrugated outer conductor 206 surrounding the insulator 204, and an insulative jacket 208 surrounding the outer conductor 206. The prepared end 210 of the coaxial cable 200 is comprised of an exposed length 212 of the center conductor 202, an exposed length of the outer conductor 206 such that at least a first exposed outer conductor corrugation 214 between first and second recessed valleys 216 and 218 and a second exposed outer conductor corrugation 220 between second and third recessed valleys 218 and 222 are exposed. The leading edge 226 of the exposed outer conductor 206 should be configured (i.e. cut) such that the leading edge 226 is part of one the recessed valleys of the corrugated outer conductor 206, the advantages of which will be described in detail below. The insulator 204 is made of a soil, flexible material, such as a polymer foam. A portion of the insulator 204 may be removed from the prepared end 210, thereby providing a “cored out” annular cavity 224 for receiving a portion of a component of the connector 10.
FIG. 2 depicts a cross-sectional view of an embodiment of the connector 10 in a first state. The connector 10 is comprised of a tubular connector body 20 comprising a first end 22, a second end 24, and an inner bore 26. The connector body 20 is comprised of a conductive material. The connector 10 is further comprised of a first insulator 40 is disposed within the inner bore 26 of the tubular connector body 20. The first insulator 40 is comprised of a first surface 42, a second surface 48, a through hole 44, and a tubular mandrel 46 extending axially from the second surface 48 of the first insulator 40. The connector 10 is further comprised of a compression cap 60 comprising a first end 62, a second end 64, and an inner bore 66 having a central shoulder 68. The compression cap 60 is configured to couple to the tubular connector body 20, and more specifically to slidably engage the second end 24 of the body 20.
The connector 10 is further comprised of means for collapsing the first exposed corrugation 214 of the outer conductor 206 of the coaxial cable 200 in the axial direction when the compression cap 60 engages the connector body 20 and is axially advanced further toward the connector body 20. The particular components of the connector 10 and the means for collapsing the outer conductor are described herein below.
The connector 10 is further comprised of a conductive compression ring 80 that comprises a first surface 84 that engages the second surface 48 of the first insulator 40, and a second surface 86 that functions as a compression surface that assists in the collapsing of the first exposed corrugation 214 of the outer conductor 206 of the coaxial cable 200. The compression ring 80 comprises a through hole 82 that engages the tubular mandrel 46 of the first insulator 40, such that the tubular mandrel 46 fits within and slidably engages the through hole 82.
The connector 10 is further comprised of an expandable clamp 90 that is structured to slide within the connector 10 and functionally engage the inner bore 26 of the connector body 20. The clamp 90 comprises a first end 92, a second end 94, a central passageway 96, and a central annular recess 100 defined between a first protruded edge 98 that extends radially inward proximate the first end 92 and a second protruded edge 102 that extends radially inward proximate the second end 94. The first end 92 of the clamp 90 functions as another compression surface that assists in the collapsing of the first exposed corrugation 214 of the outer conductor 206 of the coaxial cable 200, under the condition that the compression surface, mentioned above, is brought into proximity with the first end 92 of the clamp 90, as one of the compression cap 60 and the connector body 20 is axially advanced toward the other.
The connector 10 is further comprised of a clamp push ring 120 that is comprised of a flange 122 having an outer shoulder 124 that is structurally configured to slidably engage the inner bore 66 of the compression cap 60 and functionally engage the central shoulder of 68 of the compression cap 60. The clamp push ring 120 further comprises a first end 126 that is structured to functionally engage the second end 94 of the expandable clamp 90.
In other embodiments, the compression cap 60 is structured to functionally engage the clamp 90 directly, such that axial advancement of the compression cap 60 results in the axial advancement of the clamp 90.
The prepared cable end 210 is disposable in the connector 10, and is shown disposed within the connector 10 in FIG. 4, the connector 10 and the cable 200 being in a first state. Referring to FIGS. 2 and 4, under the condition that the prepared cable end 210 is inserted into the connector 10, the exposed first corrugation 214 of the cable end 210 is disposed within an annular volume 89 formed between the first end 92 of the expandable clamp 90 and the second surface 86 of the compression ring 80. Additionally, the second exposed corrugation 220 is disposed within the central annular recess 100 of the expandable clamp 90, and the tubular mandrel 46 extends axially within the annular cavity 224.
To reach the first position disclosed in FIG. 4, the prepared cable end 210 is inserted into the inner bore 66 of the compression cap 60 until the leading edge 226 of the corrugated outer conductor 206 engages the expandable clamp 90, as shown in FIG. 3. Upon engagement, the cable 200 is further axially advanced through the central passageway 96 so that the expandable clamp 90 expands radially outward to allow the first exposed corrugation 214 of the cable 200 to pass through the central passageway 96 of the clamp 90, and then contracts radially inward to contain the second exposed corrugation 220 of the cable 200 within the central annular recess 100 of the clamp 90. More specifically, as the first exposed corrugation 214 of the coaxial cable 200 engages the second protruded edge 102 of the expandable clamp 90, the angled first portion 217 of the first exposed corrugation 214 engages the angled second portion 97 of the second protruded edge 102 of the expandable clamp 90. This provides a camming action, wherein the first exposed corrugation 214 acts as a cam lobe, and the second protruded edge 102 of the expandable clamp 90 acts as a cam follower, thereby radially expanding the expandable clamp 90, as indicated in FIG. 3 by arrows 91.
The insertion of the cable end 210, as described above, also provides an axial force against the expandable clamp 90, as indicated by arrow 93. However, a deformable washer 130 is positioned, in the first state, within the connector 10 between the second end 24 of the conductive tubular body 20 and the first end 92 of the expandable clamp 90, such that the deformable washer 130 engages the first end 92 of the expandable clamp 90 and engages the second end 24 of the tubular connector body 20. The deformable washer 130, being engaged by the tubular connector body 20, resists the axial force 93 and prevents the expandable clamp 90 from being advanced axially by the inserted cable end 210. The deformable washer 130 also acts as a bearing against which the first end 92 of the expandable clamp 90 slides as the expandable clamp 90 radially expands and contracts as exposed corrugations 214 and 220 pass through the second protruded edge 102, as described above.
To allow the expandable clamp 90 to radially expand and contract, the expandable clamp 90 may be comprised of a plurality of sectors, for example sectors 104 and 106, that individually radially displace in relation to one another as the corrugated cable 200 passes therethrough. The plurality of sectors collectively comprise the expandable clamp 90, including the central annular recess 100, the first protruded edge 98, and the second protruded edge 102. To hold the individual sectors of the expandable clamp 90 in relative proximity to one another, the expandable clamp 90 may be further comprised of an elastic member 108 disposed around the radially displaceable sectors 104/106, thereby retaining the relative position of the sectors 104 and 106 with respect to one another, including during the radial expansion and contraction capability when the corrugation 214 and/or 220 of the prepared cable end 210 passes through and/or into the clamp 90. In one embodiment depicted in FIGS. 3 and 4, the elastic member 108 may be formed as an elastic ring. The elastic ring 108 may have a circular cross-section as shown in FIGS. 3 and 4, or the elastic member 108 may have a square, rectangular, or other cross sectional shape. The expandable clamp 90 may be provided on its outer periphery 95 with a correspondingly shaped groove which engages and the elastic member 108 and maintains the relative position of the elastic member 108 in relation to the clamp 90. The elastic member 108 may be made of an elastomer such as a rubber. In one embodiment, the elastic ring may be made of rubber or a rubber-like material. Alternatively, the elastic member 108 may be formed as a toroidal spring, such as a wound metal wire spring commonly used in lip seals. In another embodiment (not shown), the elastic member 108 may be formed as an elastic sleeve, which encloses a portion of the outer periphery 95 of the expandable clamp 90. The elastic sleeve may also be made of an elastomer such as a rubber.
Referring again to FIG. 4, the prepared cable end 210 and the connector 10 are shown in the first state. The expandable clamp 90 has expanded radially to allow the first exposed corrugation 214 of the cable 200 to pass therethrough, and then contracted radially to contain the second exposed corrugation 220 of the cable 200 within the central annular recess 101 of the clamp 90. The exposed first corrugation 214 of the cable end 210 is disposed within the annular volume 89 formed between the first end 92 of the expandable clamp 90 and the second surface 86 of the compression ring 80, and the tubular mandrel 46 extends axially within the annular cavity 224. The expandable clamp 90 of the connector 10 retains the cable 200 in place. Thereafter, under the condition that the compression cap 60 is axially advanced, the cable 200 advances therewith due to the structural engagement of the expandable clamp 90, the compression cap 60, and the outer conductor 206.
In the first state, the connector 10 and cable 200 are positioned for the compression cap 60 and the tubular connector body 20 to be further axially advanced toward one another. This is achieved by one of the following: the compression cap 60 being axially advanced toward the connector body 20 as the connector body 20 is held in place; the connector body 20 being axially advanced toward the compression cap 60 as the compression cap 60 is held in place; or each of the compression cap 60 and connector body 20 being axially advanced toward one another concurrently. The axial advancement of the compression cap 60 and the connector body 20 towards one another results in the compression cap 60 and the connector body 20 reaching a second state, wherein the cable 200 within the compression cap 60, the compression cap 60, and the connector body 20, are sufficiently coupled mechanically and electrically to allow the cable 200 to pass its signal through the connector 10 to the port (not shown) to which the connector 10 is attached. In other words, in the second state, as shown in FIG. 5, the connector 10 establishes the desired operational electrical and mechanical connections between the cable 200, the connector 10, and the port (not shown).
In the embodiment shown in FIGS. 4 and 5, the compression cap 60 and the tubular connector body 20 are structured to slidably engage one another and move in an opposing axial direction with respect to one another from the first state of FIG. 4 to the second state of FIG. 5. The axial movement of the compression cap 60 toward the connector body 20 results in the collapsing of the first exposed corrugation 214 of the outer conductor 206 of the coaxial cable 200 between the a compression surface, the first end 92 of the expandable clamp 90, and another compression surface, the second surface 86 of the conductive compression ring 80, as shown in FIG. 5. The axial advancement of the compression cap 60 toward the connector body 20 facilitates the expandable clamp 90 moving axially within the inner bore 26 of the tubular connector body 20 toward the conductive compression ring 80. This axial displacement of the expandable clamp 90 results in the expandable clamp 90 deforming an inner region 132 of the deformable washer 130, such that the expandable clamp 90 axially advances past the washer 130 through the deformed inner region 132 of the washer 30 toward the compression ring 80. Moreover, this axial advancement of the expandable clamp 90 reduces the annular volume 89 between the first end 92 of the expandable clamp 90 and the second surface 86 of the compression ring 80. The reduction of the annular volume 89 results in the first exposed corrugation 214 of the outer conductor 206 of the coaxial cable 200 collapsing between the compression surfaces, or between the first end 92 of the expandable clamp 90 and the second surface 86 of the conductive compression ring 80. In this second state, the compression surfaces, described above, collapse the first exposed corrugation 214 into a collapsed corrugation 215, the collapsed corrugation 215 being defined as the entire section of the first exposed corrugation 214 that has been folded upon itself, or buckled upon itself, to create a double thickness of the outer conductor 206. Specifically, in one embodiment, the collapsed corrugation 215 comprises two thicknesses of the outer conductor 206 in at least a portion of the collapsed corrugation 215. In another embodiment, the collapsed corrugation 215 comprises two thicknesses of the outer conductor 206 in a majority of the collapsed corrugation 215. In yet another embodiment, the collapsed corrugation 215 comprises two thicknesses of the outer conductor 206 in the entirety of the collapsed corrugation 215. The compression surfaces further press the collapsed corrugation 215 therebetween to facilitate a functional electrical connection between the corrugated outer conductor 206 of the cable 200 and the tubular connector body 20. The tubular mandrel 46 extends axially into the annular cavity 224, thereby insulating the corrugated outer conductor 206 from the central conductor 202.
The compression ring 80, against which the collapsed corrugation 215 is pressed in the second state, may further comprise an annular recess 88 in the second surface 86, the annular recess 88 being structured to receive the leading edge 226 of the first exposed corrugation 214, as shown in FIG. 4. Under the condition that the connector 10 is transitioned from the first state to the second state, the leading edge 226 enters the annular recess 88. The axial movement of the compression surfaces, 92 and 86, toward one another results in the leading edge 226 engaging the annular recess 88 and buckling within the annular recess 88 to assume the shape of the annular recess 88. The remaining portion of the collapsed corrugation 215 is compressed between the compression surfaces, 92 and 86, such that the collapsed corrugation 215 is buckled on itself between the compression surfaces 92 and 86. This two-stage buckling of the collapsed corrugation 215 enhances the electrical and mechanical connections between the corresponding components of the connector 10.
The expandable clamp 90 may be further comprised of a beveled edge 110 proximate the first end 92, which facilitates displacement of the deformable washer 130 when the compression cap 60 is axially advanced toward the connector body 20, as explained above.
Also, the inner region 132 of the deformable washer 130 may be provided with score marks, slits, or other stress-concentrators (not shown) to facilitate the deformation of the washer 130. The deformable washer 130 is made of a material that is sufficiently rigid to serve as a stop for the expandable clamp 90 when the prepared end 210 of a corrugated cable 200 is inserted into the connector 10, but is also sufficiently flexible so as to deform when the expandable clamp 90 is axially advanced toward the tubular connector body 20 during transition between the first and second states of the connector 10. The deformable washer 130 may be made of a thin, soft metal, a plastic, or other like material that allows the washer 130 to perform its function described above.
Referring again to FIG. 2, the cable connector 10 may be further comprised of a second insulator 150 disposed within the inner bore 26 of the tubular connector body 20 firstly from the first insulator 40. The second insulator 150 may be comprised of a first end 152, a second end 156, a central through-bore 158, and a flange 154 that is structurally configured to slidably engage the inner bore 26 of the tubular connector body 20 and configured to engage a shoulder 28 on the inner bore 26 of the tubular connector body 20. The connector 10 may further include a conductive central pin 170 disposed within the central through-bore 158 of the second insulator 150. The conductive central pin 170 may be comprised of a first end 172, a second end 174, and an axial socket 176 extending axially from the second end 174.
Referring also to FIGS. 4 and 5, when the coaxial cable 200 is inserted into the connector 10, the axial socket 176 of the central pin 170 receives the exposed tip 212 of the center conductor 202 of the cable 200. A plurality of slits 178 running axially along the length of the socket 176 may be cut into the central pin 170 at predetermined intervals in the socket 176, thereby defining a plurality of fingers 179 between the slits 178 which are structurally configured to expand when the exposed tip 212 of the prepared cable 210 is inserted into the axial socket 176.
The first surface 42 of the first insulator 40 may further comprise an annular rim 52 extending axially from the first surface 42, the annular rim 52 defining an annular hollow that is structured to receive the second end 174 of the central pin 170 under the condition that the compression cap 60 is axially advanced toward the tubular connector body 20 from the first state to the second state. Referring to FIG. 6, axial advancement of the compression cap 60 toward the connector body 20 to the second state results in the first surface 42 of the first insulator 40 engaging the second end 174 of the conductive central pin 170, as well as axially displacing the conductive central pin 170 within the through-bore 158 of the second insulator 150. Referring also to FIG. 7, axial advancement of the compression cap 60 toward the connector body 20 to the second state results in the first surface 42 of the first insulator 40 engaging the second end 156 of the second insulator 150. The second end 156 of the second insulator 150 may further comprise an annular recess 160 that is structured to receive the annular rim 52 of the first insulator 40.
The second state, shown in FIG. 7, is the configuration in which the connector 10 and the cable 20 are mechanically and electrically coupled. Specifically, in the second state, the connector 10 is electrically and mechanically coupled to the cable 200 to allow the cable 200 to transmit signals through the connector 10 and to the port (not shown) to which the connector 10 is further coupled. In the second state, the central pin 170 has been axially advanced beyond the first end 152 of the second insulator 150, so that the central pin 170 is connectable to a central socket of the port (not shown). Additionally; at least a portion of the deformable washer 130 is compressed and contained between the clamp push ring 120, the expandable clamp 90, and the tubular connector body 20. Some other portion of the deformable washer 130 may be disposed as shavings or other small particles (not shown) between the expandable clamp 90 and the tubular connector body 20.
The connector 10 may be further configured such that axial advancement of the compression cap 60 to the second state results in the first end 126 of the clamp push ring 120 engaging the second end 24 of the tubular connector body 20. Also, axial advancement of the compression cap 60 to the second state results in a first shoulder 70 on the inner bore 66 of the compression cap 60 to engage an outer shoulder 30 on the tubular connector body 20. These contacts between the respective parts may function as additional stops when axially advancing the cap 60 onto the tubular connector body 20.
It is to be understood that the order of the movement of the parts within the connector 10, and the collapse of the outermost corrugation 214 of the prepared cable end 210 may vary from that described above and depicted in FIGS. 4-7. For example, the first insulator 40 and conductive compression ring 80 have interference fits within the inner bore 26 of the tubular connector body 20. Therefore, axial advancement of these parts 40 and 80 within the bore 26 of the tubular connector body 20 is resisted by friction therewith. If this frictional force of resistance to motion of the first insulator 40 and conductive compression ring 80 is less than the force required to collapse the outermost exposed corrugation 214 of the coaxial cable 200, then the first insulator 40 and conductive compression ring 80 may axially advance within the bore 26 of the tubular connector body 20 before the outermost exposed corrugation 214 of the coaxial cable 200 collapses.
Additionally, for example, axial advancement of the compression cap 60 toward the connector body 20 may first cause the first surface 42 of the first insulator 40 to engage the second end 174 of the conductive central pin 170 and axially advance the conductive central pin 170 within the through-bore 158 of the second insulator 150. The compression cap 60 may be further advanced axially on the tubular connector body 20 to result in the first surface 42 of the first insulator 40 engaging the second end 156 of the second insulator 150. The compression cap 60 may be further advanced axially on the tubular connector body 20 to result in the expandable clamp 90 axially advancing within the inner bore 26 of the tubular connector body 20 toward the conductive compression ring 80, thereby reducing the annular volume 89 between the first end 92 of the expandable clamp 90 and the second surface 86 of the compression ring 80, and collapsing the first exposed corrugation 214. Further, for example, if the frictional resistance to motion of the first insulator 40 and conductive compression ring 80 within the tubular connector body 20 is approximately equal to the force required to collapse the outermost exposed corrugation 214, the displacement of these internal components 40 and 80 within the tubular connector body 20 and the collapse of the first most corrugation 214 of the cable 200 may occur concurrently as the compression cap 60 is axially advanced toward the connector body 20 from the first state to the second state.
Referring again to FIGS. 2 and 7, the connector 10 may include a first seal 12, such as an O-ring, that is disposed within a groove 13 (labeled in FIG. 8) on the outer periphery of the connector body and resides between the tubular connector body 20 and the inner bore 66 of the compression cap 60 under the condition that the connector 10 is in the second state. The connector 10 may further include a second seal 14 that is contained within the inner bore 66 and a second flange 72 of the compression cap 60. Referring also to FIGS. 4 and 5, the components of the connector 10 may be dimensioned such that prior to the cap 60 being axially advanced toward the tubular connector body 20 there is a small gap 16 between the outer shoulder 124 of the clamp push ring 120 and the central shoulder 68 of the compression cap 60. When the compression cap 60 is axially advanced toward the connector body 20 the gap 16 is eliminated. The removal of the gap 16 places the second seal 14 in an axially compressed condition, thereby causing a radial expansion of the seal 14 that in turn provides effective sealing between the jacket 208 of the cable 200 and the inner bore 66 of the compression cap 60. With the compression cap 60 sealed at one of its ends to the tubular connector body 20 by the seal 12, and sealed at the other of its ends to the cable 200 by the seal 14, moisture is prevented from entering the mechanically and electrically coupled connector 10 and cable 200, thereby preserving the electrical and mechanical connection between the connector and the cable.
Referring to FIGS. 1 and 7, the connector 10 may be provided with a fastener 180, such as a nut for engagement to the port (not shown). The fastener 180 may include a seal 182 for sealing to the port. Alternatively, the connector 10 may be provided with male threads for connection to a female port. The connector 10 may also be configured as an angled connector, such as a 90 degree elbow connector.
Referring to FIG. 8, another embodiment of the connector 10 and the annularly corrugated coaxial cable 200 with the prepared end 210 are shown aligned on a common central axis 2. FIG. 8 is a cross sectional view of the exemplary compression connector 10 during insertion of the prepared segment 210 of annular corrugated coaxial cable 200. The coaxial cable 200 of one embodiment is comprised of a hollow center conductor 202 surrounded by an insulator 204, a corrugated outer conductor 206 surrounding the insulator 204, and an insulative jacket 208 surrounding the outer conductor 206. The prepared end 210 of the coaxial cable 200 is comprised of an exposed length of the center conductor 202, the insulator 204, and the corrugated outer conductor 206. The outer conductor 206 is exposed by removing the insulative jacket 208 around the conductor 206 until at least a first exposed outer conductor corrugation 214 between first and second recessed valleys 216 and 218 and a second exposed outer conductor corrugation 220 between second and third recessed valleys 218 and 222 are exposed. The prepared end 210 should be configured (i.e. cut) such that the leading edge 226 of the outer conductor 206 is within one of the recessed valleys of the corrugated outer conductor 206, the advantages of which will be described in detail below. The insulator 204 is made of a soft, flexible material, such as a polymer foam.
The connector 10 of the various embodiments described herein is advantageous in that it is simple to install in a factory or field setting and it is reliably effective at establishing and maintaining strong contact forces between the connector 10 and the annular corrugated coaxial cable 200.
The connector 10 of one embodiment includes the conductive pin 170 and the insulator 150, the insulator 150 being disposed within the connector body 20 and slidably engaged with the inner bore 26 of the connector body 20. The insulator 150 is disposed around the conductive pin 170 so as to hold the conductive pin 170 in place. Further, the insulator 150 is positioned radially between the conductive pin 170 and the connector body 22. The conductive pin 170 provides the connection to the hollow center conductor 202 of the prepared coaxial cable segment 210 to which the connector 10 is being connected, and the insulator 150 electrically insulates the conductive pin 170 from the connector body 22 and the connector body 20. In the disclosed embodiment, the conductive pin 170 may have outwardly expanding flexible tines 332 to engage the inner diameter oldie hollow conductor 202, and a retaining element 334 to secure the tines 332 from axial movement.
In one embodiment, the inner bore 26 of the connector body 20 further comprises an engagement region 336, shown in FIG. 8 and enlarged in FIG. 11. The engagement region 336 comprises a first region 335 that extends radially inward from the inner bore 26 of the connector body 20 and a second region 337 that extends both radially inward and axially toward the prepared end 210 of the coaxial cable 200. The engagement region 336 functions as a compression surface, similar to the compression surfaces 92 and 86 in embodiments described above, in that the engagement region 336 assists in the collapse of the corrugated outer conductor 214. In one embodiment, second region 337 has an acute angle a from the longitudinal axis 2. The angle may be between 5 degrees and 60 degrees. In the disclosed embodiment, the angle of the second region 337 is approximately 45 degrees. The proximal end of the engagement region 336 may further include a planar face 338 substantially perpendicular to the longitudinal axis 2. The planar face 338 and the engagement region 336 work in concert to engage and deform the corrugated outer conductor 214 until it collapses on itself to form the collapsed corrugated outer conductor 215, under the condition that the connector is transitioned from the first state, shown in FIG. 8, to the second state, shown in FIG. 9.
In one embodiment, the second end 24 of the connector body 20 further comprises a beveled edge 342 to assist in the functional engagement of the connector body 20 with the clamp 90 as the connector 10 transitions from the first state to the second state. More specifically, the beveled edge 342 permits the clamp 90 to slidably engage the beveled edge 342 so as to ensure that the outer periphery 95 of the clamp 90 slidably engages the inner bore 26 of the connector body 20 under the condition that the compression cap 60 is axially advanced toward the connector body 20 from the first state to the second state. For example, transition from the first state to the second state results in the advancement of the compression cap 60 so that the shoulder 68 of the compression cap 60 engages the clamp push ring 120, which engages the clamp 90, which engagement axially advances the clamp 90 toward the connector body 20, such that the clamp 90 engages the beveled edge 342 of the connector body 20 to guide the outer periphery 95 of the clamp 90 to slidably and functionally engage the inner bore 26 of the connector body in the second state.
In one embodiment, the clamp 90 may also have a beveled edge 382 on the first end 92. The beveled edge 382 functions as a compression surface, similar to the compression surfaces 92 and 86 in the embodiments described above. Moreover, the beveled edge 382 is structurally compatible with the engagement region 336, such that the beveled edge 382 and the engagement region 336 work in concert to engage and deform the corrugated outer conductor 214 under the condition that the connector is transitioned from the first state to the second state. In addition, the clamp 90 may have a plurality of elastic members 108 disposed around the outer periphery 95 thereof, as shown in FIGS. 8 and 9. The elastic members 108 may be tension rings that serve to hold the individual sectors of the clamp 90 in a slightly open or expanded position. The tension rings may be fabricated from metal or plastic.
In one exemplary operation, the connector 10 of the various embodiments may be joined to the coaxial cable segment 200 generally in the following manner. The corrugated coaxial cable segment 200 may be prepared for insertion by cutting the cable at one of the corrugation valleys, and specifically at the first corrugation valley 216, or at least near the first corrugation valley 216. This offers an advantage over many prior art cable connectors that require cutting the corrugation at a peak, which can be difficult. After the cable 200 has been cut at any of the corrugation valleys to expose the first corrugation valley 216, the cable 200 can be prepared according to the respective descriptions provided above.
The connector 10 is thereafter pre-assembled to its first state. The internal elements 14, 120, 90, and 130 may be held in axial compression by inserting the seal 14 into the bore 66 of the cap 60 until it abuts the second flange 72; inserting the plush clamp ring 120 into the bore 66 of the cap 60 until it abuts with the seal 14; inserting the clamp 90 until it abuts with the clamp push ring 120; and inserting the washer 130 into the bore 66 of the cap 60 until it abuts with the clamp 90. The internal elements 150 and 170 can also be held in axial compression by inserting the insulator 150 into the bore 26 of the connector body 20 until the insulator abuts the shoulder 28 on the inner bore 26; inserting the conductive pin 170 into the central through-bore 158 of the insulator 150. In the case of the embodiments described above, the first insulator 40 may be inserted within the bore 26 of the connector body 20 and thereafter the compression ring 80 may be inserted onto the tubular mandrel 46 of the first insulator 40. The compression cap 60 and the connector body may thereafter be initially coupled together by slidably engaging the compression cap 60 with the body 20 to establish the first state of the connector 10. In the embodiments shown, the bore 66 of the cap 60 slidably engages the outer periphery of the connector body 20, until the washer 130 engages not only the clamp 90 within the compression cap 60 but also engages the second end 24 of the connector body 22, thus holding the respective components in place in the first state.
In the disclosed embodiments, the insertion of the coaxial cable 200 to the first state may be performed by hand. The corrugated coaxial cable 200 is the annular variety, although the invention is not so limited. The annular corrugations in the outer conductor 206 do not allow the clamp 90 to be threaded into place, as may be the case for spiral corrugated coaxial cable segments. Therefore, the individual sectors of the clamp 90 must spread radially outward to allow the clamp 90 to clear the corrugated sections of the outer conductor 206 in the coaxial cable 200. In one embodiment, the elastic member 108 is flexible and allows the clamp 90 to spread radially outward while constraining individual sectors of the clamp 90 from becoming free. As the cable 200 is pushed into the connector 10 through the compression cap 60, the clamp 90 extends radially outward to clear the corrugated peaks and valleys of the outer conductor 206, then settles radially inward into the corrugated valleys.
In the embodiments herein described, the transition of the connector 10 from the first state to the second state may be performed by hand or in most cases by a hydraulic tool (not shown). The tool engages the cap 60 and the connector body 20 and squeezes them together, thereby moving the connector 10 to the second state. As the hydraulic tool axially displaces the cap 60 and the body 20 together, the shoulder 68 on the cap bore 66 engages the flange 122 of the clamp push ring 120. Further axial advancement of the cap 60 and body 20 toward one another results in the clamp push ring 120 engaging the clamp 90. Because the clamp 90 is engaged with the outer conductor 206 of the cable 200, the cable 200 will also travel axially towards the connector body 20 as the clamp 90 travels axially towards the connector body 20. As noted above, the washer 130 is designed flexible enough that the clamp 90 pushes through the washer 130. Further advancement of the cap 60 results in the clamp 90 and cable 200 approaching the connector body 20.
In the another embodiment, as shown in FIG. 9, the leading edge 226 of the first exposed outer conductor corrugation 214 encounters the engagement region 336 of the connector body 20 and is deformed in a manner that provides superior electrical contact. Recalling that the outer conductor 206 has been trimmed at the corrugation valley 216, in one embodiment the planar face 338 and the engagement region 336 cause the outer conductor 214 to fold upon itself and become wedged between the engagement region 336 of the connector body 20 and the clamp engagement region 382 of the clamp 90. The folding action creates two thicknesses of conductive outer conductor 214, as the conductor 214 is collapsed onto itself to create the collapsed outer conductor 215, which significantly improves electrical contact. FIG. 10 illustrates the folded conductor 215 in an enlarged view. The connector body engagement region 336, including sections 335 and 337, folded outer conductor 215, and clamp engagement region 382 are depicted in slightly exploded view to delineate the various components. In actuality, the components are tightly compressed together.
FIG. 10 further illustrates the arrangement of components that provide frictional forces to lock the connector 10 in place. The outer diameter of the clamp 90 and the inner diameter of the connector body 20 are sized to provide a slight radial interference fit (RIF). In concert with the radial and axial friction forces provided by compression of the first exposed outer conductor corrugation 214 between the clamp 90 and the connector body 20, the connector 10, once axially advanced into the second state, cannot be taken apart without excessive force.
FIG. 11 depicts a scenario to illustrate the folding action of the first exposed outer conductor corrugation 214. The outer conductor 214 is trimmed approximately at the first corrugation valley 216. The planar face 338 of the connector body 22 passes over the leading edge 226 of the outer conductor 214 and contacts the conductor 214 approximately near the trailing inflection point 392 of the outer conductor 214, causing the conductor 214 to fold over on itself, as depicted by the arrow. One advantage of this arrangement is that an operator preparing the cable segment 200 for insertion does not need to trim the cable 200 precisely at a corrugation valley; there is provided ample leeway on either side of the valley.
In one embodiment, shown in FIG. 12 and enlarged in FIG. 13, the first region 335 that extends radially inward from the inner bore 26 of the connector body 20 may further comprise a retention feature 394 to further secure the deformed corrugated outer conductor 215 in a radial direction. In one example, the retention feature 394 is an annular recess in the first region 335, such that the first region 335 axially indented. Correspondingly, the clamp 90 may include a complimentary retention feature 396. In the illustrated example, the collapsed corrugated outer conductor 215 is sandwiched not only along the complimentary compression surfaces 336 and 382, but also between the retention features 394 and 396. In this manner, in the event the cap 60 axially retreats from the connector body 20, the radial clamping forces acting upon the outer conductor 215 in the region of the retention features 394 and 396 are unaffected and the outer conductor 215 will not jar loose. Moreover, even though the retreat of the cap 60 from the connector body 20 may result in the loss of electric coupling between the compression surfaces 336 and 382, the outer conductor 215 collapsed between retention features 394 and 396 continues to electrically couple the clamp 90 and the connector body 20, thus allowing the connector 10 to continue to provide its intended and desired function.
In one embodiment, shown in FIG. 14, the connector is in the second state. The clamp 90 further comprises a beveled edge 372, in addition to the beveled edge 382 described above. The beveled edges 372 and 382 are positioned on opposing leading corner edges of the clamp 90, beveled edge 382 being positioned radially inward of the beveled edge 372. Beveled edge 372 is angled at an acute angle from the common axis 2, and the angle of the beveled edge 372 is less than the angle of the beveled edge 382 from the common axis 2. Beveled edges 372 and 382 function as compression surfaces under the condition that the connector is transitioned from the first state to the second state.
Corresponding compressions surfaces are found in the compression ring 80 of the embodiment of FIG. 14. Specifically, the second surface 86 of the compression ring 80 further comprises angled surfaces 381 and 371 that oppose one another and generally form a v-like shape in the second surface 86. The angled surfaces 381 and 371 correspond to and compliment the beveled edges 382 and 372, respectively. In other words, the angled surface 371 is angled from the common axis 2 at approximately the angle of the beveled edge 372. Similarly, the angled surface 381 is angled from the common axis 2 at approximately the angle of the beveled edge 382. With this configuration, as the connector 10 is transitioned from the first state to the second state, thus axially displacing the clamp 90 toward the compression ring 80, the compression surfaces, 372 and 382, on the clamp ring 90 functionally engage the corresponding compression surfaces, 371 and 381, respectively, on the compression ring 80 to compress therebetween the first exposed outer conductor corrugation 214 of the cable 200 so that the corrugation 214 collapses on itself. The result is that the collapsed corrugation 215 is pressed between the compression surfaces 372 and 371 at one angle and also pressed between the compression surfaces 382 and 381 at another angle, thus forming the v-like shaped compression. This v-shaped compression provides both axial and radial compression of the connector 10 to facilitate advantageous mechanical and electrical coupling of the connector 10 to the cable 200 in the second state and to prevent the connector 10 from disengaging without undue force once the connector 10 is moved to its second state.
Additionally, in the embodiment of FIG. 14, the compression ring 80 comprises the first surface 84 that engages the second surface 48 of the first insulator 40. The first surface 84 comprises an annular recess 388 that engages an annular angled lip 346 that axially protrudes from the second surface 48 of the first insulator 40. As the connector 10 is axially transitioned from the first state to the second state, the compression ring 80 functionally engages the first insulator 40, which in turn functionally engages the conductive pin 170 to axially advance the conductive pin 170 through the central through-bore 158 of the second insulator 150, such that the pin 170 axially protrudes beyond the first end 152 of the insulator 150 so that the pin 170 can connect to the port (not shown). Moreover, transition of the connector 10 from the first state to the second state also results in the exposed center conductor 202 being axially advanced into the socket 176 of the pin 170, such that the center conductor 202 is mechanically and electrically coupled to and secured within the pin 170. As a result, in addition to the outer conductor 206 being mechanically and electrically coupled to the connector body 20, as described above, the center conductor 202 is mechanically and electrically coupled to the pin 170, so that the connector 10 satisfactorily couples, mechanically and electrically, to the port (not shown).
In one embodiment, shown in FIG. 15, the connector 10 includes the compression surfaces 382 and 372 on the clamp 90 and the compression surfaces 371 and 381 on the compression ring 80, described above. These compression surfaces 382, 372, 381, and 371 function according to the description provided above. In addition, the embodiment of FIG. 15 further includes a planar surface 389 on the first surface 84, the planar surface 389 being structured to engage the second surface 48 of the first insulator 40. The second surface 48 of the first insulator 40 further comprises a planar annular lip 345 that engages the planar surface 389. As the connector 10 is axially transitioned from the first state to the second state, the compression ring 80 functionally engages the first insulator 40, which in turn functionally engages the conductive pin 170 to axially advance the conductive pin 170 through the central through-bore 158 of the second insulator 150, such that the pin 170 axially protrudes beyond the first end 152 of the insulator 150 so that the pin 170 can connect to the port (not shown). Moreover, transition of the connector 10 from the first state to the second state also results in the exposed center conductor 202 being axially advanced into the socket 176 of the pin 170, such that the center conductor 202 is mechanically and electrically coupled to and secured within the pin 170. As a result, in addition to the outer conductor 206 being mechanically and electrically coupled to the connector body 20, as described above, the center conductor 202 is mechanically and electrically coupled to the pin 170, so that the connector 10 satisfactorily couples, mechanically and electrically, to the port (not shown).
Referring further to the drawings, FIG. 16 shows a blown-up cross-section view of a portion of an embodiment of a connector 10 as attached to a coaxial cable 200. The coaxial cable 200 may include an inner conductor 202 surrounded by an inner dielectric insulator 204. The inner conductor 202 may be formed of solid conductive material, or may be a hollow conductive member. The inner dielectric insulator 204 may be similar to those inner dielectric insulators discussed previously. An outer conductor 206 may surround the inner dielectric insulator 204. The outer conductor 206 may be tube-like, and may be solid in form or may be comprised of various braided or wrapped conductive layers. The geometry of the outer conductor 206 may be smooth, corrugated, helical, or other operable configurations.
As depicted in FIG. 16, the cable 200 is shown attached to the connector 10 in a second state, the cable components 200 having been compressed into secure mechanical position within the connector 10 from a first state via axial compression. In the second compressed state, the first insulator 40 resides proximate the conductive compression ring 80, which, in turn, resides proximate the clamp 90 of the connector 10, with a portion of the outer conductor 206 of the cable 200 mechanically sandwiched between the cooperating compression surface 381 of the conductive compression ring 80 and the corresponding cooperating compression surface 382 of the movable clamp 90. The clamp 90 may be solid or slotted. In addition, mechanical security of the second state is enhanced by the cooperating proximity of the beveled edge 371 of the conductive compression ring 80, as located with respect to the beveled edge 381 of the clamp 90. The sandwiched section of the outer conductor 206 comprises a collapsed corrugation portion 215a having a rogue leading edge 226a that hangs away from or otherwise resides apart from the rest of the collapsed corrugated portion 215a. 
When a connector embodiment 10 is attached to a coaxial cable 200 in a manner that permits the positioning of a rogue conductive member, such as the hanging leading edge 226a, there may be undesirable ramifications related to passive intermodulation (PIM) and return loss, with respect to matching the impedance properties of the connector 10 to the impedance properties of the attached cable 200. Unmatched impedance can lead to problems in signal integrity disrupting signal transmission through the cable 200 and the connector 10 and on to connected communications devices. As a result, there is a need for structure and functionality that helps prevent the presence of rogue conductive members within a coaxial cable connector.
Connector embodiments 10 may be provided with structural components to help guide conductive members into desirable locations as the conductive members are displaced during compressive attachment of the coaxial cable 200 to the connector 10. Accordingly, FIG. 17 depicts another connector embodiment 10 having a conductor displacement guiding member 500. As depicted, the conductor displacement guiding member 500 exists as a sleeve integrally extending from the first insulator 40. However, those in the art should appreciate, that embodiments of a conductor displacement guiding member 500 may also exist as independent components, such as separate rings and bushings, and/or as a structural feature integrated with the conductive compression ring 80. Moreover, those in the art should recognize that embodiments of a conductor displacement guiding member 500 may be formed of either conductive or non-conductive materials, or a combination thereof, and considerations with respect to impedance matching are important to the location and material make-up of conductor displacement guiding member embodiments 500. For example, the embodiment of the conductor displacement guiding member 500 shown in FIG. 17 may be formed of a polyetherimide plastic, such as an Ultem® resin, having advantageous properties including a high dielectric strength, natural flame resistance, and low smoke generation, as well as high mechanical properties and acceptable performance in continuous use to 340° F. (170° C.).
An embodiment of a conductor displacement guiding member 500 may be located within a connector 10 in a manner permitting prescribed contact with conductive members, such as an outer conductor 206, to help guide the conductive member into a desirable location as it is displaced during attachment of the coaxial cable 200. As depicted, the conductor displacement guiding member 500 may include guiding structures, such as the ramped guiding surface 581, configured to contact and then act upon the guided leading edge 226b as the outer conductor 206 is displaced, such that a guided collapsed corrugation portion 215b operably resides between cooperating surfaces 381 and 371 of the conductive compression ring 80 and the movable clamp 90. Notably the conductor displacement guiding member 500 helps guide the leading edge 226b to a desired location tucked up near the collapsed corrugation portion 215b. The conductive displacement guiding member 500 aids in locating the outer conductor 206 such that it is centered, and that the end 226b of the outer conductor 206 folds into a collapsed corrugation portion 215b more predictably. When a conductive member, such as the leading edge 226b of the outer conductor 206, is properly guided into a prescribed location during displacement associated with axial-compression-actuated cable attachment, embodiments of the connector 10 do not suffer the impedance, PIM, and return loss drawbacks associated with connectors having rogue conductive members, such as the rogue leading edge 226a shown in FIG. 16. Return loss and PIM are minimized through guided locating of the leading edge 226a of the outer conductor 206, thereby facilitating impedance matching. Connector embodiments 10 including conductor displacement guiding members 500 may operably incorporate structure similar to the connector structure described above with respect to FIGS. 1-15. Consideration toward cost and ease of assembly can guide those in the art to incorporation of conductor displacement guiding members 500 that ensure good connector 10 performance.
With reference to FIGS. 8-13, those in the art should recognize that the structure and functionality pertaining to all connector embodiments 10 is applicable to various connector sizes, types and genders. For example, FIGS. 8-13 depict a female type connector for connection to a separate male component. Moreover, those in the art should appreciate that the structure and functionality pertaining to all connector embodiments 10 shown in any of FIGS. 1-17 can and should be designed to maintain a coaxial form across the connection and have similar well-defined impedance as matched with the attached cable. Thus variously sized connectors 10 can and should be made to effectively operate with correspondingly sized cables. In addition, it should be appreciated that the structure and functionality described herein pertaining to embodiments of connectors 10 can be operably adapted to DIN-type connectors, BNC-type connectors, TNC-type connectors, N-type connectors, and other like coaxial cable connectors having structure and functionality that is operably commensurate with the connector embodiments 10 described herein.
While the present invention has been described with reference to a number of specific embodiments, it will be understood that the true spirit and scope of the invention should be determined only with respect to claims that can be supported by the present specification. Further, while in numerous cases herein wherein systems and apparatuses and methods are described as having a certain number of elements it will be understood that such systems, apparatuses and methods can be practiced with fewer than the mentioned certain number of elements. Also, while a number of particular embodiments have been described, it will be understood that features and aspects that have been described with reference to each particular embodiment can be used with each remaining particularly described embodiment.

## Claims

1. A coaxial cable connector, the coaxial cable connector configured to receive a coaxial cable having an inner conductor, an exposed outer corrugated conductor, an insulator disposed between the inner and outer conductors, and a protective jacket disposed over the corrugated outer conductor, the coaxial cable connector comprising:
a connector body comprising a first end, a second end, an outer diameter, and an inner bore having a diameter, the inner bore defined between the first end and the second end of the connector body;
a compression cap comprising a first end, a second end, and an inner bore defined therebetween, the inner bore of the compression cap having a diameter slightly smaller than the outer diameter of the connector body, the first end of the compression cap being structured to slidably axially engage the second end of the connector body;
a clamp having an outer diameter slightly larger than the diameter of the inner bore of the connector body, wherein the clamp is configured to slide axially within a portion of the connector body and securely engage the inner bore of the connector body, the clamp comprising a first end, a second end, an inner bore defined between the first end and the second end of the clamp for allowing the coaxial cable to axially pass therethrough, wherein the clamp is structured to engage the outer corrugated conductor of the coaxial cable;
an angled compression surface disposed within the connector body; and
a conductor displacement guiding member positioned to engage and act upon the outer corrugated conductor, wherein the conductor displacement guiding member is a sleeve integrally extending from a first insulator of the connector and is movable with respect to the clamp;
wherein slidable axial advancement of one of the connector body and the compression cap toward the other from a first position, wherein the coaxial cable is received within the connector, to a second position, wherein the clamp is slidably axially compressed into secure engagement with the inner bore of the connector body and advanced into proximity with the angled compression surface, permits engagement with the coaxial cable such that a corrugation of the outer conductor of the coaxial cable is collapsed between the clamp and the angled compression surface to facilitate electrical coupling of the outer conductor of the cable and effectuate advantageous radial clamping forces acting upon the collapsed portion of outer conductor of the cable, when the connector is moved to the second position, thereby preventing the outer conductor of the cable from disengaging without undue force and retaining mechanical coupling of the exposed outer corrugated conductor with the clamp and the angled compression surface regardless of whether the compression cap remains securely engaged to the connector body;
further wherein structure and positioning of the conductor displacement guiding member helps guide a leading portion of the outer conductor to a location folded near the collapsed corrugation portion, as the outer conductor is collapsed.

2. The coaxial cable connector of claim 1, wherein the conductor displacement guiding member is formed of a plastic material.

3. The coaxial cable connector of claim 2, wherein the plastic material is polyetherimide.

4. The coaxial cable connector of claim 1, wherein the insulator and integral conductor displacement guiding member sleeve are formed of a plastic material.

5. The coaxial cable connector of claim 1, wherein the angled compression surface is separated from the compression cap.

6. A compression coaxial cable connector comprising:
a connector body comprising a first end, a second end, an outer diameter, and an inner bore defined between the first end and the second end of the connector body;
a compression cap comprising a first end, a second end, an outer diameter, and an inner bore defined between the first end and the second end of the compression cap, the inner bore having a diameter slightly smaller than the outer diameter of the connector body and the first end of the compression cap being structured to slidably axially engage the second end of the connector body;
a clamp having an outer diameter slightly larger than a diameter of the inner bore of the connector body, the clamp comprising a first end, a second end, an inner bore defined between the first end and the second end of the clamp, wherein the clamp is slidably axially movable with the compression cap;
a first insulator, wherein at least a portion of the first insulator is located within the connector body;
an oblique compression surface disposed within the connector body, wherein slidable axial advancement of one of the connector body and the compression cap toward the other from a first position, wherein the coaxial cable is received within the coaxial cable connector, to a second position wherein the clamp is slidably axially compressed into secure engagement with the inner bore of the connector body and axially advanced into proximity with the oblique compression surface such that a corrugation of an outer corrugated conductor of a coaxial cable is collapsed between the clamp and the oblique compression surface to facilitate electrical coupling of the outer corrugated conductor and effectuate advantageous radial clamping forces acting upon the collapsed portion of outer corrugated conductor of the coaxial cable, when the coaxial cable connector is moved to the second position, thereby preventing the outer corrugated conductor of the coaxial cable from disengaging without undue force and retaining the mechanical coupling of the outer conductor of the outer conductor with the connector regardless of whether the compression cap remains securely engaged to the connector body; and
a conductor displacement guiding member located within the compression coaxial cable connector in a manner permitting prescribed contact with a conductive member of a coaxial cable to guide displacement of the conductive member, as the cable is slidably axially compressively attached to the compression coaxial cable connector;
wherein the conductor displacement guiding member is a sleeve integrally extending from the first insulator of the connector and positioned so as to contact and then act upon a leading edge of the outer corrugated conductor of the coaxial cable as the coaxial cable is displaced during compressive attachment to the compression coaxial cable connector.

7. The compression coaxial cable connector of claim 6, wherein the conductor displacement guiding member engages and guides a leading edge of the outer corrugated conductor of the coaxial cable.

8. The compression coaxial cable connector of claim 6, wherein the conductor displacement guiding member is a structural feature integrated with a conductive compression ring, the conductive compression ring including the oblique compression surface.

9. The compression coaxial cable connector of claim 6, wherein the conductor displacement guiding member is formed of a plastic material.

10. The compression coaxial cable connector of claim 9, wherein the plastic material is polyetherimide.

11. The compression coaxial cable connector of claim 6, wherein the oblique compression surface is separated from the compression cap.

12. A method of facilitating impedance matching between a coaxial cable and a coaxial cable connector, the method comprising:
obtaining a compression cap having a first end, a second end, and an inner bore having a diameter;
inserting a clamp having an inner bore into the inner bore of the compression cap, the clamp having an outer diameter;
advancing a prepared end of a coaxial cable into the second end of the compression cap and through the inner bore of the clamp until a first corrugated section of an outer corrugated conductor protrudes beyond the first end of the clamp and the inner bore of the clamp engages a second corrugated section of the outer corrugated conductor;
obtaining a connector body having a first end, a second end, an outer diameter slightly larger than the diameter of the inner bore of the compression cap, and an inner bore having a diameter slightly smaller than the outer diameter of the clamp;
inserting a first insulator within at least a portion of the connector body, wherein first insulator includes a conductor displacement guiding member being a sleeve integrally extending from the first insulator and positioned so as to contact and then act upon a leading edge of the outer corrugated conductor of the coaxial cable as the coaxial cable is displaced during compressive attachment to the compression coaxial cable connector;
coupling the compression cap to the connector body by functionally engaging the first end of the compression cap with the second end of the connector body to arrange the connector in a first position, wherein the cable is received within the coaxial cable connector;
slidably axially advancing the compression cap and the coaxial cable connector body toward one another such that the clamp slidably axially advances to a second position, wherein the clamp is securely engaged with the inner bore of the connector body and moved into proximity of an oblique compression surface disposed within the connector body so that a corrugated section of the outer conductor collapses between the clamp and the oblique compression surface to facilitate electrical coupling of the outer conductor and effectuate advantageous radial clamping forces acting upon the collapsed portion of outer corrugated conductor of the cable, when the connector is moved to the second position, thereby preventing the outer corrugated conductor of the cable from disengaging without undue force and retaining the mechanical coupling of the outer corrugated conductor of the outer conductor with the clamp and the oblique compression surface regardless of whether the compression cap remains securely engaged to the connector body; and
guiding a leading portion of the outer corrugated conductor to a location folded near the collapsed corrugation portion, by engagement with the conductor displacement guiding member as the outer corrugated conductor is collapsed, to minimize passive intermodulation and return loss associated with the leading portion of the outer corrugated conductor.

13. The method of claim 12, further comprising providing an insulator in contact with the leading portion of the outer corrugated conductor by incorporation of a plastic conductor displacement guiding member.

14. The method of claim 12, wherein the conductor displacement guiding member includes a ramped guiding surface, configured to contact and then act upon the leading portion, as the outer corrugated conductor is displaced, such that a guided collapsed corrugation portion operably resides between cooperating surfaces of a conductive compression ring and the movable clamp.

15. The method of claim 12, wherein the conductor displacement guiding member is formed of a plastic material.

16. The method of claim 15, wherein the plastic material is polyetherimide.

17. The method of claim 12, wherein the oblique compression surface is separated from the compression cap.