Abstract:
A coaxial connector having an axially moveable shell in opposition to a separate and distinct body component wherein the moveable shell contains a gripping member capable of having the front portion displaced radially inwardly by the body so that the gripping member is positioned within the connector body and between the connector body and the coaxial cable and secures the cable to the connector and environmentally seals the junction while at the same time the shell contains a structure to move a rear portion of the gripping member radially outwardly upon compression. In some embodiments disclosed herein the shell contains a structure to prevent a rear portion of the gripping member from moving radially inwardly upon compression. Other connector shell embodiments may be made from a one-piece stamping instead of a machined component and thereby deliver a manufacturing cost savings.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/951,623, filed Nov. 25, 2015, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     Field 
     The present invention relates generally to coaxial cable connectors, and particularly to coaxial cable connectors including a compression mechanism for use with coaxial cables. 
     Technical Background 
     Coaxial cable connectors such as F-connectors are used to attach coaxial cable to another object such as an appliance or junction having a terminal adapted to engage the connector. Coaxial cable F-connectors are often used to terminate a drop cable in a cable television system. The coaxial cable typically includes a center conductor surrounded by a dielectric, in turn surrounded by a conductive grounding foil and/or braid (hereinafter referred to as a conductive grounding sheath); the conductive grounding sheath is itself surrounded by a protective outer jacket. The F-connector is secured over the prepared end of the jacketed coaxial cable, allowing the end of the coaxial cable to be connected with a terminal block, such as by a threaded connection or slidable engagement with a threaded terminal of a terminal block. 
     SUMMARY 
     A coaxial connector having an axially moveable shell in opposition to a separate and distinct body component wherein the moveable shell contains a gripping member capable of having the front portion displaced radially inwardly by the body so that the gripping member is positioned within the connector body and between the connector body and the coaxial cable and secures the cable to the connector and environmentally seals the junction while at the same time the shell contains a structure to move a rear portion of the gripping member radially outwardly upon compression. In some embodiments disclosed herein the shell contains a structure to prevent a rear portion of the gripping member from moving radially inwardly upon compression. Other connector shell embodiments may be made from a one-piece stamping instead of a machined component and thereby deliver a manufacturing cost savings. 
     In some embodiments, coaxial cable connectors for connecting a coaxial cable comprising an inner conductor, an insulator layer surrounding the inner conductor, an outer conductor layer surrounding the insulator layer and an outer jacket are provided. In one embodiment, the coaxial cable connector includes a body, a shell and a gripping member. The body includes a rear end, a front end, and an internal surface extending between the rear and front ends of the body, the internal surface defining a longitudinal opening. The shell includes a rear end, a front end surrounding at least a portion of the body, an inner surface defining a longitudinal opening extending between the rear and front ends of the shell and a forwardly angled surface, the shell being axially movable over an outside portion the body between a first rearward position and a second forward position. The gripping member is adapted to secure a coaxial cable to the coaxial cable connector, the gripping member disposed at least partially within the longitudinal opening of the shell, the gripping member comprising a front end, a rear end, an outer surface, an inner surface defining an opening therein. The forward angled surface of the shell is adapted to displace at least a portion of the rear end of the gripping member radially outwardly as the shell is moved from the first rearward position toward the second forward position. 
     In another embodiment, methods for securing a coaxial cable to a coaxial cable connector are provided. In one embodiment, the method includes inserting a coaxial cable through an inner bore of a body, shell and gripping member of coaxial cable connector. The body includes a rear end, a front end, and an internal surface extending between the rear and front ends of the body. The internal surface defines a longitudinal opening. The shell includes a rear end, a front end surrounding at least a portion of the body, an inner surface defining a longitudinal opening extending between the rear and front ends of the shell and a forwardly angled surface. The shell is axially movable over an outside portion the body between a first rearward position and a second forward position. The gripping member is disposed at least partially within the longitudinal opening of the shell. The gripping member includes a front end, a rear end, an outer surface and an inner surface defining an opening therein. The method further includes axially sliding the shell in a forward direction relative to the body. The forward angled surface of the shell is adapted to displace at least a portion of the rear end of the gripping member radially outwardly as the shell is moved from the first rearward position toward the second forward position. 
     Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments, and together with the description serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  schematically depicts a cross sectional view of an example embodiment of a coaxial cable connector for coupling an end of a coaxial cable to a terminal according to one or more embodiments described and illustrated herein; 
         FIG. 2  schematically depicts a cross sectional view of an example embodiment of a gripping member and a shell of the coaxial cable connector shown in  FIG. 1  in an unassembled state according to one or more embodiments described and illustrated herein; 
         FIG. 3  schematically depicts the example embodiment of the coaxial cable connector shown in  FIG. 1  with a coaxial cable inserted into the coaxial cable connector according to one or more embodiments described and illustrated herein; 
         FIG. 4  schematically depicts a cross section of another example embodiment of a gripping member of a coaxial cable connector according to one or more embodiments described and illustrated herein; 
       a  FIG. 5  schematically depicts a cross section of another example embodiment of a gripping member and a shell of a coaxial cable connector as a sub-assembly in a first uncompressed position according to one or more embodiments described and illustrated herein; 
         FIG. 6  schematically depicts a cross section of the example embodiment of the gripping member and the shell shown in  FIG. 5  as a sub-assembly in a second compressed position according to one or more embodiments described and illustrated herein; 
         FIG. 7  schematically depicts a cross section of an example embodiment of a gripping member and a shell as a sub-assembly in a first uncompressed position according to one or more embodiments described and illustrated herein; 
         FIG. 8  schematically depicts a cross section of an example embodiment of a gripping member and a shell as a sub-assembly in a second compressed position according to one or more embodiments described and illustrated herein; 
         FIG. 9  schematically depicts a cross section of another example embodiment of a gripping member and a shell as a sub-assembly in a first uncompressed position according to one or more embodiments described and illustrated herein; 
         FIG. 10  schematically depicts a cross section of the example embodiment of the gripping member and the shell shown in  FIG. 9  as a sub-assembly in a second compressed position according to one or more embodiments described and illustrated herein; 
         FIG. 11  schematically depicts a cross section of another example embodiment of a gripping member and a shell as a partially completed sub-assembly in a first uncompressed position according to one or more embodiments described and illustrated herein; 
         FIG. 12  schematically depicts a cross section of the gripping member and the shell as a sub-assembly in which a forming tool has been introduced to complete the sub-assembly according to one or more embodiments described and illustrated herein; and 
         FIG. 13  schematically depicts a cross-section of the gripping member and the shell as sub-assembly in a final assembled condition with the forming tool removed according to one or more embodiments described and illustrated herein. 
     
    
    
     Reference will now be made in detail to various embodiment(s) of a coaxial cable connector, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. 
     DETAILED DESCRIPTION 
     Embodiments disclosed herein coaxial cable connectors used to connect a coaxial cable to an equipment port or terminal such that secure mechanical and electrical connections result. The terms “equipment port” and “terminal” may be used interchangeably herein. It should be understood that each of these terms shall mean or refer to any device or structure to which the coaxial cable connector attaches to mechanically and/or electrically connect a coaxial cable thereto. The coaxial cable connector includes attachment feature for attaching the coaxial cable connector to the equipment port or terminal. The attachment feature may be any suitable attachment device, including, without limitation, rotatable coupler, also referred to as a nut, or push-on component. A body is secured to the coupler at one end in a manner so that it does not rotate with coupler. A post is secured to and inside of the body. A shell is movably attached to the body at another end such that shell can axially move toward coupler. A gripping member is frictionally fit inside of shell. The shell accepts the coaxial cable which is inserted through shell and the gripping member and is secured to an end of post so that coaxial cable positions between post and body inside of body. The gripping member is configured to secure coaxial cable to coaxial cable connector. In this regard, when an axially compressive force is applied to shell to move shell axially toward coupler, the gripping member also moves and at least a part of gripping member is forced between body and coaxial cable. 
     The gripping member has a front end and a rear end opposite the front end, and an outer surface and an inner surface defining a longitudinal hole extending between the front end and the rear end. A first portion of the gripping member terminates at the front end. A second portion of the gripping member terminates at the rear end. The gripping member is configured to secure the coaxial cable to the coaxial cable connector. The gripping member secures the coaxial cable to the coaxial cable connector when at least part of the gripping member is forced under the body. The gripping member may be forced under body of a coaxial cable connector when driven axially forward by the shell to secure coaxial cable to the connector. When forced under the body, the first portion or front end the gripping member may be displaced radially inwardly. The shell includes a structure to move the rear end/second portion of the gripping member radially outwardly upon compression. In some embodiments, the shell includes a structure to prevent a rear portion of the gripping member from moving radially inwardly upon compression. In various embodiments, the structure may comprise, for example, a machined component, a stamped component such as a one- or multi-piece stamped component, or another structure adapted to move a rear portion of the gripping member radially outwardly upon compression and/or prevent a rear portion of the gripping member from moving radially inwardly upon compression. Various embodiments of connectors and coaxial cable assemblies are described in detail below. 
     A coaxial cable has a center or inner conductor that is surrounded by a dielectric layer. The dielectric layer (or dielectric) may also have a foil or other metallic covering. The coaxial cable then has a braided outer conductor which is covered and protected by a jacket. Typically, to prepare the coaxial cable for attachment to a coaxial cable connector, a portion of the center conductor is exposed. The jacket is trimmed back so that a portion of the dielectric (and metallic covering) and braided outer conductor are exposed. The braided outer conductor is then folded back over the jacket, to expose the dielectric (and the metallic covering if present). Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts 
       FIGS. 1 and 3  schematically depict a cross sectional view of an example embodiment of a coaxial cable connector  100  for coupling an end of a coaxial cable to a terminal. In this embodiment, the coaxial cable connector  100  includes a coupler  200  adapted to couple to the terminal. The coaxial cable connector  100  also includes a body  400  secured to the coupler  200  at one end in a manner so that the body  400  does not rotate with coupler  200 . A post  300  is secured to and disposed inside of the body  400  and comprises a backstop  20  and a contacting portion  30  extending from a collar portion  31  of the post  300 . As is clearly illustrated in  FIGS. 1 and 3 , the backstop  20 , which is illustrated with the post  300  in cross section, is positioned to engage the contacting portion  30  mid-span, at a discrete point between the collar portion  31  of the post  300  and the end of the contacting portion  30  that is in contact with the inside bore of the coupler  200 . As is clearly illustrated in  FIG. 3 , the backstop  20  defines a fulcrum at a discrete point between the collar portion  31  of the post  300  and the end of the contacting portion  30  in contact with the inside bore  22  of the coupler  200  about which the end of the contacting portion  30 , in contact with the inside bore  22  of the coupler  200 , may pivot. As will be appreciated by those familiar with the art, US 2014/0106612 A1 discloses coaxial cable connectors comprising posts with contacting portions in a variety of different configurations. 
     A shell  600  is movably attached to the body  400  at an opposite end such that the shell  600  can axially move toward coupler  200 . A gripping member  500  is frictionally fit inside of the shell  600 . The shell  600  accepts the coaxial cable which is inserted through shell  600  and the gripping member  500  and is secured to an end of the post  300  so that the coaxial cable positions between the post  300  and the body  400  inside of the body. The gripping member  500  is configured to secure the coaxial cable to the coaxial cable connector  100 . In this regard, when an axially compressive force is applied to the shell  600  to move the shell  600  axially toward the coupler  200 , the gripping member  500  also moves and at least a part of the gripping member  500  is forced between the body  400  and the coaxial cable. 
     In one embodiment, the coupler  200 , the post  300 , the body  400 , and the shell  600  may be made from a conductive material such as nickel plated brass or the like. The gripping member  500  may be made from a non-conducting material, such as a plastic such as acetal. The gripping member  500  at least partially includes a front portion  501 , a back portion  502 , a rearward facing surface  503 , an internal surface  504 , and a reduced diameter portion  505 . The shell  600  at least partially includes a front end  601 , a back end  602  and a surface  603 . The reduced diameter portion  505  creates an annular gap  506  between the gripping member  500  and the shell  600 . The surface  603  of the shell  600  is configured to drive the rearward facing surface  503  and at least a portion of the internal surface  504  of the gripping member  500  radially outwardly when driven axially against the rearward facing surface  503  by means of a reverse rake angle of the surface  603  oriented in a direction angled from the rear end  602  of the shell  600  toward the front end  601  of the shell  600  as the surface  603  extends from an inner surface of the shell  600  into a longitudinal opening defined by the shell  600 . 
       FIG. 2  schematically depicts a cross sectional view of an example embodiment of a gripping member  500  and a shell  600  of the coaxial cable connector  100  shown in  FIG. 1  in an unassembled state. As described above with reference to  FIG. 1 , the gripping member  500  includes a front portion  501 , a back portion  502 , a rearward facing surface  503 , an internal surface  504 , and a reduced diameter portion  505 . The shell  600  at least partially includes a front end  601 , a back end  602  and a surface  603 . The reduced diameter portion  505  of the gripping member  500  creates an annular gap  506  between the gripping member  500  and the shell  600 . The surface  603  of the shell  600  is configured to drive the rearward facing surface  503  and at least a portion of the internal surface  504  of the gripping member  500  radially outwardly when driven axially against the rearward facing surface  503  by means of a reverse rake angle of the surface  603  oriented in a direction angled from the rear end  602  of the shell  600  toward the front end  601  of the shell  600  as the surface  603  extends from an inner surface of the shell  600  into a longitudinal opening defined by the shell  600 . Thus, in this embodiment, a distal end of the forward angled surface extends into the longitudinal opening of the shell and is disposed forward (i.e., closer to the front end  601 ) relative to a proximal end of the forward facing surface disposed at or near (e.g., at least generally adjacent to) the inner surface of the shell  600 . 
       FIG. 3  schematically depicts the example embodiment of the coaxial cable connector  100  shown in  FIG. 1  with a coaxial cable  1000  inserted into the coaxial cable connector  100 . In  FIG. 3 , the coaxial cable connector  100  is in a closed condition in which the shell  600  has been axially moved in a forward direction over the body  400  toward the coupler  200  of the connector  100 . The front portion  501  of the gripping member  500  has been forced cylindrically into or under the body  400  and has been deformed radially inwardly towards the coaxial cable  1000 . In one embodiment, for example, the front portion  501  of the gripping member contacts an outer jacket of the coaxial cable  1000  as shown in  FIG. 3  and further environmentally seals the junction of the coaxial cable connector  100  and the coaxial cable  1000 . 
     At least a portion of the rear portion  502 , a portion of the internal surface  504 , and a portion of the rearward facing surface  503  of the gripping member  500  have been forced at least partially radially outwardly by the angled surface  603  of the shell  600  as evidenced by a volumetric reduction in an annular gap  506  and by the general shape of the resulting component configuration. 
       FIG. 4  schematically depicts a cross section of another example embodiment of a gripping member  500 ′ of a coaxial cable connector according to one or more embodiments. In the particular implementation shown in  FIG. 4 , for example, a rearward facing surface  503 ′ of the gripping member  500 ′ includes a reverse rake angle corresponding to the surface  603  of the shell  600  described above with respect to  FIGS. 1 and 2 . Thus, in the embodiment shown in  FIG. 5 , the rearward facing surface  503 ′ is angled in a direction extending from the rear end  502  of the gripping member  500  toward the front portion  501  of the gripping member  500  as the surface extends from an inner surface of the gripping member  500  into a longitudinal opening of the gripping member  500 . 
       FIG. 5  schematically depicts a cross section of another example embodiment of a gripping member  510  and a shell  610  of a coaxial cable connector as a sub-assembly in a first uncompressed position. In this embodiment, the gripping member  510  at least partially includes an outer ring  511  and an inner area  512 . The shell  610  at least partially includes an angled surface  611  and a recess  612 , such as formed by an annular channel in the shell  610 . The recess  612  of the shell provides an annular gap  513  around the gripping member in this first uncompressed position. 
       FIG. 6  schematically depicts a cross section of the example embodiment of the gripping member  510  and the shell  610  shown in  FIG. 5  as a sub-assembly in a second compressed position. In this embodiment, the shell  610  has been forced in an axially forward direction toward the gripping member  510  as it would be during compression of a coaxial cable connector. In this embodiment, at least a portion of the outer ring  511  and a portion of the inner area  512  of the gripping member  510  have been forced at least partially radially outwardly by the angled surface  611  of the shell  610  as evidenced by a volumetric reduction in annular gap  513 , an increase in volumetric space around inner area  512 , and by the general shape of the resulting component configuration. 
       FIG. 7  schematically depicts a cross section of an example embodiment of a gripping member  520  and a shell  620  as a sub-assembly in a first uncompressed position. In this embodiment, the gripping member  520  at least partially comprises a reduced diameter portion  521  and an inner area  522 . The shell  620  at least partially includes an angled surface  621  and a bore  622 . The reduced diameter portion  521  of the gripping member  520  creates annular gap  523  between the gripping member  520  and the bore  622  of the shell  620 . 
       FIG. 8  schematically depicts a cross section of an example embodiment of a gripping member  520  and a shell  620  as a sub-assembly in a second compressed position. In this embodiment, the shell  620  has been forced in an axially forward direction toward the gripping member  520  as it would be during compression of a coaxial cable connector. As such, at least a portion of the reduced diameter portion  521  and a portion of the inner area  522  of the gripping member  520  have been forced at least partially radially outwardly by the angled surface  621  of the shell  620  as evidenced by a volumetric reduction in the annular gap  523 , an increase in volumetric space around the inner area  522 , and by the general shape of the resulting component configuration. 
       FIG. 9  schematically depicts a cross section of another example embodiment of a gripping member  530  and a shell  630  as a sub-assembly in a first uncompressed position. In this embodiment, the gripping member  530  at least partially comprises a reduced diameter portion  531  and an inner area  532 . The shell  630  at least partially includes an angled surface  631  and a bore  632 . The reduced diameter portion  531  of the gripping member  530  creates annular gap  533  between the gripping member  530  and the bore  632  of the shell  630 . Additionally, in this implementation, the shell  630  may be produced by a stamping or deep draw operation that is more economical to produce than a shell made by machining or turning operations. 
       FIG. 10  schematically depicts a cross section of the example embodiment of the gripping member  530  and the shell  630  shown in  FIG. 9  as a sub-assembly in a second compressed position. In this embodiment, the shell  630  has been forced in an axially forward direction toward the gripping member  530  as it would be during compression of a coaxial cable connector. As such, at least a portion of the reduced diameter portion  531  and a portion of the inner area  532  of the gripping member  520  have been forced at least partially radially outwardly by the angled surface  631  of the shell  630  as evidenced by a volumetric reduction in the annular gap  533 , an increase in volumetric space around the inner area  532 , and by the general shape of the resulting component configuration. 
       FIG. 11  schematically depicts a cross section of another example embodiment of a gripping member  540  and a shell  640  as a partially completed sub-assembly in a first uncompressed position. In this embodiment, the gripping member  540  at least partially includes an outer diameter  541  and an inner area  542 . The shell  640  at least partially includes a structure  641  such as a curved forward facing surface and a bore  642 . Additionally, in this implementation, the shell  640  may be produced by a stamping or deep draw operation that is more economical to produce than a shell made by machining or turning operations. 
       FIG. 12  schematically depicts a cross section of the gripping member  540  and the shell  640  as a sub-assembly in which a forming tool  2000  has been introduced to complete the sub-assembly by forming the structure  641  (e.g., the curved forward facing surface) of the shell  600  radially outwardly. The forming operation captures the gripping member  540  within the shell  640  and creates an annular barrier to prevent the inner area  542  of the gripping member  540  from moving radially inwardly. 
       FIG. 13  schematically depicts a cross-section of the gripping member  540  and the shell  640  as sub-assembly in a final assembled condition with the forming tool  2000  removed. 
     It should now be understood that embodiments described herein are directed to coaxial cable connectors and methods connecting coaxial cable connectors to a coaxial cable. 
     For the purposes of describing and defining the subject matter of the disclosure it is noted that the terms “substantially” and “generally” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred. 
     It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosure. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the disclosure may occur to persons skilled in the art, the embodiments disclosed herein should be construed to include everything within the scope of the appended claims and their equivalents.