Abstract:
An improved connector for diverting signals from a first cable to a second cable including a housing having a base, a cover attached to the base, and a passageway defined by the base and cover. The base includes a channel which engages an outer cover of said first cable, a receptacle, and a device to attach the base to the first cable. The channel includes a boss which has a longitudinally extending bore which is in communication with the receptacle. The base includes a lower part of the passageway. The receptacle is defined by a substantially circumferential wall. A printed circuit board is disposed within the receptacle. A contact pin extends through an aperture in the printed circuit board and the bore, and contacts a conductor of the first cable for electrical communication between the first and cond cables. The cover includes an upper part of the passageway and a pocket which is defined by a substantially circumferential wall. Operative association of the base and cover cooperatively define the passageway to receive and retain the second cable.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to connectors, and more particularly, to a cable tap connector which diverts signals from one cable to another cable. The tap connector is compact, less expensive to manufacture, provides enhanced tuning and is easier to install. 
     A conventional cable tap connector, illustrated in FIGS. 7 and 8, is large, bulky, difficult to install, and space consuming. The connector includes two parts. A first part  300  functions as a mounting saddle. Generally, the first part has a flat bottom for connection with a desired surface S, and a top with a channel  302  for receiving the coaxial cable C. The second part  304  is essentially a reverse mirror image of the first part aside from the integral connector  306  mounted on the top surface. The first and second parts are connected by threaded fasteners  308 . 
     One major disadvantage of this prior art design is the size of the unit and difficulty of installation. In order to install the prior art tap connector, the cable must be pulled away from the mounting surface, FIG. 8, to fit the first part under the cable. Usually the cable must be entirely disconnected in order to mount the first part. 
     This consumes a large amount of installation time, thereby increasing costs. Occasionally, even if the cable is entirely disconnected, the tap connector cannot be installed because the installer will not be able to reattach the cable end connectors where necessary because the cable is too short with the tap installed. A cable would have to be installed and this is clearly problematic. 
     Another major disadvantage of the prior art tap connector is the integrated connector on the top surface, FIGS. 7 and 8. These tap connectors are most commonly installed in cable trunking or other narrow, space-limited confines such as a plenum or elevator shaft, FIG.  8 . The integrated connector of the prior art extends perpendicular to the longitudinal axis of the cable. The second cable must therefore also be connected in a perpendicular orientation unless the installer uses a more expensive ninety-degree fitting. Further, in order to maintain maximum performance, the second cable can only bend to the minimum bend radius R m  limit. Accordingly, the prior art tap connector requires a significant amount of room perpendicular to the cable in order to properly turn the second cable to run parallel to the first cable. 
     Thus, there remains a need for a cable tap connector which has a compact, space-saving, low-profile, one-side attachment, convenient installation, minimal materials, and flexible entrance/exit design. 
     SUMMARY OF THE INVENTION 
     In order to accomplish the objects of the present invention, a cable tap connector according to the present invention comprises a base, a cover and a passageway. The base is adapted to engage the outer covering of a first coaxial cable such that a contact pin may engage the conductor of the first cable. Accordingly, the signals are diverted to a second cable which extends through a passageway defined by cooperative association of the base and the cover. 
     It is therefore a general object of the present invention to provide a new cable tap connector that can be installed in situ without disturbing the first cable. 
     It is another object of the present invention to provide a new tap connector having a compact, minimum perpendicular height profile. 
     It is yet another object of the present invention to provide a new tap connector which significantly reduces materials and costs. 
     It is still another object of the present invention to provide a new tap connector with the second cable passageway parallel to the longitudinal axis of the first cable. 
     It is yet another object of the present invention to provide a new tap connector with second cable passageway defined by a operative connection of the base and cover. 
     It is still yet another object of the present invention to provide a new tap connector having unitary construction so that the connector only engages one side of the first cable and the other side of the first cable remains in its originally routed position, usually against a wall. 
     In a principal aspect of the present invention, the preferred embodiment is defined by a housing having a base, a cover, and a second cable. The base has an arcuate lower surface and a receptacle disposed on an upper surface. The lower surface has a boss extending into a channel. A bore extends through the boss into the receptacle. An exterior wall defines the receptacle which has a first part and a second part separated by a groove transverse to the longitudinal axis of the housing. A printed circuit board and contact pin are disposed within the first part. The cover includes a pocket defined by an exterior wall and has a first part and a second part separated by a groove. The base second part and the cover second part cooperatively define the passageway for the second coaxial cable. An annular resilient element connected to the second coaxial cable is received in the groove formed by cooperative association of the base and cover. A ground shield of the second cable may be attached to the printed circuit board and a conductor of the second cable is attached to the contact pin. The cover is attached to the base defining a volume including the receptacle and pocket which are sealed from exterior elements. 
     In another principal aspect of the present invention, another embodiment is defined by a housing having a base, a cover attached to the base, and a passageway cooperatively defined by the base and cover. The base includes a recess adapted to engage an outer covering of the first cable, a receptacle, a lower part of the passageway and means for attaching the base to the first cable. The channel includes a boss formed on a lower surface. The boss has a longitudinally-extending bore which is in communication with the receptacle. A substantially circumferential wall defines the receptacle and has a printed circuit board disposed therein. A contact pin extends through an aperture in the printed circuit board and the bore. The cover includes an upper part of the passageway and a pocket defined by a circumferential wall. Operative association between the base and cover cooperatively define the passageway in order to receive and retain the second cable. 
     These and other features, objects and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numerals identify like elements throughout. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the course of the following detailed description, reference will be made to the attached drawings in which: 
     FIG. 1 is perspective view of an improved coaxial cable tap connector constructed in accordance with the principles of the present invention mounted on a first coaxial cable; 
     FIG. 2 is an exploded perspective view of the connector shown in FIG. 1; 
     FIG. 3 is a side elevation view of the connector of FIG. 1; 
     FIG. 4 is a cross-sectional view of the connector of FIG. 3 taken along lines IV—IV thereof; 
     FIG. 5 is a cross-sectional view of the connector of FIG. 1 taken along lines V—V thereof; 
     FIG. 6 is a perspective view of an alternative embodiment of the connector constructed in accordance with the principles of the present invention; 
     FIG. 7 is a perspective view of a prior art tap connector; and, 
     FIG. 8 is a side elevation view of the prior art tap connector of FIG. 7 installed in a confined space. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of the embodiment of the invention. The scope of the invention is best defined by the appended claims. 
     Referring now to FIG. 1, a cable tap connector constructed in accordance with the principles of the present invention is generally designated as  20 . The connector  20  is a low-profile or reduced-height tap for diverting signals within a predetermined frequency band from a first cable  22  to a second cable  24 . The first cable  22  has an arcuately shaped outer cover configuration. 
     The connector assembly  20 , as shown in FIGS. 1 and 5, is installed on the first cable  22  as an integral one-piece unit having operatively associated a base  26 , cover  80 , passageway  90  and second cable  24 . The base  26  has a lower surface  28  which is generally recessed as viewed from one the ends  27  or  29 . An upper surface  30  generally mirrors the contour of the lower surface  28  and has a receptacle  32 , lower part  91  of the passageway  90 , and securing apparatus  34  formed thereon. The lower surface  28  and ends  61  define a channel or recess  39  having a depth D 1  which is adapted to complimentarily engage the outer cover  21  of the first cable  22 . The diametrical size of the first cable  22  is defined within a certain range. The depth D 1  also differs depending on the size of the first cable  22 , as will be recognized by those of ordinary skill in the art. Accordingly, the depth D 1  has a range of values dependent on the size of the first cable  22 . 
     The outer cover  21  is generally a plastic or other synthetic, dielectric material and preferably has an arcuately shaped outer configuration. An attachment device  50  is disposed on a substantial portion of the lower surface  28 . Preferably, the attachment device  50  is an adhesive such as double-sided foam tape; however, it will be understood by one of skill in the art that any other form of like adhesive, applied by spray or brush, will achieve desirable results. 
     A boss  54  extends from the lower surface  28  into the channel  39  an amount less than the depth D 1 . The boss  54  is may be either integrally formed with the lower surface  28 , or as a separate element and attached to the lower surface  28 . In use, illustrated in FIG. 5, the boss  54  projects through an aperture formed in the outer cover  21 , ground conductor  23 , and dielectric  56  of the first cable  22 . A bore  58  is formed in the boss  54  extending along its longitudinal axis and in communication with the receptacle  32 . The bore  58  terminates in the receptacle  32  at an aperture  60  formed in the floor  62 . 
     A securing apparatus  34  is disposed at the front  27  and rear  29  of the base  26 . Preferably, each apparatus  34  includes an outer rib  36 , an inner rib  38 , and a floor  42 , which cooperatively define a channel  40 . The floor  42  of the rear apparatus  35  is substantially coplanar with the upper surface  30 . Each channel  40  may receive an elongated strap  46  of a locking band  44  in order to provide further positive connection of the connector  20  to the first cable  22 . A segment  59  of the channel  40  of the front apparatus  37  is formed on the cover  80  as will be discussed in more detail below. 
     The receptacle  32 , as shown in FIG. 2, is defined on the upper surface  30  of the connector  20  by a circumferentially extending wall  64 . A first part  71  of the receptacle  32  is defined by an inner surface  65  and floor  62 . Preferably, the first part  71  includes a pair of parallel longitudinal sides  67 , and a front wall end  68  and a rear wall end  69 . A plurality of ribs and other support elements  66  are preferably integrally formed in the first part  71  to provide reinforcement and support for items disposed in the receptacle  32  as will be recognized by one of skill in the art and discussed below. 
     The second part  73  of the receptacle  32  includes a lower portion  91  of the passageway  90  which extends from a first end  92  adjacent the front wall and  68  to a second end  99  adjacent the outer rib  36  of the front apparatus  37  preferably along the longitudinal axis of the base  26 . The lower portion  91  is defined by a pair of substantially parallel longitudinal walls  95  and a floor  96  interconnecting the walls  95 . A groove  70  is formed in the floor  96  of the lower portion  91  at the first end  92  adjacent front wall end  68 . The groove  70  is generally aligned with the inner rib  38  of the front apparatus  37  in order to receive a resilient member  72 . The lower portion  91  is dimensioned to receive a portion of the second cable  24 . 
     A printed circuit board  41  is disposed within the first part  71  of the receptacle  32  adjacent the rear wall end  69 . A contact pin assembly  145  is secured by conventional means to the printed circuit board  41  adjacent the rear wall end  69 . The sheath  146  of the assembly  145  is preferably soldered to the printed circuit board  41  about an aperture  43 . A contact pin  45  extends through the sheath  146  and preferably has a desired range of vertical movement. The aperture  43  is formed in the printed circuit board  41  so that the contact pin  45  may also extend through the aperture  60  and bore  58 . The contact pin  45  may have an ferrite collar  47  for signal tuning purposes as will be recognized by one of skill in the art. The ferrite collar  47  is disposed on the top surface of the printed circuit board  41  around the aperture  43 . The first conductor  31  of the second cable is connected to the contact pin  45 . A solder pad  49  is disposed on an end of the printed circuit board  41  away from the aperture  43  for connection with the second conductor  25  of the second cable  24 . Additional electrically conductive traces (not shown) on the printed circuit board  41  provide the desired signal tuning levels as will be recognized by one of ordinary skill in the art. 
     A ferrite block lower portion  51  is also disposed within the receptacle  32  adjacent the front wall end  68 . A channel  55  formed in the ferrite block  51  to receive a portion of the second cable  24  and provides a signal tuning effect therefor as is well recognized by one of ordinary skill in the art. The ferrite block lower portion  51  is secured in the receptacle  32  by any available conventional means, preferably, the lower portion  51  is snap fittingly secured to the receptacle  32 , however, an adhesive such as double sided tape, glue or any other may be used to provide positive positioning. 
     The cover  80 , as shown in FIG. 4, includes a pocket  82  and an upper portion  93  of the passageway  90 . The pocket  82  is defined by a circumferentially extending wall  84  and a roof  86 . The wall  84  preferably includes a pair of parallel, longitudinal extend sides  87 , a front wall end  88 , and a rear wall end  89 . The roof  86  interconnects the sides  87  and ends  88  and  89 , so that, when the cover  80  is positioned over the base  26  the walls  64  and  84  are in substantially continuous contact about their perimeters. An upper portion  93  of the passageway  90  is defined by a pair of longitudinal, generally parallel walls  97  and a roof  98 . The upper portion  93  extends from a first end  92  adjacent the front wall end  88  to a second end  89  adjacent the outer rib  36  of the front apparatus  37  generally along the longitudinal axis of the cover  80 . A groove  81  is formed in the roof  98  of the upper portion  93  adjacent the front wall end  88 . The groove  81  is generally aligned with the inner rib  38  of the front apparatus  37  in order to receive a resilient member  72  The upper portion  93  is dimensioned to receive a portion of the second cable  24 . 
     When the cover  80  is operatively associated with the base  26  the grooves  70  and  81  cooperatively define an annular groove which receives the resilient member  72  with slight interference. The cover  80  is then preferably ultrasonically welded to the base  26  in order to hermetically seal the receptacle  32  and pocket  82  combination. An overall height H of the assembled connector is measured from the ends  61  to the exterior surface of the roof  86 . The height H remains constant regardless of the size of the first cable  22 . This illustrates the compact, reduced-height design of the present invention. Accordingly, the longitudinal axis of the passageway  90  is disposed at a location L 1 , no more than 2.3 times the depth D 1 , from the ends  61 . Whereas, the prior art device  300  shown in FIGS. 7 and 8, has a connector  306  for connection to a second cable disposed at a location L 2  at least 4 times the depth D 2 . It will be obvious to those of ordinary skill in the art that the present invention provides a significant reduction in the height H of the connector  20  and the distance of the second cable  24  from the surface S. 
     As briefly mentioned above, a segment  59  of the front apparatus  37  is formed on the cover  80 . The structural components, namely ribs  36 ,  38 , and floor  42 , are substantially the same. The channel  40  is a continuation of the channel  40  formed on the base  26  such that the strap  46  has a smooth transition form one side of the base  26  to the other. 
     A ferrite block upper portion  53  is disposed within the pocket  82  adjacent the front wall end  88 . A channel  57  formed in the ferrite block upper portion  53  to receive a portion of the second cable  24  and provide a signal tuning effect as is well recognized by one of ordinary skill in the art. The ferrite block upper portion  53  is secured in the pocket  82  by any available conventional means, preferably double-sided tape or another adhesive or glue. 
     The passageway  90  is defined by the cooperative association of the respective lower  91  and upper  93  portions of the base  26  and cover  80 . During assembly, the second cable  24  is connected as discussed above and positioned in the lower portion  91 . The cover  80  and upper portion  93  are connected to the base  26 . The upper portion  93  receives a portion of the second cable  24 . Preferably, the second cable  24  enters/exits the passageway  90  of the connector  20  along the substantially parallel to the longitudinal axis of the first cable  22 . This structural configuration greatly enhances the low-profile nature of the connector  20  by permitting the second cable  24  to exit parallel to the first cable  22  as close to the first cable  22  as permissible. The bulk or minimum perpendicular clearance height of the connector  20 , is considerably reduced over the prior art. 
     Turning now to FIG. 6, an alternative embodiment of the present invention is shown. The structure is substantially the same as previously discussed, and is advantageous over the above when a passageway  90  oriented oblique to the longitudinal axis of the first cable  22  is necessary. The lower  91  and upper  93  portions which cooperatively define the passageway  90  which may be oriented at any angle to the longitudinal axis of the first cable  22  as required. 
     Furthermore, while the particular preferred embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the teaching of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.