Abstract:
A coaxial cable splitter including an integral body with a first cable connection, a second cable connection and a third cable connection, each defining an axis. The second cable connection is a crimp sleeve, the first cable connection is a coaxial connector, and the axes are generally parallel to each other. The third cable connection is a coaxial cable connector and the axis is at an angle to the axes of the first and second cable connections. The first and third cable connections each include a center conductor which are electrically linked. The first and third cable connections each include an outer shell positioned about the center conductor which are electrically linked. A method of assembling a coaxial cable splitter with an integral body.

Description:
This application claims the benefit of Provisional Application Ser. No. 60/454,950, filed Mar. 12, 2003, the disclosure of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention generally relates to cables for use with telecommunications equipment. More specifically, the present invention relates to a coaxial cable Y-splitter. 
   BACKGROUND OF THE INVENTION 
   In telecommunications installations, it is known to have signal handling or processing equipment which has high availability requirements. Often, such equipment is installed in a paired or redundant arrangement. For example, the signal handling equipment might be in the form of a module configured to be mounted to a chassis. A redundant module may be mounted adjacent the first module. The redundant module may be connected to the first module so that the redundant module can carry out the signal handling or processing if the first module should fail. In this fashion, a failure or maintenance of the first module would not result in the loss of connectivity or failure or of transmission of the signals handled by the first module. 
   It is desirable to improve the cables which are used to connect these redundant signal processing or handling modules. These improved cables and cable assemblies may also be adaptable to other coaxial cable installations. 
   SUMMARY OF THE INVENTION 
   A coaxial cable splitter including an integral body with a first cable connection, a second cable connection and a third cable connection, each cable connection defining an axis. The second cable connection is a crimp sleeve, the first cable connection is a coaxial connector, and the axes of the first and second cable connectors are arranged generally parallel to each other. The third cable connection is a coaxial cable connector and the axis of the third cable connection is arranged at an angle to the axes of the first and second cable connections. The first and third cable connections each include a center conductor and the center conductors of the first and third cable connections are electrically linked. The first and third cable connections each include an outer shell positioned about the center conductor, the outer shell of the first cable connection electrically linked to the outer shell of the third cable connection. 
   A method of assembling a coaxial cable splitter including providing an integral housing with a first cable connection, a second cable connection and a third cable connection, each of the cable connections defining an axis. A first insulator is positioned within the first cable connection and includes a central opening oriented along the axis of the first cable connection. A first end of a center conductor is inserted within the central opening of the first insulator. The center conductor includes a second end which extends through the second cable connection along the axis of the second cable connection. A cable conductor is extended through the third cable connection and electrically linked with the center conductor. A hollow tubular outer shell is positioned about the second end of the center conductor, so that the tubular outer shell is oriented along the axis of the second cable connection. An insulator is inserted withint he tubular outer shell about the second end of the center conductor. 
   An alternative embodiment of a coaxial cable splitter including an integral body with a first cable connection, a second cable connection and a third cable connection, each cable connection defining an axis. The second cable connection is a crimp sleeve and the first cable connection is a coaxial connector, and the axes of the first and second cable connectors are arranged generally parallel to each other. The third cable connection is a coaxial cable connector and the axis of the third cable connection is arranged at an angle to the axes of the first and second cable connections. The first and third coaxial connections each include a center conductor and the center conductors of the first and third coaxial connections form an integral center conductor having an angled shape. The first and third coaxial connections each include an outer shell positioned about the center conductor. The outer shell of the first coaxial connection is electrically linked to the outer shell of the third coaxial connection. The integral center conductor is held within the housing by at a pair of insulators which electrically isolate the center conductor from the housing. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows: 
       FIG. 1  is a perspective view of a telecommunications equipment chassis with a plurality of equipment modules mounted to the chassis, and a coaxial cable splitter in accordance with the present invention linking two of the equipment modules. 
       FIG. 2  is a first perspective view of the coaxial cable splitter in accordance with the present invention shown. 
       FIG. 3  is a second perspective view of the coaxial cable splitter of  FIG. 2 . 
       FIG. 4  is a side view of the coaxial cable splitter of  FIG. 2 . 
       FIG. 5  is a side cross-sectional view of the coaxial cable splitter of  FIG. 2 , taken along the centerline of the coaxial cable. 
       FIG. 6  is a side cross-sectional view of the housing assembly of the coaxial cable splitter of  FIG. 5 , with a portion of the jack cable connection removed for clarity. 
       FIG. 7  is a first exploded perspective view of the housing assembly of the coaxial cable splitter of  FIG. 2 . 
       FIG. 8  is a second exploded perspective view of the housing assembly of  FIG. 7 . 
       FIG. 9  is an exploded side view of the housing assembly of  FIG. 7 . 
       FIG. 10  is a side view of a housing of the housing assembly of the coaxial cable splitter of  FIG. 2 . 
       FIG. 11  is a first end view of the housing of  FIG. 10 . 
       FIG. 12  is a second opposite end view of the housing of  FIG. 10 . 
       FIG. 13  is a side view of a locking barrel of the housing assembly of the coaxial cable splitter of  FIG. 2 . 
       FIG. 14  is a first end view of the locking barrel of  FIG. 13 . 
       FIG. 15  is a second opposite end view of the locking barrel of  FIG. 13 . 
       FIG. 16  is a side view of an insulator within the plug cable connection end of the housing assembly of  FIG. 7 . 
       FIG. 17  is a first end view of the plug end insulator of  FIG. 16 . 
       FIG. 18  is a second opposite end view of the plug end insulator of  FIG. 16 . 
       FIG. 19  is a side view of a center conductor of the housing assembly of  FIG. 7 . 
       FIG. 20  is a first end view of the center conductor of  FIG. 19 . 
       FIG. 21  is a second opposite end view of the center conductor of  FIG. 19 . 
       FIG. 22  is a side view of a tubular outer shell of the jack cable connection end of the housing assembly of  FIG. 7 . 
       FIG. 23  is a first end view of the jack end outer shell of  FIG. 22 . 
       FIG. 24  is a second opposite end view of the jack end outer shell of  FIG. 22 . 
       FIG. 25  is a side view of a jack end center conductor of the housing assembly of  FIG. 7 . 
       FIG. 26  is a first end view of the jack end center conductor of  FIG. 25 . 
       FIG. 27  is a second opposite end view of the jack end center conductor of  FIG. 25 . 
       FIG. 28  is a side partially exploded view of the housing assembly of  FIG. 7 , showing the plug connection end components. 
       FIG. 29  is a side partially exploded view of the housing assembly of  FIG. 7 , showing the jack connection end components. 
       FIG. 30  is a first perspective view of an alternative embodiment of a coaxial cable splitter in accordance with the present invention, including three plug connection ends. 
       FIG. 31  is a second perspective view of the coaxial cable splitter of  FIG. 30 . 
   

   DETAILED DESCRIPTION 
   In telecommunications equipment installations where a high degree of communications availability is required or desirable, it is known to install redundant or paired equipment for signal processing or switching. The redundancy permits failure of the primary piece of equipment without jeopardizing the passage of signals through the equipment. As shown in  FIG. 1 , a chassis  1  provides a location for mounting of equipment modules  2 . A first pair of modules  2 , labeled  2 A and  2 B, and a second pair of modules  2 , labeled  2 C and  2 D, are the same type of equipment modules. Modules  2 A and  2 B and modules  2 C and  2 D, respectively, are mounted adjacent each other and each module  2  includes a coaxial cable jack connection  3 . 
   Cable connections  3  of modules  2 A and  2 B, are linked to each other by a cable splitter  10 . Cable splitter  10  connects both the cable connections  3  of modules  2 A and  2 B to each other and to another piece of telecommunications equipment by a cable  4 . As shown in  FIG. 1 , both modules  2 A and  2 B are electronically linked to the downstream equipment at all times, as cable splitter  10  is a passive device without any switching circuitry. Module  2 A is the primary piece of equipment in this pair of modules  2 . If module  2 A were to fail or need to be taken out of service for routine inspection, maintenance or repair, module  2 B would still be connected to the other piece of telecommunications equipment by cable  4 . Thus, failure, repair or maintenance of module  2 A would not require taking the entire telecommunications circuit offline, which can be inconvenient and costly. 
   Referring now to  FIGS. 2 through 5 , cable splitter  10  includes a housing  12  with a first cable connection  14 , a second cable connection  16  and a third cable connection  18 . All three cable connections are part of a housing assembly  11 . As shown, first cable connection  14  is a BNC plug connector, second cable connection  16  is a crimp connector and third cable connection  18  is a BNC jack connector. A first end of a coaxial cable  20  is electrically and physically connected to second cable connection  16 , as will be discussed in further detail below. A second end of coaxial cable  20  is connected to a cable connector  22 , which is a BNC plug connector. The length of coaxial cable  20  is sufficient so that first connection  14  can be connected to cable connection  3  of module  2 A and connector  22  can be connected to cable connection  3  of module  2 B, or between cable connections  3  of modules  2 C and  2 D. 
   While cable splitter  10  is shown with a pair of BNC plug connectors, cable connection  14  and cable connector  22 , and a BNC jack connector, cable connection  18 , other configurations are anticipated and are within the scope of the present invention. All three connections might be BNC jack or BNC plug connections. Further, difference combinations of BNC jack and plug connections may be used. Alternatively, other types, styles and formats of coaxial cable connectors may be used. 
   Referring now to  FIG. 6 , cable splitter  10  includes a center conductor  26  which extends between cable connections  14  and  18 . Center conductor  26  includes an opening  25  which receives a center cable conductor  24  of cable  20  extending through connection  16 . Cable center conductor  24  is physically and electrically connected to center conductor  26  and thus to cable connections  14  and  18 . The connection can be crimped and/or soldered. Cable center conductor  24  is also electrically connected to connector  22 , so that all three connectors at cable connections  14 ,  16 , and  18  are electrically linked. Center conductor  26  is held within a central cavity  30  of housing  12  by a center conductor insulator  28 . Insulator  28  holds center conductor  26  so that a plug end  40  extends within connection  14  and a jack end  38  extends within connection  18 . Centrally located along center conductor  26  is an angled portion  42 . 
   Central cavity  30  of housing  12  includes three openings, a first opening  44  associated with first connection  14 , a second opening  34  associated with connection  16 , and a third opening  32  associated with third connection  18 . Within opening  44  is a ledge or shoulder  46  against which insulator  28  is positioned. Housing  12  generally defines a cylindrical shape and openings  44  and  34  generally extend parallel to each other and to housing  12 . Opening  32  defines an axis  48  which extends at a non-perpendicular angle to the other two openings and to housing  12 . 
   A locking barrel  36  is positioned about first cable connection  14 . Barrel  36  is rotatable mounted about housing  12  and engages bayonets extending from a tubular outer shell of a mating jack connector. Barrel  36  allows connection  14  to be selectively fastened to a mating jack connector or released from such a mating connector by rotation of barrel  36 . 
   Second cable connection  16  includes a crimp sleeve  50  and a crimp post  52 . Crimp post  52  defines opening  34  of connection  16 . When connecting a coaxial cable, such as cable  20 , to connection  16 , an inner insulation member  54  of cable  20 , which is positioned about cable center conductor  24 , is inserted through opening  34 . Cable  20  also includes an outer shield conductor  19 . Outer shield conductor  19  is positioned about crimp post  52 . Crimp sleeve  50  is placed about the outer shield conductor  19  and compressed to mechanically lock cable  20  to housing  12  and to ensure electrical contact of outer shield conductor  19  and housing  12 . 
   Housing  12  and the various elements mounted within and about housing  12  are shown in more detail in  FIGS. 7 through 12 . The exterior surface of crimp post  52  is shown with shallow threads  53  to aid in the mechanical connection between cable  20  and housing  12 . Other similar outer surfaces may also be used, such as knurling or circumferential rings may be used to aid in the mechanical connection. Barrel  36  is mounted to housing  12  with a crimp ring  56  about which barrel  36  is compressed. Positioned between crimp ring  36  and an exterior barrel ledge  60  of housing  12  is a wave washer  58 . Washer  58  is shaped to provide bias against longitudinal movement of barrel  36  and improve the locking provided by barrel  36  about a mating jack connection. A bearing washer  62  is positioned between barrel  36  and barrel ledge  60  opposite wave washer  58 . 
   A tubular outer shell  64  is inserted within opening  32  and forms part of third connection  18 . A mating portion  70  of shell  64  is sized to be received within opening  32  in an interference fit. Jack end  38  of center conductor  26  extends within shell  64  and is held generally centered and insulated from shell  64  by a jack insulator  66 . Projecting from an outer wall of shell  64  is a pair of opposing bayonets  68 . 
   About opening  44  of housing  12  is a plurality of fingers  72 . Fingers  72  are electrically connected to housing  12  and thus to the shield conductor of cable  20  connected to second connection  16 . When first connection  14  is connected to a mating connector, fingers  72  fit within an outer tubular shell such as shell  64  of third connection  18 , and a pair of slots  74  of barrel  36  engages projections such as bayonets  68  of shell  64 . Rotating barrel  36  brings a locking slot  76  corresponding to slot  74  into engagement with bayonets  68  and draws first connection  14  more securely into contact with the mating connector. Further rotation of barrel  36  moves a detent  78  (shown more clearly in  FIG. 13 ) into engagement with bayonet  68 . The bias of wave washer  58  against barrel  36  and barrel ledge  60  releasably holds bayonets  68  within detents  78 . Removal of first connection  14  from the mating connector requires a reversal of the rotation of barrel so that bayonets  68  move from detents  78  and are aligned with slots  74 . 
   Referring now to  FIGS. 13 through 15 , barrel  36  includes a textured or knurled ring  80  for improving friction and aiding in the movement of barrel  36 . Barrel  36  includes a central opening  82  which defines three portions each with a different diameter with two ledges or shoulders extending radially therebetween. From a first end  84  which extends about housing  12 , a first, largest diameter portion  90  is sized to fit over crimp washer  56  so that crimp washer  56  rests against a first shoulder  86 . Large diameter portion  90  and crimp washer  56  are very close in diameter to permit barrel  36  to be crimped down onto crimp washer  56  to rotatable hold barrel  36  to housing  12 . As shown in  FIG. 6 , wave washer  58  is captured between barrel ledge  60  and crimp washer  56 . A second, middle diameter portion  92  is sized to fit over barrel ledge  60  of housing  12  and receives bearing washer  62 . As shown in  FIG. 6 , bearing washer  62  is captured between a middle shoulder  88  and barrel ledge  60 . Wave washer  58  biases crimp washer  56  away from barrel ledge  60 , which in turn biases shoulder  88  against bearing washer  62  and bearing washer  62  against barrel ledge  60 . The third, smallest diameter portion  94  extends through opening  82  to a second end  96 . Smallest diameter portion  94  is sized to fit about fingers  72  and allow fingers  72  to be inserted within a mating jack connection. 
   Referring now to  FIGS. 16 through 18 , center conductor insulator  28  of first connection  14  includes a central channel  104  for receiving plug end  40  of center conductor  26 . A disk  98  defines a diameter sized for insertion within opening  44  of housing  12  so that insulator  28  is held within opening  44  by an interference fit. Channel  104  extends through disk  98  and through a central shaft  102 . A plurality of ribs  100  extend outward from shaft  102  to the same diameter as disk  98 . The embodiment shown includes three ribs  102  but more or fewer ribs  102  are anticipated as within the scope of the present invention. Each rib  102  includes an outer surface  112  which cooperate to define generally the same diameter as disk  98 . Disk  98  includes a taper  110  opposite ribs  102  and channel  104  includes an entry taper  108 . Tapers  108  and  110  cooperate to aid in the insertion of insulator  28  about center conductor  26  and within opening  44 . Taper  110  ends at a face  111  which defines a diameter greater than ledge  46  within opening  44 . 
   Insulator  28  further includes a recess  106  about channel  104  and taper  108 . Recess  106  receives a shoulder  114  of center conductor  26  (shown in  FIGS. 19 through 21 , below). Shoulder  114  and ledge  46  cooperate with recess  106  and face  111  to position insulator  28  within opening  44  and center conductor  26  within housing  12  and opening  32 . 
   Referring now to  FIGS. 19 through 21 , center conductor  26  includes shoulder  114  for positioning center conductor  26  within insulator  28 . A catch  116  is located between shoulder  114  and plug end  40  along a shaft portion  117  of center conductor  26  in a location that is within channel  104  of insulator  28  when shoulder  114  engages recess  106 . Catch  116  is sized larger than channel  104  and is tapered to ease insertion. On the opposite side of catch  116  from the taper is a wall  115  perpendicular to shaft portion  117 . Insulator  28  is made of a resilient deformable material and will deform to permit entry of catch  118  within channel  104 . Once center conductor  26  is positioned within channel  104 , insulator  28  will conform to the shape of catch  116 . Wall  115  cooperates with insulator  26  to resist extraction of center conductor  26  from insulator  28 . At jack end  38  of center conductor  26  is an opening  118  for receiving a jack end of a center conductor of a mating connection. Angled portion  42  provides a transition between jack end  38  and plug end  40 , which are angled with respect to each other. Opening  25  in center conductor  26  is positioned at least partially within angled portion  42 . Opening  25  may be positioned at other locations along center conductor  26  as desired to facilitate connection of cable center conductor  24  to center conductor  26 . 
   Referring now to  FIGS. 22 through 24 , tubular shell  64  includes a smaller diameter opening defined by inner wall  124  within mating portion  70  and a larger diameter opening defined by inner wall  122  within shell  64 . An insulator shelf or shoulder  120  extends between these two diameters. Shelf  120  provides a stop against which insulator  66  is positioned to set the depth of insertion of insulator  66  within shell  66 . Center conductor  26  extends into shell  64  through the smaller diameter opening defined by inner wall  124 , as shown in  FIG. 6 , above. 
   Referring now to  FIGS. 25 through 27 , jack insulator  66  includes a center shaft  126  through which is defined a conductor channel  128  for receiving jack end  38  of center conductor  26 . A plurality of ribs  130  extend from shaft  126  and each rib  130  defines an outer wall  132 . The outer walls  132  of each rib  130  cooperate to engage inner wall  122  of shell  64  and position channel  128  generally centered within shell  64 . Ribs  130  also cooperate to define a rear face  134  which engages shelf  120  within shell  64  to limit the depth of insertion of insulator  66  within shell  64 . Each rib  130  also includes a tapered portion  136  to aid the insertion of insulator  66  within shell  64 . Channel  128  includes a tapered entry  138  at rear face  134  to aid the insertion of center conductor  26  within channel  128 . 
   Referring now to  FIGS. 28 and 29 , the assembly of housing assembly  11  begins with the mounting of barrel  36  about fingers  72  of first cable connection  14 . Plug insulator  28  is inserted into opening  44  of housing  12  and positioned against shoulder  46 . Bearing washer  62  is inserted into barrel  36  through end  84  and positioned against shoulder  88 . Barrel  36  is placed on housing  12  about fingers  72  so that bearing washer  62  is positioned against barrel ledge  60 . Wave washer  58  is inserted over housing  12  into end  84  of barrel  36  and positioned against barrel ledge  60  opposite bearing washer  62 . Crimp washer  56  is inserted over housing  36  into end  84  of barrel  36  and end  84  is compressed to capture crimp washer within barrel  36  and rotatably hold barrel  36  to housing  12 . Center conductor  26  is inserted through opening  32  into central cavity  30  of housing  12  so that plug end  40  enters channel  104  of plug insulator  28 . Center conductor  26  is advanced through channel  104  until shoulder  114  engages recess  106  of insulator  28 . Jack end  38  of center conductor  26  extends through opening  32 . 
   An outer jacket  21  of cable  20  is stripped so that cable center conductor  24  and inner insulation member  54  may be extended through opening  34  of crimp post  52  into central cavity  30 . Cable center conductor  24  is inserted within opening  25  of center conductor  26  and mechanically and electrically connected to center conductor  26 . The connection between cable center conductor  24  and center conductor  26  may be crimped and/or soldered. Outer shield conductor  19  of cable  20  is placed over crimp post  52  and crimp sleeve  50  is placed over outer shield conductor  19  and crimp post  52 . Crimp sleeve  50  is compressed to mechanically and electrically connect outer shield conductor  19  to housing  12  and securely hold cable  20  to housing assembly  11 . 
   Shell  64  is positioned so that mating portion  70  can be inserted into housing  12  through opening  32  and shell  64  is pressed into housing  12 . Housing  12  is made from a conductive material and connecting shell  64  to housing  12  electrically connects shell  64  with the outer shield conductor of cable  20  and also to fingers  72  of first cable connection  14 . Jack insulator  66  is positioned for insertion into shell  64  and center conductor  26  is positioned for jack end  38  to be received within channel  128 . Jack insulator  64  is inserted into shell  64  until rear face  134  engages shelf  120  within shell  64 . 
   Referring now to  FIGS. 30 and 31 , an alternative embodiment  140  of a coaxial cable y-splitter according to the present invention is shown. Cable splitter  140  includes a housing assembly  144  with a housing  142  with first, second and third cable connections  14 ,  16  and  18 , respectively, wherein third connection  18  is a plug BNC connector rather than a jack BNC connector. 
   Although the foregoing invention has been described in detail by way of illustration and example, for purposes of clarity of understanding, it will be obvious that changes and modifications may be practiced which are within the scope of the present invention as embodied in the claims appended hereto.