Abstract:
A connector assembly for interconnection with a mating connector includes a body, a locking nut, and a restraining element. The restraining element rotatably secures the locking nut on the body of the connector assembly. The restraining element can have an annular configuration and be elastically deformable. When this configuration is utilized, the body typically includes a ramp with a groove in juxtaposition thereto. The ramp facilitates both deformation and placement of the restraining element in the groove of the body. Alternatively, the restraining element can have a substantially rigid, tubular configuration and include a flange sized and shaped to engage a portion of the locking nut. This later configuration of the restraining element is designed to be interferingly positioned on the body of the assembly. Also disclosed is a tubular tool element configured to be capable of exerting a substantially equal force upon the restraining element during manufacture of the disclosed connector assembly. The tool element is utilized to align and secure the restraining element on the body during the manufacturing process.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to electrical connectors and, more particularly, is directed toward a cable connector assembly having a coupling nut for securing two mating connector assemblies together and a method for manufacturing the cable assembly.  
           [0003]    2. Description of the Prior Art  
           [0004]    Electrical applications require connector assemblies capable of coupling both wire and cable with minimal detriment to electrical efficiency and signal transmission.  
           [0005]    A wide variety of mating connector assemblies are currently available in the prior art. Generally, one of the connector assemblies includes a connector body with a locking nut rotatably positioned thereon and the other connector assembly has an externally threaded body that is configured to receive the locking nut for securing the mating connector assemblies. The connector bodies provide a terminus for the wire or cable used in a given application. The locking nut permits interconnection of the terminus of one wire or cable, i.e., the body portion of one connector assembly, to the terminus of another wire or cable, i.e., the body portion of another connector assembly.  
           [0006]    In order to provide the desired interconnection, the locking nut must be securely positioned on the body portion of the connector assembly. In the prior art, the locking nut is typically positioned on the body using, for example, an expandable C-ring. When fully assembled, the C-ring is typically positioned in a pair of axially aligned grooves. That is, the C-ring is captured within grooves cut into the body portion and locking nut of the connector assembly. Heretofore, as discussed below, the positioning of the coupling nut on the cable assembly has been tedious and time consuming.  
           [0007]    Different techniques are typically utilized to manufacture those connector assemblies currently available in the prior art. Although effective, each method suffers from significant limitations that impact on the mechanical and operational characteristics of available connector assemblies.  
           [0008]    In one technique, the locking nut is held to the connector body by means of a C-ring that is inserted through a rectilinear aperture formed in the side of the locking nut. Typically, the rectilinear aperture in the locking nut causes a significant decrease in the overall mechanical strength of the locking nut. In particular, the locking nut can become susceptible to failure as a result of the exertion of shearing or torsional forces.  
           [0009]    In another technique, the locking nut is positioned on the body of the connector assembly. A C-ring is compressed and inserted into the locking nut from the back end of the connector assembly. The compressed C-ring is positioned in alignment with grooves in the connector body and locking nut. Once aligned, the C-ring is released. This technique also requires significant mechanical manipulation of the connector assembly during manufacture. In particular, the C-ring must be kept compressed, and the body/ring combination inserted into the locking nut quickly, so that the C-ring will not expand before it is placed in the locking nut. Should the C-ring expand before placement in the locking nut, the components will not lock together as required. Further, if the components are not aligned properly during the insertion step, the body and the locking nut can become jammed together. This later condition will prevent the locking nut from rotating as desired and impairing the value of the resulting connector assembly.  
           [0010]    A need exists for an improved apparatus and method that does not suffer from the limitations and disadvantages of prior devices. In particular, a need exists for an improved wire or cable connector assembly and an efficient method for the manufacture thereof.  
         SUMMARY OF THE INVENTION  
         [0011]    It is an object of the present invention to provide a connector assembly and a method for the manufacture thereof which does not suffer from the foregoing disadvantages and limitations.  
           [0012]    It is another object of the present invention to provide an improved cable connector assembly having a coupling nut for securing two mating connector assemblies together.  
           [0013]    It is a further object of the present invention to provide a method that facilitates the manufacture of a cable connector assembly having a locking nut for securing two mating connector assemblies together.  
           [0014]    It is yet another object of the invention to provide an apparatus and method that can be used with a variety of wire or cable substrates.  
           [0015]    It is yet a further object of the invention to provide an apparatus for interconnecting wire or cable that is simple in construction and compact in design.  
           [0016]    It is still yet another object of the present invention to provide an apparatus for interconnecting wire or cable that is easily and economically produced, and readily assembled.  
           [0017]    It is still yet a further object of the present invention to provide a method that facilitates the automated manufacture of a cable connector having a locking nut by securing the locking nut to the connector by means of a restraining element that is inserted through the front end of the connector.  
           [0018]    Other general and specific objects of the invention will in part be obvious and will in part appear hereinafter.  
           [0019]    The invention is generally characterized by a connector assembly having a body, a locking nut, and a restraining element. The connector assembly of the present invention is configured so as to be matingly engaged and disengaged from a complementary connector assembly.  
           [0020]    The body of the connector assembly of the invention generally has two ends. One end of the body is free and can be connected to the body portions of other complementarily configured connector assemblies. The other end of the body is connected to a wire or cable as desired. The body can have a variety of configurations depending on the embodiment of the invention utilized.  
           [0021]    In one embodiment of the invention, the body includes a ramp and a groove element. Preferably, the ramp has a frusto-conical configuration. More particularly, the ramp has a first portion and a second portion. The first portion is typically formed in the free end of the body. The first portion generally has a cross-sectional dimension that is smaller than the cross-sectional dimension of the second portion. The groove element is formed in the second portion of the ramp. Preferably, the groove element is dimensioned such that its size is intermediate that of the first portion of the ramp and the second portion of the ramp.  
           [0022]    In another embodiment of the invention, the body has a substantially uniform cross-sectional configuration. In this embodiment, the body is sized such that it can frictionally engage the restraining element which is discussed in detail below. The body includes a groove element that is configured to receive a washer having an annular configuration. The washer functions to assist in forming a watertight or gas-tight seal. The washer can also function to prevent the migration of debris into the connector assembly of the invention. The washer is elastically deformable so that it may be easily positioned in the groove element.  
           [0023]    The locking nut is captively held on the body. The locking nut generally has an open end and a closed end. The open end permits joining of the connector assembly of the invention to a complementarily configured connector assembly. The closed end is typically configured to engage the body of the connector assembly of the invention. More particularly, the closed end of the locking nut generally has an inwardly extending flange that interacts with the body and restraining element to rotatably and captively secure the locking nut on the body.  
           [0024]    The restraining element can have a variety of configurations depending upon the type of body employed in a given embodiment of the invention.  
           [0025]    In one embodiment of the invention, the restraining element has an annular configuration and is composed of a substantially rigid, elastically deformable material that is deformable from a relaxed state to an expanded state. This configuration for the restraining element is typically utilized in connection with an embodiment of the invention in which the body has a ramp and groove element as described above. In this configuration, the restraining element is sized and shaped such that when it is in its relaxed state it can be received on the first portion of the ramp of the body. The restraining element is slidable on and along the ramp and, as it does so, the restraining element typically expands from its relaxed state to its expanded state. The restraining element contracts back toward its relaxed state when it is moved into the groove element. Thus, when the connector assembly of the invention is fully assembled the restraining element is captively held in the groove element.  
           [0026]    In an alternative embodiment of the invention, the restraining element has a configuration that is substantially identical to that of the body. Such a similarity of configuration is required so that the restraining element can be interferingly received by the body. Although this configuration of the restraining element is typically annular, virtually any configuration can be used so long as it compliments the external configuration of the body so that the restraining element and body can be frictionally engaged and fixed against relative movement. In this embodiment of the invention, the restraining element typically includes a portion that engages the flange on the locking nut as described above. In this way, the restraining element serves to secure and captively hold the locking nut in position on the body. Operationally, this embodiment of the restraining element is press-fitted onto the body such that the two components resistively engage each other.  
           [0027]    The invention also contemplates a method for manufacturing the connector assembly of the invention. To commence the method of the invention, a body, restraining element, and locking nut having configurations as described above are obtained. The restraining element utilized will, of course, depend upon the type of body to be utilized in a given application. In the next step, the locking nut is mounted on the body. The restraining element is then coaxially and concentrically aligned with the body as required. To complete the method of the invention, the restraining element is pushed on and over the body until such time as the locking nut is rotatably restrained between the restraining element and the body.  
           [0028]    The method of the invention further contemplates the usage of a tool element. This tool element is configured to apply a selected force to the restraining element so that the restraining element is pushed with an even and consistent force axially onto the body.  
           [0029]    The invention accordingly comprises the steps and apparatus embodying features of construction, combinations of elements and arrangements of parts adapted to affect such steps, as exemplified in the following detailed disclosure, the scope of the invention being indicated in the accompanying claims.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]    A fuller understanding of the nature and objects of the present invention will become apparent upon consideration of the following detailed description taken in connection with the accompanying drawings in which:  
         [0031]    [0031]FIG. 1 is a side cutaway view of a first embodiment of the connector assembly of the invention wherein the body of the connector assembly of the invention incorporates a ramp and groove element;  
         [0032]    [0032]FIG. 2 is a side cutaway view of a second embodiment of the connector assembly of the invention wherein the restraining element is resistively held in position on the body of the connector assembly of the invention;  
         [0033]    [0033]FIG. 3 is a side cutaway view of a third embodiment of the connector assembly of the invention wherein the restraining element is resistively held in position on the body of the connector assembly of the invention and the restraining element encases a substantial portion of the body of the connector assembly of the invention; and  
         [0034]    [0034]FIG. 4 is a perspective view of a tool useful in the method of the invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]    Referring now to FIGS. 1 through 3, there is shown a connector assembly  10  embodying the invention. The connector assembly of the invention  10  generally includes a body  12 , a locking nut  14 , and a restraining element  16 . The body  12  provides a terminus for the wire or cable substrate  18  upon which the connector assembly of the invention  10  is positioned. The locking nut  14  provides a means for mechanically coupling the connector assembly of the invention  10  to a complementarily configured connector assembly. Finally, the restraining element  16  functions to secure and captively hold the locking nut  14  on the body  12 .  
         [0036]    Referring now to FIG. 1, it will be seen that the body  12  has two ends. More particularly, the body  12  has a first end  20  that is configured to be connected to another complementarily configured connector assembly. The second end  22  is affixed to a wire or cable substrate  18 . The body  12  includes a ramp  26  and a groove element  28 . The first end  20  of the body  12  typically has a cylindrical configuration. This configuration is desired as it facilitates rotatably securing the locking nut  14  in position on the body  12  in the manner described in detail below. The second end  22  also, typically, has a cylindrical configuration. Those skilled-in-the-art will appreciate, however, that the second end  22  of the body  12  can have virtually any cross-sectional configuration depending upon the application in which the connector assembly of the invention  10  is employed. The second end  22  of the body  12  typically has a cross-sectional dimension that is greater than the cross-sectional dimension of the first end  20 . This increase in cross-sectional dimensions between the first end  20  and second end  22  creates a facing surface  24 . The facing surface  24  cooperates with the restraining element  16  described below to secure the locking nut  14  rotatably in position on the body  12 . The body  12  typically is manufactured from a metal substrate, however, virtually any material having the desired mechanical strength may be employed.  
         [0037]    The ramp  26  may be located in close proximity to the terminus of the free end  20  of the body  12 . Alternatively, as shown in FIG. 1, the ramp  26  may be located distal to the terminus of the free end  20  of the body  12 . Preferably, the ramp  26  has a frusto-conical configuration. More particularly, the ramp  26  has a first portion  30  and a second portion  32 . The first portion  30  of the ramp  26  preferably has a cross-sectional dimension that is less than the cross-sectional dimension of the second portion  32  of the ramp  26 .  
         [0038]    The groove element  28  is formed in the second portion  32  of the ramp  26 . Preferably, the groove element  28  is dimensioned such that its cross-sectional dimension is intermediate the cross-sectional dimension of either the first portion  30  or the second portion  32 . The groove element  28  has an external configuration complementary to the configuration of the restraining element  16  discussed in detail below.  
         [0039]    If desired, as shown in FIG. 1, the body  12  may also include a second groove element  34 . This second groove element  34  is typically located in close proximity to the terminus of the free end  20 . The second groove element  34  is, preferably, positioned in advance of the first portion  30  of the ramp  26 . The second groove element  34  preferably is configured to captively receive a washer  36 . In operation, once positioned, the washer  36  functions to provide a watertight or gas-tight seal between the connector assembly of the invention  10  and the mating connector to which it is interconnected. The washer  36  also functions to prevent the migration of debris into the inner workings of the connector assembly of the invention  10 .  
         [0040]    As noted above, the locking nut  14  is rotatably secured on the body  12 . The locking nut  14  typically provides an encasement for at least a portion of the free end  20  of the body  12 . Typically, the locking nut  14  has a first open end  38  and a second closed end  40 . Extending radially, inwardly from the second closed end  40  is a flange  42 . As shown in FIG. 1, the flange  42  on the locking nut  14  interacts with the facing surface  24  of the body  12  and the restraining element  16  to rotatably secure the locking nut  14  in position on the body  12 .  
         [0041]    In the embodiment of the invention shown in FIG. 1, the restraining element  16  has an annular configuration. The restraining element  16  is formed from a substantially rigid, elastically deformable material for example, metal, plastic or rubber. The restraining element  16  preferably can be deformed from a relaxed state to an expanded state. The restraining element  16  retains, however, a memory of its relaxed state and, thus, returns toward that state when captured in the groove element  28 . The cross-sectional configuration ofthe restraining element  16  is substantially identical to the external configuration of the first end  20  of the body  12 . Preferably, the restraining element  16  is sized and shaped such that when it is in its relaxed state it can be received on the first portion  30  of the ramp  26  of the body  12 . The restraining element  16  is slidable on and along the ramp  26  and, as it does so, the restraining element  16  typically expands from its relaxed state to its expanded state. As noted above, the restraining element  16  contracts back toward its relaxed state when it is moved into the groove element  28 . Thus, when the connector assembly of the invention  10  is fully assembled the restraining element  16  is captively held in the groove element  28 .  
         [0042]    A second embodiment of the invention is depicted in FIG. 2. The configuration of the body  12  is substantially the same as that discussed in connection with FIG. 1. For example, the body  12  shown in FIG. 2 also has a first end  20 , designed to be connected to another complementarily configured connector assembly, and a second end  22 , which can be affixed to a wire or cable substrate  18 . The body  12  of FIG. 2, however, has a substantially cylindrical configuration along its entire length. In the first instance, this substantially cylindrical configuration is desired as it facilitates rotatably securing the locking nut  14  in position on the body  12 . This configuration is also desired as it permits resistively positioning the restraining element  16  on the body  12 . The second end  22  has a cylindrical configuration. Those skilled-in-the-art will appreciate, however, that the second end  22  of the body  12  can have virtually any cross-sectional configuration depending upon the application in which the connector assembly of the invention  10  is employed. In the embodiment of the invention as shown in FIG. 2, the second end  22  of the body  12  typically also has a cross-sectional dimension that is greater than the cross-sectional dimension of the first end  20 . This increase in cross-sectional dimensions between the first end  20  and second end  22  also creates a facing surface  24 . Like the facing surface  24  of FIG. 1, the facing surface  24  of FIG. 2 cooperates with the restraining element  16  to secure the locking nut  14  in position on the body  12 . The body  12  typically is manufactured from a metal substrate, however, virtually any material having the desired mechanical strength may be employed.  
         [0043]    If desired, as shown in FIG. 2, the body  12  can include a groove element  50 . When used, the groove element  50  is positioned such that it is located between the terminus of the free end  20  of the body  12  and a forward edge of the restraining element  16  as described in detail below. The groove element  50  is configured to receive a washer  52  having an annular configuration. The washer  52  typically has a myriad of functions. For example, the washer  52  often functions to assist in forming a watertight or gas-tight seal. The washer  52  can also function to prevent the migration of debris into the connector assembly of the invention  10 . The washer  52  is generally annular in configuration and is formed from an elastically deformable substrate material, e.g., rubber or plastic, so that it may be easily positioned in the groove element  50 .  
         [0044]    The locking nut  14  is configured substantially identical to that described in connection with FIG. 1. The locking nut  14  has a first open end  38  and a second closed end  40 . The open end  38  again provides a partial encasement for the body  12 . Extending inwardly and radially from the second end  40  is a flange  42 . The flange  42  cooperates with the restraining element  16  and a facing surface  43  formed in the body  12  to limit the travel of the restraining element as it is pushed onto the body so that the locking nut is freely rotatable when secured on the body.  
         [0045]    The restraining element  16  utilized in connection with the embodiment of the invention shown in FIG. 2 has a configuration that is substantially identical to the external configuration of the body  12 . Such similarity of configuration is required so that the restraining element  16  can be interferingly received on the body  12 . Although this configuration of the restraining element  16  is typically annular, virtually any configuration can be used so long as it compliments the external configuration of the body  12  so that the restraining element and body can be frictionally engaged and fixed against relative movement. In the embodiment of the invention shown in FIG. 2, the restraining element  16  has a first portion  54  and a second portion  56 . The first portion  54  of the restraining element  16  is configured to engage the flange  42  on the locking nut  14 . In this way, the restraining element  16  serves to secure and captively hold the locking nut  14  in position on the body  12 . That is, the locking nut  14  is captured between the first portion  54  of the restraining element  16  and the facing surface  24  of the body  12 . The second portion  56  of the restraining element  16  abuts the washer  52 . Operationally, this embodiment of the restraining element  16  is press-fitted onto the body such that the restraining element  16  and body  12  interferingly and resistively engage each other.  
         [0046]    A third embodiment of the invention is depicted in FIG. 3. The configuration of the body  12  is substantially the same as that discussed in connection with FIGS. 1 and 2. For example, the body  12  shown in FIG. 3 also has a first end  20 , designed to be connected to another complementarily configured connector assembly, and a second end  22 , which can be affixed to a wire or cable substrate  18 . The body  12  of FIG. 3, however, has a substantially cylindrical configuration along its entire length. The substantially cylindrical configuration is desired as it facilitates rotatably securing the locking nut  14  in position on the body  12  by permitting the resistive positioning of the restraining element  16  on the body  12 . The second end  22  has a cylindrical configuration. Those skilled-in-the-art will appreciate, however, that the second end  22  of the body  12  can have virtually any cross-sectional configuration depending upon the application in which the connector assembly of the invention  10  is employed. In the embodiment of the invention as shown in FIG. 3, the second end  22  of the body  12  typically also has a cross-sectional dimension that is greater than the cross-sectional dimension of the first end  20 . This increase in cross-sectional dimensions between the first end  20  and second end  22  also creates a facing surface  24 . Like the facing surface  24  of FIGS. 1 and 2, the facing surface  24  of FIG. 3 cooperates with the restraining element  16  to secure the locking nut  14  in position on the body  12 . The body  12  typically is manufactured from a metal substrate, however, virtually any material having the desired mechanical strength may be employed.  
         [0047]    The locking nut  14  is configured substantially identical to that described in connection with FIGS. 1 and 2. The locking nut  14  has a first open end  38  and a second closed end  40 . The open end  38  again provides a partial encasement for the body  12 . Extending inwardly and radially from the second end  40  is a flange  42 . The aperture created by the inwardly extending flange  42  is sufficient, however, to accommodate not only the free end  20  of the body  12  but the restraining element  16  as well. The flange  42  cooperates with the restraining element  16  and the facing surface  24  of the body  12  to secure the locking nut  14  in position.  
         [0048]    The restraining element  16  utilized in connection with the embodiment of the invention shown in FIG. 3 has a configuration that is substantially identical to the external configuration of the body  12 . Such similarity of configuration is required so that the restraining element  16  can be interferingly received on the body  12 . Although this configuration of the restraining element  16  is typically cylindrical, virtually any configuration can be used so long as it compliments the external configuration of the body  12  so that the restraining element and body can be frictionally engaged or soldered together and fixed against relative movement.  
         [0049]    In the embodiment of the invention, shown in FIG. 3, the restraining element  16  has a first portion  54  and a second portion  56 . Operationally, this embodiment of the restraining element  16  is press-fitted onto the body such that the restraining element  16  and body  12  interferingly and resistively engage each other.  
         [0050]    A section of the first portion  54  extends through the aperture created by the inwardly extending flange  42  of the locking nut  14  and abuts the body  12 . Structurally, the first portion  54  of the restraining element  16  includes a flange  90 . The flange includes a facing surface  92 . The facing surface  92  is configured to engage an inner surface of the flange  42  on the locking nut  14 . In this way, the restraining element  16  serves to secure the locking nut  14  in position on the body  12 . That is, the locking nut  14  is captured between the facing surface  92  of the first portion  54  of the restraining element  16  and the facing surface  24  of the body  12 . The first portion  54  also includes an end surface  94  configured to engage a facing surface  95  formed in the body  12 . The end surface  94  facilitates proper seating of the restraining element  16  on the body  12 .  
         [0051]    The second portion  56  of the restraining element  16  includes a radially inwardly extending flange  96 . The flange  96  is configured to engage the body  12 . Like the end surface  94  of the first portion  54 , the flange  96  of second portion  56  functions to assist in properly seating the restraining element  16  on the body  12 .  
         [0052]    The invention also contemplates a method for manufacturing the connector assembly ofthe invention  10 . To commence the method of the invention shown in FIG. 1, a body  12 , restraining element  16 , and locking nut  14  having configurations as described above are obtained. The restraining element  16  utilized will, of course, depend upon the type of body  12  to be utilized in a given application. In the next step, the locking nut  14  is mounted on the body  12 . The restraining element  16  is then coaxially and concentrically aligned with the front or free end of the body  12 . To complete the method of the invention, restraining element  16  is pushed on and up ramp  30  until such time as the restraining element is received in groove  28 , whereby locking nut  14  is rotatably restrained between the restraining means and facing surface  24  of body  12 .  
         [0053]    The method of the invention also contemplates the usage of a tool element  80  depicted in FIG. 4. The tool element  80  is configured to apply a selected force to the restraining element  16  so that the restraining element  16  is pushed with an even and consistent force axially onto the body  12 . Typically, for use of tool  80  for installation of restraining element  16  in the embodiment of the invention shown in FIG. 1, tool  80  has a series of tangs  82 . The tangs  82  flex outwardly as force is applied to the restraining element  16 , and movement on and over the body  12  is effected. In this way, the tool  80  is able to move over the length of the body  12  without becoming bound onto the surface thereof.  
         [0054]    The invention also contemplates a method for manufacturing the connector assembly of the invention  10  shown in FIG. 2. To commence the method of the invention shown in FIG. 2, a body  12 , restraining element  16 , and locking nut  14  having configurations as described above are obtained. The restraining element  16  utilized will, of course, depend upon the type of body  12  to be utilized in a given application. In the next step, the locking nut  14  is mounted on the body  12 . The restraining element  16  is then coaxially and concentrically aligned with the front or free end of the body  12 . To complete the method of the invention, the restraining element  16  is pushed onto the body  12  until it engages the facing surface  43 . Restraining element  16  and body  12  are in tight frictional engagement and constrained against relative movement. Locking nut  14  is rotatably restrained between the restraining means  16  and the facing surface  24  of the body  12 .  
         [0055]    The invention also contemplates a method for manufacturing the connector assembly of the invention  10  shown in FIG. 3. To commence the method of the invention shown in FIG. 3, a body  12 , restraining element  16 , and locking nut  14  having configurations as described above are obtained. The restraining element  16  utilized will, of course, depend upon the type of body  12  to be utilized in a given application. In the next step, the locking nut  14  is mounted on the restraining element  16 . The restraining element  16  is then coaxially and concentrically aligned with the front or free end of the body  12 . To complete the method of the invention, the restraining element  16  is pushed onto the body  12  until it engages the facing surface  95 . Restraining element  16  and body  12  are in tight frictional engagement or soldered together and constrained against relative movement. Locking nut  14  is rotatably restrained between the facing surface  92  ofthe restraining means  16  and the facing surface  24  of the body  12 .  
         [0056]    It will be understood that changes may be made in the above construction and in the foregoing sequences of operation without departing from the scope of the invention. It is accordingly intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative rather than in a limiting sense.  
         [0057]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention as described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between.