Patent Publication Number: US-8986044-B2

Title: Quick mount connector for a coaxial cable

Description:
RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 61/719,106 filed on Oct. 26, 2012 the content of which is relied upon and incorporated herein by reference in its entirety. 
     This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 61/728,484 filed on Nov. 20, 2012 the content of which is relied upon and incorporated herein by reference in its entirety. 
     This application is related to U.S. Application No. 61/583,385, filed Jan. 5, 2012, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field of the Disclosure 
     The disclosure relates generally to coaxial cable connectors, and particularly to quick mount Type F connectors for use with minimally prepared coaxial cables. 
     2. Technical Background 
     Coaxial cable connectors such as F-connectors are used to attach coaxial cables 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 ( FIG. 1 ). The F-connector is typically 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 with a threaded terminal of a terminal block. 
     Crimp style F-connectors are known wherein a crimp sleeve is included as part of the connector body. A special radial crimping tool, having jaws that form a hexagon, is used to radially crimp the crimp sleeve around the outer jacket of the coaxial cable to secure such a crimp style F-connector over the prepared end of the coaxial cable. 
     Still another form of F-connector is known wherein an annular compression sleeve is used to secure the F-connector over the prepared end of the cable. Rather than crimping a crimp sleeve radially toward the jacket of the coaxial cable, these F-connectors employ a plastic annular compression sleeve that is initially attached to the F-connector, but which is detached therefrom prior to installation of the F-connector. The compression sleeve includes an inner bore for allowing such compression sleeve to be passed over the end of the coaxial cable prior to installation of the F-connector. The end of the coaxial cable must be prepared by removing a portion of the outer braid and/or folding the outer braid back over the cable jacket. The F-connector itself is then inserted over the prepared end of the coaxial cable. Next, the compression sleeve is compressed axially along the longitudinal axis of the connector into the body of the connector, simultaneously compressing the jacket of the coaxial cable between the compression sleeve and a tubular post of the connector. An example of such a compression sleeve F-connector is shown in U.S. Pat. No. 4,834,675 to Samchisen A number of commercial tool manufacturers provide compression tools for axially compressing the compression sleeve into such connectors. 
     Referring to  FIGS. 1 ,  1 A, and  1 B, a coaxial cable  100  is illustrated and the method in which the end of the coaxial cable  100  is prepared. Referring to  FIG. 1 , the coaxial cable  100  has a center conductor  102  that is surrounded by a dielectric layer  104 . The dielectric layer (or dielectric)  104  may also have a foil or other metallic covering  106 . Coaxial cable  100  then has a braided outer conductor  108  which is covered and protected by a jacket  110 . Typically, to prepare the coaxial cable  100  for attachment to a coaxial cable connector, a portion of the center conductor  102  is exposed as illustrated in  FIG. 1A . The jacket  110  is trimmed back so that a portion of the dielectric  104  (and metallic covering  106 ) and braided outer conductor  108  are exposed. The braided outer conductor  108  is then folded back over the jacket  110 , to expose the dielectric (and the metallic covering  106  if present). 
       FIG. 1B  illustrates the coaxial cable of  FIG. 1A  with an end prepared for insertion into coaxial connector  10 . The connector  10  has a coupler  11  beyond which the center conductor  102  extends and is attached to a body  13 . A post  12  used to secure the coaxial cable  100  relative to the coaxial connector  10  is positioned inside body  13 . As can be seen in  FIG. 1B , the post  12  is inserted into cable  100  between the braided outer conductor  108  and dielectric  104 . The post  12  can cause problems for the coaxial connector  10  as well as the installer. In addition to an installer having to prepare the end of the coaxial cable  100 , which requires time and effort, the post  12  can skive the coaxial cable  100 , tearing the braided outer conductor  108  or the jacket  110 . Additionally, it can be difficult to insert the post  12  into the coaxial cable  100 . 
     It is known in the coaxial cable field, generally, that collars or sleeves within a coaxial cable connector can be compressed inwardly against the outer surface of a coaxial cable to secure a coaxial cable connector thereto. For example, in U.S. Pat. No. 4,575,274 to Hayward, a connector assembly for a signal transmission system is disclosed wherein a body portion threadedly engages a nut portion. The nut portion includes an internal bore in which a ferrule is disposed, the ferrule having an internal bore through which the outer conductor of a coaxial cable is passed. As the nut portion is threaded over the body portion, the ferrule is wedged inwardly to constrict the inner diameter of the ferrule, thereby tightening the ferrule about the outer surface of the cable. However, the connector shown in the Hayward &#39;274 patent can not be installed quickly, as by a simple crimp or compression tool. Rather, the mating threads of such connector must be tightened, as by using a pair of wrenches. Additionally, the end of the coaxial cable must be prepared by stripping back the outer jacket and the conductive grounding sheath, all of which takes time, tools, and patience. 
     SUMMARY OF THE DETAILED DESCRIPTION 
     Embodiments disclosed herein include a coaxial cable connector for coupling an end of a coaxial cable to a terminal. The coaxial cable has an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor. The coaxial cable connector may comprise a coupler, a body, a shell, a ferrule, and a compression ring. The body may have an internal surface extending between front and rear ends of the body. The internal surface defines a longitudinal opening. The body may be rotatably attached to the coupler. The shell may have an outer surface and an internal surface, the internal surface defining an opening through the shell. The internal surface of the shell may slidingly engage at least a portion of the rear end of the body. The ferrule may be disposed adjacent to the body and have a plurality of fingers with inwardly directed engagement features, such as barbs, and a channel with a wall having an inwardly facing surface with inner projections. The compression ring may be disposed within the shell and may engage the rear end of the ferrule. The compression ring may have an internal surface. Advancing the shell toward the coupler may cause the compression ring to drive the rear portion of the ferrule inwardly. This may cause the plurality of fingers to flex inwardly toward the coaxial cable forcing the engagement features against the coaxial cable. This also may cause the compression ring to provide a biasing force against the channel forcing the inner projections of the inwardly facing surface of the wall to bite into the coaxial cable. 
     The coaxial cable connector may also comprise a retainer a contact and an insulator. The retainer may seat in a retainer channel in the body. The retainer provides a biasing force to rotatably attach the body to the coupler. The contact may have an attachment portion, adapted to retain and be mechanically connected to and be electrically continuous with the inner conductor of the coaxial cable. The insulator may position around the contact and friction fit to the internal surface of the body. 
     Additional features and advantages are set out 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, 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 one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial cross section of a coaxial cable as is known in the prior art; 
         FIG. 1A  is a partial cross section of the coaxial cable of  FIG. 1  with the end prepared for installation in a coaxial cable connector; 
         FIG. 1B  is a partial cross section of a prior art coaxial connector with a coaxial cable prepared as shown in  FIG. 1A  installed therein; 
         FIG. 2  is an exploded, perspective view of an exemplary embodiment of a coaxial connector; 
         FIG. 3  is a cross sectional view of the assembled coaxial cable connector of  FIG. 2 ; 
         FIG. 4  is a detail, cross sectional view of an exemplary embodiment of a ferrule in coaxial cable connector of  FIGS. 2 and 3 ; 
         FIG. 5  is a partial cross sectional view of a coaxial cable with the end prepared; 
         FIG. 6  is a cross sectional view of the coaxial cable connector of  FIGS. 2 and 3  in an un-compressed or open condition with the prepared coaxial cable of  FIG. 5  inserted therein; 
         FIG. 7  is a cross sectional view of the coaxial cable connector of  FIGS. 2 and 3  and the prepared coaxial cable of  FIG. 5  inserted therein with the coaxial cable connector fully engaged with the coaxial cable; 
         FIG. 8  is a cross sectional view of an exemplary embodiment of a coaxial cable connector; 
         FIG. 9  is a cross sectional view of the coaxial cable connector of  FIG. 8  and the prepared coaxial cable of  FIG. 5  inserted therein with the coaxial cable connector fully engaged with the coaxial cable; 
         FIG. 10  is a cross sectional view of an exemplary embodiment of a coaxial cable connector; 
         FIG. 11  is a cross sectional view of the coaxial cable connector of  FIG. 10  and the prepared coaxial cable of  FIG. 5  inserted therein with the coaxial cable connector fully engaged with the coaxial cable. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all embodiments are shown. Indeed, the concepts may be embodied in many different forms and should not be construed as limiting herein. Whenever possible, like reference numbers will be used to refer to like components or parts. 
     Embodiments disclosed herein include a coaxial cable connector for coupling an end of a coaxial cable to a terminal. The coaxial cable has an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor. In various embodiments, the coaxial cable connector may comprise, for example, a coupler, a body, a shell, a ferrule, and a compression ring. The body may have an internal surface extending between front and rear ends of the body, with the internal surface defining a longitudinal opening. The body may also advantageously be rotatably attached to the coupler, with the shell having an outer surface, and an internal surface defining an opening through the shell. The internal surface of the shell may slidingly engage at least a portion of the body, and with the ferrule being disposed adjacent to the body and comprising one of more fingers with inwardly directed engagement features, such as, for example, barbs, and a channel with a wall having an inwardly facing surface with inner projections. The compression ring may have an internal surface and be disposed within the shell for engaging the rear end of the ferrule. 
     The coaxial cable connector may also comprise a retainer a contact and an insulator. The retainer may seat in a retainer channel in the body. The retainer provides a biasing force to rotatably attach the body to the coupler. The contact may have an attachment portion, adapted to retain and be mechanically connected to and be electrically continuous with the inner conductor of the coaxial cable. The insulator may position around the contact and friction fit to the internal surface of the body. 
     Referring now  FIGS. 2 and 3 , there is shown a coaxial cable connector  200 .  FIG. 2  is an exploded, cross sectional view, while  FIG. 3  is an assembled cross sectional view. Both views illustrate coaxial cable connector  200  unengaged or, in other words, without a coaxial cable inserted therein. Coaxial cable connector  200  has coupler  202 , body  204 , contact  206 , ferrule  208 , compression ring  210 , shell  212 , O-ring  214 , retainer  216 , seal  218 , insulator  220 , and O-ring  221 . 
     Body  204  extends between front end  222  and rear end  224  defining longitudinal opening  226 . Body  204  also has outer surface  228  and inner surface  230 . Inner surface  230  includes first bore  232  and second bore  234 . Insulator  220  positions around contact  206  and press or friction fits to body  204  at inner surface  230  at thickened wall portion  236  of inner surface  230 . Thickened wall portion  236  along with annular projection  238  separates first bore  232  from second bore  234 . Rearward face  240  of annular projection  238  provides a stop for insulator  220 . Retainer  216  seats in retainer channel  242  of body  204  and provides a biasing force to rotatably attach and secure body  204  to coupler  202 . 
     Shell  212  has outer surface  244  and internal surface  246  defining opening  248  therethrough. Shell  212  has a front end  250  and rear end  251 . Annular ring  252  engages and is retained on body  204  by annular projection  254 . In this manner, shell  212  is slidably connected to body  204 . Shell  204  may be made from brass, or any other appropriate material. 
     Compression ring  210  is disposed within opening  248  of shell  212 . Compression ring  210  has front end  256  and rear end  258 , outer surface  260  and internal surface  262 . Front end  256  has tapered surface  263 . Outer surface  260  of compression ring  210  is disposed against internal surface  246  of shell  212 . Compression ring  210  has tapered surface  264  proximate rear end  258 . O-ring  221  positions between rear end  258  of compression ring  210  and rear end  251  of shell  212  within opening  248 . O-ring  221  provides for environmental protection of coaxial connector  200  at shell  212  when coaxial cable is inserted into shell  212  as described below. 
     Ferrule  208  has front portion  268  and rear portion  270  and is disposed within opening  248  of shell  212 . Ferrule  208  has front end  272  which may be disposed against rear end  224  of body  204  and rear end  274 . Rear end  274  has tapered surface  275  to match and position against tapered surface  264  of compression ring  210 . Additionally, a portion of front portion  268  and rear portion  270  may be disposed within and against internal surface  262  of compression ring  210 . 
     Coupler  202  has front end  276 , back end  278 , and opening  280  extending therebetween. Opening  280  of coupling portion  202  has internal surface  282 . Internal surface  282  includes threaded portion  284 . Coupler  202  has inwardly lip  288  which rotatably meets body  204  at thickened wall portion  236 . Coupler  202  has smooth outer surface  290  adjacent front end  276  and may have hexagonal configuration adjacent back end  278 . Coupler  202  may be made from a metallic material, such as brass, and may be plated with a conductive, corrosion-resistant material, such as nickel, but it may be made from any appropriate material. Opening  280  receives O-ring  214 , which locates around body  204  proximate first end  222  of body  204  at forward face  241  of thickened wall portion  236 . O-ring  214  provides for environmental protection of coaxial connector  200  at coupler  202  when the coupler  202  is connected to an equipment port (not shown). 
     Referring now to  FIG. 4 , a detail cross section of ferrule  208  is illustrated. Front portion  268  has wall  300  defining passage  302  which extends from front end  272  to rear portion  270 . Rear portion  270  has at least one finger and may in some embodiments comprise a plurality of fingers  304  extending circumferentially around rear portion  270 . Fingers  304  are defined by longitudinal slots  306  extending from rear end  274  of ferrule  208  through rear portion  270  and partially into front portion  268 . Slots  306  end prior to front end  272  of front portion  268 . Front portion  268  connects with rear portion  270  at step  308 . Front end  272  may have a forward facing tapered surface  310  extending to flange  312 . Step  308  may have a rearward facing tapered surface  314 . Rearward facing tapered surface  314  may be disposed against tapered surface  263  of first end  256  of compression ring  210 . Flange  312  and step  308  may form channel  316 . Fingers  304  may have inwardly facing barbs  318 . Wall  300  has an inner surface  319  with inward projections  320 . 
     Body  204 , coupler  202 , ferrule  208 , back nut  502  and compression ring  210 , may be made of metal such as, without limitation, brass and preferably plated with a conductive material such as nickel-tin. Shell  212  and gripping member  504  may be made of plastic such as, without limitation, acetal. Retaining ring  216  may be made from a brass alloy such as ECO Brass and may or may not be plated or coated. Insulator  220  is preferably made of plastic such as, without limitation, polymethylpentene also known as TPX® Polymethylpentene available from Mitsui Chemicals America, Inc., Rye Brook, N.Y. Contact  206  is preferably made of a copper alloy such as beryllium copper and preferably plated with a conductive material such as nickel-tin 
       FIG. 5  illustrates coaxial cable  400  in a prepared state for use with coaxial cable connector  200 . Coaxial cable  400  is substantially like coaxial cable  100  noted above. However, it is different as to how the cable end is prepared for use. As illustrated in  FIG. 5 , coaxial cable  400  has center conductor  402  that is surrounded by dielectric layer  404 . Coaxial cable  400  has braided outer conductor  408  which is covered and protected by jacket  410 . In  FIG. 5 , dielectric layer  404  is not visible as it may be cut flush with, and, thereby, covered by, braided outer conductor  408 . Dielectric layer (or dielectric)  404  may also have foil or other metallic covering (also covered by braided outer conductor  408 ). From the end  412  of coaxial cable  400 , center conductor  402  is exposed by removing dielectric layer  404 , foil or other metallic covering, braided outer conductor  408 , and jacket  410 . A second portion of the coaxial cable  400  then has only jacket  410  removed, leaving dielectric layer  404 , foil or other metallic covering and braided outer conductor  408  intact. As will be appreciated by those skilled in the art, however, due to the distinctive features of connector  200 , as discussed herein, braided outer conductor  408  of coaxial cable  400  does not have to be folded back over jacket  410 , resulting in less time than other methods of preparation. 
     The assembly of coaxial cable connector  200  will now be discussed with reference to  FIGS. 6 and 7 . As can be seen in  FIG. 6 , prepared coaxial cable  400  is inserted through opening  248  of shell  212 , through rear portion  270  of ferrule  208 , and, therefore, through compression ring  210 . Dielectric  404  and outer conductor  408  terminate at rear end  224  of body  204  at inner surface  319  of wall  300 . Inner conductor  402  extends through and beyond front end  272  of ferrule  208  into contact  206  and is retained by attachment portion  207  of contact  206 . In this way, electrical and mechanical continuity and connection is established between contact  206  and inner conductor  402 . 
       FIG. 7  illustrates the coaxial cable connector  200  in fully engaged stage. After the coaxial cable  400  is inserted into the coaxial cable connector  200  as described above with reference to  FIG. 6 , the rear end  251  of the shell  212  is slidingly advanced over outer surface of body  204  toward coupler  202 . The annular ring  252  of the shell  212  engages the retaining groove  253  of body  204  and prevents the backward movement of the shell  204  relative to the body  202 . Shell  204  engages the compression ring  210  causing the tapered surface  264  proximate back end  258  of compression ring  210  to engage tapered surface  275  of rear end  274  of ferrule  208 . The force of tapered surface  264  on tapered surface  275  drives the rear portion  270  of ferrule  208  inwardly causing fingers  304  to flex inwardly toward coaxial cable  400  forcing barbs  318  against jacket  410 . Similarly, tapered surface  263  of first end  256  of compression ring  210  is forced against rearward facing tapered surface  314  of ferrule  208  providing a biasing force causing inward projections  320  of inner surface  319  of wall  300  to bite into coaxial cable  400  and, particularly, outer conductor  408 . This may also cause inward projections  320  to bite into dielectric  404  underneath outer conductor  408 . In this manner, barbs  318  and inner projections  320  retain coaxial cable  400  in the proper position in the coaxial cable connector  200 . This also provides for appropriate pull strength for the coaxial cable  400 . 
     Referring now to  FIG. 8  an exemplary embodiment of coaxial cable connector  500  is illustrated. Wherever possible, the same numbers for the same components as used for coaxial cable connector  200 , will be used to describe coaxial cable connector  500 . Additionally, components with the same or same or similar function as in coaxial cable connector  200  may not be described again with respect to coaxial cable connector  500 . Coaxial cable connector  500  includes O-ring  214 , O-ring  221 , body  204 ′, coupler  202 , retaining ring  216 , insulator  220 , contact  206 , slotted ferrule  208 ′, back nut  502 , shell  212 ′, gripping member  504 , and compression ring  210 ′. Coupler  202  is rotatably attached to body  204 ′ by means of retaining ring  216 . Back nut  502  contains O-ring  221 , shell  212 ′, gripping member  504 , compression ring  210 ′ and ferrule  208 ′. Back nut  502  is threadedly attached to body  204 ′ or, alternatively may be slideably press fit with body  204 ′. Insulator  220  is press or friction fit within body  204 ′ and houses contact  206  by means of a barbed attachment feature. Body  204 ′, coupler  202 , ferrule  208 , back nut  502  and compression ring  210 ′ may be made of metal such as, without limitation, brass and preferably plated with a conductive material such as nickel-tin. Shell  212 ′ and gripping member  504  may be made of plastic such as, without limitation, acetal. Retaining ring  216  may be made from a brass alloy such as ECO Brass and may or may not be plated or coated. Insulator  220  is preferably made of plastic such as, without limitation, polymethylpentene. Contact  206  is preferably made of a copper alloy such as beryllium copper and preferably plated with a conductive material such as nickel-tin. 
       FIG. 9  illustrates coaxial cable connector  500  in fully engaged stage. Coaxial cable  400  is inserted into coaxial cable connector  500  in the same manner as described above for coaxial cable connector  200  with reference to  FIG. 6 . After coaxial cable  400  is inserted into coaxial cable connector  500 , back nut  502  is advanced toward coupler  202 . Advancing the back nut forces shell  212 ′ against gripping member  504 , which forces gripping member  504  against compression ring  210 ′ causing gripping member  504  to deform towards coaxial cable  400  pressing against jacket  410 . This action also forces compression ring  210 ′ against ferrule  208 ′ in the same manner as described above with respect to the front portion  268  of ferrule  208  with reference to  FIG. 7  providing a biasing force causing inward projections  320 ′ of inner surface  319 ′ of wall  300 ′ to bite into coaxial cable  400  and, particularly, outer conductor  408 , which may also cause inward projections  320 ′ to bite into dielectric  404  underneath outer conductor  408 . In this manner, gripping member  504  and inner projections  320 ′ retain coaxial cable  400  in the proper position in the coaxial cable connector  200  and provide for appropriate pull strength for the coaxial cable  400 . 
     Referring now to  FIGS. 10 and 11 , there is illustrated an exemplary embodiment of coaxial cable connector  600 .  FIG. 10  illustrates coaxial cable connector  600  in an unengaged state, while  FIG. 11  illustrates coaxial cable connector  600  with coaxial cable  400  inserted therein and with the coaxial cable connector  600  in a fully engaged stage. Wherever possible, the same numbers for the same components as used for coaxial cable connectors  200  and  500 , will be used to describe coaxial cable connector  600 . Additionally, components with the same or same or similar function as in coaxial cable connector  200  and  500  may not be described again with respect to coaxial cable connector  600 . Ferrule  208 ″ is disposed against body  204 ″ and has a collapsible groove  602 . As shell  212 ″ is advanced toward coupler  202 , shell  212 ″ engages compression ring  210 ″. Shell  212 ″ forces compression ring  210 ″ against gripping member  504  causing gripping member  504  to deform towards coaxial cable  400  pressing against jacket  410  in the same manner as described above with respect to  FIG. 9 . Additionally, compression ring  210 ″ forces gripping member  504  against ferrule  208 ″ and, thereby, forces ferrule  208 ″ against body  204 ″, causing collapsible groove  602  to collapse driving a portion of ferrule  208 ″ radially inward to engage coaxial cable  400  and, in particular, outer conductor  408 . Ferrule  208 ″ may also engage dielectric  404  underneath outer conductor  408 . Engagement of ferrule  208 ″ with the coaxial cable  400  provides appropriate pull strength for the coaxial cable  400 . 
     Many modifications and other embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. 
     It is intended that the embodiments cover the modifications and variations of the embodiments provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.