Patent Publication Number: US-9419349-B2

Title: Coaxial cable connector having a fastener and anti-rotation projections

Description:
FIELD OF THE INVENTION 
     The present invention is directed to a contact assembly for use with a coaxial cable. In particular, the invention is directed to a coaxial contact assembly which provides a secure electrical connection and which is easy to install. 
     BACKGROUND OF THE INVENTION 
     Electrical connection of an eyelet terminal to a bolt or stud in a vehicle electrical system typically requires manipulation of three pieces: eyelet terminal, nut and tool. The nut is easily dropped, leading to higher scrap cost and possibly impairing the vehicle&#39;s function. A shortage of either eyelet terminals or nuts in a sub-assembly can hold up the entire vehicle assembly operation. Attempting to tighten an eyelet terminal on a stud is difficult and awkward since the terminal tends to rotate with the nut and tool, especially if space constraints require a one-handed operation. 
     One prior art solution to the foregoing problems is the use of an eyelet terminal with a nut rotatably captured over the eyelet. Such captured nut terminals prove useful for low amperage (40-50 amps) applications allowing the use of relatively small gauge wire (e.g. 12 AWG) and thin, easily folded metal blanks for the terminals. 
     It would, therefore, be beneficial to provide a contact assembly for use with a coaxial cable which is easy to assemble and which minimizes the number of components used during assembly. It would also be beneficial to provide such a contact assembly which can be positioned and fastened at the same time, thereby reducing assembly time. 
     SUMMARY OF THE INVENTION 
     An embodiment is directed to a contact assembly for connecting to a coaxial cable. The contact assembly includes a first conductive member, a second conductive member and an insulator. The first conductive member provides a mechanical and an electrical engagement with a metallic shield of the coaxial cable and provides a mechanical engagement with an insulative jacket of the coaxial cable. The second conductive member provides a mechanical and an electrical engagement with a conductive center core of the coaxial cable. The second conductive member has a fastening member rotatably attached thereto. An insulator is positioned and secured between the first conductive member and the second conductive member. The insulator provides electrical isolation between the first conductive member and the second conductive member. In various embodiments, the second conductive member includes a first crimp barrel and a second crimp barrel, with the first crimp barrel provided to make the mechanical and the electrical engagement with the center core of the coaxial cable and the second crimp barrel provided to make the mechanical engagement to a dielectric insulator of the coaxial cable. 
     An embodiment is directed to a contact assembly for connecting to a coaxial cable. The contact assembly includes a first conductive member, a second conductive member and an insulator. The first conductive member includes first crimping tabs and second crimping tabs. The first crimping tabs are provided to make mechanical engagement with an insulative jacket of the coaxial cable. The second crimping tabs are provided to make mechanical and electrical engagement with a metallic shield of the coaxial cable. The second conductive member includes a first crimp barrel and a second crimp barrel. The first crimp barrel is provided to make a mechanical and an electrical engagement with a center core of the coaxial. The second crimp barrel is provided to make a mechanical engagement to a dielectric insulator of the coaxial cable. The insulator is positioned and secured between the first conductive member and the second conductive member. The insulator provides electrical isolation between the first conductive member and the second conductive member. 
     An embodiment is directed to a contact assembly for connecting to a coaxial cable. The contact assembly includes a first conductive member, a second conductive member and an insulator. The first conductive member includes first crimping tabs and second crimping tabs. The first crimping tabs are provided to make mechanical connection with an insulative jacket of the coaxial cable. The second crimping tabs are provided to make mechanical and electrical connection with a metallic shield of the coaxial cable. The first conductive member includes anti-rotation projections which are configured to engage and make electrical connection to a mating component. The second conductive member includes a core engaging portion with a first crimp barrel and a second crimp barrel. The first crimp barrel is provided to make a mechanical and an electrical connection with a center core of the coaxial cable. The second crimp barrel is provided to make a mechanical connection to a dielectric insulator of the coaxial cable. The insulator is positioned and secured between the first conductive member and the second conductive member. The insulator provides electrical isolation between the first conductive member and the second conductive member. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative contact assembly attached to a coaxial cable. 
         FIG. 2  is a bottom perspective view of the contact assembly of  FIG. 1 . 
         FIG. 3  is a top perspective view of the contact assembly of  FIG. 1 . 
         FIG. 4  is a top exploded perspective view of the contact assembly of  FIG. 1 . 
         FIG. 5  is a bottom exploded perspective view of the contact assembly of  FIG. 1 . 
         FIG. 6  is a top perspective view of an alternate illustrative contact assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     It will be understood that spatially relative terms, such as “top”, “upper”, “lower” and the like, may be used herein for ease of description to describe one element&#39;s or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “over” other elements or features would then be oriented “under” the other elements or features. Thus, the exemplary term “over” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     As best shown in  FIGS. 4 and 5 , a contact assembly  10  according to the present invention includes a first conductive member  12 , an insulator  14  and a second conductive member  16 . As best shown in  FIGS. 3 and 6 , the first conductive member  12  is provided in mechanical and electrical engagement with a metallic shield  22  of a coaxial cable  20 . The first conductive member  12  is also provided in mechanical engagement with the insulative jacket  24  of the cable  20 . The second conductive member  16  is provided in mechanical and electrical engagement with a conductive center core  26  of the cable  20 . A dielectric insulator  28  surrounds the core  26  to electrically isolate the core  26  from the shield  22 . As coaxial cables  20  are known in the art, a further explanation of the cable  20  will not be provided. The assembly  10  is attachable to any suitable mating component such that the assembly  10  may be electrically connected to the component. For example, the assembly  10  may be attached to a vehicle antenna having a threaded mounting post, or other suitable mounting member. 
     In the illustrative embodiment shown, the first conductive member  12  and the second conductive member  16  are formed from a flat blank of electrically conductive metal such as copper with a tin plating. Alternatively, the first conductive member  12  and the second conductive member  16  may be made from any materials having the desired conductive and mechanical properties, including, but not limited to, sheet metal, such as spring steel. The insulator  14  is made from any dielectric insulative material, such as plastic, which provides sufficient electrical insulation to electrically isolate the first conductive member  12  from the second conductive member  16 . 
     As best shown in  FIGS. 2, 4 and 5 , the first conductive member  12  includes a shield or cable engaging portion  30  for crimping around the stripped end of the cable  20  in conventional manner to form a secure electrical connection. In the illustrative embodiment shown, the cable engaging portion  30  has two sets of crimping tabs. A first set of crimping tabs  32  is typically crimped around the insulative jacket  24  of the cable  20  to provide a mechanical connection and/or engagement between the cable engaging portion  30  and the cable  20 . A second set of crimping tabs  34  is crimped onto an exposed portion of the metallic shield  22  to provide the mechanical and electrical connection and/or engagement between the metallic shield  22  and the first conductive member. While the first conductive member  12  is shown as crimped to the cable  20 , other methods of termination may be used. 
     The first conductive member  12  also includes a mating portion  36  which extends from the cable engaging portion  30 . The mating portion  36  includes an insulator mounting portion  38  with an opening  40  which is dimensioned to receive a mounting post therein. The mating portion  36  includes insulator location tabs  42 , insulator securing tabs  44  and anti-rotation projections  46 . 
     In the illustrative embodiment shown, the insulator location tabs  42  extend from the insulator mounting portion  38  in a direction which is essentially perpendicular to the plane of the insulator mounting portion  38 . The insulator location tabs  42  have projection or barbs  43  which extend from free ends thereof. In the illustrative embodiment, two insulator location tabs  42  are provided, however, other numbers of insulator location tabs  42  may be provided in other embodiments. 
     The insulator securing tabs  44  also extend from the insulator mounting portion  38  in a direction which is essentially perpendicular to the plane of the insulator mounting portion  38 . The insulator securing tabs  44  have mounting tabs  48  which extend from the end of the insulator securing tabs  44  which are removed from the insulator mounting portion  38 . The mounting tabs  48  are angled and extend inward of the insulator securing tabs  44 . The insulator securing tabs  44  can be resiliently displaced when the mating portion  36  is mounted to the insulator  14 , as will be more fully described. In the illustrative embodiment, three insulator securing tabs  44  are provided, however, other numbers of insulator securing tabs  44  may be provided in other embodiments. 
     The anti-rotation projections  46  extend at an angle from the insulator mounting portion  38 . The anti-rotation projections  46  extend from the insulator mounting portion  38  in an opposite direction as the insulator securing tabs  44 . In the illustrative embodiment, the anti-rotation projections  46  are barbs or cantilevered tooth members which are configured to engage and make electrical connection to the mating component. The anti-rotation projections may have any suitable configuration for engagement with a contact surface or mounting surface of the mating component. 
     As best shown in  FIGS. 4 and 5 , the insulator  14  has a generally cylindrical configuration with a first surface  50 , a second surface  52  and a side surface  54  which extends between the first surface  50  and the second surface  52 . The insulator  14  has an opening  56  which extends from the second surface  52  to the first surface  50 . The opening  56  is dimensioned to receive the mounting post therein. Location openings  58 ,  59  also extend from the second surface  52  to the first surface  50 . In the illustrative embodiment, two location openings  58  and two location openings  59  are provided, however, other numbers of location openings  58 ,  59  may be provided in other embodiments. Recesses  60  are provided along the side surface  54 . The recesses  60  are dimensioned to receive the insulator securing tabs  44  therein. In the illustrative embodiment, three recesses  60  are provided, however, other numbers of recesses  60  may be provided in other embodiments. 
     A positioning member and a nut or fastener holder  62  are provided on the insulator  14 . The fastener holder  62  extends from the first surface  50  and is positioned proximate the side surface  54 . However, other configurations and numbers of the fastener holder  62  may be used without departing from the scope of the invention. In addition, in various embodiments, the insulator  14  may not have a fastener holder  62  (as shown in  FIG. 6 ). 
     As best shown in  FIGS. 3, 4 and 5 , the second conductive member  16  includes a core engaging portion  70 . In the illustrative embodiment shown, the core engaging portion  70  has a first crimp barrel  71  which crimps around the stripped end of the center core  26  of the cable  20  to form a secure mechanical and electrical connection and/or engagement between the center core  26  and the second conductive member  16 . In addition, the core engagement portions  70  has a second crimp barrel  73  for crimping to the dielectric insulator  28  of the cable  20  to provide a secure mechanical connection and/or engagement between the dielectric insulator  28  and the second conductive member  16 . The cooperation of the second conductive member  16  with the dielectric insulator  28  provides additional mechanical structure to support the connection between the first crimp barrel  71  which the stripped end of the center core  26 . This provides a more secure and stable electrical connection between the second conductive member  16  and the cable  20  than is obtainable using the welding techniques of the prior art. 
     The second conductive member  16  also includes a mating portion  72  which extends from the core engaging portion  70 . The mating portion  72  includes an opening  74  which is dimensioned to receive and make an electrical engagement with the mounting post therein. The mating portion  72  includes insulator location tabs  76 , fastener or nut securing tabs  78  and a positioning member receiving recess  80 . 
     In the illustrative embodiment shown, the insulator location tabs  76  extend from the mating portion  72  in a direction which is essentially perpendicular to the plane of the mating portion  72 . The insulator location tabs  76  have projections or barbs  77  which extend from free ends thereof. In the illustrative embodiment, two insulator location tabs  76  are provided, however, other numbers of insulator location tabs  76  may be provided in other embodiments. 
     The fastener securing tabs  78  also extend from the mating portion  72  in a direction which is essentially perpendicular to the plane of the mating portion  72 . The fastener securing tabs  78  extend from the mating portion  72  in an opposite direction as the insulator location tabs  76 . The fastener securing tabs  78  have mounting tabs  82  which extend from the end of fastener securing tabs  78  which is removed from the mating portion  72 . The mounting tabs  82  extend in a direction which is essentially perpendicular to the plane of the mating portion  72 . In the illustrative embodiment, three fastener securing tabs  78  are provided, however, other numbers of fastener securing tabs  78  may be provided in other embodiments. 
     The fastening member receiving recess  80  is configured to receive the fastener holder  62  therein, allowing the second conductive member  16  to be properly positioned on the first surface  50  of the insulator  14  while allowing the fastener holder  62  to extend from the first surface  50  of the insulator  14  beyond the mating portion  72  of the second conductor member  16 . A fastener  84 , such as, but not limited to a nut, cooperates with the fastener holder  62 , as will be more fully described. 
     As best shown in  FIGS. 2 and 3 , when assembled, the insulator location tabs  42  of the first conductive member  12  are inserted into the corresponding location openings  58  of the insulator  14 . The interaction of the location tabs  42  and the barbs  43  with the corresponding location openings  58  ensures that the insulator  14  will be properly positioned and secured relative to the first conductive member  12 . In this position, opening  40  aligns with opening  56  to allow the mounting post of the mating component to be inserted therethrough. 
     The first conductive member  12  and the insulator  14  are maintained in position by the cooperation of the insulator securing tabs  44  with the insulator  14 . During assembly of the insulator  14  and the first conductive member  12 , the recesses  60  of the insulator  14  are aligned with the insulator securing tabs  44 . The insulator  14  is then inserted between the insulator securing tabs  44 , causing the insulator securing tabs  44  to be resiliently deformed outwardly to allow the insulator  14  to move past the mounting tabs  48  of the insulator securing tabs  44 . As the insulator  14  is moved proximate to or in engagement with the mating portion  36  of the first conductive member  12 , the insulator  14  is moved past the mounting tabs  48 , allowing the insulator securing tabs  44  to resiliently return toward their unstressed position, positioning the insulator securing tabs  44  in the recesses  60  of the insulator  14 . As this occurs, the mounting tabs  48  are moved into engagement with the recesses  60 , causing the mounting tabs  48  to frictionally engage the recesses  60  to prevent the unwanted removal of the first conductive member  12  from the insulator  14 . In addition, the insulator location tabs  42  of the first conductive member  12  are dimensioned to frictionally engage the corresponding location openings  58  of the insulator  14  to help maintain and secure the first conductive member  12  in a position relative to the insulator  14 . 
     As assembly occurs, in embodiments in which the fastener  84  is to be used, the fastener  84  is inserted between the fastener securing tabs  78 . In the embodiment shown in  FIG. 3 , the fastener securing tabs  78  cooperate with three sides of the fastener  84  to temporarily hold the fastener  84  in position relative to the second conductive member  16 . In this position, the fastener  84  is maintained proximate the second conductive member  16  by the cooperation of the mounting tabs  82  with the fastener  84 . 
     As assembly occurs, the insulator location tabs  76  of the second conductive member  16  are inserted into the corresponding location openings  58  of the insulator  14 . The interaction of the location tabs  76  and the barbs  77  with the corresponding location openings  59  and the positioning of the positioning member  62  in the fastening member receiving recess  80  ensures that the insulator  14  will be properly positioned and secured relative to the second conductive member  16 . In this position, opening  74  aligns with opening  56  to allow the mounting post of the mating component to be inserted therethrough. In addition, the insulator location tabs  76  of the second conductive member  16  are dimensioned to frictionally engage the corresponding location openings  58  of the insulator  14  to help maintain the second conductive member  16  in position relative to the insulator  14 . 
     In embodiments in which a fastener  84  is used, the positioning member  62  cooperates with the fastener  84  when the second conductive member  16  is properly secured to the insulator  14 . In this fully assembled position, the positioning member  62  and the fastener securing tabs  78  cooperate to prevent the removal of the fastener  84  from the second conductive member  16 . However, the fastener  84  is rotatably attached to the second conductive member  16 , allowing the fastener  84  to rotate when maintained in this position, thereby allowing the fastener or fastener  84  to be rotated to tighten the fastener  84  and the contact assembly  10  to a threaded mounting post or the like. While the assembly of the illustrative embodiment has been described with reference to the method described above, other methods and assembly steps may be performed without departing from the scope of the invention. In addition, the particular order of the method steps described may be varied. 
     When fully assembled, the insulator  14  electrically isolates the first conductive member  12  from the second conductive member  16 , thereby allowing the second conductive member  16  to conduct signal transmissions while the first conductive member provides shielding. In the illustrative embodiment the assembly uses a 26 AWG gauge wire which is able to accommodate a signal strength of up to 100 mA. However, the invention is not limited to the wire gauge and signal strength of the illustrative embodiment. 
     While the invention has been described with reference to an illustrative embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments and methods are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.