Patent Publication Number: US-2022224045-A1

Title: Coaxial connector assembly having locking ferrule

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Ser. No. 63/217,111, filed Jun. 30, 2021, and U.S. Provisional Application Ser. No. 63/135,560, filed Jan. 8, 2021, the content of which is relied upon and incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure generally relates to coaxial connector assemblies, and particularly a coaxial connector assembly, having a locking ferrule. 
     A coaxial cable is characterized by having an inner electrical conductor, an outer electrical conductor, and a dielectric between the inner and outer electrical conductors. The inner electrical conductor may be hollow or solid. At the end of coaxial cable, a connector or connector assembly is attached to allow for mechanical and electrical coupling of the coaxial cable. 
     Connectors and connector assemblies for attachment to coaxial cables have been used throughout the coaxial cable industry for a number of years. One type of coaxial cable has an annularly corrugated outer conductor and a plain cylindrical inner conductor. Generally, connectors and connector assemblies that attach to these types of coaxial cables are different from those where the outer electrical conductors are smooth or uncorrugated. 
     For example, one connector assembly type includes a single annular clamping portion that meshes with the last valley or outermost valley of the corrugated outer conductor, providing a single circumferential point of contact. Without additional axial reinforcement from the coaxial cable connector, physical gyrations of the cable found in field applications due to weather and vibration can cause undue stress and, ultimately, material fatigue of the corrugated cable outer conductor. 
     The aforementioned example clearly shows there is a continuing need for improved high-performance coaxial cable connectors and connector assemblies. There is a particular need for connectors and connector assemblies that can be installed and uninstalled easily and quickly under field conditions. Also, since these connectors and connector assemblies are generally installed in the field, they should be configured for pre-assembly, so that the possibility of dropping and losing small parts, misplacing o-rings, damaging or improperly lubricating o-ring, or other assembly errors in the field are minimized. Additionally, it should be possible for the coaxial cable connector to be installed and removed without the use of any special tools. 
     In view of the aforementioned needs, as well as other issues with prior connector and connector assembly designs, alternatives are desired. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a coaxial connector assembly in accordance with embodiments disclosed herein; 
         FIG. 2  is an enlarged detail view, Detail  2 - 2 , of a portion of the coaxial connector assembly shown in  FIG. 1 . 
         FIG. 3  is a cross-sectional view of an exemplary coaxial cable; 
         FIG. 4  is a photograph of a cross-section of a coaxial connector assembly in a first position in accordance with embodiments disclosed herein; and 
         FIG. 5  is a photograph of a cross-section of the coaxial connector assembly, shown in  FIG. 4 , in a second position in accordance with embodiments disclosed herein; 
     
    
    
     The figures and photographs are not necessarily to scale. Like numbers used in the figures and the photographs may be used to refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure or photograph is not intended to limit the component in another figure labeled with the same number. 
     DETAILED DESCRIPTION 
     Various exemplary embodiments of the disclosure will now be described with particular reference to the drawings. Exemplary embodiments of the present disclosure may take on various modifications and alterations without departing from the spirit and scope of the disclosure. Accordingly, it is to be understood that the embodiments of the present disclosure are not to be limited to the following described exemplary embodiments, but are to be controlled by the features and limitations set forth in the claims and any equivalents thereof. 
     Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     Spatially related terms, including but not limited to, “lower,” “upper,” “beneath,” “below,” “above,” and “on top,” if used herein, are utilized for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation in addition to the particular orientations depicted in the figures and described herein. For example, if an object depicted in the figures is turned over or flipped over, portions previously described as below or beneath other elements would then be above those other elements. 
     Cartesian coordinates are used in some of the Figures for reference and are not intended to be limiting as to direction or orientation. 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “top,” “bottom,” “side,” and derivatives thereof, shall relate to the disclosure as oriented with respect to the Cartesian coordinates in the corresponding Figure, unless stated otherwise. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. 
     As shown particularly in  FIG. 1 , disclosed herein is an embodiment of a coaxial connector assembly  1000 . This embodiment of the coaxial connector assembly  1000  includes a forward outer body  200 , a forward inner body  250 , an intermediate body  300 , a post  400 , a rearward outer body  500 , a first rear inner body  600 , a second rear inner body  650 , a locking ferrule  700 , a dielectric  800 , and a center conductor  900 . In addition, the coaxial connector assembly  1000  also includes seals  330 ,  360 . Additional seals may also be incorporated, depending on the environmental needs of a particular application. Moreover, the particular structure of the coaxial connector assembly  1000 , as shown in  FIG. 1 , should not be construed as limiting. The connector assembly may include additional or fewer elements, depending upon various factors. Such factors include, but are not limited to environmental conditions, cost, ease of assembly, and ease of manufacture. 
     The forward outer body  200 , which may also be referred to as a nut, is rotatably attached to the intermediate body  300 . This particular construction of the forward outer body  200  includes a plurality of body portions at various heights. Specifically, the forward outer body  200  includes an outer end body portion  210 , an intermediate body portion  212 , an inner end portion  214 , chamfers  216 ,  218  positioned at each end, a bore  220 , and a lip  222 . The forward outer body  200  may also include engaging means such as threads. 
     The forward inner body  250  is positioned between the forward outer body  200  and the intermediate body  300 . The forward inner body  250  is configured to mate with the outer configuration of the intermediate body. The forward inner body  250  includes an outer surface  252  in sliding engagement with the bore  220  of the forward outer body  200 . 
     The intermediate body  300  includes a plurality of outer step portions  302 ,  304 ,  306 ,  308  with grooves  310 ,  312  positioned between step portions  302 ,  304  and  306 ,  308 . The intermediate body  300  also includes a plurality of inner step portions  320 ,  322 ,  324 ,  326  and an angled end portion  328 . 
     The post  400  is fit within the inner step portion  326  of the intermediate body  300 . The post  400  includes a post bore  402 , and a tang  404 . The tang  404  extends inwardly to couple with the locking ferrule  700 . The tang  404  includes a forward tang portion  404   a , an intermediate tang portion  404   b , and a rearward tang portion  404   c . The forward tang portion  404   a  extends radially inward, the intermediate tang portion  404   b  is integrally attached to the forward tang portion  404   a  and extends axially toward the locking ferrule  700 . The rearward tang portion  404   c  is inwardly angled for engagement with the locking ferrule  700 . The rearward tang portion  404   c  is may be flexible such that upon engagement with the locking ferrule  700 , the rearward tang portion  404   c  is inwardly and outwardly movable. The post  400  also includes end surfaces  406 ,  408 , which respectively engage with the intermediate body  300  and the locking ferrule  700 . 
     Referring to  FIGS. 1, 2, 4, and 5 , the rearward outer body  500  is configured for engagement with the post  400 , the locking ferrule  700 , the first rear inner body  600 , and the second rear inner body  650 . The rearward outer body  500  includes a plurality of outer sections: two end outer sections  502 ,  506 , and a middle outer body section  504 . The middle outer body section  504  preferably has a larger diameter than the two end outer sections  502 ,  506 . The rearward outer body  500  includes two end rearward outer body bores  503 ,  505 , a middle outer body bore  507 , a sloped engagement element  508 , and a recessed area  510 . 
     The locking ferrule  700  and the first rear inner body  600  and the second rear inner body  650  are configured for positioning onto a prepared end PE of a corrugated coaxial cable  100 , which includes a corrugated outer conductor  125  ( FIGS. 4 and 5 ). The locking ferrule  700  includes a front ferrule end  702 , a back ferrule end  704  having a plurality of foot portions  705 , a plurality of slots  706 , a tapered surface  708 , an inwardly extending projection  709 , and a plurality of ridges  710 . The front ferrule end  702  is configured to engage with the post  400 . The plurality of ridges  710  are configured to engage with valleys in the corrugated coaxial cable  100 , as shown particularly in  FIGS. 4 and 5 . And the back ferrule end  704  is configured for engagement with a recessed area  510  in the rearward outer body  500  in a first position, shown in  FIG. 4 , and the first rear inner body  600  in a second position, as shown in  FIG. 5 . In the first position shown in  FIG. 4 , the cable  100  has been installed into the rearward outer body and the ferrule. When the cable is inserted, the peaks of the corrugated outer conductor presses the ferrule outwardly, making room for the ferrule to move forward. Once over the peaks of the corrugated cable, ridges of the ferrule fall into place, locking the cable. In the second position shown in  FIG. 5 , the rearward outer body  500  has been tightened such that the locking ferrule  700  moves inwardly, locking the corrugated outer conductor even more and applying pressure on the cable moving the cable into the second position. In this stage of the compression, a portion of the locking ferrule is reduced in diameter, locking the corrugated outer conductor between the post  400  and the locking ferrule  700 . 
     The plurality of slots  706  in the locking ferrule  700  provide the locking ferrule  700  with spring-like characteristics. Accordingly, the plurality of slots  706  facilitate spring-like engagement of the locking ferrule  700  upon coupling with the corrugated outer conductor  125 , the rearward outer body  500  and the first rear inner body  600 . The plurality of ridges  710  also facilitate engagement with the corrugated outer conductor  125  by nature of the ridges themselves, resulting in a locking effect. This locking effect is used to effectively hold the cable in position during installation, assists in seating the cable properly during tightening of the assembly, and locks the cable in position upon completion of the installation process. 
     The dielectric  800  can be manufactured from various materials, including TPX® Polymethylpentene polymer; PTFE Teflon®, and TOPAS® plastic. The dielectric  800  is preferably solid with a central bore  802  extending therethrough. Optionally, the dielectric can include a series of radially-spaced holes, which may be used to maintain the characteristic impedance of the transmission path and thereby minimize signal reflections. 
     The center conductor  900  extends through the central bore  802  of the dielectric and is supported thereby. The center conductor  900  extends between a first end formed as a male pin and an opposing second end formed as a compressible female socket, extending within the post. 
     Referring to  FIG. 3 , the cable  100  generally includes at least a center conductor  105 , a cable dielectric  120 , a corrugated outer conductor  125 , and a jacket  130 . The center conductor  105  is annular and thus includes an inner diameter  110  and an outer diameter  115 . A cable dielectric  120  surrounds the outer diameter  115  of the center conductor  105 , while the corrugated outer conductor  125  surrounds the cable dielectric  120 , and the jacket  130  surrounds the corrugated outer conductor  125 . In  FIG. 3 , a forward end  103  of the corrugated coaxial cable  100  is shown in a “prepared state,” meaning that an end of the corrugated coaxial cable  100  a portion of the jacket  130  has been removed such that the corrugated outer conductor  125  is fully exposed and ready for positioning in the coaxial connector assembly  1000 . 
     As shown particularly in  FIGS. 4 and 5 , the locking ferrule  700  is configured to substantially engage with the corrugated outer conductor  125  of the corrugated coaxial cable  100  after the jacket  130  has been stripped back to expose a portion of the corrugated outer conductor  125 . 
     Each component is preferably made of at least one metallic material, such as brass or another comparable material, and can also be plated with at least one conductive material, such as nickel-tin. 
     For the purposes of describing and defining the subject matter of the disclosure it is noted that the terms “substantially” and “generally” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. 
     It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosure. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the disclosure may occur to persons skilled in the art, the embodiments disclosed herein should be construed to include everything within the scope of the appended claims and their equivalents.