Patent Publication Number: US-8529294-B2

Title: Coaxial connector with coupling nut

Description:
BACKGROUND OF THE INVENTION 
     The subject matter described and/or illustrated herein relates generally to coaxial connectors, and more particularly, to a coaxial connectors having coupling nuts. 
     Different types and configurations of connectors are known for interconnecting electrical components such as coaxial cables, circuit boards, and/or the like. Generally, coaxial cables have a circular geometry formed with a central conductor having one or more conductive wires surrounded by a cable dielectric material. The dielectric material is surrounded by a cable braid that serves as a ground, and the cable braid is surrounded by a cable jacket. In most coaxial cable applications, it is preferable to match the impedance between source and destination electrical components located at opposite ends of the coaxial cable. Consequently, when sections of coaxial cable are interconnected by coaxial connector assemblies, or when the coaxial cable is connected to a coaxial connector assembly for use with a circuit board, it is preferable that the impedance remain matched through the interconnection. 
     Sometimes referred to as RF connectors, coaxial connector assemblies are used with and are employed in a wide variety of electrical and electronic devices and packages. Coaxial connector assemblies include two complementary coaxial connectors such as a plug and a jack. The complementary coaxial connectors mate together, for example to establish an electrical connection between electrical components. Coaxial connectors sometimes include a coupling nut that couples with the complementary coaxial connector to hold the coaxial connectors together and thereby maintain the electrical connection therebetween. It may sometimes be desirable to integrally form the coupling nut with the housing of a coaxial connector. But, integrally forming the coupling nut with the housing may impose structural limitations that prevent the coaxial connector from having structure that facilitates providing the coaxial connector with an impedance that substantially matches the electrical components interconnected by the coaxial connector assembly. For example, structure that facilitates providing the coaxial connector with the substantially matching impedance may prevent the creation of a thread on a coupling nut that is integrally formed with the housing. 
     There is a need for a coaxial connector that has an integrally formed housing and coupling nut and also includes structure that facilitates substantially matching an impedance of the coaxial connector with an electrical component. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, a coaxial connector is configured to mate with a mating connector. The coaxial connector includes a housing that is at least partially electrically conductive, an inner electrical contact held by the housing, and an outer electrical contact. The outer electrical contact is concentrically arranged with the inner electrical contact such that the outer electrical contact is spaced radially apart from the inner electrical contact. The outer electrical contact defines a plug that is configured to be received within a receptacle of the mating connector. A coupling nut is configured to mechanically secure the electrical connector to the mating connector. The coupling nut is integrally formed with the housing and includes a radially inner surface having a thread configured to engage a thread of the mating connector. 
     In another embodiment, a housing is provided for a coaxial connector that is configured to mate with a mating connector. The housing includes a base having a contact cavity configured to hold an inner electrical contact. The base is at least partially electrically conductive. The housing also includes an outer electrical contact integrally formed with the base of the housing. The outer electrical contact defines a plug that is configured to be received within a receptacle of the mating connector. The housing further includes a coupling nut configured to mechanically secure the base of the housing to the mating connector. The coupling nut is integrally formed with the base of the housing and includes a radially inner surface having a thread configured to engage a thread of the mating connector. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary embodiment of a coaxial connector. 
         FIG. 2  is a front elevational view of an exemplary embodiment of a housing of the coaxial connector shown in  FIG. 1 . 
         FIG. 3  is a cross section of the housing shown in  FIG. 2  taken along line  3 - 3  of  FIG. 2 . 
         FIG. 4  is a cross section of the coaxial connector shown in  FIG. 1  taken along line  4 - 4  of  FIG. 1 . 
         FIG. 5  is a cross-sectional view illustrating the coaxial connector shown in  FIGS. 1 and 4  mated with an exemplary embodiment of a complementary coaxial connector. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of an exemplary embodiment of a coaxial connector  10 . The coaxial connector  10  includes a housing  12 , an inner electrical contact  14 , an outer electrical contact  16  ( FIGS. 2-5 ), and a coupling nut  18 . The coaxial connector  10  is configured to mate with a complementary coaxial connector  20  ( FIG. 5 ) to establish an electrical connection therebetween. The coupling nut  18  is configured to mechanically secure the coaxial connector  10  to the complementary coaxial connector  20 . More specifically, the coupling nut  18  mechanically couples with the complementary coaxial connector  20  to hold the coaxial connectors  10  and  20  together and thereby maintain the electrical connection therebetween. As will be described in more detail below, the coupling nut  18  is formed integrally with the housing  12  and the outer electrical contact  16  defines a plug  22  ( FIGS. 2-5 ). The complementary coaxial connector  20  may be referred to herein as a “mating connector”. 
     In the exemplary embodiment, the coaxial connector  10  is shown as terminating the end  24  of a coaxial cable  26 . Alternatively, the coaxial connector  10  may terminate and/or be mounted to any other type of electrical component, such as, but not limited to, a circuit board (not shown) and/or the like. Moreover, the coaxial connector  10  may be electrically connected to any type of electrical component via the coaxial cable  26 . The exemplary embodiment of the coaxial connector  10  is an electrical plug and the exemplary embodiment of the complementary coaxial connector  20  is an electrical jack that is configured to receive a portion of the coaxial connector  10  therein. 
       FIG. 2  is a front elevational view of an exemplary embodiment of the housing  12  of the coaxial connector  10  ( FIGS. 1 ,  4 , and  5 ).  FIG. 3  is a cross section of the housing  12  taken along line  3 - 3  of  FIG. 2 . Referring to  FIGS. 2 and 3 , the housing  12  includes a base  28  and the coupling nut  18 . Optionally, and as will be described below, the outer electrical contact  16  is formed integrally with the housing  12  such that the housing  12  includes the outer electrical contact  16 . 
     The housing  12  extends a length L (not labeled in  FIG. 2 ) along a central longitudinal axis  30  from an end  32  to a mating end  34 . The coaxial connector  10  is configured to mate with the complementary coaxial connector  20  ( FIG. 5 ) through the mating end  34 . The base  28  of the housing  12  extends a length L 1  (not labeled in  FIG. 2 ) from the end  32  to an end  36  of the base  28 . The end  36  of the base  28  includes an end wall  38 . The base  28  includes a contact cavity  40  that is configured to hold the inner electrical contact  14  ( FIGS. 1 ,  4 , and  5 ) therein. More specifically, the contact cavity  40  is configured to hold an electrically insulating member  42  ( FIGS. 4 and 5 ) that holds the inner electrical contact  14 . Reception of the insulating member  42  within the contact cavity  40  is illustrated in  FIG. 4 . The end  32  of the housing  12  may be referred to herein as “another end”. 
     Referring solely to  FIG. 2 , the base  28  optionally includes one or more mounting ears  44  for mounting the housing  12  to a support, such as, but not limited to, a panel, a rack, and/or the like. In the exemplary embodiment, the mounting ears  44  include openings  46  for receiving threaded or other fasteners that hold the housing  12  to the support. But, the mounting ears  44  may each additionally or alternatively include any other structure for holding the housing  12  to the support, such as, but not limited to, a clip, a latch, a snap-fit structure, a press-fit structure, and/or the like. 
     Referring again to  FIGS. 2 and 3 , the base  28  is at least partially electrically conductive. In the exemplary embodiment, the base  28  is formed entirely from one or more electrically conductive materials such that a substantial entirety the base  28  is electrically conductive. Alternatively, the base  28  includes one or more dielectric materials (e.g., a dielectric layer applied to an electrically conductive material, or vice versa) such that only a portion of the base  28  is electrically conductive. 
     The outer electrical contact  16  extends outwardly from the end wall  38  of the base  28 . The outer electrical contact  16  projects from the base wall  38  into a cavity  48  of the coupling nut  18 . In the exemplary embodiment, the outer electrical contact  16  is a cylindrical tube that extends a length L 2 , along the length L of the housing  12 , from the end wall  38  to an end  50  of the outer electrical contact  16 . In addition or alternatively to the cylindrical tube shape, the outer electrical contact  16  may have include one or more other shapes. The outer electrical contact  16  includes a radially (relative to the axis  30 ) inner surface  52  and a radially (relative to the axis  30 ) outer surface  54 . A radial thickness T of the outer electrical contact  16  is defined between the surfaces  52  and  54 . The contact cavity  40  that extends through the base  28  also extends through the outer electrical contact  16 . In other words, the outer electrical contact  16  includes an internal passage that is bounded by the radially inner surface  52  and forms an extension of the contact cavity  40  of the base  28 . 
     As described above, the outer electrical contact  16  defines a plug  22 . The plug  22  is configured to be received within a receptacle  56  ( FIG. 5 ) of the complementary coaxial connector  20  ( FIG. 5 ). The radially outer surface  54  of the outer electrical contact  16  defines a mating interface  58  at which the contact  16  mates with an outer electrical contact  60  ( FIG. 5 ) of the complementary coaxial connector  20 . More specifically, the radially outer surface  54  of the outer electrical contact  16  is configured to engage a radially (e.g., relative to the axis  30 ) inner surface  62  ( FIG. 5 ) of the outer electrical contact  60  of the complementary coaxial connector  20  to establish an electrical connection between the contacts  16  and  60 . In the exemplary embodiment, the radially outer surface  54 , and thus the mating interface  58 , of the outer electrical contact  16  extends cylindrically along the central longitudinal axis  30  of the housing  12 . The radially outer surface  54  and the mating interface  58 , in the exemplary embodiment, also extend cylindrically along a connection axis  64  ( FIG. 5 ) along which the coaxial connector  10  and the complementary coaxial connector  20  are configured to mate. The outer electrical contact  60  may be referred to herein as an “outer mating contact”. 
     Optionally, the outer electrical contact  16  is formed integrally with the housing  12  such that the housing  12  includes the outer electrical contact  16 . More specifically, the outer electrical contact  16  is optionally formed integrally with the base  28  and the coupling nut  18  of the housing  12 . As used herein, two or more items are “integrally formed” when the items are formed as a single continuous structure. In contrast, two or more items are not “integrally-formed” if the items are formed as two or more discrete structures. In some embodiments, two or more items are considered to be formed as a single continuous structure if the items are incapable of being separated without damaging (such as, but not limited to, cutting through) at least one of the items. Optionally, two or more items are “formed as a single continuous structure” whether or not the two or more items are formed from the same materials and/or are formed simultaneously. In some embodiments, two or more items are considered to be formed as discrete structures if the items are engaged with each other after formation of both of the items and/or if the items are mechanically joined together after formation of both of the items using a mechanical fastener (e.g., an adhesive, a clip, a clamp, a weld, a solder joint, a threaded fastener, a non-threaded fastener, and/or the like). Optionally, two or more items are “formed as discrete structures” whether or not the two or more items are formed from the same materials and/or are formed simultaneously. 
     The size, shape, material, material properties, and/or the like of the outer electrical contact  16  may be selected to provide the coaxial connector  10 , the complementary coaxial connector  20 , and/or an assembly of the connectors  10  and  20  with a predetermined impedance. For example, the predetermined impedance may substantially match an impedance of the coaxial cable  26 , an electrical component (not shown) that is electrically connected to the coaxial connector  10  via the coaxial cable  26 , a circuit board (not shown), an electrical component that is electrically connected to the coaxial connector via the complementary coaxial connector, and/or the like. One example of selecting a size, shape, material, material properties, and/or the like of the outer electrical contact  16  to provide the predetermined impedance includes selecting the value of an inner diameter D of the outer electrical contact  16 . Other examples of selecting a size, shape, material, material properties, and/or the like of the outer electrical contact  16  to provide the predetermined impedance include (in addition or alternatively to selecting the value of the inner diameter D) selecting the value of the length L 2  of the contact  16  and/or selecting the value of the radial thickness T of the contact  16  to provide the predetermined impedance. 
     The coupling nut  18  is formed integrally with the housing  12  such that the housing  12  includes the coupling nut  18 . More specifically, the coupling nut  18  is formed integrally with the base  28  of the housing  12 . In embodiments wherein the outer electrical contact  16  is formed integrally with the housing  12 , the coupling nut  18  is formed integrally with the outer electrical contact  16 . 
     Referring solely to  FIG. 3 , the coupling nut  18  extends a length outwardly from the base wall  38  of the housing base  28  to a free end, which defines the mating end  34  of the housing. The coupling nut  18  includes a radially (relative to the axis  30 ) inner surface  66  and a radially (relative to the axis  30 ) outer surface  68 . The coupling nut  18  includes the cavity  48 . More specifically, the cavity  48  extends into the coupling nut  18  through the mating end  34  to the base wall  38 . The radially inner surface  66  of the coupling nut  18  defines a radial boundary of the cavity  48 , while the base wall  38  defines a rear boundary of the cavity  48 . As will be described below, the cavity  48  is configured to receive the outer electrical contact  60  of the complementary coaxial connector  20  therein. The outer electrical contact projects into the cavity  48 . As can be seen in  FIG. 3 , the coupling nut  18  optionally surrounds at least a portion of the end  50  of the outer electrical contact  16 . 
     As described above, the coupling nut  18  is configured to mechanically secure the coaxial connector  10  to the complementary coaxial connector  20 . The radially inner surface  66  of the coupling nut  18  includes a thread  70  that is configured to engage a thread  72  ( FIG. 5 ) of the complementary coaxial connector  20  to threadably connect the coupling nut  18  to the complementary coaxial connector  20 , as will be described and illustrated below. Optionally, and as can be seen in  FIG. 3 , the thread  70  overlaps the outer electrical contact  16  along the length L of the housing  12  such that the thread  70  surrounds at least a portion of an edge  74  of the end  50  of the outer electrical contact  16 . The radially outer surface  68  of the coupling nut  18  optionally includes a thread  76 , for example for threadably connecting a seal or other covering that protects the coaxial connectors  10  and  20  from environmental contamination when mated together. 
     The housing  12  may be fabricated using any method, process, structure, means, and/or the like. For example, the housing  12  may be fabricated using an injection molding process, such that the housing  12  is an injection molded housing. More specifically, and for example, the base  28 , the coupling nut  18 , and optionally the outer electrical contact  16  may be integrally formed using an injection molding process. However, the base  28 , the coupling nut  18 , and optionally the outer electrical contact  16  are not limited to being integrally formed using an injection molding process. Rather, any other suitable process may be used to integrally form the base  28 , the coupling nut  18 , and optionally the outer electrical contact  16 , such as, but not limited to, die casting and/or the like. 
       FIG. 4  is a cross section of the coaxial connector  10  taken along line  4 - 4  of  FIG. 1 . The coaxial cable  26  has been omitted from  FIG. 4  for clarity. The inner electrical contact  14  is held by the housing  12  and is concentrically arranged (about the axis  30 ) with the outer electrical contact  16  such that the contacts  14  and  16  are spaced radially (relative to the axis  30 ) apart from each other. More specifically, the insulating member  42  is held within the contact cavity  40  and the inner electrical contact  14  is held within a contact opening  78  of the insulating member  42 . The insulating member  42  extends radially (relative to the axis  30 ) between the inner electrical contact  14  and the housing base  28 . Optionally, the insulating member  42  extends radially (relative to the axis  30 ) between the inner electrical contact  14  and the outer electrical contact  16 . In some alternative embodiments wherein the insulating member  42  does not extend radially (relative to the axis  30 ) between the inner electrical contact  14  and the outer electrical contact  16 , an air gap may be provided radially (relative to the axis  30 ) between the inner electrical contact  14  and the outer electrical contact  16 . 
     In the exemplary embodiment, the inner electrical connect  14  is held within the contact opening  78  of the insulating member  42  using a snap-fit connection. But, the inner electrical contact  14  may be held within the contact opening  78  of the insulating member  42  using any other method, structure, means, connection type, and/or the like, such as, but not limited to, using a press-fit connection and/or the like. Similar to the inner electrical contact  14 , the insulating member  42  is held within the contact cavity  40  using a snap-fit connection in the exemplary embodiment. However, the insulating member  42  may be held within the contact cavity  40  using any other method, structure, means, connection type, and/or the like, such as, but not limited to, using a press-fit connection and/or the like. 
     The exemplary embodiment of the inner electrical contact  14  is a pin. The pin is a male contact that is configured to be received within a female contact (e.g., an inner electrical contact  80  of the complementary coaxial connector  20 ). However, the inner electrical contact  14  is alternatively a female contact that is configured to receive a male contact. Moreover, when provided as a male contact, the inner electrical contact  14  is not limited to the pin, but rather may have any other shaped, configured, and/or the like male contact. 
     As described above, in the exemplary embodiment, the coaxial connector  10  terminates the coaxial cable  26 . Although not shown herein, the inner and outer electrical contacts  14  and  16 , respectively, engage respective inner and outer electrical conductors (not shown) of the coaxial cable  26  to establish an electrical connection between the inner electrical contact  14  and the inner electrical conductor and between the outer electrical contact  16  and the outer electrical conductor. 
       FIG. 5  is a cross-sectional view illustrating the coaxial connector  10  mated with the coaxial connector  20 . The connectors  10  and  20  mate together along the connection axis  64 . The inner electrical contact  14  of the coaxial connector  10  is engaged with the inner electrical contact  80  of the complementary coaxial connector  20  such that an electrical connection is established therebetween. 
     The outer electrical contact  16  of the coaxial connector  10  is engaged with the outer electrical contact  60  of the complementary coaxial connector  20  such that the contacts  16  and  60  are electrically connected together. More specifically, the plug  22  of the outer electrical contact  16  is received within the receptacle  56  of the outer electrical contact  60 . The radially outer surface  54 , and thus the mating interface  58 , of the outer electrical contact  16  is engaged with the radially inner surface  62  of the outer electrical contact  60  to establish the electrical connection between the contacts  16  and  60 . As can be seen in  FIG. 5 , when the connectors  10  and  20  are mated together, the outer electrical contact  16  of the coaxial connector  10  extends radially (relative to the axis  64 ) between the outer electrical contact  60  of the complementary coaxial connector  20  and the inner electrical contact  14 . The outer electrical contact  60  of the complementary coaxial connector  20  may be referred to herein as an “outer mating contact”. 
     The outer electrical contact  60  of the complementary coaxial connector  20  is received within the cavity  48  of the coupling nut  18  when the connectors  10  and  20  are mated together. In the exemplary embodiment, the outer electrical contact  60  of the complementary coaxial connector  20  includes the thread  72 , which extends on a radially (relative to the axis  64 ) outer surface  82  of the contact  60 . The thread  70  of the coupling nut  18  is interlocked with the thread  72  of the complementary coaxial connector  20  to threadably connect the coupling nut  18  to the complementary coaxial connector  20  and thereby hold the connectors  10  and  20  mated together. To interlock the threads  70  and  72 , the housing  12  of the coaxial connector  10  and the complementary coaxial connector  20  are rotated about the connection axis  64  relative to each other. Optionally, an end  84  of the outer electrical contact  60  abuts the base wall  38 . 
     The embodiments described and/or illustrated herein may be implemented in any type of coaxial connector for use interconnecting any type(s) of electrical components. Examples of coaxial connector types include, but are not limited to, N connectors, BNC connectors, TNC connectors, ETNC connectors, SMA connectors, SMB connectors, SMC connectors, F connectors, and/or the like. 
     The embodiments described and/or illustrated herein may provide a coaxial connector that has an integrally formed housing and coupling nut and also includes structure that facilitates substantially matching an impedance of the coaxial connector with an electrical component. 
     Exemplary embodiments are described and/or illustrated herein in detail. The embodiments are not limited to the specific embodiments described herein, but rather, components and/or steps of each embodiment may be utilized independently and separately from other components and/or steps described herein. Each component, and/or each step of one embodiment, can also be used in combination with other components and/or steps of other embodiments. When introducing elements/components/etc. described and/or illustrated herein, the articles “a”, “an”, “the”, “said”, and “at least one” are intended to mean that there are one or more of the element(s)/component(s)/etc. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc. Moreover, the terms “first,” “second,” and “third,” etc. in the claims are used merely as labels, and are not intended to impose numerical requirements on their objects. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described and/or illustrated herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the description and illustrations. The scope of the subject matter described and/or illustrated herein should therefore be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure. 
     While the subject matter described and/or illustrated herein has been described in terms of various specific embodiments, those skilled in the art will recognize that the subject matter described and/or illustrated herein can be practiced with modification within the spirit and scope of the claims.