Patent Publication Number: US-2021167563-A1

Title: Coaxial cable assemblies having pinching and gripping elements

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Application Ser. No. 62/942,742, filed Dec. 2, 2019, and U.S. Application Ser. No. 63/059,701, filed Jul. 31, 2020. The content of each priority application is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure generally relates to coaxial cable assemblies, and particularly connector assemblies, having pinching and gripping elements, that connect with coaxial cables, having corrugated outer conductors. 
     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 attached 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, particularly 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. 
     SUMMARY 
     Disclosed herein are various embodiments of coaxial cable connector assemblies for attachment to a corrugated coaxial cable, having a center conductor, a dielectric surrounding the center conductor, and a corrugated outer conductor surrounding the dielectric. Related methods are also disclosed herein. 
     According to a first aspect, a coaxial connector assembly, for attachment to a corrugated coaxial cable, includes a rear outer body, having an engagement element, to be received over a portion of the corrugated coaxial cable and a front subassembly. The front subassembly is configured for partial insertion into the rear outer body. The front subassembly includes, among other things, a front body shell, having a deformable end portion and a rearward annular extension spaced apart from the deformable end portion such that a pinching space is formed between the deformable end portion and the rearward annular extension. Upon coupling of the rear outer body with the front body shell, a portion of the corrugated outer conductor is configured for positioning within the pinching space. In addition, during the coupling, the deformable end portion is inwardly urged toward the rearward annular extension by the engagement element such that the portion of the corrugated outer conductor is pinched while positioned within the pinching space. 
     According to a second aspect, a coaxial connector assembly includes a front subassembly and an alternative version of a rear outer body to be received over a portion of the corrugated coaxial cable. The rear outer body includes an engagement element that slidingly engages with the corrugated outer conductor upon coupling. The front subassembly is configured for partial insertion into the rear outer body. The front subassembly includes a front body shell, having an end portion and a ferrule spaced apart from the end portion such that a gripping space is formed between the end portion and the ferrule. Upon coupling of the rear outer body ( 402 ) with the front body shell, a portion of the corrugated outer conductor is positioned within the gripping space and the ferrule is inwardly urged toward the end portion by the engagement element such that the portion of the corrugated outer conductor is gripped while positioned within the gripping space. 
     According to a third aspect, a method of making a connector assembly to be attached to a corrugated coaxial cable includes the steps of: forming a rear outer body to be received over a prepared end of the corrugated coaxial cable, with the rear outer body including an engagement element defined therein; forming a front subassembly to engage the rear outer body, with the front subassembly including a front body shell having a deformable end portion and a rearward annular extension spaced apart from the deformable end portion such that a pinching space is formed between the deformable end portion and the rearward annular extension, coupling the rear outer body with the front body shell, and positioning a portion of the corrugated outer conductor within the pinching space. 
     Additional features and advantages will be set forth 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 which follows, 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 embodiments, and together with the description serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an exploded cross-sectional view of a seal-cable assembly; 
         FIG. 1B  is an assembled cross-sectional view of the seal-cable assembly shown in  FIG. 1A ; 
         FIG. 2A  is a cross-sectional view of the seal-cable assembly shown in  FIG. 1A  before assembly with a first rear outer body embodiment; 
         FIG. 2B  is a cross-sectional view of the seal-cable assembly shown in  FIG. 1A  after assembly with the rear outer body shown in  FIG. 2A ; 
         FIG. 3  is a cross-sectional view of a first connector subassembly in accordance with embodiments disclosed herein; 
         FIG. 4  is a cross-sectional view of the first connector subassembly shown in  FIG. 3  assembled with the rear outer body and the seal-cable assembly shown in  FIG. 2B ; 
         FIG. 5  is a cross-sectional view of the seal-cable assembly shown in  FIG. 1A  after assembly with a second rear outer body embodiment; 
         FIG. 6  is a cross-sectional view of a second connector subassembly in accordance with embodiments disclosed herein; 
         FIG. 7  is a cross-sectional view of the second connector subassembly shown in  FIG. 6  assembled with the rear outer body shown and the seal-cable assembly shown in  FIG. 5 ; 
     
    
    
     The figures are not necessarily to scale. Like numbers used in the figures 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 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. 
     Disclosed herein are embodiments of connector assemblies  200 ,  400  configured for positioning onto a prepared cable-seal assembly. 
       FIGS. 1A and 1B  show cross sectional views of a portion of a corrugated coaxial cable  100  and a seal  150 , configured as an o-ring. Specifically,  FIG. 1A  shows an exploded view of the corrugated coaxial cable  100  and the seal  150  and  FIG. 1B  shows the corrugated coaxial cable  100  and the seal  150  assembled to form a cable-seal assembly  160 . The cable-seal assembly  160  can be assembled with the connector subassemblies disclosed herein, as will be further described. 
     The corrugated coaxial cable  100  includes a center conductor  105 , a dielectric  120 , a corrugated outer conductor  125 , and a jacket  130 . The center conductor  105  is annular and thus includes an inside diameter  110  and an outside diameter  115 . The dielectric  120  surrounds the outside diameter  115  of the center conductor  105 , the corrugated outer conductor  125  surrounds the dielectric  120 , and the jacket  130  surrounds the corrugated outer conductor  125 . In both  FIGS. 1A and 1B , 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 a connector assembly. 
     As shown particularly in  FIG. 1B , the seal  150  is configured for positioning adjacent to or within an outermost valley  126  of the corrugated outer conductor  125 . In this embodiment, the seal  150  is configured as an o-ring, having a circular cross-section. Other seal configurations, with different cross-sectional shapes, however, may be used. 
     Each embodiment of the connector assemblies disclosed herein is preferably preassembled before shipment and includes a rear outer body and a front subassembly. Each rear outer body and front subassembly are thus attached to one another so that they can be shipped from the factory to the field and then installed onto a prepared end of a corrugated coaxial cable. 
       FIG. 2A  shows an exploded view of a rear outer body  202  and a cable-seal assembly  160  with the cable being in a prepared state having a prepared end  170 , while  FIG. 2B  shows the rear outer body  202  positioned onto the prepared end  170 , forming a partially assembled connector assembly  200 . The rear outer body  202  is preferably manufactured from at least one metallic material such as brass and plated with a conductive, corrosion resistant material such as a nickel-tin alloy. 
     Referring to  FIGS. 2A and 2B , the rear outer body  202  includes a front end  208 , a back end  210 , external gripping portions  212   a ,  212   b , a recess  213  positioned between the external gripping portions  212   a ,  212   b , and an outer body opening  214  extending between the front end  208  and the back end  210  with respect to a longitudinal axis A. The rear outer body  202  further includes a threaded portion  216  adjacent the front end  208  for engagement with a front subassembly  204 , which will be further described. The threaded portion  216  is represented schematically by dashed line T 1 . 
     The rear outer body  202  additionally includes an engagement element  220  configured for positioning adjacent to the seal  150  and engaging the corrugated outer conductor  125  upon coupling of the rear outer body  202  with a portion of the corrugated coaxial cable  100  in the prepared state. Specifically, the engagement element  220  inwardly extends toward the prepared end  170  of the corrugated coaxial cable  100  for direct engagement with the corrugated outer conductor  125 . The engagement element  220  includes a seal engagement face  230  configured for positioning adjacent the seal  150 , an internal surface  232  configured for engagement with the corrugated outer conductor  125 , and an angled face  234  positioned angularly at a face angle α, with respect to the seal engagement face  230 . The face angle α can range from about 5 degrees to about 30 degrees. In some embodiments, the angled face  234  is also configured for engagement with the corrugated outer conductor  125 . The angled face  234  also facilitates entry the prepared end  170  of the corrugated coaxial cable  100  into the rear outer body  202  and acts as a stop for the seal  150 . The rear outer body  202  additionally includes include forward inner diameters  222 ,  224  adjacent the front end  208  and an rearward diameter  225  adjacent the back end  210 . The rearward diameter  225  of the rear outer body  202  is of sufficient size to slide over the seal  150 . The forward inner diameters  222 ,  224  are configured for engagement with the seal  150 , the corrugated coaxial cable  100 , and the front subassembly  204 , as will be described with respect to  FIG. 4 . 
     Referring to  FIGS. 3 and 4 , the front subassembly  204  includes a front body shell  260 , an insulator  300 , and a contact element  320 . The front body shell  260  has a first shell end  262 , a second shell end  264 , external gripping portions  266   a ,  266   b , and a body shell opening  268  extending between the first shell end  262  and the second shell end  264  with respect to longitudinal axis A. The front body shell  260  also has a deformable end portion  269 , an annular shoulder  270 , and internal diameters  272   a ,  272   b . The deformable end portion  269  includes a neck portion  284  connected to the annular shoulder  270  and a nub portion  286  connected to the neck portion  284 . The neck portion  284  has a cross-section that is sufficiently thin and configured to flex, thus allowing the nub portion  286  to move when a force is applied to the front body shell  260 . The annular shoulder  270  cooperates with the threaded portion  216  of rear outer body  202  to secure the rear outer body  202  to the front subassembly  204 . 
     In addition to the aforementioned elements, the front body shell  260  includes an intermediary shell portion  274 , a forward annular extension  280   a , and a rearward annular extension. The intermediary shell portion  274  is configured within the front body shell  260  to form a shoulder  275  upon which the insulator  300  is positioned against. The forward annular extension  280   a  has an extension end  281   a  that extends slightly past the first shell end  262  and a first annular channel  276   a  positioned between the external gripping portion  266   a  and the forward annular extension  280   a . The forward annular extension  280   a  preferably includes first and second extension diameters  282   a ,  282   b  with the first extension diameter  282   a  being slightly larger than the second extension diameter  282   b . Extending from a bottom portion  271  of the annular shoulder  270  is the rearward annular extension  280   b . The rearward annular extension  280   b  extends within the front body shell  260  such that the second shell end  264  is spaced apart from the extension end  281   b  of the rearward annular extension  280   b . And disposed between the rearward annular extension  280   b  and the deformable end portion  269  is a second annular channel  276   b . The front body shell  260  is preferably made from one or more metallic materials, e.g. brass and brass composite materials, and plated with a conductive, corrosion resistant material such as a nickel-tin alloy. 
     Also included within the front subassembly is the insulator  300 . The insulator includes a bore  302  aligned with respect to longitudinal axis A and an outer surface  304 . In preferred configurations, the insulator  300  further includes an insulator channel  306 . The insulator  300  is manufactured from an electrically insulative material Examples of such materials include, but are not limited to, foam-based materials and acetal. 
     As shown particularly in  FIGS. 3 and 4 , the contact element  320  includes a contact back end  322 , having a tapered portion  324  that engages with the center conductor  105 . The contact element  320  also preferably has a plurality of slots  326  at the contact back end  322  which allow the contact element  320  to flex as necessary and make physical and electrical contact with the center conductor  105 . The contact element  320  additionally includes a contact front end  328  that has a female configuration to receive a male configured mating component (not shown). But alternatively, the contact front end  328  of contact element  320  may have a male configuration. The contact element  320  is made from a metallic material such as beryllium copper, is preferably heat treated and is preferably plated with a conductive, corrosion resistant material such as a nickel-tin alloy. 
     The installation of the connector assembly  200  will now be described with respect to  FIG. 4 . If not already separated from one another, the rear outer body  202  and front subassembly  204  should be separated from one another, i.e., unscrewed from one another in preferred embodiments, before assembly. The rear outer body  202  is then placed over the prepared corrugated coaxial cable  100 , i.e. after the jacket  130  of the corrugated coaxial cable  100  has been stripped back to expose a portion of the corrugated outer conductor  125 . During installation, the contact element  320  aligns and engages with the inside diameter  110  of the center conductor  105 . To the extent that the contact element  320  is larger than the inside diameter  110  of the center conductor  105 , slots  326  allow the contact element  320  to radially compress to fit within the center conductor  105 . Simultaneously, the deformable end portion  269  is inwardly urged when pushed against the engagement element  220  such that the corrugated outer conductor  125  is pinched between the deformable end portion  269  and the rearward annular extension  280   b . The pinching of the corrugated outer conductor  125  occurs within a pinching space  288  formed between the deformable end portion  269  and the rearward annular extension  280   b . The front subassembly  204  also preferably includes a seal  350  configured to prevent exposure to water and other elements. 
     Referring to  FIGS. 5-7 , a second embodiment of a connector assembly  400  ( FIG. 7 ) similarly includes a rear outer body  402  and a front subassembly  404 . The rear outer body  402  has a front body end  408 , a back body end  410 , an external gripping portion  412 , and an outer body opening  414 , extending between the front body end  408  and the back body end  410  with respect to a longitudinal axis A′. The rear outer body  402  preferably includes a threaded portion adjacent the front body end  408 , represented schematically by dashed line T 2 , for threadingly engaging the front subassembly  404  with the rear outer body  402 . The rear outer body is preferably made from at least one metallic material such as brass and plated with a conductive, corrosion resistant material such as a nickel-tin alloy. 
     The rear outer body  402  additionally includes an inwardly extending engagement element  420  configured for positioning adjacent to the seal  150  and sliding engagement with the corrugated outer conductor  125  upon coupling with the corrugated outer conductor  125 . Preferably, the seal  150  is configured for positioning adjacent to or within an outermost valley  126  of the corrugated outer conductor  125  such that the engagement element  420  abuts against the seal, as particularly shown in  FIG. 5 . The rear outer body  402  additionally includes forward inner diameters  422 ,  424  on the front end  208  and rearward diameters  425   a ,  425   b ,  425   c . The forward inner diameters  422 ,  424  are configured for engagement with the front subassembly  404 . And the rearward diameters  425   a ,  425   b ,  425   c  are of sufficient size to slide over the seal  150 . 
     Referring to  FIGS. 6 and 7 , the front subassembly  404  includes a front body shell  460 , a seal  550 , an insulator  600 , a contact element  620 , and a ferrule  700 . The front body shell  460  has a front shell end  462 , a back shell end  464 , external gripping portions  466   a ,  466   b , and a body shell opening  468  extending between the front shell end  462  and the back shell end  464  with respect to a longitudinal axis A′. The front body shell  460  also has an end portion  469 , which may or may not be deformable, an annular shoulder  470 , internal diameters  472   a ,  472   b ,  472   c , external recesses  474   a ,  474   b ,  474   c , and an interior stop  476 . The external recess  474   b  is configured such that the seal  550  can be seated therein and the external recess  474   c  is configured to seat a portion of the ferrule  700 . The annular shoulder  470  cooperates with the threaded portion  416  of the rear outer body  402  to secure the rear outer body  402  with the front subassembly  404 . The front body shell  460  is preferably made from at least one metallic material, such as brass, and plated with at least one conductive, corrosion resistant material, such as a nickel-tin alloy. 
     The seal  550  is configured to prevent exposure to water and other elements, particularly upon assembly with the rear outer body  402 , as shown in  FIG. 7 . The seal  550  is shown having a substantially circular cross-section, however, the cross-sectional shape is exemplary. The seal may have any cross-sectional shape. The seal material is elastomeric and thus conformable to the seal both the recess and the space between the rear outer body and the front body shell upon assembly. 
     The insulator  600  preferably has the same configuration as the insulator  300  of the first connector assembly embodiment. Accordingly, the insulator includes a bore  602  aligned with respect to longitudinal axis A′ and an outer surface  484 . In preferred configurations, the insulator further includes an insulator channel  606 . In the connector assembly  400 , the insulator  600  is positioned to abut against the interior stop  476  of the front body shell  460 . The insulator  600  is also preferably made from an electrically insulative material such as a foam-based material or acetal. 
     As shown particularly in  FIG. 7 , the contact element  620  includes a contact front end  622  and a contact back end  624 . The contact front end  622  has a female configuration to receive a male configured mating component (now shown). The back end  624  includes a tapered portion  626  that engages with the center conductor  105 . The contact element  620  is also configured to flex as necessary and make physical and electrical contact with the center conductor  105 . The contact element is also preferably made from at least one metallic material, such as beryllium copper. In preferred embodiments, the contact element is also heat treated and plated with at least one conductive, corrosion resistant material, e.g. a nickel-tin alloy. 
     The ferrule  700  is configured to 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 . The ferrule is preferably made of at least one metallic material, such as brass, and plated with at least one conductive material, such as nickel-tin. 
     Referring back to  FIG. 6 , the ferrule  700  includes a front ferrule end  702 , a back ferrule end  704 , a plurality of slots  706 , a tapered surface  708 , and a plurality of annular ridges  710 . The front ferrule end  702  has an inwardly extending projection  712  that fits within the external recess  474   c . At the opposite end, the back ferrule end  704  is configured for engagement with the corrugated outer conductor  125 . The plurality of slots  706  in the ferrule  700  provide the ferrule  700  with spring-like characteristics. Accordingly, the plurality of slots  706  facilitate spring-like engagement of the ferrule  700  upon coupling with the corrugated outer conductor  125 , the rear outer body  402  and the engagement element  420 . The plurality of annular ridges  710  also facilitate engagement with the corrugated outer conductor  125  by nature of the ridges themselves. 
     Upon coupling of the rear outer body  402  with the ferrule  700 , as shown in  FIG. 7 , the corrugated outer conductor is positioned within a gripping space  788  formed between the end portion  469  of the front body shell  404  and the ferrule  700 . Also upon coupling of the front body shell  404  with the ferrule  700  and the rear outer body  402 , at least one of the annular ridges  710  ( FIG. 6 ) engages with the outermost valley  126  of the corrugated outer conductor  125  such that a portion of the ferrule  700  is sandwiched between the engagement element  420  and the corrugated outer conductor  125 . 
     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.