Patent Document

FIELD OF THE INVENTION 
     The present invention relates to coaxial connectors. More specifically, the present invention relates to a coaxial connector for slidably mating with another coaxial connector. 
     BACKGROUND OF THE INVENTION 
     In the telecommunications industry, it is known to use circuit modules in a chassis mounted in equipment racks to provide connection and cross-connection for telecommunications circuits. These modules may incorporate coaxial connectors along the one of their edges, the modules being designed for insertion into the chassis such that these connectors interface with mating coaxial connectors incorporated into the chassis. 
     The connectors incorporated into the chassis must be durable enough to withstand repeated insertions and removals of the module connectors, as the modules may be removed and reinserted multiple times. Manufacturing and insertion tolerances required that these chassis connectors also be capable of accepting modules which might be inserted slightly out of alignment. Also, these chassis connectors often provide some degree of engagement force against the modules connectors, such as springs or others tabs, which are capable of withstanding multiple insertion/extraction cycles. High manufacturing costs, breakage of parts and poor connections are concerns needing attention. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a telecommunications coaxial connector comprising a body with a first open end, an opposite second open end and an axial opening defined through the body and a cap positioned about the first open end. The cap is electrically connected with the body and includes a side wall, an open end aligned with the axial opening, and a continuous ring about the open end of the cap and an integral spring member defined in the side wall. A center conductor is positioned within the axial opening such that the center conductor extends into the cap and an insulator electrically isolates the center conductor from the body. 
     The present invention also relates to a telecommunications chassis including a bulkhead with coaxial telecommunications connectors with electrically connected ends and an enclosure with open ends, the bulkhead positioned across an open end with the coaxial telecommunications connectors within the enclosure. The coaxial telecommunications connectors each having a body with a first open end, an opposite second open end and an axial opening defined through the body, and a cap positioned about the first open end. The cap is electrically connected with the body and includes a side wall, an open end aligned with the axial opening, a continuous ring about the open end of the cap and an integral spring member defined in the side wall, and a center conductor positioned within the axial opening such that the center conductor extends into the cap and an insulator electrically isolating the center conductor from the body. 
     The present invention further relates to a method of assembling a telecommunications coaxial connector. 
     The present invention further relates to a method of forming a cap for a telecommunications coaxial connector. 
     A variety of advantages of the invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows: 
     FIG. 1 is a front perspective view of a telecommunications rack mount chassis according to the present invention. 
     FIG. 2 is a rear perspective view of the telecommunications rack mount chassis of FIG.  1 . 
     FIG. 3 is a front view of the telecommunications rack mount chassis of FIG.  1 . 
     FIG. 4 is a side view of the telecommunications rack mount chassis of FIG.  1 . 
     FIG. 5 is a cross-sectional view of the telecommunications rack mount chassis of FIG. 1, taken along line  5 — 5  in FIG.  3 . 
     FIG. 6 is a front perspective view of a prior art telecommunications circuit module for use with the telecommunications rack mount chassis of FIG.  1 . 
     FIG. 7 is a rear perspective view of the telecommunications circuit module of FIG.  6 . 
     FIG. 8 is a side view of a bulkhead mount coaxial connector according to the present invention. 
     FIG. 9 is a first exploded view of the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 10 is a second exploded view of the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 11 is a cross-sectional view of the bulkhead mount coaxial connector of FIG. 8, taken along line  11 — 11 . 
     FIG. 11A is a cross-sectional view of a bulkhead mount coaxial connector of FIG. 11 mated with a module mount coaxial connector of the telecommunications circuit module of FIG.  7 . 
     FIG. 12 is a first perspective view of an end cap according to the present invention for the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 13 is a second perspective view of the end cap of FIG.  12 . 
     FIG. 14 is a first perspective view of a center conductor for the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 15 is a second perspective view of the center conductor of FIG.  14 . 
     FIG. 16 is a first perspective view of a first center conductor insulator for the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 17 is a second perspective view of the first center conductor insulator of FIG.  16 . 
     FIG. 18 is a first perspective view of a second center conductor insulator for the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 19 is a second perspective view of the second center conductor insulator of FIG.  18 . 
     FIG. 20 is a perspective view of a first alternative end cap according to the present invention for the bulkhead mount coaxial connector of FIG.  8 . 
     FIG. 21 is a perspective view of a second alternative end cap according to the present invention for the bulkhead mount coaxial connector of FIG.  8 . 
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to exemplary aspects of the present invention that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     In the telecommunications industry, facility installations often require switching and cross-connect equipment to be mounted in dense, rack-mounted central location. Such an installation might involve one or more equipment bays and a variety of network elements connected throughout the facility led to the proximity of the bays or racks. Chassis installed in the racks with back plane connections linked to these network elements might then be pre-wired to these network elements. When the network elements need to be utilized to provide telecommunications connectivity to a particular part of the facility, a circuit module is then installed in the appropriate slot in a chassis. 
     For telecommunications installations such as these, the use of coaxial cable for the network elements is common. In conjunction with the coaxial cable, coaxial connectors may be installed on the back plane of the chassis. As well, coaxial connectors might be used on the modules to connect with these back plane connectors and thus with the network elements. It is known for the back plane connectors to mate with the network elements via a coaxial connector and for the modules to have the same type of coaxial connector. For example, the back plane connectors might provide BNC connectors for linking to the network elements and also have a connector that is able to mate with BNC connectors on the rear of the modules. The use of other types of coaxial connectors, or other similar connectors, is also anticipated. 
     Referring now to FIGS. 1 through 5, a chassis  10  for use in a telecommunications equipment rack is shown. Chassis  10  includes a top  26 , a bottom  28  and opposing sides  24  and  30 , which cooperate to define an interior with a first opening  12  and a opposing second opening  11 . Along first opening  12  in both top  26  and bottom  28  are defined a series of module attachment openings  18 . Mounted within chassis  10  on top  26  and bottom  28  proximate first opening  12  are module guides  34 . Centrally located within chassis  10 , extending from top  26  to bottom  28  and approximately parallel to sides  24  and  30  is a support  32 . Extending outward from sides  24  and  30  proximate first opening  12  are mounting flanges  14  with mounting holes  16  defined for mounting chassis  10  to a rack (not shown) along with additional chassis  10  or other equipment. Second opening  11  is further defined by a back plane  21  to which are mounted coaxial bulkhead connectors  20 . An edge connector strip  23  provides electrical power for circuit tracing. Extending beyond back plane  21 , sides  24  and  30  also provide support to cable guides  22 , which provide support and protection to those network elements that are led to second opening  11 . 
     Referring now to FIGS. 6 and 7, a module  36  for use with a chassis  10  is shown. Module  36  includes a first pair of coaxial connectors  38  mounted to a first rear edge  48  and a second pair of coaxial connectors  38  mounted to a second rear edge  50 , the two rear edges being offset from one another. Module  36  also includes a face plate  46  on which are found an IN switching port  52 , an OUT switching port  54  and a monitor port  60 . Switching jacks  53  and  55 , monitor jack  61 , and cables  57 , link ports  52 ,  54  and  60  to connectors  38 . A tracer lamp  56  and a tracer lamp switch  58  are provided for circuit tracing. Power for tracing lamp  56  is provided through a mating edge connector  59  for mating with an edge connector strip  23 . 
     Extending through face plate  46  are two fasteners  40  which engage openings  18  on chassis  10  when module  36  is inserted into opening  12 . Housing  44  connects face plate  46  to back planes  48  and  50  and includes a pair of guide tabs  42  which interface with module guides  34  to properly orient and position module  36  within chassis  10 . When module  36  is inserted into chassis  10  such that tabs  42  interface with module guide  34  and fasteners  40  engage openings  18 , coaxial connectors  38  are correctly positioned to slidably mate with module interface ends  62  of bulkhead connectors  20  and thus to any network elements connected to network interface ends  64  of bulkhead connectors  20 . 
     Module  36  is an example cross-connect module commercially available from ADC Telecommunications, Inc., catalog no. DSX-4U-MBRC. It is to be appreciated that other modules can interface with chassis  10 . Chassis  10  can further be configured with a variety of other arrangements to slidably receive other modules for slidably mating with coaxial bulkhead connectors  20  with the coaxial connectors of the modules. 
     FIG. 8 shows bulkhead connector  20  including a body  68 , an end cap  66 , a network interface end  64  and a module interface end  62 . A pair of opposed, outwardly projecting bayonets  67  extend from body  68  proximate network interface end  64 . Bayonets  67  cooperate with structure of a network coaxial cable (not shown) to securely connect the network cable to network interface end  64 . FIGS. 9 and 10 show the internal parts comprising bulkhead connector  20 , including a center conductor  74 , a pair of insulators  72  and  70  into which center conductor  74  is inserted, and end cap  66 . Center conductor  74 , and insulators  70  and  72  are mounted within cavity  80  of body  68 . Cavity  80  extends through the length of body  68 , from network element interface opening  64  to opposing opening  76  proximate end cap  66 . Defined proximate opposing end  76  are mounting ring  82  and ledge  78 . FIG. 11 shows bulkhead connector  20  in cross-sectional view with center conductor  74 , and insulators  70  and  72  inserted within cavity  80  and end cap  66  in place about mounting ring  82 . 
     Referring now to FIGS. 12 and 13, end cap  66  includes barrel  92 , ring portion  84  with doubled edge  86  and shoulder  90 , and ledge  88  connecting ring portion  84  and barrel  92 . It is anticipated that end cap  66  will be made of a resilient, elastic metallic material such as phosphor bronze. Other similar materials of suitable elasticity and conductivity may also be used. In barrel  92  are four springs  94 . Each spring  94  comprises an outward flared portion  93  and a ramped end  95 . It is anticipated that the number of springs  94  can vary and may include only one. About module interface end  62  of end cap  66  is a closed end  65 , which defines an opening  63 . Closed end  65  is bevel shaped to facilitate mating with a coaxial connector  38  of a module  36  that might be slightly mis-aligned. Springs  94  as shown are attached to barrel  92  of end cap  66  proximate ledge  88  and extend toward closed end  65 . Referring again to FIGS. 8 and 11, a gap  96  is defined between closed end  65  and ramped end  95  of each spring  94 . The end of ramped end  95  adjacent gap  96  rests below the outer surface of closed end  65  so that ramped end  95  will not catch on coaxial connector  38  as coaxial connector  38  is mated with bulkhead connector  20 . End cap  66  is suitable for manufacture by a deep drawing process although other methods of manufacture are anticipated as being suitable in keeping with principles of the present invention. 
     Referring now to FIG. 8, three outer diameters are defined by end cap  66 . A first outer diameter A is defined by barrel  92 . A second outer diameter C is defined by ring portion  84 . And a third outer diameter B is defined by springs  94 . 
     FIG. 11A is a cross-sectional view of a coaxial connector  38 , such as shown mounted to a module  36 , with a coaxial bulkhead connector  20  inserted. 
     It is anticipated that springs  94  of end cap  66  could be configured as shown in FIGS. 20 and 21. In FIG. 20, an alternative end cap  166  is shown for use with a body  68 . End cap  166  includes one or more springs  194  which extend along barrel  192 . Springs  194  are attached to barrel  192  proximate closed end  165  and extend away from closed end  165 . In FIG. 21, springs an alternative end cap  266  is shown for use with a body  68 . End cap  266  includes one or more springs  294  which extend along barrel  292 . Springs  294  are attached to barrel  292  and extends parallel to closed end  265 . Aside from the differences in the direction and orientation of the springs, end caps  166  and  266  are otherwise identical to end cap  66 . 
     It is anticipated that end cap  66  may be formed by a variety of known metal forming methods, such as deep drawing. The process of drawing end cap  66  begins with a flat piece of an appropriately conductive metal, such as phosphor bronze. This flat piece of material is formed into a cylindrical shape or barrel having a closed end, an open end and a flange about the open end. An opening is formed in the closed end of the barrel, the opening being smaller in diameter than the barrel. About the barrel between the open end and the closed end are formed one or more resilient springs which extend beyond the diameter of the barrel. The flange about the open end of the barrel is formed to enable the cap to be mounted to an electrical connector body such as body  68  as part of the assembly of bulkhead connector  20 . 
     Referring now to FIGS. 14 and 15, center conductor  74  includes a connector end  120 , a mating end  118 , a first mounting ledge  114  and a second mounting ledge  116 , adjacent mating end  118 . Mating end  118  as shown is suitable for engaging the center conductor of a BNC coaxial connector. It is anticipated that bulkhead connector  20  will be adapted for use with other types of coaxial connectors and that mating end  118  will be altered as necessary to mate with the center conductor of these connectors. Referring now to FIGS. 16 and 17, insulator  70  includes a central opening  106 , outer bearing surfaces  108 , and arms  110  with locking tabs  112 . Referring now to FIGS. 18 and 19, insulator  72  includes a central opening  98 , tab  100 , and equal sized wings  102  extending from body  104 . It is anticipated that a variety of alternative designs for insulators are possible, provided they perform the required functions of holding center conductor  74  within cavity  80  and electrically insulating center conductor  74  from body  68 . 
     When assembled as shown in FIG. 11, center conductor  74  extends through central opening  98  of insulator  72  with tab  100  resting against second mounting ledge  116 . Wings  102  extend to contact body  68  and hold mating end  118  centered within cavity  80 . Center conductor  74  also extends through central opening  106  of insulator  70  with locking tabs  112  engaging first mounting ledge  114 . End cap  66  is fit about mounting ring  82  with shoulder  90  resting against ledge  78 . As shown, end cap  66  and body  68  are appropriate for the use of swaging or press fitting to fixedly hold end cap  66  to body  68 . It is anticipated that other forms of mechanical joining of end cap  66  and body  68  may be used without altering end cap  66  and body  68  beyond the principles of the present invention. Connector end  120  of center conductor  74  extends through opposing opening  76  and into barrel  92  of end cap  66 . Bearing surfaces  108  of insulator  70  rest against body  68  to hold connector end  120  centered barrel  92 . Insulator  70  includes a inner surface  122  that rests against a first inner surface  122  within body  68  and insulator  72  includes a inner surface  126  that rests against a second inner surface  128  within body  68  when insulators  70  and  72  engage center conductor  74 . The combination of insulators  70  and  72  engaging center conductor  74  and inner surfaces  124  and  128  holds center conductor  74  within body  68 . 
     Having described preferred aspects and embodiments of the present invention, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are hereto appended.

Technology Category: h