Sealed coaxial cable connector and related method

• US 6,790,081 B2
• Filed: 05/08/2002
• Issued: 09/14/2004
• Est. Priority Date: 05/08/2002
• Status: Expired due to Term

• Current Assignee: PPC Broadband Incorporated (Belden Inc.)
• Original Assignee: Corning Gilbert Incorporated (Corning Incorporated)
• Inventors: Lutz, William B., Burris, Donald A., Sundvold, Steven E., Wood, Kenneth S., Durst, Herman P., Kearsey, David M.
• Primary Examiner(s): Abrams, Neil
• Application Number:
  US10/142,274
• Publication Number:
  US 20030211778A1
• Time in Patent Office: 860 Days
• Field of Search: 439/578, 439/584, 439/585
• US Class Current: 439/578
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 9/0521 Connection to outer conductor by action of a nut

Abstract

A coaxial cable connector includes a coupler, a post and a body member. One end of the body member includes a lip that is inserted through the opening in an annular collar of the coupler. In a cable-installed position, the shank of the post is received in the body member to form an annular chamber which is sufficiently narrow to compress the outer conductor and the jacket of a coaxial cable to establish a distal seal. Tightening of the coupler to the terminal compresses the lip between the flange of the post and the annular collar for establishing a proximal seal. Related methods also are provided.

Claims

1. A connector for coupling an end of a coaxial cable to a terminal, the coaxial cable comprising an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor, the connector comprising:

(a) a coupler comprising

(i) a substantially cylindrical portion having a receiving port for engaging the terminal, and

(ii) an annular collar extending radially inward from the substantially cylindrical portion to provide a collar opening having an opening diameter;

(b) a body member comprising

(i) a distal body end and a proximal body end,

(ii) a proximal body section receivable in the collar opening and comprising a lip at the proximal body end, the lip having an outer lip diameter greater than the opening diameter, the body member being sufficiently resilient for flexible insertion of the lip through the collar opening, and

(iii) a distal body section extending away from the proximal body section, the distal body section comprising an inner surface portion; and

(c) a post comprising

(i) a distal post end and a proximal post end, the distal post end sized for insertion between the dielectric and the outer conductor,

(ii) a radially extending post flange movable within the receiving port, and

(iii) a post shank extending from the post flange, the post shank forming a post channel sufficient in diameter to receive the inner conductor and the dielectric, the post shank being sufficient in length to extend from the lip to the inner surface portion,

wherein the post is movable between a cable insertion position, in which the post flange is spaced apart from the lip and the distal post end is sufficiently spaced apart from the inner surface portion for inserting the coaxial cable into the body member, and a cable-installed position, in which the post shank is received in the body member to form an annular chamber between the post shank and the inner surface portion, the annular chamber being sufficiently narrow to compress the outer conductor and the jacket with the post shank and the inner surface portion for establishing a distal seal, and

wherein tightening the coupler to the terminal compresses the lip between the post flange and the annular collar for establishing a proximal seal.

2. The connector of claim 1, wherein:

each of the coupler and the terminal comprises respective threads; and

the coupler and the terminal, when the respective threads are engaged and tightened, compress the lip between the post flange and the annular collar for establishing the proximal seal.

3. The connector of claim 1, wherein the coupler comprises a nut.

4. The connector of claim 1, wherein the body member comprises plastic.

5. The connector of claim 1, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another.

6. The connector of claim 5, wherein the collar is disposed between the lip and the annular shoulder.

7. The connector of claim 6, wherein the lip and the annular shoulder are spaced apart by a sufficient distance to permit limited axial movement of the annular collar of the coupler therebetween before the coupler is engaged with the terminal, the limited axial movement permitting free-spinning movement of the coupler relative to both the post and the body member until the coupler is engaged with the terminal.

8. The connector of claim 1, wherein the lip has a forward chamfer.

9. The connector of claim 1, wherein the proximal body section and the distal body section are each cylindrical.

10. The connector of claim 1, wherein the inner surface portion comprises a tapered region tapering radially inward in a direction from the proximal body end towards the distal body end.

11. The connector of claim 10, wherein the post shank is sufficient in length to extend from the lip to the tapered region.

12. The connector of claim 1, wherein the lip comprises an elastically deformable material for elastically deforming when the lip is compressed between the post flange and the annular collar.

13. The connector of claim 1, wherein the lip comprises a plastically deform able material for plastically deforming when the lip is compressed between the post flange and the annular collar.

14. The connector of claim 1, wherein the post shank has an outer surface comprising at least one barb.

15. The connector of claim 1, wherein the post has an outer surface comprising a plurality of barbs.

16. The connector of claim 1, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, the annular shoulder having a distal shoulder end, and wherein the post has an outer surface comprising at least one barb abutting against the distal shoulder end when the post is in the cable installed position.

17. The connector of claim 1, wherein the post is concentric with the coupler and the body member.

18. The connector of claim 1, wherein in the cable installed position, the post flange abuts against the proximal end of the body member.

19. The connector of claim 1, wherein the post flange has an outer diameter greater than the opening diameter.

20. The connector of claim 1, wherein the connector is free of any O-rings for sealing engagement between the coupler, the body member, and the post.

21. A connector for coupling an end of a coaxial cable to a terminal, the coaxial cable comprising an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor, the connector comprising:

(a) a coupler comprising

(i) a substantially cylindrical portion having a receiving port for engaging the terminal, and

(ii) an annular collar extending radially inward from the substantially cylindrical portion to provide a collar opening having an opening diameter;

(b) a body member comprising

(i) a distal body end and a proximal body end,

(ii) a proximal body section receivable in the collar opening and comprising a lip at the proximal body end, the lip having an outer lip diameter greater than the opening diameter, the body member being sufficiently resilient for flexible insertion of the lip through the collar opening, and

(iii) a distal body section extending away from the proximal body section; and

(c) a post comprising

(i) a distal post end and a proximal post end, the distal post end sized for insertion between the dielectric and the outer conductor,

(ii) a radially extending post flange movable within the receiving port, and

(iii) a post shank extending from the post flange, the post shank forming a post channel sufficient in diameter to receive the inner conductor and the dielectric,

wherein the post is movable between a cable-insertion position, in which the post flange is spaced apart from the lip and the coaxial cable is insertable into the body member, and a cable-installed position, in which a post flange abuts the lip, and

wherein tightening the coupler to the terminal compresses the lip between the post flange and the annular collar for establishing a proximal seal.

22. The connector of claim 21, wherein:

each of the coupler and the terminal comprises respective threads; and

the coupler and the terminal, when the respective threads are engaged and tightened, compress the lip between the post flange and the annular collar to establish the proximal seal.

23. The connector of claim 21, wherein the coupler comprises a nut.

24. The connector of claim 21, wherein the body member comprises plastic.

25. The connector of claim 21, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another.

26. The connector of claim 25, wherein the collar is disposed between the lip and the annular shoulder.

27. The connector of claim 26, wherein the lip and the annular shoulder are spaced apart by a sufficient distance to permit limited axial movement of the collar of the coupler therebetween before the coupler is tightened to the terminal, the limited axial movement permitting free-spinning movement of the coupler relative to both the post and the body member until the coupler is engaged with the terminal.

28. The connector of claim 21, wherein the lip has a forward chamfer.

29. The connector of claim 21, wherein the proximal body section and the distal body section are each cylindrical.

30. The connector of claim 21, wherein the lip comprises a plastically deformable material for plastically deforming when the lip is compressed between the post flange and the annular collar.

31. The connector of claim 21, wherein the lip comprises an elastically deformable material for elastically deforming when the lip is compressed between the post flange and the annular collar.

32. The connector of claim 21, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, the annular shoulder having a distal shoulder end, and wherein the post has an outer surface comprising at least one barb abutting against the distal shoulder end when the post is in the cable installed position.

33. A method for coupling an end of a coaxial cable to a terminal using a connector, the coaxial cable comprising an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor, the method comprising:

(a) providing a coupler comprising a substantially cylindrical portion having a receiving port for engaging the terminal, and an annular collar extending radially inward from the substantially cylindrical portion to provide a collar opening having an opening diameter;

(b) providing a body member comprising a distal body end and a proximal body end, a proximal body section, and a distal body section, the proximal body section being receivable in the collar opening and comprising a lip at the proximal body end, the lip having an outer lip diameter greater than the opening diameter, the body member being sufficiently resilient for flexible insertion of the lip through the collar opening, the distal body section extending away from the proximal body section and comprising an inner surface portion;

(c) inserting the lip through the collar opening while flexing the lip inward to situate the proximal body section in the collar opening;

(d) providing a post comprising a distal post end, a proximal post end, a radially extending post flange movable within the receiving port, and a post shank having a post channel;

(e) passing the coaxial cable into the body member;

(f) moving the post shank through the coupler and into the body member and inserting the post shank between the dielectric and the outer conductor of the coaxial cable to receive the dielectric and the inner conductor in the post channel and to compress the outer conductor and the jacket in an annular chamber between the post shank and the inner surface portion for establishing a distal seal; and

(g) engaging the coupler with the terminal and compressing the lip between the post flange and the annular collar for establishing a proximal seal.

34. The method of claim 33, wherein:

each of the coupler and the terminal comprises respective threads; and

the engaging (g) comprises tightening the respective threads of the coupler and the terminal to compress the lip between the post flange and the annular collar for establishing the proximal seal.

35. The method of claim 34, wherein the coupler comprises a nut.

36. The method of claim 33, wherein the inner surface portion comprises a tapered region tapering radially inward in a direction from the proximal body end towards the distal body end.

37. The method of claim 34, wherein the post shank is sufficient in length to extend from the lip to the tapered region.

38. The method of claim 33, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, and wherein the (c) inserting comprises situating the collar between the lip and the annular shoulder.

39. The method of claim 38, wherein the (c) inserting comprises spacing the lip and the annular shoulder apart by a sufficient distance to permit limited axial movement of the collar between the lip and the annular shoulder before the coupler is engaged with the terminal, the limited axial movement avoiding significant engagement of the collar with the lip and permitting free-spinning movement of the coupler relative to both the post and the body member until the coupler is engaged with the terminal.

40. The method of claim 33, wherein the lip has a forward chamfer for facilitating the (c) inserting.

41. The method of claim 33, wherein the (e) passing comprises maintaining the post flange and the lip axially spaced from one another.

42. The method of claim 33, wherein the post shank has an outer surface comprising at least one barb, and wherein the (f) moving comprises trapping the outer conductor and the jacket of the coaxial cable with the barb.

43. The method of claim 33, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, the annular shoulder having a distal shoulder end, and the post shank has an outer surface comprising at least one barb, and wherein the (f) moving comprises abutting the barb against the distal shoulder end to prevent forward movement of the post relative to the distal shoulder end.

44. The method of claim 33, wherein the (f) moving comprises abutting the post flange against the proximal end of the body member.

45. The method of claim 33, wherein the compressing of the lip between the post flange and the annular collar comprises elastically deforming the lip.

46. The method of claim 33, wherein the compressing of the lip between the post flange and the annular collar comprises plastically deforming the lip.

47. A method for coupling an end of a coaxial cable to a terminal using a connector, the coaxial cable comprising an inner conductor, a dielectric surrounding the inner conductor, an outer conductor surrounding the dielectric, and a jacket surrounding the outer conductor, the method comprising:

(a) providing a coupler comprising a substantially cylindrical portion having a receiving port for engaging the terminal, and an annular collar extending radially inward from the substantially cylindrical portion to provide a collar opening having an opening diameter;

(b) providing a body member comprising a proximal body end, a distal body end, a proximal body section comprising a lip having an outer lip diameter greater than the opening diameter, and a distal body section extending axially away from the proximal body section;

(c) inserting the lip through the collar opening while flexing the lip inward to situate the proximal body section in the collar opening;

(d) providing a post comprising a distal post end, a proximal post end, a radially extending post flange movable within the receiving port, and a post shank having a post channel;

(e) passing the coaxial cable into the body member;

(f) moving the post shank through the coupler and into the body member and inserting the post shank between the dielectric and the outer conductor of the coaxial cable to receive the dielectric and the inner conductor in the post channel and to receive the outer conductor and the jacket in an annular chamber between the post shank and the inner surface portion;

(g) engaging the coupler with the terminal and compressing the lip between the post flange and the annular collar for establishing a proximal seal.

48. The method of claim 47, wherein:

each of the coupler and the terminal comprises respective threads; and

the engaging (g) comprises tightening the respective threads of the coupler and the terminal to compress the lip between the post flange and the annular collar for establishing the proximal seal.

49. The method of claim 48, wherein the coupler comprises a nut.

50. The method of claim 47, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, and wherein the (c) inserting comprises situating the collar between the lip and the annular shoulder.

51. The method of claim 50, wherein the (c) inserting comprises spacing the lip and the annular shoulder apart by a sufficient distance to permit limited axial movement of the collar between the lip and the annular shoulder before the coupler is tightened to the terminal, the limited axial movement avoiding significant engagement of the collar with the lip and permitting free-spinning movement of the coupler relative to both the post and the body member until the coupler is engaged with the terminal.

52. The method of claim 47, wherein the lip has a forward chamfer for facilitating the (c) inserting.

53. The method of claim 47, wherein the post shank has an outer surface comprising at least one barb, and wherein the (f) moving comprises trapping the outer conductor and the jacket of the coaxial cable with the barb.

54. The method of claim 53, wherein the body member further comprises an annular shoulder integrally connecting the proximal body section and the distal body section to one another, the annular shoulder having a distal shoulder end, and wherein the (f) moving comprising abutting the barb against the distal shoulder end to prevent forward movement of the post relative to the distal shoulder end.

55. The method of claim 47, wherein the (f) moving comprises abutting the post flange against the proximal end of the body member.

56. The method of claim 47, wherein the compressing of the lip between the post flange and the annular collar comprises elastically deforming the lip.

57. The method of claim 47, wherein the compressing of the lip between the post flange and the annular collar comprises plastically deforming the lip.