Sealed coaxial cable connector and related method

• US 6,916,200 B2
• Filed: 05/10/2004
• Issued: 07/12/2005
• 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:
  US10/842,070
• Publication Number:
  US 20040219833A1
• Time in Patent Office: 428 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 connector is provided for coupling an end of a coaxial cable to a terminal, such as a cable terminal, a terminal for coupling to another connector, and the like The connector includes a coupler, such as a nut, having a receiving port for engaging the terminal. The coupler also includes an annular collar. The connector also includes a body member, one end of which includes a lip. The lip is inserted through the collar opening. The other end of the body section includes an inner surface portion. The connector still further includes a post, an end of which is sized for insertion between the dielectric and the outer conductor of the cable. The post further includes a post flange and a post shank. The post shank forms a post channel sufficient in diameter to receive the inner conductor and the dielectric of the cable. The post is movable between a cable-insertion position and a cable-installed position. In the cable-installed position, 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 is sufficiently narrow in this cable-installed position to compress the outer conductor and the jacket with the post shank and the inner surface portion for establishing a distal seal. Tightening of the coupler to the terminal compresses the lip between the post flange 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 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;

a body member comprising a proximal body section comprising a lip and an annular shoulder, wherein the annular collar is disposed between the lip and the annular shoulder, and a distal body section having an inner surface with an inner surface portion; and

a post comprising;

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

a radially extending post flange, and

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 annular collar to the inner surface portion;

wherein the post is movable between a cable-insertion position, in which 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 inserted 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;

wherein the annular shoulder integrally connects the proximal body section and the distal body section to one another, the annular shoulder having a distal shoulder end, and wherein the post shank has an outer surface comprising at least one barb abutting against the distal shoulder end when the post is in the cable-installed position.

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

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

4. The connector of claim 1 wherein the proximal body section comprises a proximal body end and the distal body section comprises a distal body end, the proximal body end being in closer proximity to the coupler than the distal body end, and wherein the annular shoulder integrally connects the proximal body section and the distal body section to one another.

5. The connector of claim 1 wherein the proximal body section comprises a proximal body end and the distal body section comprises a distal body end, the proximal body end being in closer proximity to the coupler than the distal body end, and 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.

6. The connector of claim 5 wherein the post shank is sufficient in length to extend from the proximal body end to the tapered region.

7. The connector of claim 1 wherein the proximal body section comprises a proximal body end, and wherein in the cable-installed position, the post flange abuts against the proximal body end of the body member.

8. 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 an outer portion providing a receiving port for coupling to the terminal, and an annular collar extending radially inward from the outer portion to provide a collar opening having an opening diameter;

(b) providing a plastic body member comprising an inner surface portion;

(c) inserting the body member into the annular collar to join the coupler and the body member to one another;

(d) providing a metallic post comprising a distal post end, a proximal post end, a radially extending post flange movable within the receiving port, and a post shank extending from the post flange, the distal post end sized for insertion between the dielectric and the outer conductor, 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 annular collar to the inner surface portion,

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

(f) moving the post 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;

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; and

wherein the annular shoulder integrally connects 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.

9. The method of claim 8, wherein the coupler is made from a metallic material.

10. The method of claim 8 wherein the proximal body section comprises a proximal body end and the distal body section comprises a distal body end, the proximal body end being in closer proximity to the coupler than the distal body end, and 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 method of claim 10 wherein the post shank is sufficient in length to extend from the proximal body end into the tapered region.

12. The method of claim 8 wherein the (e) passing comprises maintaining the post flange and the annular collar axially spaced from one another.

13. The method of claim 8 wherein the proximal body section comprises a proximal body end and the distal body section comprises a distal body end, the proximal body end being in closer proximity to the coupler than the distal body end, and wherein the (f) moving comprises abutting the post flange against the proximal end of the body member.

14. 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, wherein the end of the cable comprises an exposed portion of the dielectric, the method comprising:

(a) providing a connector comprising;

a coupler comprising a substantially cylindrical portion having a receiving port for engaging the terminal;

a body member comprising a distal body end and a proximal body end, a proximal body section, and a distal body section, the distal body section extending away from the proximal body section and comprising a reduced diameter inner surface portion;

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;

wherein the coupler is rotatably engaged about an outer surface of the proximal end of the body member,

wherein an elevated portion of an outer surface of the post shank is engaged with an inner surface of the proximal end of the body member,

wherein part of the post shank is disposed within the body member, and wherein an inner surface of the body member and an outer surface of the part of the post shank disposed therein form an annular chamber, wherein the distal post end is spaced sufficiently axially apart from the reduced diameter inner surface portion to allow insertion of the coaxial cable into the annular chamber;

(b) passing the coaxial cable into the annular chamber until an end of the dielectric is proximate the proximal post end, wherein the distal post end is inserted between the dielectric and the outer conductor, and wherein an end of the center conductor and an end of the dielectric are received in the post channel;

(c) driving the body and post axially together, wherein the outer conductor and the protective outer jacket are compressed between the post shank and the reduced diameter inner surface portion of the body member, thereby establishing a distal seal.

15. The method of claim 14 further comprising, after (c), engaging the coupler with the terminal and compressing the proximal body end, thereby establishing a proximal seal.

16. The method of claim 15 wherein the engaging compresses a part of the body member between the post flange and the coupler.

17. The method of claim 15 wherein the coupler has a threaded inner surface and the terminal is threaded, and wherein engagement of the coupler onto the terminal comprises threadedly engaging the coupler onto the terminal.

18. The method of claim 14 wherein in (b), the end of the coaxial cable is passed into the distal body end of body until the end of the dielectric of the coaxial cable is flush with the proximal post end.

19. The method of claim 14 wherein in (b), the end of the dielectric of the coaxial cable is not flush with the proximal post end.

20. The method of claim 14 wherein after (b) the end of the coaxial cable is spaced away from the inner surface region.

21. The method of claim 14 wherein the longitudinal axes of post shank and the coaxial cable substantially coincide.

22. The method of claim 14 wherein in (c) the post and the cable are driven simultaneously together with the body.

23. The method of claim 14 wherein in (c) the cable end remains flush with the proximal post end as the body and post are brought axially together.

24. The method of claim 14 wherein in (c) the body member and the post flange are advanced axially toward each other sufficiently to place the post flange in close proximity to the proximal body end.

25. The method of claim 14 wherein in (c) the body member and the post flange are advanced axially toward each other sufficiently to place the post flange in abutting relationship with the proximal body end.

26. The method of claim 14 wherein axial egress of the post out of the body member is limited by mutually engageable surfaces on the post and the body.

27. The method of claim 14 wherein the coupler comprises an annular collar extending radially inward from the substantially cylindrical portion to provide a collar opening having an opening diameter.

28. The method of claim 27 wherein the proximal body section is receivable in the collar opening, and wherein the proximal body section comprisesa lip at the proximal body end, the lip having an outer lip diameter greater than the opening diameter.

29. The method of claim 28 wherein the body member is sufficiently resilient for flexible insertion of the lip through the collar opening.

30. 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 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;

a body member comprising a proximal body section comprising a lip and an annular shoulder, wherein the annular collar is disposed between the lip and the annular shoulder, and a distal body section having an inner surface with an inner surface portion; and

a post comprising;

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

a radially extending post flange, and

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 annular collar to the inner surface portion;

wherein the post is movable between a cable-insertion position, in which 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 inserted 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 the proximal body section comprises a proximal body end, and wherein in the cable-installed position, the post flange abuts against the proximal body end of the body member.

31. 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 an outer portion providing a receiving port for coupling to the terminal, and an annular collar extending radially inward from the outer portion to provide a collar opening having an opening diameter,

(b) providing a plastic body member comprising an inner surface portion;

(c) inserting the body member into the annular collar to join the coupler and the body member to one another;

(d) providing a metallic post comprising a distal post end, a proximal post end, a radially extending post flange movable within the receiving port, and a post shank extending from the post flange, the distal post end sized for insertion between the dielectric and the outer conductor, 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 annular collar to the inner surface portion,

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

(f) moving the post 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;

wherein the proximal body section comprises a proximal body end and the distal body section comprises a distal body end, the proximal body end being in closer proximity to the coupler than the distal body end, and wherein the (f) moving comprises abutting the post flange against the proximal end of the body member.