The present disclosure relates generally to connectors for terminating coaxial cable. More particularly, the present invention relates to axially compressible connectors for hardline or semi-rigid coaxial cables.
Coaxial cables are commonly used in the cable television industry to carry cable TV signals to television sets in homes, businesses, and other locations. A hardline coaxial cable may be used to carry the signals in distribution systems exterior to these locations and a flexible coaxial cable is then often used to carry the signals within the interior of these locations. Hardline or semi-rigid coaxial cable is also used where a high degree of radio-frequency (RF) shielding is required.
The hardline cable includes a solid wire core or inner conductor, typically of copper or copper-clad aluminum, surrounded by a solid tubular outer conductor. The outer conductor is also usually made of copper or aluminum. Dielectric material or insulation separates the inner and outer conductors. The outer conductor is covered with a cable jacket or sheath of plastic to provide protection against corrosion and weathering.
Threaded cable connectors, as shown in U.S. Pat. Nos. 5,352,134 and 6,019,636, have been employed to provide more even compression of the connector. Such connectors typically utilize some form of clamping mechanism that radially compresses the outer conductor of the cable against a tubular mandrel upon axial threaded movement of the connector components to retain the cable in the hardline connector. The clamping mechanism may include a conical sleeve surrounded by an outer sleeve which forces the conical sleeve to radially compress upon axial movement of the outer sleeve with respect to the conical sleeve. The length of the conical closure sleeve typically closes the full length of the mechanism with equal forces around the circumference of the mandrel. The resulting forces closing down on the coaxial cable compress the cable around the outside of the mandrel creating a formed bond on the outside surface.
The ability of a connector to make a solid ground connection to the outer sheath of hardline CATV cables has always been required to achieve long term performance with respect to RFI shielding effectiveness of the connector as well as facilitate proper signal transmission through the connector with minimal loss or disruption of said signal. Connectors throughout the CATV industry have been made with all metal mandrel support sleeves and also have been made with all plastic mandrel support sleeves. While all-metal versions may hold up very well strength wise over time and temperature, the all-plastic versions are susceptible to creep and can weaken over time and temperature.
Some conventional hardline coaxial cable connectors experience less than desirable electrical performance resulting from poor return loss performance. The return loss performance can be degraded by mismatched impedance or reflection, particularly at the front end of hardline connectors. Outside diameter changes of the collet and inside diameter changes of the front body surrounding the collet cause impedance changes along the connector, which in turn hurts return loss performance of the connector.
For example, the industry standard for electrical performance of hardline connectors is −25 dB return loss over a frequency range of 5 MHz to 1794 MHz. Before that, the industry standard was −30 dB return loss over a frequency range of 5 MHz to 1002 MHz or 5 MHz to 1218 MHz. However, the continually increasing demand for more bandwidth for signal transmissions over copper wire has led to a desire to provide hardline connectors capable of improved electrical performance across a wider frequency bandwidth, for example, a bandwidth of 5 MHz to 3 GHz or greater. Until now, persons of ordinary skill in the art were not able to achieve such improved electrical performance at the wider bandwidth extending to 3 GHz or greater.
In the case of conventional hardline connectors (e.g., one piece, two piece, and three piece), as signals are transmitted over a wider frequency bandwidth, electrical performance of such connectors degrades. Consequently, persons of ordinary skill in the art thought that it was not possible to provide hardline connectors (e.g., one piece, two piece, or three piece) that could be configured to achieve satisfactory electrical performance (e.g. −20 dB or better) over a wider frequency bandwidth of 5 MHz to 3 GHz or greater.
It may be desirable to provide a hardline connector that overcomes one or more of the aforementioned disadvantages of hardline connectors. That is, it may be desirable to provide a hardline connector having improved return loss performance over a wider frequency bandwidth without degrading other performance of the connector, such as electrical, mechanical, and environmental performance. For example, it may be desirable to provide a hardline connector that is configured to achieve a return loss of −20 dB or better over a frequency range of 5 MHz to 3 GHz or greater, but persons of ordinary skill in the art have not been able to do so. Similarly, it may be desirable to provide a hardline connector that is configured to achieve a return loss of −30 dB to −35 dB over a frequency range of 5 MHz to 3 GHz or greater, but persons of ordinary skill in the art have not been able to do. Further, it may be desirable to provide a hardline connector that is configured to achieve a return loss of −20 dB or better over a frequency range of 5 MHz to 6 GHz, but persons of ordinary skill in the art have not been able to do.
It may be desirable to provide a hardline connector having components and geometrical features designed to achieve high levels of return loss performance, but persons of ordinary skill in the art have not been able to do. It may be desirable to eliminate areas within the connector having impedance levels that deviate significantly from 75 ohms (above or below) by bringing the peaks and valleys of such impedance levels closer to 75 ohms, but persons of ordinary skill in the art have not been able to do.
In accordance with various embodiments of the present disclosure, a hardline connector for providing high frequency performance includes a front body assembly configured to be threadedly coupled with an interface port, a mid body assembly configured to be threadedly coupled with the front body assembly, and a back nut assembly configured to be threadedly coupled with the mid body housing.
In some aspects, the hardline connector is configured to achieve a return loss of −20 dB or better over a frequency range of 5 MHz to 3 GHz or greater, with such performance results being unexpected to one of ordinary skill in the art. In some aspects, the hardline connector is configured to achieve a return loss of −30 dB to −35 dB over a frequency range of 5 MHz to 3 GHz or greater, with such performance results being unexpected to one of ordinary skill in the art. In some aspects, the hardline connector is configured to achieve a return loss of −20 dB or better over a frequency range of 5 MHz to 6 GHz, with such performance results being unexpected to one of ordinary skill in the art.
In some aspects, the front body assembly includes a front body housing, a collet, and a nonconductive collet insulator configured to electrically insulate the collet from the front body housing.
In various aspects, the front body housing is configured to house the collet and the collet insulator.
According to some aspects, the collet includes a pin portion configured to extend through the collet insulator and extend from a forward end of the front body housing and a gripping portion configured to receive a center conductor of a hardline coaxial cable.
According to various aspects, the mid body assembly includes a mid body housing having a forward end configured to be threadedly coupled with a rearward end of the front body housing and a rearward end configured to receive the hardline coaxial cable.
In some aspects, the mid body assembly includes a nonconductive seizure bushing and a tubular conductive metal mandrel supported within the mid body housing.
According to various aspects, a forward facing surface of the seizure bushing includes a plurality of fins extending in the forward direction and being configured to be received in a plurality of longitudinal grooves in an inner wall of the front body housing when the mid body housing is threadedly coupled with the front body housing such that the seizure bushing is prevented from rotating relative to the front body housing.
In various aspects, the collet insulator includes radially spaced apart inner and outer cylindrical walls connected to one another at a forward end by a radial wall and radially extending ribs between the inner and outer cylindrical walls configured to provide radial strength to the collet insulator.
According to some aspects, the collet insulator extends from a rearward facing surface of an end wall at the forward end of the front body housing to a forward facing surface at a forward end of the gripping portion of the collet.
In some aspects, the mid body assembly includes a split tube clamp radially surrounding a portion of the conductive metal mandrel and a tubular ramp radially surrounding at least a portion of the tubular clamp.
In various aspects, the back nut assembly includes a back nut, a seal driver, and an O-ring.
According to some aspects, the back nut has a forward end configured to be threadedly coupled with a rearward end of the mid body housing and configured to receive the hardline coaxial cable.
According to various aspects, the ramp is configured to be moved forward relative to the clamp when the back nut is threadedly coupled with the mid body housing such that such that the ramp and the clamp are configured to engage one another, thereby causing the clamp to radially compress an outer conductor of the hardline coaxial cable onto the tubular conductive metal mandrel.
In some aspects, the seal driver is configured to be urged in a rearward direction relative to the back nut when the back nut is threadedly coupled with the mid body housing so as to compress the first O-ring to provide a seal between the back nut and the hardline coaxial cable.
According to various aspects, the connector is configured to improve return loss performance over a wider frequency bandwidth without degrading electrical, mechanical, and environmental performance of the connector by minimizing peaks and valleys of impedance levels within the connector relative a desired 75 ohm impedance.
Various aspects of the hardline coaxial connector, as well as other embodiments, objects, features and advantages of this disclosure, will be apparent from the following detailed description of illustrative embodiments thereof, which is to be read in conjunction with the accompanying drawings.
Referring first to
The coaxial cable 1000 generally includes a solid center conductor 1002 typically formed from a conductive metal, such as copper, copper clad aluminum, copper clad steel, or the like capable of conducting electrical signals therethrough. Surrounding the cable center conductor 1002 is a cable dielectric 1004, which insulates the cable center conductor to minimize signal loss. The cable dielectric 1004 also maintains a spacing between the cable center conductor 1002 and a cable outer conductor or shield 1006. The cable dielectric 1004 is often a plastic material, such as a polyethylene, a fluorinated plastic material, such as a polyethylene or a polytetrafluoroethylene, a fiberglass braid, or the like. The cable shield or outer conductor 1006 is typically made of metal, such as aluminum or copper, and is often extruded to form a hollow tubular structure with a solid wall having a smooth exterior surface. An insulative cable jacket 1008 surrounds the cable outer conductor 1006 to further seal the coaxial cable 1000. The cable jacket 1008 is typically made of plastic, such as polyvinylchloride, polyethylene, polyurethane, or polytetrafluoroethylene. When the cable is prepared for termination, a length of the dielectric 1004 is removed from the forward end of the cable 1000, leaving a radial space between the center conductor 1002 and the outer conductor 1006.
The connector 100 includes a plurality of components generally having a coaxial configuration about an axis defined by the center conductor 1002 of the coaxial cable 1000. The front body assembly 112 includes a front body housing 116 and a terminal pin assembly 118 supported by the front body housing 116. The front body housing 116 is formed with an axial bore configured to cooperatively contain the terminal pin assembly 118 and is made from an electrically conductive material such as aluminum, brass or the like. The front body housing 116 is formed with a threaded portion 120 at its forward end and a rearward threaded portion 122 at its rearward end opposite the forward threaded portion.
The terminal pin assembly 118 includes a conductive collet 180, a collet insulator 182, and a seizure bushing 184. The collet 180 includes a pin portion 181 and an opposite gripping portion 183. The gripping portion 183 includes a plurality of fingers configured to receive the center conductor 1002 of the cable 1000. The collet insulator 182 surrounds a portion of the collet 180, including the gripping portion 183, and provides insulation between the conductive collet 180 and the conductive front body housing 116. As shown, the collet insulator 182 extends from a forward end of the front body housing 116 to the rearward end of the collet 180. The pin portion 182 extends out of the front body housing 116 from the forward end and is configured to be received by an interface port (not shown), as would be understood by persons skilled in the art. The collet insulator 182 is also configured to assist with alignment of the collet 180 with the center conductor 1002 of the cable 1000 being terminated with the connector 100.
The forward threaded portion 120 of the front body housing is configured to cooperate with devices located in the field that receive the pin portion 181 of the collet 180. An O-ring 124 is provided around the forward threaded portion 120 to improve the seal that is made with the device receiving the pin portion 181 of the collet 180, and a portion of the exterior perimeter of the entry body housing 116 may be provided with a hexagonal shape to accommodate the use of tools during installation.
The seizure bushing 184 includes a forward end 185 an opposite rearward end 186. The forward end 185 includes an opening that tapers from the forward end 185 toward the rearward end 186 and is configured to receive a rearward end of the collet insulator 182 that tapers opposite to the forward end 185. The opposite tapers of the forward end 185 of the seizure bushing 184 and the rearward end of the collet insulator 182, which surrounds the gripping portion 183 of the collet 180, are configured to cause the gripping portion 183 of the collet 180 to be radially compressed onto the center conductor 1002 as the seizure bushing 184 is moved forwardly relative to the collet insulator 182 and the collet 180. The rearward end 186 includes an opening that tapers from the rearward end 186 toward the forward end 185 to assist with guiding the center conductor into the gripping portion 183 of the collet 180. The seizure bushing 184 also includes an annular flap 187 configured to be received in an annular groove 117 of the front body housing 116. The seizure bushing 184 may be made of a nonconductive material, for example, plastic, that is strong enough to radially compress the gripping portion 183 of the collet 180 on the center conductor 1002.
The rearward threaded portion 122 of the front body assembly 112 is configured to be threadedly coupled with the mid body assembly 113. The rearward threaded portion 122 includes an inward rim face 126 configured to engage an outer face of a mandrel 132 of the mid body assembly 113.
The mid body assembly 113 of the connector 100 includes a mid body housing 128 having an axial bore and a compression subassembly 130 rotatably supported within the axial bore. The compression subassembly 130 generally includes the mandrel 132, a ramp 134, and a clamp 136. An O-ring 125 is provided around the rearward threaded portion 122 to improve the seal between the front body housing 116 and the mid body housing 128.
The back nut assembly 114 of the connector 100 includes a back nut (or end cap) 129, seal driver 143, a first O-ring 142, and a second O-ring 145 arranged in a coaxial relationship about the central axis of the mid body housing 128. The first O-ring 142 improves the seal between the back nut 129 and the cable 1000 upon assembly, and the second O-ring 145 improves the seal between the back nut 129 and the mid body housing 128.
The mid body housing 128 is made from an electrically conductive material, such as aluminum, brass, or the like, and includes an internally threaded portion 144 at its forward end, which cooperates with the rearward threaded portion 122 of the entry body housing 116 so that the two connector portions may be threadedly coupled together. Similarly, the back nut 129 may be made from an electrically conductive material, such as aluminum, brass, or the like, and includes an externally threaded portion 131 at its forward end, which cooperates with a rearward threaded portion 133 of the mid body housing 128 so that the two connector portions may be threadedly coupled together. The exterior surface of the mid body housing 128 and/or the back nut 129 may be provided with a hexagonal shape to accommodate the use of tools to facilitate such threaded coupling.
The back nut 129 and the seal driver 143 are formed with an axial bore 146 dimensioned to receive the outside diameter of the cable 1000 in snug fitting relationship. At a forward end of the mid body housing 128, opposite the back nut 129, the mid body housing 128 is formed with a forward axial bore 147 communicating with the rearward axial bore 146 and dimensioned to accommodate the outer diameter of the mandrel 132. The back nut 129 is preferably formed with an annular shoulder 148 that prevents rearward movement of the ramp 134, and thus the clamp 136, as the clamp 136 is radially compressed, as will be discussed in further detail below.
The mandrel 132 includes a tubular body portion 152 terminating at a forward flanged portion 154. The mandrel 132 is made from metal. The outside diameter of the tubular body portion 152 of the mandrel 132 is dimensioned to be fitted within the inner diameter of the outer conductor 1006 of the coaxial cable 1000. Also, the inside diameter of the tubular body portion 152 is dimensioned to provide a passageway to receive the center conductor 102 of the cable 1000 after the cable has been prepared for termination, wherein a length of the dielectric 1004 has been removed from the forward end of the cable 1000. The mandrel 132 has an axial length that extends through the clamp 136 and into the back nut 129.
The ramp 134 is preferably made from an electrically conductive material, such as aluminum or brass, and includes an exterior surface 158 configured to be received within the forward axial bore 147 of the mid body housing 128. The ramp 134 terminates at a rearward edge 160, which is configured to engage the annular shoulder 148 of the back nut 129 and a forward end of the seal driver 143.
The clamp 136 is generally in the form of a split tube having a gap 166 extending the full length of the clamp. The gap 166 permits the diameter of the clamp 136 to be reduced more easily so that the clamp can be uniformly, radially compressed around the mandrel 132 upon rearward axial movement of the mandrel 132. An inner surface 168 of the clamp may be provided with structure to enhance gripping of the outer surface of the cable. Such structure may include internal threads, teeth or some other form of textured surface.
As mentioned above, the outer surface of the clamp 136 is provided with a circumferential ramped portion 162, which engages a forward end 170 of the ramp 134, opposite the rearward edge 160, upon forward axial movement of the ramp 134 to radially compress the clamp 136. The ramped portion 162 defines a conical segment of the clamp 136 that tapers radially inwardly in the rearward direction. A rearward portion of the clamp 136 is received in an axial bore of the ramp 134.
Operation and installation of the connector 100 will now be described. The front body assembly 112 is threadedly coupled with an interface port (not shown), by way of the threaded portion 120 of the front body housing 116. The end of the coaxial cable 1000 that is to be inserted through the back nut assembly 114 and into the rearward end of the mid body housing 128 is prepared in a conventional manner. The back nut assembly 114 is slid over the prepared end of the coaxial cable 1000, and the prepared end of the cable 100 is inserted into the mid body assembly 113 with the center conductor 1002 extending through the seizure bushing 184 and into the gripping portion 183 of the collet 180 and the outer conductor 1006 between the outer surface of the tubular body portion 152 of the mandrel 132 and the inner surface of the clamp 136.
The mid body housing 128 is threadedly coupled and rotated with respect to the front body housing 116 such that a forward end of the flange portion 154 of the mandrel 132 bears against a rearward facing shoulder of the seizure bushing 184 and urges the seizure bushing 184 in a forward direction relative to the collet insulator 182. The opposite tapering surfaces of the front end of the seizure bushing 184 and the rearward end of the collet insulator 182 engage one another, radially compressing the collet insulator 182 on the gripping portion 183 of the collet 182, which in turn radially compresses the gripping portion 183 of the collet 182 onto the center conductor 1002.
The back nut 129 is threadedly coupled and rotated with respect to the mid body housing 128. As the back nut 129 moves axially relative to the mid body housing 128, the seal driver 143 and the annular shoulder 148 of the back nut 129 urge the ramp 134 in a forward axial direction relative to the clamp 136. The forward translation of the ramp 134 causes the forward end 170 of the ramp 134 to engage the outer ramp portion 162 of the clamp 136, resulting in a radial compression of the clamp 136 onto the outer conductor 1006 of the cable 1000. The radial compression of the clamp 136 reduces the overall diameter of the clamp 136 and reduces the gap 166 of the ferrule so that the inner surface 168 of the clamp 136 bites down on the exposed portion of the outer cable conductor 1006 and presses the outer conductor 1006 against the mandrel 132.
Referring now to
The connector 300 includes a plurality of components generally having a coaxial configuration about an axis defined by the center conductor 1002 of the coaxial cable 1000. The front body assembly 312 includes a front body housing 316 (or front or first body or front or first body portion) and a terminal pin assembly 318 supported by the front body housing 316. Referring to
As shown in
The forward threaded portion 320 of the front body housing 316 is configured to cooperate with devices located in the field that receive the pin portion 381 of the collet 380. An O-ring 324 is provided around the forward threaded portion 320 to improve the seal that is made with the device receiving the pin portion 381 of the collet 380, and a portion 3165 of the exterior perimeter of the entry body housing 316 may be provided with a hexagonal shape to accommodate the use of tools during installation. The rearward threaded portion 322 of the front body housing 316 is configured to be threadedly coupled with the mid body assembly 313.
As shown in
Referring to
The back nut assembly 314 of the connector 300 includes a back nut or end cap 329 (or back or third body or back or third body portion), seal driver 343, a first O-ring 342, and a second O-ring 345 arranged in a coaxial relationship about the central axis of the mid body housing 328. The first O-ring 342 is configured to improve the seal between the back nut 329 and the cable 1000 upon assembly, and the second O-ring 345 is configured to improve the seal between the back nut 329 and the mid body housing 328.
The mid body housing 328 is made from an electrically conductive material, such as aluminum, brass, or the like, and includes an internally threaded portion or engagement portion 344 at its forward end, which cooperates with the rearward threaded portion 322 of the entry body housing 316 so that the two connector portions may be threadedly coupled together. Similarly, the back nut 329 may be made from an electrically conductive material, such as aluminum, brass, or the like, and includes an externally threaded portion or engagement portion 331 at its forward end, which cooperates with a rearward threaded portion or engagement portion 333 of the mid body housing 328 so that the two connector portions may be threadedly coupled together. The exterior surface of the mid body housing 328 and/or the back nut 329 may be provided with a hexagonal shape to accommodate the use of tools to facilitate such threaded coupling.
As shown in
As shown in
Referring now to
As illustrated in
As mentioned above, the outer surface of the clamp 336 is provided with a circumferential ramped portion 362, which engages a forward end 370 of the ramp 334, opposite the rearward edge 360, upon forward axial movement of the ramp 334 to radially compress the clamp 336. The ramped portion 362 defines a conical segment 3621 of the clamp 336 that tapers radially inwardly in the rearward direction. A rearward portion 3362 of the clamp 336 is received in an axial bore 3341 of the ramp 334.
Operation and installation of the connector 300 will now be described. The front body assembly 312 is threadedly coupled with an interface port (not shown), by way of the threaded portion 320 of the front body housing 316. The end of the coaxial cable 1000 that is to be inserted through the back nut assembly 314 and into the rearward end of the mid body housing 328 is prepared in a conventional manner. The back nut assembly 314 is slid over the prepared end of the coaxial cable 1000, and the prepared end of the cable 300 is inserted into the mid body assembly 313 with the center conductor 1002 extending through the seizure bushing 384 and into the gripping portion 383 of the collet 380 and the outer conductor 1006 between the outer surface of the tubular body portion 352 of the mandrel 332 and the inner surface of the clamp 336.
The mid body housing 328 is threadedly coupled and rotated with respect to the front body housing 316 such that the seizure bushing 384 is urged in a forward direction relative to the front body housing 316 and the collet 380. As the seizure bushing 384 enters the front body housing, each of the fins 388 is received by one of the grooves 361 in the inner wall of the front body housing 316 to prevent relative rotation between the seizure bushing 384 and the front body housing 316. The opposite tapering surfaces of the front end of the seizure bushing 384 and the gripping portion 383 of the collet 380 engage one another, radially compressing the gripping portion 383 of the collet 380 onto the center conductor 1002.
The back nut 329 is threadedly coupled and rotated with respect to the mid body housing 328. As the back nut 329 moves axially relative to the mid body housing 328, the seal driver 343 and the annular shoulder 348 of the back nut 329 urge the ramp 334 in a forward axial direction relative to the clamp 336 and the mid body housing 328. The forward translation of the ramp 334 causes (i) a forward tapered end of the clamp 336 to engage an oppositely tapered inner wall of the mid body housing 328, (ii) the forward end 370 of the ramp 334 to engage the outer ramp portion 362 of the clamp 336, and/or (iii) a tapered inner surface of the clamp 336 to engage a rearward end of the clamp 336, thereby resulting in radial compression of the clamp 336 onto the outer conductor 1006 of the cable 1000 at multiple regions along a length of the clamp 336. The radial compression of the clamp 336 reduces the overall diameter of the clamp 336 and reduces the gap 366 so that the inner surface 368 of the clamp 336 bites down on the exposed portion of the outer cable conductor 1006 and presses the outer conductor 1006 against the mandrel 332. The axial movement of the back nut 329 relative to the mid body housing 328 also urges the seal driver 343 in a rearward direction to compress the first O-ring 342 to provide an environmental seal between the back nut 329 and the outer conductor 1006 or the jacket 1008 of the cable 1000.
As best illustrated in
As another example, the collet insulator 382 includes a reduced amount of material relative to conventional insulators, which minimizes peaks and valleys of impedance levels within the connector relative to a desired 75 ohm impedance (i.e., the connector is nearly perfectly matched to 75-ohm hardline cable) so as to achieve improved electrical performance over a frequency range of 5 MHz to 3 GHz or greater. As described above, the collet insulator 382 includes the inner and outer cylindrical walls 3821, 3822 that are separated by a hollowed out region. Also, the length of the collect insulator 382 is reduced to a distance between the rearward facing surface 3161 of the front body housing 316 and the forward facing surface 3832 of the gripping portion 383 of the collet 380, and the collet insulator 382 does not surround the gripping portion 383. The collet insulator 382 thus improves return loss and insertion loss performance of the connector 300.
As shown in
As shown in
Although the illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.
Various changes to the foregoing described and shown structures will now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims.
This application claims the benefit of U.S. Provisional Application No. 63/289,625, filed Dec. 14, 2021, pending, and U.S. Provisional Application No. 63/361,391, filed Dec. 15, 2021, pending, the disclosures of which are hereby incorporated by reference herein in their entirety.
Number | Date | Country | |
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63361391 | Dec 2021 | US | |
63289625 | Dec 2021 | US |