Patent Application
20180183192
The present invention relates generally to electronic devices, and more particularly to coaxial cable connectors.
Coaxial cables transmit radio frequency (“RF”) signals between transmitters and receivers and are used to interconnect televisions, cable boxes, DVRs, DVD players, satellite receivers, modems, and other electrical devices and electronic components. Typical coaxial cables include an inner conductor surrounded by a flexible dielectric insulator, a foil layer and/or a metallic braided sheath or shield, and a flexible polyvinylchloride jacket. The RF signal is transmitted through the inner conductor. The conductive sheath provides a ground and inhibits electrical and magnetic interference with the RF signal in the inner conductor.
Coaxial cables must be fit with cable connectors to be coupled to female posts of electronic components. Connectors typically have a connector body, a threaded fitting or coupling nut mounted for rotation on an end of the connector body, a bore extending into the connector body from an opposed end to receive the coaxial cable, and an inner post within the bore coupled in electrical communication with the fitting. Generally, connectors are crimped onto a prepared end of a coaxial cable to secure the connector to the coaxial cable. The connectors must also maintain electrical connection, continuity, and signal shielding with the female post of an electronic component despite rotation, tugging, bending, or other movement of the cable and the connector. Movement of the cable and the connector may occur suddenly if an object contacts the cable or connector, but may also occur slowly over time, such as from cyclical heating and cooling or wind loads on outside installations.
Some approaches to maintaining continuity have focused on maintaining a connection between the coupling nut and the female post by biasing the nut in an axial direction so as to force the nut into continuity. This has generally been accomplished by loading the nut axially with a continuity washer or other shimming device. Typically, such biasing devices are disposed axially between the nut and the body of the connector and urge the nut axially forward into contact with a forward flange on the post. However, should the biasing device not provide an even force continuously around the entire device, the nut may not mate continuously flush against the post, which can lead to leaks in signal, degradation of continuity, and impingement of RF interference into the connector. Further, if the connector is bent, such as frequently occurs when the cable extending from the connector flexes or is bent, the nut will not mate continuously flush against the post, leading to the above-stated problems. These problems are accentuated when the nut is not sufficiently tightened onto the electronic component, which often occurs when homeowner or other end user applies the connector onto the female post. An improved connector is needed which provides reliable continuity despite the level or accuracy of torque on the connector.
A cable connector includes a body having a longitudinal axis, an inner post, an outer barrel mounted to the inner post, and a fitting mounted to the inner post. The inner post includes a front, a rear, and an outwardly-directed front flange at the front. The fitting includes a front, a rear, and an inwardly-directed rear flange at the rear. The fitting is mounted on the inner post so that the front and rear flanges overlap to define a toroidal volume. A wave washer and a lock washer each carried in the toroidal volume. When the fitting is applied to a female post, the wave washer and the lock washer are compressed between the front and rear flanges and exert an axial bias on the front and rear flanges to prevent axial separation of the fitting and the female post.
The above provides the reader with a very brief summary of some embodiments discussed below. Simplifications and omissions are made, and the summary is not intended to limit or define in any way the scope of the invention or key aspects thereof. Rather, this brief summary merely introduces the reader to some aspects of the invention in preparation for the detailed description that follows.
Referring to the drawings:
Reference now is made to the drawings, in which the same reference characters are used throughout the different figures to designate the same elements.
Briefly, as a matter of explanation, the phrase “electronic component,” as used throughout the description, includes any electrical device having a female post or mating port to receive a male coaxial cable connector for the transmission of RF signals such as cable television, satellite television, internet data, and the like. The term “electronic component” also specifically includes wall jacks, wall installations, exterior cable box hookups, and like components. Further, the embodiment of the connector 10 shown throughout the drawings is an F connector for use with an RG6 coaxial cable for purposes of example, but it should be understood that the description below is also applicable to other types of coaxial cable connectors and other types of cables. Moreover, much of the structure of the connector 10 is non-limiting and non-specific, as will be explained below.
The connector 10 includes a body 11 having opposed front and rear ends 12 and 13, a fitting 14 mounted for rotation on the front end 12 of the body 11, an inner post 15, and an outer barrel 16 proximate the rear end 13 of the body 11. The connector 10 has rotational symmetry with respect to a longitudinal axis A illustrated in
The outer barrel 16 shown in the drawings is non-specific and non-critical to the connector 10, and the embodiment of the outer barrel 16 may be substituted with other suitable outer barrels for coaxial cable connectors. In the embodiment shown in
The compression bands 22 and 23 are identical, and are thinned portions of the sidewall of the outer barrel 16 so as to create areas of flexion and deformation in the outer barrel 16. The compression band 22 includes a first wall, a second wall, and a bend formed therebetween. The first and second walls project radially inward toward from the axis A. The first wall is formed proximate to the rear 21, the second wall is formed forward of the first wall, and the bend is a flexible, thin, annular portion of the sidewall 24 of the outer barrel 16 between the first and second walls, defining a living hinge therebetween. The first and second walls are oriented obliquely with respect to the longitudinal axis A when the outer barrel 16 is in an uncompressed condition, and they converge toward each other. A V-shaped annular channel is thus defined between the first and second walls. When the connector 10 is compressed axially, such as would occur when it is applied onto the cable and compressed in a compression tool, the compression band 22 deforms, with the first and second walls collapsing and moving into each other, causing the bend to flex, and urging it radially inward toward the inner post 15. Regardless of the compression band structure of the outer barrel 16, the outer barrel terminates in a radially inwardly-turned flange or lip 25 at the front 20, which includes a forwardly-directed, annular, contact face 26. The lip 25 couples the outer barrel 16 to the inner post 15 with a snug fit.
Still referring to
The outer surface 33 at the rear 31 of the inner post 15 is formed with several annular ridges 34 projecting toward the front 30 and extending radially outward from axis A. As the term is used in this description, “radial” means directed, extending, or aligned along a radius extending from the axis A. Moreover, the term “axial” means directed, extending, or aligned parallel to the axis A. Still further, the terms “forward,” “ahead,” and the like are used to generally indicate a direction toward the front end 12 of the body 11, and the terms “rearward,” “behind,” and the like are used to generally indicate a direction toward the rear end 13 of the body 11. The ridges 34 are axially spaced apart from each other proximate to the rear 31 of the inner post 15. The ridges 34 provide grip on the cable when the cable is applied in the coaxial cable connector 10 to hold the cable and prevent the cable from backing out of the connector 10.
The inner post 15 varies in outer diameter along its length, and as such, includes a number of raised or tiered annular faces toward the front 30, each spaced apart axially along the inner post 15. One of the faces is a contact face 35 for the inwardly-directed lip 25 of the outer barrel 16, opposing the contact face 26 on the inner post 15. The contact face 35 is a smooth, annular face having an outer diameter corresponding to the inner diameter of the lip 25, such that the lip 25 is snug fit onto the contact face 35; the outer barrel 16 is thus mounted to the inner post 15 at the contact face 35 in snug-fit engagement.
A second face—a fitting face 36—is forward of the contact face 35. The fitting face 36 has a larger diameter than the contact face 35 and is thus stepped out radially outwardly with respect to the contact face 35. A rearwardly-directed, annular shoulder 37 is formed between the contact and forward faces 35 and 36. While the contact and fitting faces 35 and 36 are axially aligned, the shoulder 37 is radially aligned. The shoulder 37 confronts the front 20 of the outer barrel 16 and thus limits relative axial movement of the outer barrel 16 over the inner post 15.
A front flange 38 terminates the fitting face 36 at its forward end, extending radially outward to an outer diameter greater than the outer diameter of the fitting face 36. The front flange 38 has a radially-aligned, forward face 40 and an opposed radially-aligned, rear face 39 directed rearward. Both the rear and forward faces 39 and 40 of the front flange 38 are oriented substantially normal to the fitting face 36 of the inner post 15.
Referring still to
The fitting 14 is a sleeve having a front 49 and an opposed rear 41, an integrally-formed ring portion 42 proximate to the front 49, and an integrally-formed nut portion 43 proximate to the rear 41. The nut portion 43 is mounted at the front end 12 of the body 11 on the inner post 15 for rotation about the axis A, so that the entire fitting 14 is mounted for free rotation on the inner post 15.
The ring portion 42 has a smooth annular outer surface, while the nut portion 43 has a hexagonal outer surface 44 to receive the jaws of a tool. The ring and nut portions share a common inner surface 44. The inner surface 44 is formed with radially inwardly-directed threads for threaded engagement with a female post of an electronic component. An interior space 45 extends into the fitting 14 from a mouth formed at the front 49 of the nut 14 to an opening formed at the rear 41. The interior space 45 is bound by the shared inner surface 44 of the ring and nut portions.
The fitting 14 is carried on the inner post 15. At its rear 41, the fitting 14 includes a radially inwardly-directed rear flange 46 with a forward face 47 and an inner face 48. The rear flange 46 has an inner diameter at the inner face 48, which inner diameter corresponds to the outer diameter of the fitting face 36 of the inner post 15, such that the rear flange 46 has a snug bearing fit on the fitting face 36. This snug bearing fit mounts the fitting 14 to the inner post 15. The rear flange 46 is also in contact with the front 20 of the outer barrel 16 at the lip 25, thereby limiting axial movement of the fitting 14 and the outer barrel 16 with respect to each other. The rear face of the rear flange 46 is thus co-radial with the shoulder 37 on the inner post 15, meaning it is registered and aligned radially with the shoulder 37. In front of the rear flange 46, and behind the threaded inner surface 44 of the fitting 14, a plain inner surface 59 extends axially. The plain inner surface 59 is inwardly directed, normal to the rear flange 46, and smooth.
A toroidal volume 50 is between the fitting 14 and the inner post 15. The toroidal volume 50 is defined radially between the fitting face 36 of the inner post 15 and the plain inner surface 59 of the fitting 14, and is defined axially between the rear face 39 of the front flange 38 on the inner post 15 and the forward face 47 of the fitting 14. The toroidal volume 50, in the embodiment shown in the drawings, thus has a roughly rectangular cross-section; this may change, however, depending on the orientation of the contact face 36, the rear face 39, the plain inner surface 59, and the forward face 47, as occurs when different fittings or inner posts are used. For instance, when the fitting 14 terminates with a rear flange 46 that has an oblique forward face 47, the toroidal volume will have a parallelogram cross-section.
The toroidal volume 50 has a long dimension in the axial direction compared to a short dimension in the radial direction. The toroidal volume 50 is aligned so that its long dimension is parallel to the axial direction and its short dimension is parallel to the radial direction. One bounding side of the long dimension of the toroidal volume 50, along the outer side of the toroidal volume 50, is defined by the plain inner surface 59 of the nut 14. The opposing bounding side of the long dimension, or the inner surface of the toroidal volume 50, is defined by the fitting face 36 of the inner post 15. One bounding side of the short dimension, at the front end of the toroidal volume 50, is defined by the rear face 39 of the inner post 15. The opposing bounding side of the short dimension, or the rear end of the toroidal volume 50, is defined by the forward face 47 of the rear flange 46.
Two locking elements, defining a progressive lock washer assembly 70, are carried within the toroidal volume 50. The progressive lock washer assembly 70 provides a continuous and sufficient axial load between the fitting 14 and the inner post 15 to maintain electrical continuity between the fitting 14 and the inner post 15. The progressive lock washer assembly 70 provides the connector 10 with a very low torque requirement, so that homeowners and other end users can easily apply the connector 10 manually without a tool, and without concern that the connector 10 may be insufficiently tightened.
The locking elements of the progressive lock washer assembly 70 are uniquely combined and arranged, so that their combination and arrangement allows the connector 10 to maintain electrical continuity with an electronic component regardless of the level of torque applied to the fitting 14, while also preventing accidental loosening or separation of the connector 10 from the electronic component. The locking elements of the progressive lock washer assembly 70 include a wave washer 51 and a lock washer 52. The wave washer 51 and the lock washer 52 are confined within the toroidal volume 50, and the wave washer 51 is disposed in front of the toroidal volume 50.
The exploded view of
The lock washer 52 is disposed behind the wave washer 51 when installed in the connector 10. The lock washer 52 includes a continuous solid annular body with a parallelogram cross-section having a flat front face 71, a flat rear face 72, an inner edge 73, and an outer edge 74. The lock washer 52 has a bent or bowl-shaped configuration defining four lobes around its extent: two forward lobes 75 and 76 and two rearward lobes 77 and 78. The forward lobes 75 and 76 are bent forwardly, thus defining convex sections of the lock washer 52 (from a forward perspective). The two opposed rearward lobes 77 and 78 are bent rearward to define concave sections of the lock washer 52. From behind, the forward lobes 75 and 76 are concave and the rearward lobes 77 and 78 are convex. The forward lobes 75 and 76 are circumferentially offset from each other and from the rearward lobes 77 and 78: the peak of the forward lobe 75 is approximately ninety degrees offset with respect to the peaks of the rearward lobes 77 and 78, which are also each approximately ninety degrees offset with respect to the peak of the forward lobe 76. In other words, the lobes 75-78 are each spaced apart by quarter-arcs of the body of the lock washer 52. The lobes 75 and 76 are diametrically offset from each other; the lobes 77 and 78 are diametrically offset from each other.
Turning now to
In the loose condition of the progressive lock washer assembly 70, shown in
The toroidal volume 50 is uncompressed because the connector 50 is not yet tightened on the female post of the electronic component. Nevertheless, electrical continuity is maintained between the fitting 14 and the inner post 15 through the physical contact between those elements. The bowl-shaped configuration of both the wave washer 51 and the lock washer 52 produces a tension pressing axially outward, against the rear face 39 of the front flange 38 of the inner post 15 and the forward face 47 of the rear flange 46 of the fitting 14. This tension exerts an axial bias between the front flange 38 and the rear flange 46, which urges the toroidal volume 50, at all times, toward the lengthened dimension B.
When the connector 10 is to be installed on the electronic component, the fitting 14 is to be applied to the female post 80. When the fitting 14 is applied to the female post 80, the toroidal volume 50 changes, and the progressive lock washer assembly 70 changes as well. To apply the connector 10 onto the female post 80, the ring portion 42 of the fitting 14 is aligned with the female post 80 and the threaded inner surface 44 is threadably engaged with the female post 80 by rotating the fitting 14 onto the female post 80. Rotation is continued until the female post 80 (shown in broken line in
The toroidal volume 50 thus compresses or contracts from the lengthened condition shown in
Further, when the female post 80 is applied to and seated within the fitting 14, and the toroidal volume 50 is contracted, the wave washer 51 and the lock washer 52 each exert an axial bias between the front flange 38 of the inner post 15 and the rear flange 46 of the fitting 14. This causes the inner post 15 to be urged forwardly from the fitting 14, thereby urging and maintaining the physical contact between the female post 80 and the front 30 of the inner post 15, which prevents axial separation of the fitting 14 and the female post 80 and thus maintains electrical continuity between the two.
A preferred embodiment is fully and clearly described above so as to enable one having skill in the art to understand, make, and use the same. Those skilled in the art will recognize that modifications may be made to the description above without departing from the spirit of the invention, and that some embodiments include only those elements and features described, or a subset thereof. To the extent that modifications do not depart from the spirit of the invention, they are intended to be included within the scope thereof.
This application the benefit of U.S. Provisional Application No. 62/439,859, filed Dec. 28, 2016, which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62439859 | Dec 2016 | US |
