Cable connector and method of terminating a cable

Abstract

A cable connector that includes an inner subassembly that includes a coupling nut for coupling to a mating connector or port and a post end for electrically connecting to a cable. An outer body includes separable sections that form an inner bore when assembled. The inner bore is configured to receive at least the post end of the inner subassembly. Each section of the outer body has a proximal end and a distal end and the distal ends are configured to accept the cable. The sections are releasably engaged for assembly of the outer body around at least a portion of the inner subassembly.

Claims

1. A cable connector, comprising: an outer body having sections configured to releasably engage one another to form an inner bore; an inner subassembly including a coupling nut and a post end receivable in the inner bore of the outer body, the post end being configured for insertion into a prepared end of a cable so that an outer conductor of the cable is in electrical grounding contact with the post of the inner subassembly; and at least one creep compensation insert received in the inner bore of the outer body, the creep compensation insert being configured to limit material creep of an outer jacket of the cable when terminated to the cable connector, wherein two creep compensation inserts are received in respective recessed areas in inner surfaces of the sections of the outer body and surround the post end.

2. The cable connector of claim 1, wherein the at least one creep compensation insert is a sleeve inserted over the post end.

3. The cable connector of claim 1, further comprising a connecting piece connecting ends of the sections of the outer body, the connecting piece is coupled to a portion of the inner subassembly between the coupling nut and the post end.

4. The cable connector of claim 1, wherein the outer body is formed of a dielectric material and is a unitary one-piece member.

5. The cable connector of claim 1, wherein the creep compensation insert is formed of silicone.

6. Method of terminating a cable with a cable connector, the cable connector comprising an outer body and an inner subassembly, comprising the steps of: assembling the outer body to the inner subassembly with separable sections of the outer body being disengaged and in an open position; after assembling the outer body to the inner subassembly, terminating a prepared end of the cable with a post end of the inner subassembly, thereby electrically connecting the cable and the inner subassembly; and after terminating the prepared end of the cable with the post end of the inner subassembly, releasably engaging the separable sections of the outer body together in a closed position, thereby clamping the cable therebetween, wherein the step of assembling the sections of the outer body together includes snap fitting the sections.

7. The method of claim 6, wherein the outer body is dielectric and the inner subassembly is conductive.

8. The method of claim 6, wherein the sections of the outer body are releasably engaged via cooperating engagement features at either proximal or distal ends of the sections.

9. The method of claim 8, further comprising the step of releasing the cooperating engagement features of the sections of the outer body to disengage the sections of the outer body from the cable and move the sections to the open position.

10. The method of claim 6, further comprising the step of inserting at least one creep compensation insert in the outer body prior to clamping the cable, the creep compensation insert is configured to limit material creep of an outer jacket of the cable when clamping the cable.

11. A cable connector, comprising: an outer body having sections configured to releasably engage one another to form an inner bore; an inner subassembly including a coupling nut and a post end receivable in the inner bore of the outer body, the post end being configured for insertion into a prepared end of a cable so that an outer conductor of the cable is in electrical grounding contact with the post of the inner subassembly; and at least one creep compensation insert received in the inner bore of the outer body, the creep compensation insert being configured to limit material creep of an outer jacket of the cable when terminated to the cable connector, wherein the at least one creep compensation insert is a sleeve inserted over the post end.

12. A cable connector, comprising: an outer body having sections configured to releasably engage one another to form an inner bore; an inner subassembly including a coupling nut and a post end receivable in the inner bore of the outer body, the post end being configured for insertion into a prepared end of a cable so that an outer conductor of the cable is in electrical grounding contact with the post of the inner subassembly; and at least one creep compensation insert received in the inner bore of the outer body, the creep compensation insert being configured to limit material creep of an outer jacket of the cable when terminated to the cable connector, wherein the creep compensation insert is formed of silicone.

13. Method of terminating a cable with a cable connector, the cable connector comprising an outer body and an inner subassembly, comprising the steps of: assembling the outer body to the inner subassembly with separable sections of the outer body being disengaged and in an open position; after assembling the outer body to the inner subassembly, terminating a prepared end of the cable with a post end of the inner subassembly, thereby electrically connecting the cable and the inner subassembly; and after terminating the prepared end of the cable with the post end of the inner subassembly, releasably engaging the separable sections of the outer body together in a closed position, thereby clamping the cable therebetween, wherein the outer body is dielectric and the inner subassembly is conductive.

14. Method of terminating a cable with a cable connector, the cable connector comprising an outer body and an inner subassembly, comprising the steps of: assembling the outer body to the inner subassembly with separable sections of the outer body being disengaged and in an open position; after assembling the outer body to the inner subassembly, terminating a prepared end of the cable with a post end of the inner subassembly, thereby electrically connecting the cable and the inner subassembly; after terminating the prepared end of the cable with the post end of the inner subassembly, releasably engaging the separable sections of the outer body together in a closed position, thereby clamping the cable therebetween; and inserting at least one creep compensation insert in the outer body prior to clamping the cable, the creep compensation insert is configured to limit material creep of an outer jacket of the cable when clamping the cable.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings are incorporated in and constitute a part of this specification. It is to be understood that the drawings illustrate only some examples of the disclosure and other examples or combinations of various examples that are not specifically illustrated in the figures may still fall within the scope of this disclosure. Examples will now be described with additional detail through the use of the drawings, in which:

(2) FIG. 1 is a perspective view of a cable connector according to an example of the present disclosure, showing an outer body thereof in a closed (assembled) position;

(3) FIG. 2 is a perspective view of the cable connector illustrated in FIG. 1, showing the outer body in an open (non-assembled) position;

(4) FIG. 3 is a partial perspective view of the inside of the outer body of the cable connector illustrated in FIG. 1;

(5) FIG. 4 is a perspective view of the outside of the outer body of the cable connector illustrated in FIG. 1; and

(6) FIGS. 5A and 5B are perspective views of an inner subassembly of the cable connector illustrated in FIG. 1.

(7) FIG. 6 is a perspective view of the cable connector according to an example of the present disclosure;

(8) FIG. 7 is a perspective view of the connector illustrated in FIGS. 1 and 6, showing the connector in an open position with creep compensation inserts provided therein and a prepared end of the cable terminated to the connector;

(9) FIGS. 8A and 8B are exploded views of the connector illustrated in FIGS. 1 and 6, showing a creep compensation insert according to another example of the present disclosure;

(10) FIGS. 9A-9D illustrates the steps of terminating a coaxial cable to the connector illustrated in FIGS. 1 and 6 according to an exemplary method of the present disclosure;

(11) FIG. 10 shows steps for preparing a cable for termination to the connector illustrated in FIGS. 1 and 6;

(12) FIGS. 11A-11C are various views of a tool for preparing the cable for termination shown in FIG. 9A;

(13) FIGS. 12A and 12B are views of a conventional PVC cable jacket under high pressure and the distortion that results; and

(14) FIGS. 13A and 13B are cross-sectional views of a conventional compression F connector.

DETAILED DESCRIPTION

(15) The present disclosure generally relates to a cable connector that comprises can inner subassembly that includes a coupling nut for coupling to a mating connector or port and a post end for electrically connecting to a cable; and an outer body that includes separable sections forming an inner bore configured to receive at least the post end of the inner subassembly. Each section has a proximal end and a distal end, and the distal ends are configured to accept the cable. And the sections are releasably engaged for assembly of the sections together in a closed position around at least a portion of the inner subassembly.

(16) Referring to the figures, the present disclosure relates to a cable connector 100 and methods for terminating a coaxial cable 10 to the same, that facilitates assembly to and proper termination of the cable. In general, the cable connector 100 according to an example of the present disclosure comprises an inner subassembly 102 and an outer body 104 at least partially surrounding the inner subassembly 102. In one example of the present disclosure, the inner subassembly 102 is formed of any metal or conductive material for electrical connection with the cable and the outer body 104 is formed of any plastic or dielectric material.

(17) In one example of the present disclosure, the method for terminating the coaxial cable 10 to the connector according to the present disclosure improves grounding therebetween. The cable connector 100 may be structured to provide a 360° or near 360° grounding surface area and uniform or substantially uniform constant pressure between the cable 10 and the post or post end 110 of the connector 100. The connector 100 is designed to optimize the grounding interconnect between the connector's post or post end 110 and the cable's outer conductor or braiding 14, such as by optimizing the metal-to-metal contact between the post or post end 110 and cable braiding 14 by using the maximum surface area of the post or post end 110 and cable braiding 14; applying a uniform constant pressure over the braiding 14 onto the connector post or post end 110; and/or ensuring the interconnect is hermetically sealed from air and moisture when assembled.

(18) The connector and methods of the present disclosure are designed to optimize the grounding interconnect between the connector 100 and the cable 10 while also allowing for the standard steps in cable preparation, such as folding the cable braiding 14 back over the cable's outer jacket 12 to provide a lead-in for the connector's post end 110. The connector and methods of the present disclosure also prevent damage or distortion to the cable braiding 14 by the post end 110, which in turn provides optimum metal-to-metal contact between cable braiding 14 and connector post end 110. In addition, the connector and methods of the present disclosure prevent the installer/technician from inadvertently touching the cable braiding 14, thus preventing any possible contamination to the interconnection point. The present disclosure further provides material creep compensation of the cable's outer jacket 12, while being able to apply a uniform or near uniform nominal pressure over the length of the cable braiding/post interconnect without deforming the cable jacket material, which is typically a PVC material.

(19) Inner subassembly 102 may comprise a post end 110, an opposite coupling end 112, and a transition portion 114 therebetween, as best seen in FIGS. 5A and 5B. Coupling end 112 may be similar to a coupling nut of a coaxial cable connector, for example, configured to mate with another connector or a mating port, such as by threading or pushing the coupling end 112 onto the mating port. In one example, the coupling end 112 may include an inner spring 115 (FIG. 6) to assist with mechanical and electrical engagements with the mating connector or post. Post end 110 may be similar to a post of a coaxial cable connector, for example, that is configured to terminate a prepared end of the cable 10, thereby electrically connecting the post end 110 and the cable. Transition portion 114 is designed to support outer body 104. Transition portion 114 may include an inner shoulder 116 at or near the post end 110 and in communication with the coupling end 112 for electrical contact with the mating port. In an example, the post end 110, the coupling end 112, and the transition portion 114 form a unitary one-piece member.

(20) Outer body 104 surrounds at least the post end 110 of the inner subassembly 102, and may also extend over the transition portion 114 leaving at least part of the coupling end 112 exposed, as seen in FIGS. 1, 2, and 6. Outer body 104 may comprise separable half sections 120 and 122 connected by a connecting piece 124. The half sections 120 and 122 may be assembled together over the inner assembly 102 in a closed position, as seen in FIG. 1, to form an inner bore 106. FIGS. 2 and 7 show the half sections 120 and 122 in an open non-assembled position and the prepared end of the cable 10 terminated to the post end 110. Connecting piece 124 may comprise a ring body, as seen in FIGS. 2 and 4, that couples to the transition portion 114 of inner subassembly 102, such as by a press fit. In one example, connecting piece 124 includes one or more keying features 126 (FIGS. 2 and 4), such as an inwardly extending detent or detents, that engages one or more corresponding key features 128 (FIG. 5B), such as a notch or notches, on the transition portion 114 of the inner subassembly 102. In an example of the present disclosure, the half sections 120 and 122 and the connecting piece 124 form a unitary one-piece outer body.

(21) Half sections 120 and 122 of outer body 104 may have distal ends 130a and 130b, respectively, opposite proximal ends 132a and 132b and remote from the connecting piece 124, that are configured to accept the cable when the half sections 120 and 122 are assembled in the closed position. Releasable engagement features can be provided on the inside of the half sections 120 and 122 for assembling the half sections 120 and 122 together. The distal ends 130a and 130b can include a set of cooperating engagement features 140 and 142. Proximal ends 132a and 132b that are opposite the distal ends 130a and 130b, respectively, may include another set of cooperating engagement features 150 and 152. In one example, the engagement feature 140 on distal end 130a of half section 120 and the engagement feature 152 at the end 132b of the other half section 122 may be one or more inwardly extending tabs 144 and 154, respectively; and the corresponding engagement feature 142 on distal end 130b of the half section 122 and the corresponding engagement feature 150 on the end 132a of the half section 120 may be one or more openings 146 and 156, respectively, sized to receive the tabs 144 and 154, respectively, in a snap fitting engagement. It will be understood that the tabs and openings of the engagement features may be provided on any portion or end of the outer body half sections 120 and 122, and in any arrangement, as long as the half sections 120 and 122 may be releasably engaged to one another. It will also be understood that other known engagements may be used to assemble the half sections 120 and 122 together at their distal ends 130a and 130b and their opposite ends 132a and 132b. In one example, the free ends 148 of the tabs 144 at distal ends 130a and 130b may extend through and past the openings 146 such that the free ends 148 are exposed outside of the outer body 104, as seen in FIG. 1, thereby facilitating release of the snap engagement and separation of the half sections 120 and 122 to the open non-assembled position.

(22) Each of the outer body half sections 120 and 122 may include a creep compensation insert or lining 160 respectively, on an inner surface thereof, respectively as seen in FIGS. 2 and 7. The inserts 160 are configured to form a compression sleeve when the half sections are assembled onto the cable and designed to compress the prepared end of the cable. The inserts 160 may be a dielectric material, such as silicone or a stepped silicone lining, for example. The inner surfaces of the half sections 120 and 122 may also include cable jacket retention features 162 configured to grab the outer jacket 12 of the cable. The cable jacket retention features 162 may be positioned at the distal ends 130a and 130b of each half section, respectively. The retention features 162 may be, for example, one or more inwardly extending teeth, which may be located adjacent to or near each insert 160, as seen in FIG. 3.

(23) Each creep compensation insert 160 is receivable in the connector body's inner bore 106 between the post end 110 and the inner surface of each half section 120 and 122. Each creep compensation insert 160 can be configured to limit material creep of the outer jacket 12 (FIG. 7) of the cable 10. In one example, the inserts 160 comprises first and second sleeve parts or halves designed to fit in recessed areas 164 of the inner surfaces of the connector body's half sections 120 and 122, respectively. In an alternative example, the insert 160′ may be a unitary one-piece sleeve, as seen in FIGS. 8A and 8B, that fits around the post end 110 with space therebetween for receiving the prepared end 20 of the cable 10.

(24) Creep compensation inserts 160 or sleeve 160′ may be formed of any rubber or rubber-like material with a specific sure hardness that will provide material creep compensation at the point of compression of the cable's outer jacket 12, when clamping the outer body's half sections 120 and 122 together, and maintain pressure at this point after the outer jacket 12 has deformed. Material creep (or cold flow) is the tendency of a solid material, particularly plastics, to move slowly or deform permanently under the influence of mechanical stresses. It can occur as a result of long-term exposure to high levels of stress that are still below the yield strength of the material. In an example, the insert 160 or sleeve 160′ is formed of silicone rubber which has a sure hardness that is less than the tensile strength and elongation break percentage of PVC, which is the most common material for the cable's outer jacket 12. That is, the silicone inserts or sleeve are softer than the PVC outer jacket. Although silicone is disclosed, any material that has the same or similar type sure hardness and tensile strength Mpa (Newton per square meter force) along with a high elongation break percentage can also be used. The inner surfaces of the connector body's half sections 120 and 122 may have expansion relief grooves 166 (FIG. 8A) therein that allow expansion of the inserts 160 or sleeve 160.

(25) A method of assembling the cable connector 100 and terminating a cable therein, according to the present disclosure, may comprise the steps assembling the outer body 104 to the inner subassembly 102 by coupling the connecting piece 124 of the outer body 104 with a portion of the inner subassembly 102. For example, the ring body of the connection piece 124 may be press fit onto the transition portion 114 of the inner subassembly 102. When coupling the connection piece 124 to the inner subassembly 102, the outer body's half sections 120 and 122 are disengaged and in an open position. Then a prepared end of the cable may be terminated to the post end 110 of the inner subassembly 102 with the half sections 120 and 122 of the outer body 104 remaining in the open position. Because the outer body half sections 120 and 122 are open, the installer may easily see inside of the connector 100 and thus see whether the prepared end of the cable has been properly terminated to the post end 110. In an example, the cable's outer jacket may sit flush with a front face 116 (FIG. 5B) of the connector body 114, upon termination of the cable.

(26) Once the cable end has been properly terminated, the outer body half sections 120 and 122 may be assembled together via the cooperating engagement features 140, 142 and 150, 152 to a closed position, thereby clamping the cable therebetween to ensure a proper mechanical and electrical connection to the cable connector 100.

(27) An exemplary method of terminating the cable 10 with the coaxial connector 100 may initially comprise preparing the termination or prepared end 20 of the cable for receiving the connector's post end 110. Initially, an end portion of the cable's outer jacket 12 at the termination end 20 is removed to expose a portion 22 of the outer conductor or braid 14, the portion 22 being commensurate with the end portion removed from the outer jacket 12, as seen in FIG. 9A. The cable's inner conductor 24 is also exposed and extends beyond the outer conductor or braid 14. Next, one or more lateral slits 26 are formed in a predetermined portion 28 of the outer jacket 12 and in the outer conductor or braid 14, at the cable's termination end 20. In an example, the one or more lateral slits 26 and the jacket's predetermined portion 28 have a length substantially equal to the length of the connector's post end 110, as seen in FIG. 9B. In an example, there are two lateral slits 26 formed on opposite sides of the cable's outer jacket 12, as seen in FIG. 9B.

(28) The above steps may be done with just one cable preparation or stripping tool 200, seen in FIGS. 11A-11C. The tool 200 of the present disclosure may be configured to provide the industry standard ¼ ¼ cable preparation and to also have the unique features of being able to then apply the two lateral cable jacket slits 26 to the cable's outer jacket at the same time. This may be accomplished by pressing in two lateral buttons 202 on the end of the tool, which then engage two lateral cutting blades 204 (FIG. 10) which cut through the cable's jacket 12 and any foil bonded underneath the jacket 12. This then allows the split portions of the cable jacket 12 (formed by lateral slits 26) to open, as the connector's post end 110 is inserted underneath the cable's outer conductor or braid 14. This allows grounding pressure to be applied by the cable jacket 12 via the creep compensation inserts 160 or sleeve 160′.

(29) As seen in FIGS. 9C and 9D, the exposed portion 22 of the cable's braiding 14 may then be folded over the end of the outer jacket 12 to provide a post lead-in 30 at the termination end 20 of the cable 10. The post end 110 may then be installed onto the cable's termination end 20 by inserting the post end 110 into and through the post lead-in 30 of the outer conductor 14, thereby electrically connecting the cable's outer conductor or braid 14 and the post end 110.

(30) During insertion of post end 110 into the cable's termination end 20, the cable's jacket 12 will open at the slits 26 (as seen in FIG. 9D), leaving the cable's braiding 14 formed over the post end 110. This leaves a gap, e.g. a minimum 1 mm gap, between each split portions of the cable jacket 12. The connector body's half sections 120 and 122, which have the creep compensation inserts 160 fitted therein (e.g. in the recessed areas 164), are then closed around the cable jacket 12 and its split portions, which are then easily compressed by the creep compensation inserts 160. Alternatively, the one-piece sleeve 160′ may be mounted directly onto the connector's post end 110 and then the outer body half sections 120 and 122 may be closed around the sleeve 160′. Each way can be accomplished without exceeding the cable jacket's tensile strength and thus applies a uniform or nearly uniform 360° pressure to the entire or nearly the entire length of the post 110 end. This provides optimum metal-to-metal contact, and thus optimum grounding connection over time between connector 100 and the cable 10.

(31) Without the two lateral slits and gap of the present disclosure, pressure is forced over the entire solid cable PVC jacket 12, the jacket in effect forming a 360-degree tube. This pressure then must transfer onto the cable's internal braiding 14, and then onto the connector's post in order to form the required grounding pressure. In addition, there is typically a metal foil bonded onto the inner part of the cable jacket, which is typically PVC. As such, when a conventional connector compresses the PVC jacket to apply pressure onto the connector's post, a very large amount of pressure must be applied onto the PVC jacket in order to deform the jacket and allow it to transfer the pressure onto the post for a proper grounding connection.

(32) The lateral slits 26 of the present disclosure allow the jacket 12 to split open and leave a gap when the post end is inserted into the cable's prepared end. As a result, the jacket 12, such as a PVC jacket with bonded, foil is no longer a solid 360-degree tube. This allows any compression pressure over the split portions of the split cable jacket 12 to be applied immediately and directly onto the cable' outer conductor or braiding 14, and hence onto the connector's post end 110 for grounding. Optimum grounding pressure can now be applied via the cable jacket 12 without exceeding the PVC polymer tensile strength and elongation break percentage. This also prevents material creep and ensures optimum cable/grounding to the connector post end 110 over time. Another advantage of the present disclosure is the pressure is applied down the full length of the connector post end 110, thereby ensuring optimum grounding surface area.

(33) It will be apparent to those skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings that modifications, combinations, sub-combinations, and variations can be made without departing from the spirit or scope of this disclosure. Likewise, the various examples described may be used individually or in combination with other examples. Those skilled in the art will appreciate various combinations of examples not specifically described or illustrated herein that are still within the scope of this disclosure. In this respect, it is to be understood that the disclosure is not limited to the specific examples set forth and the examples of the disclosure are intended to be illustrative, not limiting.

(34) As used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “comprising,” “including,” “having” and similar terms are intended to be inclusive such that there may be additional elements other than the listed elements.

(35) Additionally, where a method described above or a method claim below does not explicitly require an order to be followed by its steps or an order is otherwise not required based on the description or claim language, it is not intended that any particular order be inferred. Likewise, where a method claim below does not explicitly recite a step mentioned in the description above, it should not be assumed that the step is required by the claim.

(36) It is noted that the description and claims may use geometric or relational terms. These terms are not intended to limit the disclosure and, in general, are used for convenience to facilitate the description based on the examples shown in the figures. In addition, the geometric or relational terms may not be exact. For instance, walls may not be exactly perpendicular or parallel to one another because of, for example, roughness of surfaces, tolerances allowed in manufacturing, etc., but may still be considered to be perpendicular or parallel.