US0081 13 875B2
`
`(12) United States Patent
`Malloy et al.
`
`(10) Patent No.:
`
`(45) Date of Patent:
`
`US 8,113,875 B2
`*Feb. 14, 2012
`
`(54) CABLE CONNECTOR
`
`(75)
`
`Inventors: Allen L. Malloy, Elmira Heights, NY
`(US); Charles Thomas, Athens, PA
`(US); Mike Dean, Waverly, NY (US);
`Bruce Hauver, Sr., Elmira, NY (US)
`
`(73) Assignee: Belden Inc., St. Louis, MO (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. l54(b) by 134 days.
`
`This patent is subject to a terminal dis-
`claimer.
`
`(21) Appl.No.: 12/568,149
`
`(22)
`
`Filed:
`
`Sep. 28, 2009
`
`(58) Field of Classification Search ................ .. 439/578,
`439/63, 584
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1,734,506 A
`2,258,737 A
`2,394,351 A
`2,460,304 A
`2,544,654 A
`2,544,764 A
`
`11/1929 Walter
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`
`(Continued)
`
`CA
`
`FOREIGN PATENT DOCUMENTS
`2096710
`11/1994
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`(65)
`
`Prior Publication Data
`
`US 2011/0117774 A1
`
`May 19, 2011
`
`Notice of Allowance for U.S. Appl. No. 12/568,160, mail date Apr.
`18, 2011, 8 pages.
`
`Related U.S. Application Data
`
`(Continued)
`
`(60) Provisional application No. 61/101,185, filed on Sep.
`30, 2008, provisional application No. 61/101,191,
`filed on Sep. 30, 2008, provisional application No.
`61/155,246,
`filed on Feb. 25, 2009, provisional
`application No. 61/155,249, filed on Feb. 25, 2009,
`provisional application No. 61/155,250, filed on Feb.
`25, 2009, provisional application No. 61/155,252,
`filed on Feb. 25, 2009, provisional application No.
`61/155,289,
`filed on Feb. 25, 2009, provisional
`application No. 61/155,297, filed on Feb. 25, 2009,
`provisional application No. 61/175,613, filed on May
`5, 2009, provisional application No. 61/242,884, filed
`on Sep. 16, 2009.
`
`(51)
`
`Int. Cl.
`(2006.01)
`H01R 9/05
`(52) U.S.Cl.
`..................................................... .. 439/578
`
`Primary Examiner — Jean F Duveme
`(74) Attorney, Agent, or Firm — Foley & Lardner LLP
`
`(57)
`
`ABSTRACT
`
`A coaxial cable connector for coupling a coaxial cable to a
`mating connector includes a connector body having a forward
`end and a rearward cable receiving end for receiving a cable.
`A nut is rotatably coupled to the forward end ofthe connector
`body. An annular post is disposed within the connector body,
`the annular post having a forward flanged base portion
`located adjacent a rearward portion of the nut. An annular
`notch is formed in the forward flanged base portion. A biasing
`element is retained in the annular notch, and the biasing
`element extends towards a forward end of the nut in an
`
`uncompressed state.
`
`
`
`24 Claims, 8 Drawing Sheets
`
`/—10
`14
`
`I
`
`30
`
`,,. 24
`' ”
`
`I
`
`37
`
`
`
`A PPC Exhibit 2015
`
`Coming v. PPC
`|PR2016—O1573
`
`

`
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`D>>D>>>>>>>>>>>>>D>>>>>D>D>>>>>>>>>>>>D>D>>>>>D>>>D>D>D>D>>D>D>D>D>D>D>>>D>D>D>D>>D>D>D>D>>>D>D>D>D>D>D>D>D>D>D>D>>
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`US 8,113,875 B2
`Page 2
`
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`
`>>>D>>>>>D>>>>>D>>>>>D>D>>>>>>D>>>>>>D>>>>>>D>>>D>D>D>D>>>D>D>D>D>D>D>D>D>D>D>D>>D>>D>D>D>>D>D>D>D>D>>D>D>D>D>D>D>>D>D>
`
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`>>>D>>>>>D>>>>>D>>>>>D>D>>>>>>D>>>>>>D>>>>>>D>>>D>D>D>D>>>D>D>D>D>D>D>D>D>D>D>D>>D>>D>D>D>>D>D>D>D>D>>D>D>D>D>D>D>>D>D>
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`US 8,113,875 B2
`Page 3
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`gggggggr/aggmmW/awwwwwwwwgggggmggg>>>>>>>>u>>a>u>>a>u>>a>>>a>>>a>>>>>>>>>>>>>>>>>>>>>>>>>a>
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`Vlontena
`Vlontena
`Vlontena
`
`Islam
`Youtsey
`Palinkas et al.
`
`

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`US 8,113,875 B2
`Page 4
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`10/2004 Chen
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`11/2004 Derenthal
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`12/2004 Holliday
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`1/2002 Rodrigues et al.
`2002/0013088 A1
`3/2004 Kodaira
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`2004/0224552 A1
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`............... .. 439/578
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`...............H 439/578
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`2010/0081322 A1,,
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`12/1972
`32 11 008 A1
`10/1983
`
`DE
`DE
`DE
`DE
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`DE
`DE
`DE
`
`DE
`DE
`EP
`EP
`EP
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`FR
`FR
`FR
`FR
`FR
`GB
`GB
`GB
`GB
`GB
`GB
`JP
`JP
`JP
`JP
`W0
`W0
`W0
`
`102289
`41 28 551 A1
`0 072 104
`0 116 157
`0 167 738
`0 265 276 B1
`2 232 846
`2 234 680
`2 462 798
`4 494 508
`2 524 722
`589697
`1087228
`1 270 846
`2 019 665 A
`2 079 549 A
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`OTHER PUBLICATIONS
`
`_
`_
`Notice ofA11owance for U.S. Appl. No. 12/568,179, n1a11 date Mar.
`21, 2011, 10 pages.
`Office Action for U.S. Appl. No. 12/568, 160, mail date Jul. 22, 2010,
`7 pages.
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`?3°1:1::Sct10n for US. Appl. No. 12/568,160, mall date Sep. 8,2010,
`Response to Office Action for U.S. Appl. No. 12/568, 160, filed Aug.
`231 201°’ 3 Pa‘é‘°~S~
`_
`Response to Office Action for U.S.App1. No. 12/568,160, filed Mar.
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`Statement of Substance of Interview, Terminal Disclaimer and State-
`ment Under 37 CFR3.73(b) for U.S. Appl. No. 12/568, 179, filed Jun.
`30, 2011, 5 pages.
`
`* cited by examiner
`
`

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`

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`U.S. Patent
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`Feb. 14, 2012
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`
`1
`CABLE CONNECTOR
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application claims priority under 35. U.S.C. §119,
`based on U.S. Provisional Patent Application Nos. 61/101,
`185 filed Sep. 30, 2008, 61/101,191, filed Sep. 30, 2008,
`61/155,246, filed Feb. 25, 2009, 61/155,249, filed Feb. 25,
`2009, 61/155,250, filed Feb. 25, 2009, 61/155,252, filed Feb.
`25,2009, 61/155,289, filed Feb. 25, 2009, 61/155,297, filed
`Feb. 25, 2009, 61/175,613, filed May 5, 2009, and 61/242,
`884, filed Sep. 16, 2009, the disclosures of which are all
`hereby incorporated by reference herein.
`The present application is also related to co-pending U.S.
`patent application Ser. Nos. 12/568,160, entitled “Cable Con-
`nector,” filed, Sep. 28, 2009, and U.S. patent application Ser.
`No. 12/568,179, entitled “Cable Connector,” filed Sep. 28,
`2009, the disclosures of which are both hereby incorporated
`by reference herein.
`
`BACKGROUND OF THE INVENTION
`
`Connectors are used to connect coaxial cables to various
`
`electronic devices such as televisions, antennas, set-top
`boxes, satellite television receivers, etc. Conventional coaxial
`connectors generally include a connector body having an
`annular collar for accommodating a coaxial cable, and an
`annular nut rotatably coupled to the collar for providing
`mechanical attachment of the connector to an external device
`
`and an armular post interposed between the collar and the nut.
`The annular collar that receives the coaxial cable includes a
`
`cable receiving end for insertably receiving a coaxial cable
`and, at the opposite end ofthe connector body, the annular nut
`includes an internally threaded end that permits screw
`threaded attachment of the body to an external device.
`This type of coaxial connector also typically includes a
`locking sleeve to secure the cable within the body of the
`coaxial connector. The locking sleeve, which is typically
`formed of a resilient plastic, is securable to the connector
`body to secure the coaxial connector thereto. In this regard,
`the connector body typically includes some form of structure
`to cooperatively engage the locking sleeve. Such structure
`may include one or more recesses or detents formed on an
`inner annular surface of the connector body, which engages
`cooperating structure formed on an outer surface of the
`sleeve.
`
`Conventional coaxial cables typically include a center con-
`ductor surrounded by an insulator. A conductive foil is dis-
`posed over the insulator and a braided conductive shield
`surrounds the foil-covered insulator. An outer insulative
`
`jacket surrounds the shield. In order to prepare the coaxial
`cable for termination with a connector, the outer jacket is
`stripped back exposing a portion of the braided conductive
`shield. The exposed braided conductive shield is folded back
`over the jacket. A portion of the insulator covered by the
`conductive foil extends outwardly from the jacket and a por-
`tion of the center conductor extends outwardly from within
`the insulator.
`
`Upon assembly, a coaxial cable is inserted into the cable
`receiving end of the connector body and the annular post is
`forced between the foil covered insulator and the conductive
`
`shield of the cable. In this regard, the post is typically pro-
`vided with a radially enlarged barb to facilitate expansion of
`the cable jacket. The locking sleeve is then moved axially into
`the connector body to clamp the cable jacket against the post
`barb providing both cable retention and a water-tight seal
`
`65
`
`US 8,113,875 B2
`
`2
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`around the cable jacket. The connector can then be attached to
`an external device by tightening the internally threaded nut to
`an externally threaded terminal or port of the external device.
`The Society of Cable Telecommunication Engineers
`(SCTE) provides values for the amount of torque recom-
`mended for connecting such coaxial cable connectors to vari-
`ous external devices. Indeed, most cable television (CATV),
`multiple systems operator (MSO), satellite and telecommu-
`nication providers also require their installers to apply a
`torque requirement of 25 to 30 in/lb to secure the fittings
`against the interface (reference plane). The torque require-
`ment prevents loss of signals (egress) or introduction of
`unwanted signals (ingress) between the two mating surfaces
`of the male and female connectors, known in the field as the
`reference plane.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an isometric view of an exemplary embodiment of
`a coaxial cable connector;
`FIG. 2 is a cross-sectional view of the coaxial cable con-
`
`nector of FIG. 1 in an unconnected configuration;
`FIG. 3 is a cross-sectional view of the coaxial cable con-
`
`nector of FIG. 2 in a connected configuration;
`FIG. 4 is a cross-sectional view of another exemplary
`embodiment of the coaxial cable connector of FIG. 1 in an
`
`unconnected configuration;
`FIG. 5 is a cross-sectional view of the coaxial cable con-
`
`nector of FIG. 4 in a connected configuration;
`FIG. 6 is a cross-sectional view of another exemplary
`implementation of the coaxial cable connector of FIG. 1 in an
`unconnected configuration;
`FIG. 7 is a cross-sectional view of the coaxial cable con-
`
`nector of FIG. 6 in a connected configuration; and
`FIGS. 8A-8C illustrate an exemplary biasing element con-
`sistent with an exemplary embodiment.
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`A large number of home coaxial cable installations are
`often done by “do-it yourself” laypersons who may not be
`familiar with such torque standards. In these cases,
`the
`installer will typically hand-tighten the coaxial cable connec-
`tors instead ofusing a tool, which can result in the connectors
`not being properly seated, either upon initial installation, or
`after a period of use. Upon immediately receiving a poor
`signal, the customer typically calls the CATV, MSO, satellite
`or telecommunication provider to request repair service.
`Obviously, this is a cost concern for the CATV, MSO, satellite
`and telecommunication providers, who then have to send a
`repair technician to the customer’s home.
`Moreover, even when tightened according to the proper
`torque requirements, another problem with such prior art
`connectors is the connector’s tendency over time to become
`disconnected from the external device to which it is con-
`
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`nected, due to forces such as vibrations, heat expansion, etc.
`Specifically,
`the internally threaded nut
`for providing
`mechanical attachment ofthe connector to an external device
`
`60
`
`has a tendency to back-off or loosen itself from the threaded
`port connection of the external device over time. Once the
`connector becomes sufiiciently loosened, electrical connec-
`tion between the coaxial cable and the external device is
`
`broken, resulting in a failed condition.
`FIGS. 1-3 depict an exemplary coaxial cable connector 10
`consistent with embodiments described herein. As illustrated,
`
`

`
`US 8,113,875 B2
`
`3
`connector 10 may include a connector body 12, a locking
`sleeve 14, an annular post 16, and a rotatable nut 18.
`In one implementation, connector body 12 (also referred to
`as a “collar”) may include an elongated, cylindrical member,
`which can be made from plastic, metal, or any suitable mate-
`rial or combination of materials. Connector body 12 may
`include a forward end 20 operatively coupled to armular post
`16 and rotatable nut 18, and a cable receiving end 22 opposite
`to forward end 20. Cable receiving end 22 may be configured
`to insertably receive locking sleeve 14, as well as a prepared
`end of a coaxial cable in the forward direction as shown by
`arrow A in FIG. 2. Cable receiving end 22 of connector body
`12 may further include an inner sleeve engagement surface 24
`for coupling with the locking sleeve 14. In some implemen-
`tations, inner sleeve engagement surface 24 is preferably
`formed with a groove or recess 26, which cooperates with
`mating detent structure 28 provided on the outer surface of
`locking sleeve 14.
`Locking sleeve 14 may include a substantially tubularbody
`having a rearward cable receiving end 30 and an opposite
`forward connector insertion end 32, movably coupled to inner
`sleeve engagement surface 24 of the connector body 12. As
`mentioned above, the outer cylindrical surface of locking
`sleeve 14 may be configured to include a plurality ofridges or
`projections 28, which cooperate with groove or recess 26
`formed in inner sleeve engagement surface 24 of the connec-
`tor body 12 to allow for the movable connection of sleeve 14
`to the connector body 12, such that locking sleeve 14 is
`lockingly axially moveable along the direction of arrow A
`toward the forward end 20 of the connector body from a first
`position, as shown, for example, in FIG. 2 to a second, axially
`advanced position (shown in FIG. 1). When in the first posi-
`tion, locking sleeve 14 may be loosely retained in connector
`10. When in the second position, locking sleeve 14 may be
`secured within connector 10. In some implementations, lock-
`ing sleeve 14 may be detachably removed from connector 10,
`e.g., during shipment, etc., by, for example, snappingly
`removing projections 28 from groove/recess 26. Prior to
`installation, locking sleeve 14 may be reattached to connector
`body 12 in the manner described above.
`In some additional implementations, locking sleeve 14
`may include a flanged head portion 34 disposed at the rear-
`ward cable receiving end 30 of locking sleeve 14. Head por-
`tion 32 may include an outer diameter larger than an inner
`diameter of the body 12 and may further include a forward
`facing perpendicular wall 36, which serves as an abutment
`surface against which the rearward end 22 ofbody 12 stops to
`prevent further insertion of locking sleeve 14 into body 12. A
`resilient, sealing O-ring 37 may be provided at forward facing
`perpendicular wall 36 to provide a substantially water-tight
`seal between locking sleeve 14 and connector body 12 upon
`insertion of the locking sleeve within the body and advance-
`ment from the first position (FIG. 2) to the second position
`(FIG. 1).
`As mentioned above, connector 10 may further include
`annular post 16 coupled to forward end 20 of connector body
`12. As illustrated in FIGS. 2 and 3, armular post 16 may
`include a flanged base portion 200 at its forward end for
`securing annular post 16 within annular nut 18. Additional
`details relating to flanged base portion 200 are set forth in
`additional detail below. Armular post 16 may also include an
`annular tubular extension 40 extending rearwardly within
`body 12 and terminating adjacent rearward end 22 of connec-
`tor body 12. In one embodiment, the rearward end of tubular
`extension 40 may include a radially outwardly extending
`ramped flange portion or “barb” 42 to enhance compression
`of the outer jacket of the coaxial cable and to secure the cable
`
`10
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`within connector 10. Tubular extension 40 of annular post 16,
`locking sleeve 14, and connector body 12 together define an
`annular chamber 44 for accommodating the jacket and shield
`of an inserted coaxial cable.
`
`As illustrated in FIGS. 1-3, armular nut 18 may be rotatably
`coupled to forward end 20 of connector body 12. Armular nut
`18 may include any number ofattaching mechanisms, such as
`that ofa hex nut, a knurled nut, a wing nut, or any other known
`attaching means, and may be rotatably coupled to connector
`body 12 for providing mechanical attachment of the connec-
`tor 10 to an external device via a threaded relationship. As
`illustrated in FIGS. 2 and 3, nut 18 may include an annular
`flange 45 configured to fix nut 18 axially relative to armular
`post 16 and connector body 12. In one implementation, a
`resilient sealing O-ring 46 may be positioned in annular nut
`18 to provide a water resistant seal between connector body
`12, annular post 16, and armular nut 18
`Connector 10 may be supplied in the assembled condition,
`as shown in the drawings, in which locking sleeve 14 is
`pre-installed inside rearward cable receiving end 22 of con-
`nector body 12. In such an assembled condition, a coaxial
`cable may be inserted through rearward cable receiving end
`30 oflocking sleeve 14 to engage armular post 16 of connector
`10 in the manner described above. In other implementations,
`locking sleeve 14 may be first slipped over the end of a coaxial
`cable and the cable (together with locking sleeve 14) may
`subsequently be inserted into rearward end 22 of connector
`body 12.
`In either case, once the prepared end of a coaxial cable is
`inserted into connector body 12 so that the cable jacket is
`separated from the insulator by the sharp edge of annular post
`16, locking sleeve 14 may be moved axially forward in the
`direction of arrow A from the first position (shown in FIGS. 2
`and 3) to the second position (shown in FIG. 1). In some
`implementations, advancing locking sleeve 14 from the first
`position to the second position may be accomplished with a
`suitable compression tool. As locking sleeve 14 is moved
`axially forward, the cable jacket is compressed within annular
`chamber 44 to secure the cable in connector 10. Once the
`
`cable is secured, connector 1 0 is ready for attachment to a port
`connector 48 (illustrated in FIG. 3), such as an F-81 connec-
`tor, of an external device.
`As illustrated in FIG. 3, port connector 48 may include a
`substantially cylindrical body 50 having external threads 52
`that match internal threads 54 of armular nut 18. As will be
`discussed in additional detail below, retention force between
`annular nut 18 and port connector 48 may be enhanced by
`providing a substantially constant load force on the port con-
`nector 48.
`
`To provide this load force, flanged base portion 200 of
`annular post 1 6 may be configured to include an annular notch
`205 for retaining a biasing element 210. As illustrated in
`FIGS. 2 and 3, flanged base portion 200 may include a step
`configuration including a first annular step portion 215 and a
`second annular step portion 220. First armular step portion
`215 may further include a forward, substantially planar sur-
`face 225, that defines an end of armular post 16. In one
`implementation, armular notch 205 may include an annular
`groove formed in an outer surface of first armular step portion
`215.
`
`Biasing element 210 may include a conductive, resilient
`element configured to provide a suitable biasing force
`between annular post 16 and rearward surface 66 of port
`connector 48. The conductive nature of biasing element 210
`may facilitate passage of electrical and radio frequency (RF)
`
`

`
`US 8,113,875 B2
`
`5
`signals from armular post 16 to port connector 48 at varying
`degrees of insertion relative to port connector 48 and connec-
`tor 10.
`
`In one implementation, biasing element 210 may include
`one or more coil springs, one or more wave springs (single or
`double waves), one or more a conical spring washers (slotted
`or unslotted), one or more Belleville washers, or any other
`suitable biasing element, such as a conductive resilient ele-
`ment (e.g., a plastic or elastomeric member impregnated or
`injected with conductive particles), etc.
`As illustrated in FIGS. 8A-8C, biasing element 210 may
`include a two-peak wave washer having an inside diameter
`“dz.” and an outside diameter “do.” In one implementation, the
`inside diameter dz of biasing element 210 may be sized sub-
`stantially similarly to a diameter of armular notch 205, such
`that biasing element 210 may be retained within annular
`notch 205. In one configuration (not shown), a forward edge
`of first annular step portion 215 may be configured to include
`a beveled or charnfered surface for facilitating insertion of
`biasing element 210 into annular notch 205.
`In an initial, uncompressed state (as shown in FIG. 2),
`biasing element 210 may extend a length “z” beyond forward
`surface 64 of annular post 16. Upon insertion of port connec-
`tor 48 (e.g., via rotatable threaded engagement between
`threads 52 and threads 54 as shown in FIG. 3), rearward
`surface 66 of port connector 48 may come into contact with
`biasing element 210. In a position of initial contact between
`port connector 48 and biasing element 210 (not shown), rear-
`ward surface 66 of port connector 48 may be separated from
`forward surface 64 of annular post 16 by a distance “z.” The
`conductive nature of biasing element 210 may enable effec-
`tive transmission of electrical and RF signals from port con-
`nector 48 to armular post 16 even when separated by distance
`z, effectively increasing the reference plane of connector 10.
`In one implementation, the above-described configuration
`enables a functional gap or “clearance” of less than or equal to
`approximately 0.043 inches, for example 0.033 inches,
`between the reference planes,
`thereby enabling approxi-
`mately 270 degrees or more of “back-off” rotation of annular
`nut 18 relative to port connector 48 while maintaining suit-
`able passage of electrical and/or RF signals.
`Continued insertion ofport connector 48 into connector 10
`may cause biasing element 210 to compress, thereby provid-
`ing a load force between flanged base portion 200 and port
`connector 48 and decreasing the distance between rearward
`surface 66 of port connector 48 and forward surface 64 of
`annular post 16. This load force may be transferred to threads
`52 and 54, thereby facilitating constant tension between
`threads 52 and 54 and facilitating a decreased likelihood that
`port connector 48 becomes loosened from connector 10 due
`to external forces, such as vibrations, heating/cooling, etc.
`The above-described connector may pass electrical and RF
`signals typically found in CATV, Satellite, closed circuit tele-
`vision (CCTV), voice of Internet protocol (VoIP), data, video,
`high speed Internet, etc., through the mating ports (about the
`connector reference planes). Providing a biasing element, as
`described above, may also provide power b