U.S. patent application number 09/813034 was filed with the patent office on 2001-11-29 for hdtv camera cable connector.
This patent application is currently assigned to Kings Electronics Co., Inc.. Invention is credited to Bateman, Steve, Kennedy, Jim, Nguyen, Hiep V..
Application Number | 20010046354 09/813034 |
Document ID | / |
Family ID | 26893379 |
Filed Date | 2001-11-29 |
United States Patent
Application |
20010046354 |
Kind Code |
A1 |
Nguyen, Hiep V. ; et
al. |
November 29, 2001 |
HDTV camera cable connector
Abstract
A cable connector is disclosed for hybrid cables having optical
fibers, power lines, and audio lines. In one embodiment, the cable
connector includes male and female portions having corresponding
male and female contact pins for the power and audio lines, and
forwardly-biased ferrules housing the optical fibers. All the lines
and optical fibers are secured in an insulator device by an
insulator lock that lockably engages a receptacle of the insulator
device. Each hybrid cable is further secured and sealed with a grip
member and a crimp ring. The cable connector of the present
invention allows for field serviceability without the use of
potting compounds.
Inventors: |
Nguyen, Hiep V.; (Charlotte,
NC) ; Bateman, Steve; (Waxhaw, NC) ; Kennedy,
Jim; (Rock Hill, SC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Kings Electronics Co., Inc.
Rock Hill
SC
|
Family ID: |
26893379 |
Appl. No.: |
09/813034 |
Filed: |
March 20, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60198001 |
Apr 18, 2000 |
|
|
|
Current U.S.
Class: |
385/53 ;
385/75 |
Current CPC
Class: |
G02B 6/3817 20130101;
G02B 6/3849 20130101 |
Class at
Publication: |
385/53 ;
385/75 |
International
Class: |
G02B 006/38 |
Claims
That which is claimed:
1. A connector for securing two cables having fiber optic and
electrical lines and having an outer sheath conductor, the
connector comprising: a male portion and a female portion operable
to slidably engage one another, the male portion including at least
one ferrule defining a central opening therethrough for receiving
an optical fiber, at least one contact pin for receiving a power
line, at least one contact pin for receiving an audio line, an
insulator device defining a plurality of channels therethrough, the
channels formed to receive the at least one ferrule, the at least
one power line contact pin, and the at least one audio line contact
pin, the insulator device also defining a recessed annular channel
at one end, and an insulator lock defining a plurality of channels
therethrough corresponding to the channels defined by the insulator
device, the insulator lock formed to releaseably engage the
recessed annular channel of the insulator device such that the
ferrule and the contact pins are secured when the insulator lock is
in the engaged position; a grip member having a body portion
defining a central opening for receiving one of the cables such
that the outer sheath conductor of the cable is positioned outside
of the central opening; and a crimp ring positioned about the body
portion of the grip member for securing the outer sheath conductor
of the cable.
2. A connector according to claim 1, further comprising a metallic
spacer positioned between the body portion of the grip member and
the crimp ring.
3. A connector according to claim 1, further comprising a tubular
spacer positioned between the insulator device and the grip member
for further securing the cable in the connector.
4. A connector according to claim 3, wherein the tubular spacer is
formed of a thermoplastic material.
5. A connector according to claim 1, wherein the male portion
includes two ferrules, two power line contact pins, and two audio
line contact pins.
6. A connector according to claim 1, wherein the insulator device
is formed from an insulative material selected from the group
consisting of polycarbonate and ABS plastic.
7. A connector according to claim 1, further comprising a bias
member for biasing the at least one ferrule towards the end of the
insulator device opposite the end defining the annular channel.
8. A connector for securing two cables having fiber optic and
electrical lines and having an outer sheath conductor, the
connector comprising: a male portion and a female portion operable
to slidably engage one another, the female portion including a
ferrule defining a central opening therethrough for receiving an
optical fiber, at least one contact pin having opposing ends, and
defining a opening at one end for receiving a power line and a
slotted opening at the other end for receiving a corresponding
contact pin from the male portion, at least one contact pin having
opposing ends, and defining an opening at one end for receiving an
audio line and a slotted opening at the other end for receiving a
corresponding contact pin from the male portion, an insulator
device defining a plurality of channels therethrough, the channels
formed to receive the at least one power line contact pin and the
at least one audio line contact pin, the insulator device also
defining a recessed annular channel at one end, and an insulator
lock defining a plurality of channels therethrough corresponding to
the channels defined by the insulator device, the insulator lock
formed to releaseably engage the recessed annular channel of the
insulator device such that the ferrule and the contact pins are
secured to the insulator device when the insulator lock is in the
engaged position; a grip member having a body portion defining a
central opening for receiving one of the cables such that the outer
sheath conductor of the cable is positioned outside of the central
opening; and a crimp ring positioned about the body portion of the
grip member for securing the outer sheath conductor of the
cable.
9. A connector according to claim 8, further comprising a metallic
spacer positioned between the body portion of the grip member and
the crimp ring.
10. A connector according to claim 8, further comprising a tubular
spacer positioned between the insulator device and the grip member
for further securing the cable in the connector.
11. A connector according to claim 8, wherein the female portion
includes two ferrules, two power line contact pins, and two audio
line contact pins.
12. A connector according to claim 8, further comprising a bias
member for biasing the at least one ferrule towards the end of the
insulator device opposite the end defining the annular channel.
13. A connector for securing two cables having fiber optic and
electrical lines, the connector comprising: a male portion and a
female portion operable to slidably engage one another, each of the
male and female portions comprising: at least one ferrule defining
a central opening therethrough for receiving an optical fiber, the
ferrule of the male portion and the ferrule of the female portion
being biased forwardly into an abutting relationship so that light
can travel between the ferrules, at least one contact pin for
receiving associated power lines, the power line contact pin of the
male portion defining an opening at one end for receiving a power
line and having a tip at the other end operable to engage a slotted
opening defined in the power line contact pin of the female
portion, and an insulator device defining a plurality of channels
therethrough, the channels formed to receive the at least one
ferrule and the at least one contact pin, each of the insulator
devices also defining a receptacle at one end; and an insulator
lock defining a plurality of channels therethrough corresponding to
the channels defined by the insulator device, the insulator lock
being formed to releaseably engage the receptacle of the insulator
device such that the ferrule and contacts pins extending
therethrough are secured in the insulator device when the insulator
lock is in the engaged position.
14. A connector according to claim 13, wherein the male portion and
the female portion each include two ferrules, two power line
contact pins, and two audio line contact pins.
15. A connector according to claim 13, further comprising a bias
member positioned adjacent the at least one ferrule for biasing the
least one ferrule towards the end of the insulator device opposite
the end defining the receptacle thereof.
16. A connector according to claim 13, wherein the receptacle is in
the form of a recessed annular channel.
17. A method of terminating a pair of hybrid cables each having at
least one optical fiber, at least one power line, and at least one
audio line, the method comprising: securing the at least one power
line and the at least one audio line of each hybrid cable in
corresponding contact pins; securing the least one optical fiber of
each hybrid cable in an opening formed through a ferrule;
positioning the at least one contact pin and the at least one
ferrule of each hybrid cable in channels formed through an
insulator device defining a receptacle at one end; and securing the
at least one contact pin and the at least one ferrule in the
insulator device by inserting an insulator lock formed to engage
the receptacle of the insulator device.
18. A method according to claim 17, further comprising sealing the
hybrid cable by positioning a grip member about the at least one
optical fiber, at least one power line, and at least one audio line
of each hybrid cable so that an outer sheath conductor of each
hybrid cable is exposed, and mechanically pressing a crimp ring
about the exposed outer sheath conductor so that the outer sheath
conductor is interposed between the grip member and the crimp
ring.
19. A method according to claim 18, wherein the sealing step
includes positioning a resilient washer and an end cap about the
hybrid cable.
20. A method according to claim 17, further comprising positioning
the insulator devices of the hybrid cables in an abutting
relationship so that the respective audio line contact pins and
power line contact pins of each hybrid cable engage one another,
and so that the respective ferrules of each hybrid cable abut one
another so that the optical fibers secured within ferrules form a
continuous path for light to pass.
21. A method according to claim 17, further comprising positioning
a tubular spacer between the insulator device and the grip member
on each hybrid cable for further securing the hybrid cable.
22. A method according to claim 17, further comprising biasing the
at least one ferrule of each optical fiber towards the end of the
respective insulator device opposite the end defining the
receptacle.
23. A connector for terminating a hybrid cable containing at least
one electrical conductor and at least one optical fiber arranged
side-by-side within the cable, comprising: an outer housing
defining a passage extending axially therethrough for receiving an
end of the cable; an insulator device secured within the passage of
the outer housing, the insulator device defining at least first and
second side-by-side apertures formed axially therethrough; a
contact member configured to be attached to an end of the at least
one electrical conductor of the cable and to be inserted axially
into the first aperture of the insulator device from one end
thereof and to be slid axially up against a stop defined by the
insulator device, and a ferrule configured to be attached to an end
of the at least one optical fiber with the fiber extending through
a bore formed through the ferrule, the ferrule being configured to
be inserted axially into the second aperture of the insulator
device from said one end thereof and to be slid axially up against
another stop defined by the insulator device; and an insulator lock
received axially into said one end of the insulator device and
defining at least a pair of passages for passage of the at least
one electrical conductor and optical fiber therethrough, the
insulator device and insulator lock being configured such that the
insulator lock removably snaps into said one end of the insulator
device behind the at least one contact member and ferrule to
prevent the contact member and ferrule from being withdrawn out
said one end of the insulator device.
24. A connector according to claim 23, wherein the insulator device
defines six apertures formed axially therethrough.
25. A connector according to claim 23, further comprising a grip
member for securing an outer conductive braid of the hybrid cable
that is positioned about the at least one electrical conductor and
the at least one optical fiber.
26. A connector for terminating a hybrid cable, comprising: an
outer housing defining a passage extending axially therethrough for
receiving an end of the cable; an insulator device secured within
the passage of the outer housing, the insulator device defining at
least first and second side-by-side apertures formed axially
therethrough; a contact member configured to be attached to an end
of the at least one electrical conductor of the cable and to be
inserted axially into the first aperture of the insulator device
from one end thereof and to be slid axially up against a stop
defined by the insulator device, and a ferrule configured to be
attached to an end of the at least one optical fiber with the fiber
extending through a bore formed through the ferrule, the ferrule
having a diameter of at least 1.5 mm and being configured to be
inserted axially into the second aperture of the insulator device
from said one end thereof and to be slid axially up against another
stop defined by the insulator device; and an insulator lock
received axially into said one end of the insulator device and
defining at least a pair of passages for passage of the at least
one electrical conductor and optical fiber therethrough, the
insulator device and insulator lock being configured such that the
insulator lock removably snaps into said one end of the insulator
device behind the at least one contact member and ferrule to
prevent the contact member and ferrule from being withdrawn out
said one end of the insulator device.
27. A connector according to claim 26, wherein the ferrule has a
diameter of between 2.0-2.5 mm.
Description
FIELD OF THE INVENTION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/198,001, filed Apr. 18, 2000. The present
invention relates to cable connectors, and more particularly to
cable connectors capable of transferring signals over both optical
fibers and conventional electrical wires.
BACKGROUND OF THE INVENTION
[0002] In the broadcast and video industries, coaxial, twinaxial,
and triaxial cables have been relied upon heavily for transmission
purposes, particular at bandwidths up to around 750 MHz. These
cables could be terminated in a conventional manner with a wide
range of connectors that were available from many manufacturers.
One particular connector is called a "Tri-Loc.RTM." connector,
available from Kings Electronics (http://www.kingselectronics.com).
However, with the move towards high definition television (HDTV)
and other applications that require higher signal transmission
rates compared to the conventional transmission rates, the
broadcast and video industries are, in many applications, replacing
coaxial, twinaxial, and triaxial cables with a hybrid cable that
comprises a combination of electrical conductors and single-mode
optical fibers. These hybrid cables permit digital signal
transmissions at increased transmission rates over longer distances
when compared to the conventional cables. Hybrid cables are
available from many manufacturers, such as Commscope
(http://www.commscope.com). To keep up with the changes in the
cable construction, these industries also require a connector to
suitably connect these hybrid cables.
[0003] For conventional power and signal wires, typically a plug
and socket arrangement is provided for connecting the wires, which
are usually copper wires. Many applications require a minimal
contacting relationship in order to sufficiently transfer the
signal. Connection beyond the minimal contacting relationship is
not necessary, because the connection is made through the
circumference of the respective plug and socket. Optical fibers,
however, require special connections in order to properly transfer
signals.
[0004] Fiber optic cables and connectors have been used for some
time in the telecommunications and broadcast industries. In fact,
fiber optic cables have become the standard transmission line
through which information is sent. Many different types of fiber
optic cables and connectors are present in the market place. A
common method of making a connection between two optical fibers is
to align the fibers such that the faces of the fibers oppose one
another in an abutting relationship. This relationship enables the
light pulses or signal transmissions travelling along the optical
fibers to be transferred across the splice. If the face of one
fiber is misaligned relative to the adjacent face of the other
fiber, however, light is lost and quality of transmission is
affected. It is therefore extremely important for fiber optic
cables to have a low-tolerance fitting between splices.
[0005] A typical hybrid cable connector and technique uses several
non-reusable components and urethane potting materials to isolate,
secure, and protect the optical fibers and electrical conductors
within the respective male and female bodies of the connector. The
problem with such a connector and technique is that the potting
compound is required to make the connection structurally sound,
electrically insulated, and waterproof. As a result, the potting
compound has to be poured or coated over the respective lines and
cured before the connection can be tested, which requires a
significant amount of time. If the connection needs to be redone,
however, the components that are coated with the potting compound
must be thrown away and the process must start from the beginning.
This can be a time consuming and wasteful exercise, particular if
the connection between the optical fibers is difficult to achieve
and must be repeated multiple times.
[0006] Another problem with conventional hybrid connectors and
techniques is that these connectors are not serviceable in the
field. More specifically, conventional hybrid connectors do not
provide a method of repairing damaged optical fibers except by a
machine polishing technique that typically must be performed by the
manufacturer. This is particularly troublesome to the equipment
operator working in an unpredictable environment. For example, if
an HDTV camera operator is transmitting from an outside sporting
event, and the cable connecting the camera to the transmission
source is severed or damaged, conventional connectors and
techniques require the operator to disconnect the hybrid cable and
install a new cable. Thus, an operator is required to carry spare
or backup cables in case of the above-mentioned occurrences, which
adds cost and bulk to the operator's assignment. In addition, the
camera operator is required to send the severed or damaged cable
(with attached connectors) to the manufacturer so that the
manufacturer can repair the cable. Disadvantageously, this further
adds expense and time to the operator's activities.
[0007] Accordingly, there is a need to provide a hybrid cable
connector that can be adjusted and repaired in the field without
having to be completely replaced or without wasting many
components. There is also a need to provide a hybrid cable
connector that is easy to connect to a hybrid cable and that
provides structural integrity, electrical insulation, and
protection against water without the use of potting compounds.
SUMMARY OF THE INVENTION
[0008] These and other needs are provided, according to the present
invention, by a hybrid cable connector capable of connecting two
hybrid cables having optical fibers and electrical wires.
Advantageously, the hybrid cable connector of the present invention
is field serviceable, thus allowing an operator to repair a damaged
or broken hybrid cable in the field of operation instead of
requiring the operator to disconnect the cable and send it back to
the manufacturer for repair. Specifically, the hybrid cable
connector and associated technique allows for the optical fibers to
be prepared and repaired by the operator using hand tools while in
the field. In addition, the hybrid cable connector of the present
invention provides a unique insulator lock that provides structural
integrity, electrical insulation, and waterproof protection to the
optical fibers and electrical wires. Thus, the hybrid cable
connector of the present invention does not require the use of
potting compounds or other materials which add cost, time, and
complexity to the connector and associated repair methods.
[0009] In particular, the hybrid cable connector of the present
invention comprises male and female portions that cooperate to
connect two hybrid cables. Each portion includes an outer housing
defining a passage extending axially therethrough for receiving an
end of a cable. Each portion also includes an insulator device
having proximal and distal ends secured within the passage of the
outer housing. In one embodiment, the housing comprises a strong
metallic material, although non-metallic materials may also be
used. The insulator device defines six channels therethrough for
receiving two optical fibers or lines, two power lines, and two
audio lines. Each line is attached to a respective connection
contact, such as a contact pin or ferrule. The insulator lock
slidably engages the insulator device, such as by a removable
snapping action, for restricting the movement of the contacts
within the insulator device. A spacer is provided for further
structural integrity within the housing of the male and female
portions of the connector. The housings of the male and female
portions include a keying feature that resembles a tongue and
groove configuration. In this regard, the male and female portions
are prevented from rotating relative to one another.
[0010] To connect the hybrid cable to the connector of the present
invention, the power and audio lines are terminated to the
respective contacts by crimping or soldering. In one embodiment,
the contacts for the power and audio lines comprise a conductive
material, such as beryllium copper. In one embodiment, the optical
fibers or lines are terminated pursuant to assembly instructions
provided by Alcoa Fujikura Telecommunications. In particular, an
Alcoa Fujikura field connection kit including a publication
entitled "Assembly Instructions For AFL Field Master.TM. ST
Connectors Using Loctite 680 Adhesive," form No. AFM 307-130, which
is expressly incorporated herein by reference, is particularly
useful in preparing the optical fibers for assembly within the male
and female portions of the connector. Advantageously, the Alcoa
field connection kit includes ceramic ferrules that receive the
optical fibers. Other ferrules and contact members are also
included in the kit. Once all the optical fibers and electrical
conductors have been properly prepared, they are axially inserted
into the respective insulator device in a predetermined pattern
that corresponds to the pattern in the opposite insulator device. A
bias member or spring is provided adjacent each optical fiber for
biasing the optical fiber towards the open end of the insulator
device. Specifically, the spring biases the contact members and
ferrules against respective stops defined by the insulator device.
Thus, the spring ensures positive contact between the corresponding
optical fibers from the respective male and female portions. The
insulator lock slidably engages the distal end of the respective
insulator device and is secured thereto by a locking interference
fit, such as a snap fit, between the insulator device and the
insulator lock. The spacer is slidably engaged over the hybrid
cable until it is adjacent the insulator lock. The hybrid cable,
which in one embodiment includes an outer conductive braid, is
secured to the respective housing by a crimp ring. The crimp ring
provides sufficient strength between the cable and the connector to
withstand a minimum of 120 pounds of pull force. A rubber-type
washer is also provided to seal the inside of the housing from the
environment.
[0011] The connector according to the present invention is capable
of the following minimum performance requirements:
1 Optical Wave Length: 1000 nm-1500 nm Insertion Loss: 0.5 dB
maximum Return Loss: -45 dB maximum Operating Temperature Range:
-20.degree. C. to +70.degree. C. Operating Humidity: <95% RH (at
+40.degree. C.)
[0012] In addition, the connector of the present invention will
meet the testing requirements of Underwriters Laboratories (UL),
the Canadian Standards Association (CSA), or other similar
authorities appropriate to the intended use of the connector.
[0013] Thus, the hybrid cable connector of the present invention
provides important advancements in the state of the art.
Specifically, the connector of the present invention can be
adjusted in the field without wasting components as can occur when
using potting compounds and/or other conventional methods. In
addition, the locking interference fit between the insulator device
and the insulator lock of the present invention allows for a secure
connection between the opposing optical fibers and electrical
conductors of the male and female portions of the connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Having thus described the invention in general terms,
reference will not be made to the accompanying drawings, which are
not necessarily drawn to scale, wherein:
[0015] FIG. 1 is an enlarged sectional side view of a male portion
of a connector according to one embodiment of the present
invention;
[0016] FIG. 2 is an enlarged sectional side view of a female
portion of a connector according to one embodiment of the present
invention;
[0017] FIG. 3 is an enlarged sectional end view of a hybrid cable
for use with the connector of the present invention;
[0018] FIG. 4 is an enlarged sectional side view of a conductor pin
according to one embodiment of the present invention;
[0019] FIG. 5A is an enlarged side view of a male tubular connector
body according to one embodiment of the present invention;
[0020] FIG. 5B is a sectional end view of the connector body of
FIG. 5A;
[0021] FIG. 6 is an enlarged sectional side view of a female
contact pin according to one embodiment of the present
invention;
[0022] FIG. 7A is a sectional side view of a male insulator device
according to one embodiment of the present invention;
[0023] FIG. 7B is a sectional end view of the insulator device of
FIG. 7A;
[0024] FIG. 8A is a sectional side view of a female tubular
connector body according to one embodiment of the present
invention;
[0025] FIG. 8B is a sectional end view of the connector body of
FIG. 8A;
[0026] FIG. 9A is a sectional side view of a female insulator
device according to one embodiment of the present invention;
[0027] FIG. 9B is a sectional end view of the insulator device of
FIG. 9A;
[0028] FIG. 10A is a side view of an insulator lock according to
one embodiment of the present invention;
[0029] FIG. 10B is an end view of the insulator lock of FIG.
10A;
[0030] FIG. 11 is an end view of a tubular spacer according to one
embodiment of the present invention;
[0031] FIG. 12 is a sectional side view of a grip spacer according
to one embodiment of the present invention;
[0032] FIG. 13 is a sectional side view of a grip member according
to one embodiment of the present invention; and
[0033] FIG. 14 is a sectional side view of a fitting member
according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0034] Turning to the drawings, FIGS. 1 and 2 show the male portion
100 and female portion 200 of the connector 10 according to one
embodiment of the present invention. The connector 10 is preferably
for use with a hybrid cable, as shown in FIG. 3. The hybrid cable
30 comprises two optical fibers 36, two power lines 38, and two
audio lines 40. In one embodiment, the optical fibers and lines are
surround by a conductive braid 34, which is preferably formed of
copper, although other metals may also be used. An insulative
sheath 32 surrounds the braid 34. Referring to FIG. 1, the male
portion 100 is shown with a removable cap 101 that protects the
open end 104 connector from the environment when not engaged with
the female portion 200. The male portion includes a housing 102 and
a spring body 103. The spring body 103 includes projections 105
that extend outwardly and define an angled surface 105a. The angled
surfaces 105a of the projections 105 allow the male member 100 and
female member 200 to be slidably engaged until locked together. A
spacer 140 surrounds the spring body 103. At least one projection
105 extends outwardly from the spring body 103. The spring body 103
defines a central opening that houses an insulator device 108. The
insulator device 108 comprises an insulative material, such as
polycarbonate or ABS plastic, although other materials can also be
used. The insulator device 108 defines six openings therethrough,
as discussed more fully below. A contact pin 112 extends through
the insulator device 108 and defines an opening 113 at the distal
end of the pin for receiving one of the power lines 38. Similarly,
a contact pin 110 extends through the insulator device 108 and
defines an opening 111 for receiving one of the audio lines 40.
[0035] A ferrule 114 also extends through the insulator device. In
one embodiment, the ferrule 114 comprises an insulative material
and defines a central opening therethrough for receiving one of the
optical fibers 36. A bias member 116, which may be in the form of a
coil spring, is positioned adjacent the ferrule 114 for biasing the
ferrule towards the open end 104 of the male portion 100. As
discussed below, the ferrule 114 abuts an opposing ferrule 218 (see
FIG. 2) so that the corresponding optical fibers housed within each
ferrule form a continuous path for light to pass. In addition, an
insulator lock 150 is positioned proximate the ferrule 114 for
securing the ferrule and contact pins 110, 112. Advantageously, the
insulator lock 150 secures the ferrule 114 and contact pins 110,
112 in a quick, easy, snap-like fashion, which enables the
components of the connector to be assembled in the field without
potting compounds. Moreover, if the alignment of the ferrule 114 or
the contact pins 110, 112 is poor during assembly or becomes poor
sometime after assembly, the insulator lock 150 can be easily
removed and the positioning of the misaligned ferrule or pins can
be realigned. Thus, the connector can be easily repaired without
removing solidified potting compound and reapplying new potting
compound, as would be required by conventional connectors.
[0036] A tubular spacer 220 is positioned proximate the insulator
device 108. As shown in more detail in FIG. 12, the spacer is
generally "C" shaped and defines a side opening 221 and a central
opening 223. In one embodiment, the spacer 220 is formed of a
resilient material, such as a thermoplastic. To further secure and
seal the cable 30, a grip member 122 is positioned adjacent the
spacer 220. A grip spacer 124 is positioned around a portion of the
grip member 122. A fitting member 226 surrounds the grip spacer
124. A washer 128, which in one embodiment is formed of a resilient
rubber-like material, is positioned adjacent the fitting member
226. An end cap 130 surrounds the washer 128.
[0037] The female portion 200 is shown with a removable cap 201
that protects the open end 204 connector from the environment when
not engaged with the male portion 100. The female portion includes
a housing 202 and an insulator device 208. The outer body 202
defines at least one groove 205. A bias member 207 extends inwardly
from the outer body 292. The insulator device 208 comprises an
insulative material, such as polycarbonate or ABS plastic, although
other materials could also be used. The insulator device 208
defines six openings therethrough, as discussed more fully below. A
contact pin 212 extends through the insulator device 208 and
defines an opening 213 at the distal end of the pin for receiving
one of the contact pins 112 connected to one of the power lines 38.
Similarly, a contact pin 210 extends through the insulator device
208 and defines an opening 211 for receiving one of the contact
pins 110 connected to one of the audio lines 40.
[0038] The ferrule 218 also extends through the insulator device
208. In one embodiment, the ferrule 218 comprises an insulative
material and defines a central opening or bore therethrough for
receiving one of the optical fibers 36. Preferably, the ferrule has
a diameter of at least 1.5 mm, such as between 2.0-2.5 mm, although
ferrules having smaller dimensions may also be used. The central
opening or bore of the ferrule, however, remains the same
regardless of the diameter of the ferrule. As described above, the
opposing ferrules 114 and 218 position opposing optical fibers 36
in an abutting relationship for light transmission. A bias member
216, which may also be in the form of a coil spring, is positioned
adjacent the ferrule 218 for biasing the ferrule towards the open
end 204 of the female portion 200. Another insulator lock 250,
which is otherwise identical to the insulation lock 150, secures
the ferrule 218 and contact pins 210, 212.
[0039] A tubular spacer 220 is positioned proximate the insulator
device 208 for further securing the hybrid cable. A grip member 122
is positioned adjacent the spacer 220. A grip spacer 124 is
positioned around a portion of the grip member 122. A fitting
member 226 surrounds the grip spacer 124. A crimp ring 227
surrounds the grip spacer 124. A washer 228, which in one
embodiment is formed of a rubber-like material, is positioned
adjacent the fitting member 226. An end cap 230 surrounds the
washer 228.
[0040] FIG. 4 shows a detailed view of a conductor pin 180, such as
pins 110 and 112, for connecting electrical wires. The pin 180 has
an elongate body 182 and a tip 184 at one end. The other end
defines an opening 183 for receiving and securing an audio or power
line, such as by crimping or soldering. Other techniques may also
be used.
[0041] FIGS. 5A and 5B show a tubular connector body 400 that can
be attached to the male portion 100. The connector body 400
includes a center portion 406 and a gripping portion 410. In one
embodiment, the gripping portion 410 has a knurled surface 408. The
center portion 406 includes an extending tab portion 404 that acts
as a guide, as discussed more fully below. The center portion 406
defines at least one opening 402 for receiving a corresponding
projection 105 of the male portion 100. The connector body 400 is
made from a wear-resistant metal, such as brass.
[0042] FIG. 6 shows a detailed view of a female contact pin 600,
such as contact pins 210 and 212 for connecting electrical wires.
The contact pin 600 includes a main body portion 602 and defines an
opening 603 at one end for receiving a wire, such as an audio or
power line. The other end defines a slotted opening 604 for
engaging a corresponding male pin, such as the contact pin 180. The
contact pin 600 is formed of a conductive material, such as
beryllium copper.
[0043] FIGS. 8A and 8B show detailed views of the insulator device
108 shown in FIG. 1. The insulator device 108 comprises a main body
151 and defines a groove 152 in the outer surface thereof. At least
two side-by-side apertures are defined axially through the
insulator device 108. In a preferred embodiment, six channels are
defined through the main body 151. In particular, two channels 154
receive the power lines 38 of the hybrid cable 30 via the contact
pins 112, two channels 158 receive the audio lines 40 via the
contact pins 110, and two channels 156 receive the optical fibers
36 via the ferrules 114. A pair of shoulders or stops 187, 227 are
defined by the insulator device 108 for retaining the contact pins
110, 112 and ferrules 114. Advantageously, the insulator device 108
includes a receptacle or recessed annular channel 160 for mating
with the insulator lock 150 to secure the contact pins 110, 112 and
ferrules 114 as described above.
[0044] FIGS. 8A and 8B show a connector body 500 for use with the
female portion 200 shown in FIG. 2. The connector body 500 is made
from a wear-resistant metal, such as brass, and includes a center
portion 506 and a gripping portion 510. In one embodiment, the
gripping portion 510 has a knurled surface 508. The center portion
506 defines a slot 504 for receiving the extending tab portion 404
of the male connector body 400. In this regard, the extending tab
portion 404 and slot 504 act as guides so that the corresponding
electrical conductors (power and audio) and optical fibers are
properly aligned.
[0045] FIGS. 9A and 9B show detailed views of the female insulator
device 208. The insulator device 208 comprises a main body 251 and
defines an extending tab portion 252 that mates with the groove 152
of the insulator device 108. In this regard, the mating extending
tab portion 252 and groove 152 ensure that the corresponding male
and female contacts are properly aligned. Six channels that
correspond to the channels defined in the insulator device 108 are
defined in the insulator device 208. In particular, two channels
254 receive the power lines 38 of the hybrid cable 30 via the
contact pins 212, two channels 258 receive the audio lines 40 via
the contact pins 210, and two channels 256 receive the optical
fibers 36 via the ferrules 218. Advantageously, the insulator
device 208 includes a receptacle 260, which in one embodiment is a
recessed annular channel, for mating with the insulator lock 250 to
secure the contact pins 210, 212 and ferrules 218 into place.
[0046] FIGS. 10A and 10B show detailed views of one of the
insulator locks 150 and 250. The lock 150 includes a body 300
defining six channels or passages therethrough. In particular,
channels 302 correspond to the channels 154 and 254, channels 306
correspond to the channels 158 and 258, and channels 304 correspond
to the channels 156 and 256. Advantageously, the lock 150 includes
a raised portion 130, such as an annular lip, for engaging the
recessed annular channels 160, 260 and forming an interference fit
therebetween. In the engaged position, the audio lines 40, power
lines 38, and optical fibers 36 are restricted from movement. The
lock 150 can be removed, however, by disengaging the snap-like
interference fit between the lock and the annular channels 160, 260
so that the electrical conductors and optical fibers can be
repaired, adjusted, or the like.
[0047] FIG. 12 shows a detailed view of the grip spacer 124. In one
embodiment, the grip spacer 124 is formed of a conductive material,
such as bronze, although other materials may also be used. The grip
spacer 124 includes a tubular body 124a and defines a central
opening 124b therethrough. The grip spacer 124 slidably engages the
grip member 122 for securing the braid 34 of the hybrid cable 30.
In particular, the grip spacer 124 is disposed about the knurled
surface 122c of the grip member 122 such that the braid 34 is
interposed therebetween.
[0048] FIG. 13 shows a detailed view of the grip member 122. The
grip member 122 includes a body 122a and a flared portion 122b. In
one embodiment, the body 122a includes the knurled surface 122c
mentioned above. A central opening 122d is defined through the grip
member 122. The grip member 122 is formed of a conductive material,
such as brass.
[0049] FIG. 14 shows a detailed view of the fitting member 226
shown in FIGS. 1 and 2. The fitting member 226 comprises a tubular
body 242 that is made from a conductive material, such as brass.
The body 242 defines a central opening 240. The body 242 also
includes an annular shoulder 244 which defines a retaining lip 246.
In this regard, the fitting member 226 helps secure the grip member
122 and grip spacer 124.
[0050] In light of the foregoing, consider the following example
wherein a hybrid cable becomes damaged in the field. By way of
comparison, recall that many conventional cable connectors require
that the entire damaged cable be replaced with a new cable so that
the damaged cable can be sent to a factory for repairs. This, of
course, requires the repair operator to carry at least one
replacement cable, which is cumbersome and expensive. Other
conventional cable connectors that allow for repairs in the field
require that potting compounds be used to secure the optical fibers
and/or electrical conductors.
[0051] As described above, potting compounds are disadvantageous
because the optical fibers and electrical conductors are
permanently secured, which prevents adjustments due to
misalignment, etc. Potting compounds also increase the complexity
and cost of the repair, as the potting compound must be removed
(which typically destroys the surrounding components) and new
potting compound must be applied. Further, potting compounds are
messy and add time to the repair process.
[0052] Advantageously, the cable connector and methods of the
present invention allow for field repairs without using potting
compounds. In the example wherein a cable is to be repaired in the
field, the repair according to one embodiment of the present
invention is as follows: First, the components used to secure the
cable, including the grip member, spacer, resilient washer, and
insulator lock, are either slid over the cable or about the optical
lines and electrical conductors. The electrical conductors or wires
are then stripped to a prescribed length, and the exposed wires are
secured to respective contact pins, which may be male or female
depending on the splice connection. In one embodiment, the contact
pins are secured to the exposed wires by crimping, although other
methods of securing may also be used. Next, the optical fibers are
stripped according to Alcoa Fujikura's assembly instructions for
AFL Field Master.TM. ST connectors and inserted through the
associated bias member.
[0053] The exposed optical fiber is threaded through the ferrule
and secured thereto according to the recommended Alcoa
instructions. The exposed end of the optical fiber is then made
flush with the end of the ferrule and hand polished. All of the
ferrules and contact pins are then inserted into the insulator
device. The insulator lock is then slid into engagement with the
insulator device such that the raised portion of the insulator lock
releaseably locks with the receptacle of the insulator device. In
this manner, the optical fibers and electrical conductors are
secured in the insulator device of the respective male or female
portion of the connector. To further secure and seal each end of
the spliced hybrid cable, the tubular spacer is positioned about
the cable, and the grip member, grip spacer, washer, and fitting
member are positioned and tightened about the cable as shown and
described above.
[0054] Thus, the hybrid cable connector 10 of the present invention
provides important advancements in the state of the art.
Specifically, the connector 10 of the present invention can be
adjusted in the field without wasting components as can occur when
using potting compounds and/or other conventional methods.
* * * * *
References