JP7675064B2 - Ganged Coaxial Connector Assembly - Google Patents

Description

RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Application No. 62/652,526, filed April 4, 2018, No. 62/677,338, filed May 29, 2018, No. 62/693,576, filed July 3, 2018, and No. 62/804,260, filed February 12, 2019, the disclosures of which are hereby incorporated by reference in their entireties. This application is a continuation-in-part of U.S. patent application Ser. No. 16/375,530, filed April 4, 2019, which claims the benefit of this application.

The present invention relates generally to electrical cable connectors, and more particularly to ganged connector assemblies.

Coaxial cables are commonly used in RF communication systems. Coaxial cable connectors can be applied to terminate coaxial cables, for example in communication systems where a high level of precision and reliability is required.

The connector interface provides a connection/disconnection function between a cable terminated with a connector having a desired connector interface and a corresponding connector having a mating connector interface attached to a device or to an additional cable. Some coaxial connector interfaces utilize a retainer (often provided as a threaded coupling nut) that draws the connector interface pair into secure electrical and mechanical engagement when a coupling nut rotatably held on one connector is threaded onto the other connector.

Alternatively, the connection interface may also have blind-mate features, allowing for push-on interconnections where physical access to the connector body is limited and/or where the interconnecting parts are coupled in a manner where precise alignment is difficult or not cost-effective (e.g., a connection between an antenna and a transceiver coupled together via a rail system or the like). To accommodate misalignment, the blind-mate connector may be provided with lateral and/or longitudinal spring action to accommodate a limited degree of insertion misalignment. Blind-mate connectors may be particularly well-suited for use in "ganged" connector configurations where multiple connectors (e.g., four connectors) are attached to one another and mated simultaneously to a mating connector.

Due to limited space on devices such as antennas or radios, and the increasing number of ports required, there may be a demand for interfaces that provide higher density port spacing and reduce the effort and skill required to repeatedly make many connections.

In a first aspect, an embodiment of the present invention relates to a mating connector assembly including a first connector assembly and a second connector assembly. The first connector assembly includes a plurality of first coaxial connectors mounted on a mounting structure and a first shell. The second connector assembly includes a plurality of second coaxial connectors, each of which is connected to a corresponding coaxial cable and mated to a corresponding first coaxial connector. The second connector assembly includes a second shell surrounding the second coaxial connector, the second shell defining a plurality of electrically insulated cavities, each of which is located within a corresponding cavity. In a mated state, the second shell is located inside the first shell.

In a second aspect, an embodiment of the present invention relates to a mating connector assembly including a first connector assembly and a second connector assembly. The first connector assembly includes a plurality of first coaxial connectors mounted on a mounting structure. The second connector assembly includes a plurality of second coaxial connectors, each of which is connected to a corresponding coaxial cable and mated to a corresponding first coaxial connector. The second connector assembly includes a shell surrounding the second coaxial connector, the shell defining a plurality of electrically insulated cavities, each of which is disposed within a corresponding cavity. In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated to a corresponding second coaxial connector.

In a third aspect, an embodiment of the present invention relates to a mating connector assembly including a first connector assembly and a second connector assembly. The first connector assembly includes a plurality of first coaxial connectors and a first shell, each of the first coaxial connectors being connected to a corresponding first coaxial cable, the first shell defining a plurality of electrically insulated first cavities, each of the first coaxial connectors being disposed in the corresponding first cavity. The second connector assembly includes a plurality of second coaxial connectors and a second shell, each of the second coaxial connectors being connected to a corresponding second coaxial cable, the second shell defining a plurality of electrically insulated second cavities, each of the second coaxial connectors being disposed in the corresponding second cavity. In a mated state, the second shell is located inside the first shell, and each of the first coaxial connectors is mated to the corresponding second coaxial connector.

In a fourth aspect, an embodiment of the present invention relates to a shell for an assembly of ganged connectors, the shell comprising a base, a plurality of towers extending from the base, each tower being circumferentially discontinuous and having a gap, each tower defining a peripheral cable cavity configured to receive a peripheral cable through the gap, and a plurality of transition walls, each transition wall extending between two adjacent towers. The transition walls and the gap define a central cavity configured to receive a central cable.

In another aspect, an embodiment of the present invention relates to a mating connector assembly comprising a first connector assembly including a plurality of first coaxial connectors mounted on a mounting structure, and a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a respective coaxial cable and mated to a respective first coaxial connector. The second connector assembly includes a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically insulated cavities, each of the second coaxial connectors being disposed within a respective cavity. In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated to a respective second coaxial connector. Each of the second coaxial connectors includes an outer connector body located within a respective cavity, and a clearance gap exists between the outer connector body and the shell.

In yet another aspect, an embodiment of the present invention relates to a mating connector assembly comprising a first connector assembly including a plurality of first coaxial connectors mounted on a mounting structure, and a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a respective coaxial cable and mated to a respective first coaxial connector. The second connector assembly includes a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically insulated cavities, each of the second coaxial connectors being disposed within a respective cavity. In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated to a respective second coaxial connector. Each of the second coaxial connectors includes an outer connector body located within a respective cavity, and a clearance gap exists between the outer connector body and the shell. Each of the outer connector bodies includes a flange extending radially outward. The flange includes a forwardly extending protrusion defining a trepan gap with the outer connector body.

FIG. 2 is a rear perspective view of an assembly of mating ganged coaxial connectors according to an embodiment of the present invention. FIG. 2 is a top view of the mating assembly of FIG. 1; FIG. 2 is a cross-sectional view of the mating assembly of FIG. 1 from above. 2 is an enlarged cross-sectional view of the mating assembly of FIG. 1 showing one mated pair of connectors; FIG. 2 is a front perspective view of the ganged instrument connector assembly of the assembly of FIG. 1; FIG. 6 is a rear perspective view of the ganged instrument connector assembly of FIG. 5 . 6 is a rear perspective view of the mounting plate of the ganged instrument connector assembly of FIG. 5; FIG. 6 is a rear perspective view of the outer shell of the ganged instrument connector assembly of FIG. 5. FIG. FIG. 6 is a greatly enlarged, partial perspective view showing exemplary mounting screws and their corresponding holes in the mounting plate of the ganged instrument connector assembly of FIG. 6 is a perspective view of the ganged cable connector assembly of FIG. 1 being inserted into the shell of the ganged instrument connector of FIG. 5; FIG. FIG. 11 is a greatly enlarged perspective view showing a latch on a housing of the ganged cable connector assembly of FIG. 10; 12 is a greatly enlarged plan view showing the latch of FIG. 11 inserted into a slot on the shell of FIG. 8. 11 is a greatly enlarged, partial cross-sectional top view of the housing and forward end of the outer conductor body of the cable connector of FIG. 10; FIG. 11 is a greatly enlarged, partial, cross-sectional top view of the cable connector of FIG. 10 showing the housing and an intermediate portion of the outer conductor body. FIG. 11 is a greatly enlarged, partial cross-sectional top view of the housing and rear end of the outer conductor body of the cable connector of FIG. 10; FIG. FIG. 13 is a rear perspective view of an assembly of mating ganged coaxial connectors according to a further embodiment of the present invention. FIG. 17 is a front perspective view of the assembly of FIG. 16 with the ganged device connector detached from the ganged cable connector. FIG. 17 is a front cross-sectional view of the assembly of FIG. 16. FIG. 17 is a cross-sectional top view of the ganged cable connector in the assembly of FIG. 16; 20 is a cross-sectional view of one cable connector in FIG. 19 from above. FIG. 17 is a schematic diagram showing sixteen of the assemblies of FIG. 16, illustrating how adjacent assemblies can interlock. FIG. 13 is a perspective view of another assembly of mating ganged connectors according to an embodiment of the present invention. FIG. 23 is a cross-sectional view from above of the mating assembly of FIG. 22. FIG. 23 is an enlarged partial cross-sectional top view of the mating connector of FIG. 22. FIG. 23 is a cross-sectional front view of the mating connector of FIG. 22. FIG. 1 is a perspective view of an assembly of a mating ganged assembly connector and a non-mating device connector assembly according to an embodiment of the present invention. 13 is a perspective view of an assembly of a mating ganged assembly connector and a non-mating device connector assembly according to an additional embodiment of the present invention. FIG. 28 is a perspective view of the assembly of FIG. 27, illustrating how the mating assembly may be secured by a screwdriver. 13 is a perspective view of an assembly of a mating ganged assembly connector and a non-mating device connector assembly according to a further embodiment of the present invention. FIG. FIG. 2 is a cross-sectional view of another assembly of mating ganged assembly connectors according to an embodiment of the present invention, in which the spring used to provide axial float relative to the connectors of the cable connector assembly is shown in a relaxed position. FIG. 31 is a cross-sectional view of the assembly of FIG. 30, where the spring is shown in a compressed position. 1 is a perspective view of another mating ganged assembly connector having a toggle assembly for securing the cable connector assembly to the equipment connector assembly according to an embodiment of the present invention; FIG. FIG. 32B is a side view of the toggle assembly shown in FIG. 32A with the latch in its unlocked position; FIG. 32B is a side view of the toggle assembly shown in FIG. 32A with the latch in its locked position; FIG. 13 is a cross-sectional view of another assembly of mating ganged assembly connectors having quarter turn screws used to secure the cable connector assembly to the equipment connector assembly in accordance with an embodiment of the present invention. FIG. 34 is an enlarged cross-sectional view of the assembly of FIG. 33. 34 is an enlarged perspective view showing mounting holes in a mounting plate in the instrument connector assembly of FIG. 33. FIG. 36 is an enlarged, opposite perspective view showing the mounting holes of FIG. 35 . 37A-37C are sequential views showing the insertion and fastening of the quarter turn screw of FIG. 33 into the mounting hole of FIG. 35 and FIG. 36. FIG. 2 is a cross-sectional view of an assembly of mating ganged connectors according to an embodiment of the present invention, illustrating how a fastening screw is captured by a flap within a housing of the cable connector assembly. FIG. 2 is a side view of a connector body for use in an assembly of mating connectors according to an embodiment of the present invention, the connector body being shown after machining but before drawing and cutting. FIG. 40 is a side view showing the connector body of FIG. 39 after drawing. 40 is a cross-sectional side view of the connector body of FIG. 39 after drawing and cutting. FIG. 2 is a cross-sectional top view of a mating connector pair suitable for use in a mating ganged assembly, the connectors being shown in an unmated state. 1 is a top cross-sectional view of a mating connector pair suitable for use in a mating ganged assembly according to another embodiment, the connectors being shown in an unmated state. FIG. 42B is an enlarged partial cross-sectional view of a portion of the interface in the assembly of FIG. 42A shown in an unmated state. FIG. 42B is an enlarged partial cross-sectional view of a portion of the outer connector body of the assembly of FIG. 42A shown in an unmated state. FIG. 43 is a cross-sectional view from above of the connector of FIG. 42 shown in a mated state. FIG. 42B is a cross-sectional top view of the mating connector pair of FIG. 42A, the connectors shown in a mated state. FIG. 43B is an enlarged partial cross-sectional view showing a portion of the interface in the assembly of FIG. 43A shown in a mated state. FIG. 43B is an enlarged, partial cross-sectional view of a portion of the outer connector body of the assembly of FIG. 43A shown in a mated state. FIG. 13 is a perspective view of an assembly of mating ganged connectors according to a further embodiment of the present invention. FIG. 45 is a front view of the instrument connector assembly of the assembly of FIG. 44. FIG. 45 is a front perspective view of the shell of the cable connector assembly in the assembly of FIG. 44. FIG. 47 is a rear perspective view of the shell of FIG. 46 with two cables inserted inside the shell. FIG. 47 is a perspective view of an insert for use with the shell of FIG. 46; 45 is a perspective cross-sectional view of a cable connector assembly used in the assembly of FIG. 44, showing the insert of FIG. 48 inserted into the shell of FIG. 46. FIG. FIG. 47 is an enlarged perspective view of the central cavity of the shell of FIG. 46. FIG. 50 is an enlarged cross-sectional view of the cable connector assembly of FIG. 49 . FIG. 45 is a perspective view of the assembly of FIG. 44, with the shell shown as transparent for clarity. FIG. 45 is a partial side cross-sectional view of the mating assembly of FIG. 44. FIG. 54 is an enlarged partial cross-sectional side view of the mating assembly of FIG. 53; 13 is a cross-sectional view showing an assembly of mating connectors according to a further embodiment of the present invention. FIG. 56 is an enlarged partial cross-sectional view of the assembly of FIG. 55. 11 is a cross-sectional view of one pair of mating connectors in an assembly of mating connectors according to yet another embodiment of the present invention. FIG. 58 is an end perspective view of a shell in a ganged cable connector assembly used in the assembly of FIG. 57; 13 is a cross-sectional view of one pair of mating connectors in an assembly of mating connectors according to yet another embodiment of the present invention. FIG. FIG. 59 is an end view of one connector of the cable connector assembly and the shell of the cable connector assembly of FIG. 58, showing the anti-rotation feature of the shell. 13 is a perspective view of a connector in a ganged cable connector assembly according to yet another embodiment of the present invention; FIG. 65 is an end view showing the connector of FIG. 62 inserted into the shell of FIG. 64. 63 is a shell in a cable connector assembly using the connector of FIG. 62. 1 is a side cross-sectional view of another cable connector assembly according to an embodiment of the present invention, the connector being shown in a partially assembled state; FIG. 66 is a side cross-sectional view of the cable connector assembly of FIG. 65, the connector being shown in a fully assembled state. 1 is a side cross-sectional view of another cable connector assembly according to an embodiment of the present invention, the connector being shown in a fully assembled state; FIG. 68 is an enlarged, partial view showing a portion of the assembly of FIG. 67.

The present invention will now be described with reference to the accompanying drawings, in which specific embodiments of the invention are shown. However, the present invention may be embodied in many different forms and should not be construed as being limited to the embodiments shown and described herein, but rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It will also be understood that the embodiments disclosed herein can be combined in any manner and/or in any combination to provide many additional embodiments.

Unless otherwise defined, all technical and scientific terms used in this disclosure have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terms used in the following description are for the purpose of describing particular embodiments only and are not intended to limit the invention. When used in this disclosure, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Also, when an element (e.g., a device, circuit, etc.) is referred to as being "connected" or "coupled" to another element, it will be understood that the element may be directly connected or coupled to the other element or that there may be intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements.

Referring now to the drawings, an assembly of mating ganged connectors, generally designated 100, is shown in Figures 1-15. The assembly 100 includes a ganged equipment connector assembly 105 including four coaxial equipment connectors 110, and a ganged cable connector assembly 140 including four coaxial cable connectors 150. These components are described in more detail below.

3 and 4, each of the device connectors 110 includes an inner contact 112, a dielectric spacer 114 circumferentially surrounding a portion of the inner contact 112, and an outer conductor body 116 circumferentially surrounding the dielectric spacer 114 and electrically insulated from the inner contact 112. An O-ring 117 is mounted in a groove in a middle portion of the outer conductor body 116.

A flat plate 120 provides a common mounting structure for the instrument connectors 110. As can be seen from FIG. 7, the plate 120 includes four aligned holes 121, each of which is surrounded by a recess 122 located on its rear side. The recesses 122 are continuous with each other. Each recess 122 has two or three pockets 123 that extend radially outward through the thickness of the plate 120. In addition, ten holes 130 are arranged near the periphery of the plate 120.

3-5, the shell 124 is attached to the plate 120 and extends forwardly therefrom. The shell 124 is typically formed from a polymeric material and is generally scalloped with each "scallop" 125 partially surrounding one of the holes 121. The shell 124 is held in place by posts 128 extending radially outward from the rear edge of the scallops 125 and terminating in a ring 126 (see FIG. 8), which is received in a recess 122 in the plate 120 and the post 128 is received in a pocket 123. A barb 116a on the outer conductor body 116 helps hold the shell 120 in place. As can be seen from FIGS. 1, 2 and 8, the two endmost scallops 125 include latch openings 138.

As can be seen from FIGS. 8, 9A, and 9B, ten access openings 134 are located on the rear edge of the scallop 125, each aligned with a corresponding hole 130. Screws 136 are inserted through the holes 130 (with access provided by the access openings 134) to attach the plate 120 to an electronic device, such as a remote radio head. The location of the access openings 134, and the location of the holes 130, allows the plate 120 (and thus the instrument connector assembly 110) to be fixedly attached to the electronic device in a relatively small space.

The shell 124 may be formed by injection molding, and in particular may be injection molded with the mounting plate as an insert so that the ring 126 and post 128 may be integrally formed in place during the molding process.

3 and 4, the cable connector assembly 140 includes four cables 142, each having an inner conductor 143, a dielectric layer 144, an outer conductor 145 (in this case the outer conductor is corrugated, but could also be smooth, braided, etc.), and a jacket 146. Each of the cables 142 is connected to one of the connectors 150.

Each connector 150 includes an inner contact 152, a dielectric insulator 154a, 154b, and an outer conductor body 156. The inner contact 152 is electrically connected to the inner conductor 143 via a press-fit joint, and the outer conductor body 156 is electrically connected to the outer conductor 145 via a solder joint 148. A spring basket 158 having fingers 158a is positioned within a cavity in the outer conductor body 156.

The shell 160 circumferentially surrounds each outer conductor body 156 of the connector 150, electrically insulating the outer conductor bodies from each other within the cavity 165. A shoulder 161 on the shell 160 is positioned to abut against a shoulder 157 on the outer conductor body 156 (see FIG. 14). A strain relief 162 covers the interface between the cable 142 and the connector 150, and a barb 156b on the outer conductor body 156 helps hold the strain relief 162 in place. As can be seen from FIG. 4 and FIGS. 13-15, the inner diameter of the shell 160 is slightly larger than the outer diameter of the outer conductor body 156 such that gaps g1, g2 exist. In addition, as shown in FIG. 13, the free end of the outer conductor body 156 extends slightly further toward the mating connector 110 than the shell 160. FIG. 15 shows that a gap g3 exists between the shell 160 and the strain relief 162.

As shown in Figures 3 and 4, the connectors 110, 150 are mated by inserting the cable connector assembly 140 into the instrument connector assembly 105. More specifically, the shell 160 is inserted into the shell 120 with each cavity 165 located within the corresponding scallop 125. This operation aligns each connector 150 of the cable connector assembly 140 with the corresponding connector 110 of the instrument connector assembly 105. As shown in Figures 3 and 4, the inner contacts 152 of the connector 150 receive the inner contacts 112 of the connector 110, and the free end of the outer conductor body 116 is received in the gap between the outer conductor body 156 and the spring fingers 158a of the spring basket 158. Notably, the spring fingers 158a provide radial pressure onto the outer conductor body 116 and do not "bottom" the outer conductor body 116 axially, which is characteristic of some connector interface configurations, such as the 4.3/10, 4.1/9.5, and 2.2/5 interfaces. The cable connector assembly 140 is maintained in place relative to the instrument connector assembly 140 via the latches 164 of the shell 160 engaging the latch openings 138.

13, the free end of the outer conductor body 156 does not reach the plate 120, forming a gap g4 therebetween. The presence of the gaps g3, g4 allows the connectors 150 of the cable connector assembly 140 to move axially relative to their respective mating connectors 110 when mating is required (e.g., due to manufacturing tolerances and the like). In addition, the presence of the gaps g1, g2 between the outer conductor body 156 and the shell 160 allows the connectors 150 to move radially relative to the connectors 110 when such movement is required.

Also, as mentioned above, the shell 160 on the cable connector assembly 140 electrically insulates the connectors 150 from each other, thereby electrically isolating a mated pair of connectors 110, 150 from adjacent pairs. This configuration allows the mating connectors 110, 150 to be closely spaced (thereby saving space in the overall connector assembly 100) without sacrificing electrical performance.

The illustrated assembly 100 illustrates connectors 110, 150 that meet the specifications of a "2.2/5" connector and may be particularly suitable for such connectors since these connectors are typically small and used in tight spaces.

Referring now to Figures 16-21, there is shown another embodiment of an assembly of mating ganged connectors generally designated 200. Assembly 200 is similar to assembly 100 in that an instrument connector assembly 205 having four connectors 210 is mated to a cable connector assembly 240 having four connectors 250. The differences between assemblies 105, 205 and assemblies 140, 240 are described below.

The device connector assembly 205 includes a plate 220 with two recesses 224 on its top and bottom edges, and two ears 222 with holes 223 extending from the top and bottom edges, each ear 222 vertically aligned with a corresponding recess 224 on the opposite edge. The ears 222 and recesses 224 are positioned between adjacent holes 230 in the plate 220. The cable connector assembly 240 has a shell 260 with four ears 262 with holes 263 aligned with the ears 222 and holes 223. Screws 266 are inserted into the holes 263 and 223 to keep the assemblies 205, 240 mated.

As can be seen from FIG. 21, the plates 220 are configured to nest with respect to adjacent plates 220. FIG. 21 shows a schematic of sixteen assemblies 200 arranged in a 4×4 array, where the ears 222 of one plate 220 are received within the recesses 224 of an adjacent plate 220. This configuration allows adjacent assemblies 200 to be tightly packed together, thereby conserving space.

22-25, there is shown an assembly 300. The assembly 300 includes a first cable connector assembly 305 and a second cable connector assembly 340. The connector 310 of the first cable connector assembly 305 is similar to the connector 110 described above, and the connector 350 of the second cable connector assembly 340 is similar to the connector 150 described above. However, the connectors 310, like the connector 350, are arranged in a square 2×2 pattern. The connector 310 is held in place via strain relief 320, spacer 322, and housing 324. Similarly, the connector 350 and cable 345 are held in place via strain relief 352, spacer 354, and housing 356 having panel 358. The strain reliefs 320, 352 and spacers 322, 354 allow the connectors 310, 350 to "float" relative to each other to facilitate interconnection. As shown in FIG. 24, when the assembly 300 is fully mated, the free end of the housing 324 of the first cable connector assembly 305 contacts a panel 358 of the housing of the second cable connector assembly 340, thereby providing an axial stop to prevent the fingers 358a of the spring basket 358 of the connector 350 from "bottoming out" against the outer conductor body 316 of the connector 310.

25, in some embodiments, the housings 324, 352 of the connector assemblies 305, 340 include a slightly rounded upper portion (compared to a generally straight lower portion). This difference serves as an orientation feature to ensure that the assemblies 305, 340 are properly oriented relative to one another for mating, which further ensures that the connectors 310, 350 are each aligned to mate with the correct mating connector.

26-29, additional embodiments of ganged connectors are shown therein. FIG. 26 shows an assembly 400 consisting of an instrument connector assembly 405 consisting of four connectors 410 mounted in a 2×2 array on a mounting plate 420, and a cable connector assembly 440 consisting of four connectors (not visible in FIG. 26) and four cables 442. The connectors 410 are similar to the connector 110 described above, and the connectors of the cable connector assembly 440 are similar to the connector 140 described above. A strain relief 462 surrounds and insulates the connectors of the cable connector assembly 440, and a shell 460 extends forward of the strain relief 462. A mounting hole 464 is centrally located in the strain relief 462 and the shell 460. The shell 460 also includes an access opening 466 at its free end positioned to receive a screw for the mounting plate 420.

26, the cable connector assembly 440 is mated to the instrument connector assembly 405 with the connector of the cable connector 440 mated to the mating connector 410. The assemblies 405, 440 are maintained in mated condition by screws or other fasteners inserted through mounting holes 464 and into mounting holes 426 of the mounting plate 420. The shell 460 abuts against the surface of the mounting plate 420.

It should be noted that if formed of a resilient polymer or elastomeric material such as TPE, the shell 460 may provide additional strain relief and may aid in "centering" the individual connectors of the cable connector assembly 440. The resilience of the material biases the individual connectors toward a "center" position, making them easier to align with their respective mating connectors 405. This effect may also aid in centering the entire cable connector assembly 440, since centering two of the connectors of the cable connector assembly 440 may aid in centering the entire assembly 440. In addition, the shell 460 may also allow the individual connectors to pivot or move if necessary for alignment.

27, another embodiment of the assembly 500 is illustrated therein. The assembly 500 is similar to the assembly 400, except that the instrument assembly 505 includes a connector 550 mounted on the mounting plate 520 and similar to the connector 440, and the cable connector assembly 540 includes a connector similar to the connector 410. As a result, the mounting plate 520 can be made slightly smaller than the mounting plate 420, thereby saving space on the instrument. FIG. 28 illustrates how the assemblies 505, 540 may be secured together using a screwdriver used to drive a fastening screw through a centrally located hole in the mounting plate 520 and the cable connector assembly 540. FIG. 38 illustrates an alternative configuration 500', in which a fastening screw 572 is used to connect the instrument assembly 505' to the cable connector assembly 540'. The fastening screw 572 is held in place by a flap 574 that surrounds the mounting hole 564. The head of the fastening screw 572 is larger than the mounting hole 564, so that after the head of the fastening screw 572 passes through the mounting hole 564 (the material of the shell 560' is sufficiently elastic to stretch to allow the head of the fastening screw 572 to pass through), the flap 574 captures the fastening screw 572 in place. Alternatively, the head of the screw 572 can be captured within the mounting hole 564 itself via an interference fit.

29, there is shown an assembly 600 including an instrument connector assembly 605 and a cable connector assembly 640. In this embodiment, a coupling nut 666 is utilized that mounts against a threaded ring 622 on the mounting plate 620 to secure the assemblies 605, 640 in mated condition.

30 and 31, there is shown another embodiment of an assembly generally designated 700. Assembly 700 is similar to assembly 500 described above, except that connectors 710 mounted within cable connector assembly 740 include a helical spring 780 surrounding each connector 750. Spring 780 extends between an inner surface of shell 760 and protrusion 782 on outer conductor body 716. Spring 780 allows connector 710 to float axially relative to shell 760.

As a potential alternative, spring 780 may be replaced with a Belleville washer, which may be a separate component, or may be insert molded into shell 760 (in which case the washer may include spiked or spoked edges to improve mechanical integrity at the joint). Spring 780 may also be replaced with an elastomeric spacer or the like.

32A-32C, another embodiment of an assembly is shown therein and generally designated 800. Assembly 800 may be similar to either of assemblies 400, 500, but includes a toggle assembly 885 having an L-shaped latch 886 attached to a shell 860 of a cable connector assembly 840 at a pivot 887 and a pin 888 attached to a mounting plate 820 of an instrument connector assembly 805. A handle 889 extends generally parallel to a finger 890 on the latch 886 and generally perpendicular to an arm 891 extending between the finger 890 and the pivot 887. The finger 890 includes a recess 895 adjacent to the arm 891. The handle 889 includes a slot 896 (see FIG. 32A).

The latch 886 can be pivoted to engage the pin 888 via the handle 889 to secure the assemblies 805, 840 together. When the finger 890 first contacts the pin 888, the handle 889 is pivoted relatively easily to the latched position. When the latch 886 is pivoted sufficiently so that the finger 890 moves relative to the pin 888 so that the pin 888 slides into the recess 895, the assembly 800 is fully locked by the toggle assembly 885. In the locked position, because the handle 889 is approximately horizontal with respect to the pin 888 and approximately perpendicular to the line between the pivot axis 887 and the recess 895, a significant mechanical force is required on the handle 889 to move the latch 886 out of the recess 895 and back to the unlocked position. In the illustrated embodiment, the force required on the handle 889 to move the latch 886 to the locked position may be less than 27 lb-ft, while the force required to move the handle 889 from the locked position may be 50 lb-ft or more, and may even require the use of a screwdriver, wrench, or other lever inserted into the slot 896 to generate sufficient force. Thus, once locked, the assembly 800 tends to stay locked.

33-37C, another embodiment of an assembly is shown therein and generally designated 900. Assembly 900 is similar to assembly 500, except that a quarter turn screw 990 is used to secure cable connector assembly 940 to instrument connector assembly 905. As shown in FIG. 35, mounting hole 991 in mounting plate 920 is configured to allow for the insertion of protruding flange 992 of quarter turn screw 990. FIG. 36 shows that on the opposite side of mounting plate 920, mounting hole 991 is surrounded by a circular recess 993 with two additional recesses 994 extending radially therefrom. 37A-37C show how a quarter-turn screw 990 can be inserted into a mounting hole 991 (FIG. 37A) and driven to rotate a quarter turn (shown midway in FIG. 37B) so that a flange 992 is received in a recess 994 (FIG. 37C).

Referring again to FIG. 38, the assembly 500' shown therein also includes a metal tube 595 through which the fastening screw 572 can be inserted, providing a positive stop to prevent over-tightening of the fastening screw 572. The assembly 500' also shows a groove 596 on the inner surface of the shell 560' that can capture a rim 597 on the housing 524' to aid in securing the assembly 505', 540'.

39-41, an outer conductor body suitable for use in a mating ganged assembly is shown therein and generally designated 1056. The outer conductor body 1056 includes a spring washer type structure and operation that may replace the spring 780 shown in FIGS. 30 and 31. As shown in FIG. 39, the outer conductor body after machining has radially extending fins 1058. The fins 1058 are drawn or otherwise formed into a frusto-conical configuration (shown by 1058' in FIG. 40). The inner diameter of the fins 1058' is then cut from the remainder of the outer conductor body 1056 (see FIG. 41). In this configuration, the fins 1058' may function as springs that allow for axial adjustment of the outer conductor body 1056.

The process described above can provide a Belleville washer type spring that may be preferable to a separate washer by allowing the inner diameter of the fin 1058' (which may be a critical dimension in achieving the desired spring action) to closely match the outer diameter of the outer conductor body 1056.

42 and 43, there are shown mating connectors 1105, 1150 for an alternative assembly, generally designated 1100. The connectors 1105, 1150 are similar to those in assembly 700 described above, and have associated springs 780 to allow axial float. However, the outer conductor body 1156 of the connector 1150 includes a sloped surface 1157 forward of a shoulder 1158, and the spring 1150 is captured between the shoulders 1182, 1158. The shell 1160 includes a rim 1161 with a sloped inner surface 1162.

As can be seen in FIG. 42, in the open position, the rim 1161 abuts against the forward face of the shoulder 1158. As shown in FIG. 43, when the connector 1150 moves into mating with the connector 1105, the forward face of the rim 1161 compresses the spring 1180 against the shoulder 1182. The ramps 1157, 1162 interact upon mating, gradually centering and radially aligning the connectors 1105, 1150. In some embodiments, there is a slight interference fit between the ramps in the closed position.

This configuration can provide distinct performance advantages. When both electrical contacts (inner and outer conductors) of the mating connectors are radial, as is the case for the 4.3/10, 2/2.5, and Nex10 interfaces, the axial clamping force between the mating connectors is not directly required for electrical contact, but only to provide mechanical stability. Specifically, the axial clamping force between the mating connectors is required to keep the axes of the two mating connectors aligned, thereby preventing relative movement of the electrical contact surfaces due to bending, vibration, and the like. Such relative axial movement can directly cause PIM and can also generate debris that further causes PIM. (Experiments have demonstrated this behavior for the 4.3/10 interface.)

The two clamping or interference portions spaced apart along the outer conductor body 1156 in the closed position of FIG. 43 provide a means for creating such desired axial stability. Additionally, the ramps 1157, 1162 allow radial float initially and gradually guide the axis of the floating connector (i.e., connector 1150) into alignment with the fixed connector (i.e., connector 1105) and hold it in a fixed position when fully advanced. The angle of the ramps 1157, 1162 can be adjusted to provide the required mechanical advantage based on the force of the latch mechanism used. In some embodiments, this configuration may not require any axial float, in which case the spring 1180 may be omitted. The interference area can be increased as needed to increase stability at the expense of radial float.

42A-42C and 43A-43C, there is shown another assembly generally designated 1100'. In this embodiment, axial float is provided by a spring 1180' similar to the spring shown for assembly 1100. However, radial float is controlled differently by the inner and outer diameters of the outer connector body 1116', 1154' at the interface, the outer diameter of the rear end of the outer connector body 1154', and the angled transition surface 1155'. As shown in FIGS. 42A-42C, in the unmated state, the connector 1150' is allowed to float axially and radially based on the spring 1180'. However, in the mated state of FIGS. 43A-43C, mating of the outer connector bodies 1116', 1154' tends to radially align the connector 1150', and as it floats rearward, the inclined transition surface 1155' radially aligns the rear end of the outer connector body 1154. When this occurs, however, there is still an opportunity for axial float as the outer connector body 1154' moves rearward. The clearance at both ends of the outer conductor body 1154' is minimal enough that this interaction can be used to maintain the mated state without other external means. (Indeed, one skilled in the art will recognize that this concept can be used with a single connector pair and is not limited to ganged connectors as illustrated herein.) Also, as mentioned above, in some embodiments, the spring 1180' may be omitted when the resilience of the shell 1160' can provide sufficient resilience to allow any axial float required.

Those skilled in the art will appreciate that the above assemblies may have different configurations. For example, while the connectors are shown as being either "in-line" or in a rectangular M x N array, other configurations such as circular, hexagonal, staggered, or the like may be used. Also, while each assembly is shown as having four pairs of mating connectors, fewer or more connectors may be used in each assembly. An example assembly having five pairs of connectors is shown in Figures 44-54, generally designated 1200, and includes an instrument connector assembly 1205 having five connectors 1210 and a cable connector assembly 1240 having five connectors 1250 connected to five cables 1242. As shown in Figures 46 and 47, the connectors 1210 and 1250 are arranged in a crisscross pattern, with one of the connectors 1210, 1250 surrounded by four other connectors 1210, 1250 spaced 90 degrees apart. In this configuration, one potential problem that can arise is the proximity of the connectors. For larger cables and connectors, the wall thickness of the material surrounding the cavities is often too thin, so there may not be enough space between the connectors 1210 to allow each of the connectors 1250 to have its own cavity as shown in Figure 26 (either as separate shells or as a single shell with four cavities).

This drawback can be overcome by the use of a shell 1260, shown in Figures 46-54. The shell 1260 has a generally square footprint with an outer rim 1262 surrounding a base 1261. Four towers 1263 extend from the base 1261. Each tower 1263 defines a peripheral cavity 1267, but is discontinuous in that it includes a radially inward gap 1264. Each tower 1263 includes a recess 1265 at one end with a lip 1265a extending radially inward from the forward end of the recess 1265 (see Figures 53 and 54). A transition wall 1269 spans adjacent towers 1263, with the effect that a central cavity 1266 is defined by the transition wall 1269 and the gap 1264. Each of the transition walls 1269 includes a recess 1268 (see Figure 50).

Referring now to FIG. 48, an annular insert 1270 is shown therein. The insert 1270 is discontinuous and has a gap 1271 in the main wall 1273. Four blocks 1274 having arc-shaped outer surfaces 1275 extend radially outward from the main wall 1273. Snap projections 1276 extend radially outward from the main wall 1273 between each pair of adjacent blocks 1274.

The structure of the assembly 1240 can be understood by reference to Figures 47, 49-51, 53, and 54. A terminated cable 1242 having a connector 1250 attached to its end is inserted through the central cavity 1266. The cable 1242 is then forced radially outward through one of the gaps 1264 and into the corresponding peripheral cavity 1267, with the tower 1263 being sufficiently flexible to allow the cable 1240 to flex to allow passage through the gap 1264. The connector 1250 is positioned relative to the shell 1260 with the rear end of the outer body 1252 of the connector 1250 nested within the recess 1265 and captured by the lip 1265a (see Figures 53 and 54). This process is repeated three more times until all four peripheral cavities 1267 are filled (see FIG. 47, which shows two cables 1240 in place within the shell 1260).

Next, the fifth end cable 1242 is threaded through the central cavity 1266 and the connector 1250 is positioned relative to the shell 1260. The insert 1270 is slid over the cable 1242 (i.e., the cable 1242 passes through the gap 1271 in the insert 1270) and oriented so that the block 1274 fits between the transition walls 1269. The insert 1270 is then slid along the cable 1242 into the central cavity 1266 until the snap projection 1276 snaps into the recess 1265 (see FIG. 49). This interaction locks the last (middle) cable 1242 in place. The cable connector assembly 1240 can then be mated to the instrument connector assembly 1205 as shown in FIG. 52.

It can be seen that the above-described configuration, with four cables serving as the "corners" of a "square" and a fifth cable located in the center of the "square," can provide space-related advantages to the assembly. In particular, the cables can be arranged in this manner with a smaller footprint than similar cables arranged in a circular pattern. Similarly, if the same footprint area is used, the illustrated "square" arrangement can include larger cables while still providing performance advantages (such as improved attenuation).

It will also be appreciated that the assembly 1240 may be formed with four cables 1242 (each residing in a peripheral cavity 1267) and with the central cavity 1266 filled with a circular (rather than annular) insert.

55 and 56, there is shown another assembly generally designated 1300. Assembly 1300 is similar to assembly 1200 and includes an instrument connector assembly 1305 having a connector 1310 and a cable connector assembly 1340 having a connector 1350 and a shell 1360. Cable connector assembly 1340 includes two O-rings 1380, 1382 in a recess in the outer conductor body 1356 of connector 1350 that provide a seal against the outer conductor body 1316 of connector 1310. Alternatively, as shown in FIGS. 57 and 58, assembly 1400 includes an instrument connector assembly 1405 and a cable connector assembly 1440 that provides a seal via one O-ring 1480 positioned similarly to O-ring 1380 and a second O-ring 1485 positioned between the outer conductor body 1456 and the shell 1460. In these examples, the O-rings are positioned to provide two separate seals between the assemblies to ensure that water does not seep into the electrical contact area between the outer conductor bodies of the connectors. As another alternative, assembly 1500 is similar to assembly 1400, but includes a molded-in seal protrusion 1590 that is part of shell 1560 rather than O-ring 1485.

60 and 61, the shell 1460 of the cable connector assembly 1440 shown in FIG. 58 has a cavity 1467 with a generally hexagonal shaped portion 1468, but with chamfered corners 1468a between the "hexagonal" sides 1468b. In other words, the portion 1468 has 12 sides: six long sides 1468b and six short sides 1468a. As shown in FIGS. 60 and 61, this configuration can prevent the connector 1450 from over-rotating in the cavity 1467 (which can damage the cable and/or generate debris that can adversely affect performance) while still allowing the same degree of radial float.

As another example addressing the desire for some radial float of the connector while limiting twisting, a connector assembly 1600 is shown in Figures 62-64. In this embodiment, the connector 1650 of the cable connector assembly 1640 has teeth 1669 on the outer conductor body 1654 and the shell 1660 has corresponding recesses 1670 (in the embodiment illustrated herein, the connector 1650 has six teeth 1669 and the shell 1660 has six recesses 1670, although more or fewer teeth/recesses may be included). This configuration also reduces the degree of twisting between the connector 1650 and the shell 1660, which may protect the cable and prevent the generation of undesirable debris, but allows some radial float.

65 and 66, there is shown another cable connector assembly generally designated 1700. Assembly 1700 is similar to assemblies 1200, 1300, 1400, 1500, and 1600 in that an instrument connector assembly 1705 has a connector 1710 that mates with a cable connector assembly 1740 having a connector 1750 within a shell 1760. A spring 1780 provides the ability for radial adjustment of the outer connector body 1756 relative to the shell 1760. In this embodiment, the outer connector body 1756 has a radially outward flange 1784 located forward of a flange 1782 (which captures the forward end of the spring 1780). The flange 1784 has a trepan gap 1786 on its forward surface (with a projection 1785 located radially outward of the gap 1785). Also, at the rear end of the outer connector body 1756, there is a larger clearance gap C between the outer connector body 1756 and the shell 1760 than in the assembly 1500 shown in FIG. 59. The outer connector body 1716 of the connector 1710 has a chamfered outer edge 1719 at its forward end 1718.

As shown in FIG. 65, during initial mating of the connectors 1710, 1750, the inner contacts 1754 of the connector 1750 engage the inner contacts 1712 of the connector 1710, thereby providing a first "centering" action for the connector 1750. This action also causes the spring 1780 to "bottom out." As mating continues (FIG. 66), the spring 1780 opens slightly, which causes the chamfered outer edge 1719 of the outer connector body 1716 to contact the protrusion 1785. This interaction provides a second "centering" action for mating, which allows the clearance gap C between the rear portion of the outer connector body 1756 and the shell 1760 to be larger than in other embodiments.

As shown in Figs. 67 and 68, which describe assembly 1700', a third centering action may also be included. In this embodiment, an angled surface 1799 is present at the radially outward corner of gap 1786'. Thus, as mating of connectors 1710, 1750' progresses, chamfered outer edge 1719 contacts angled surface 1799 near the completion of full mating, which action provides further centering action to connector 1750'. Thus, the three different centering actions provided by assembly 1700' can further ensure centering of connector 1750' relative to connector 1710, which also allows for the use of a larger clearance gap C.

Those skilled in the art will also recognize that the manner in which mating assemblies may be secured together for mating may be varied so that different types of fastening features may be used. For example, the fastening features may include the numerous latches, screws, and coupling nuts described above, but may alternatively include bolts and nuts, press fits, detents, bayonet-style "quick lock" mechanisms, and the like.

The above is illustrative of the present invention and should not be construed as limiting the present invention. Although several exemplary embodiments of the present invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without substantially departing from the novel teachings and advantages of the present invention. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the claims. The present invention is defined by the following claims, including equivalents of the claims therein.
The present disclosure also includes the following aspects.
[Aspect 1]
1. A mating connector assembly comprising:
a first connector assembly including a plurality of first coaxial connectors mounted on the mounting structure;
a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a corresponding coaxial cable and mated with a corresponding first coaxial connector;
a second connector assembly including a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically isolated cavities, each of the second coaxial connectors being disposed within a corresponding cavity;
In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated with a corresponding second coaxial connector,
A mating connector assembly, wherein each of the second coaxial connectors includes an outer connector body positioned within a respective cavity, a clearance gap existing between the outer connector body and the shell.
[Aspect 2]
2. The mating connector assembly of claim 1, wherein each of the outer connector bodies includes a first radially outwardly extending flange and a spring, the spring being disposed between the first flange and the shell.
[Aspect 3]
3. The mating connector assembly of claim 2, wherein each of the outer connector bodies includes a second radially outwardly extending flange positioned forward of the first flange.
[Aspect 4]
4. The mating connector assembly of claim 3, wherein the second flange includes a forwardly extending projection defining a trepan gap with the outer connector body.
[Aspect 5]
5. The mating connector assembly of claim 4, wherein a free end of a respective one of the first coaxial connectors is fitted within the trepan gap of the outer connector body.
[Aspect 6]
6. The mating connector assembly of claim 5, wherein the free end includes a radially outwardly chamfered edge.
[Aspect 7]
7. The mating connector assembly of claim 6, wherein the trepan gap includes a chamfered surface positioned to engage the chamfered edge of the free end.
[Aspect 8]
1. A mating connector assembly comprising:
a first connector assembly including a plurality of first coaxial connectors mounted on the mounting structure;
a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a corresponding coaxial cable and mated with a corresponding first coaxial connector;
a second connector assembly including a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically isolated cavities, each of the second coaxial connectors being disposed within a corresponding cavity;
In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated with a corresponding second coaxial connector,
Each of the second coaxial connectors includes an outer connector body located within a respective cavity, a clearance gap being present between the outer connector body and the shell;
each of the outer connector bodies includes a radially outwardly extending flange;
The flange includes a forwardly extending projection that defines a trepan gap with the outer connector body.
[Aspect 9]
9. The mating connector assembly of claim 8, wherein a free end of a respective one of the first coaxial connectors is fitted within the trepan gap of the outer connector body.
[Aspect 10]
10. The mating connector assembly of claim 9, wherein the free end includes a radially outwardly chamfered edge.
[Aspect 11]
11. The mating connector assembly of aspect 10, wherein the trepan gap includes a chamfered surface positioned to engage the chamfered edge of the free end.

Claims (6)

1. A mating connector assembly comprising:
a first connector assembly including a plurality of first coaxial connectors mounted on the mounting structure;
a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a corresponding coaxial cable and mated with a corresponding first coaxial connector;
a second connector assembly including a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically isolated cavities, each of the second coaxial connectors being disposed within a corresponding cavity;
In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated with a corresponding second coaxial connector,
Each of the second coaxial connectors includes an outer connector body located within a respective cavity, a clearance gap being present between the outer connector body and the shell ;
Each of the outer connector bodies includes a first flange extending radially outward and a spring, the spring being disposed between the first flange and the shell;
a mating connector assembly , each of the outer connector bodies including a radially outwardly extending second flange positioned forward of the first flange . The mating connector assembly of claim 1 , wherein the second flange includes a forwardly extending projection defining a trepan gap with the outer connector body. The mating connector assembly of claim 2 , wherein a free end of a respective one of the first coaxial connectors is fitted within the trepan gap of the outer connector body. The mating connector assembly of claim 3 , wherein said free end includes a radially outwardly chamfered edge. The mating connector assembly of claim 4 , wherein the trepan gap includes a chamfered surface positioned to engage the chamfered edge of the free end. 1. A mating connector assembly comprising:
a first connector assembly including a plurality of first coaxial connectors mounted on the mounting structure;
a second connector assembly including a plurality of second coaxial connectors, each of the second coaxial connectors being connected to a corresponding coaxial cable and mated with a corresponding first coaxial connector;
a second connector assembly including a shell surrounding the second coaxial connectors, the shell defining a plurality of electrically isolated cavities, each of the second coaxial connectors being disposed within a corresponding cavity;
In a mated state, the shell abuts against the mounting structure, and each of the first coaxial connectors is mated with a corresponding second coaxial connector,
Each of the second coaxial connectors includes an outer connector body located within a respective cavity, a clearance gap being present between the outer connector body and the shell;
each of the outer connector bodies includes a radially outwardly extending flange;
the flange includes a forwardly extending projection defining a trepan gap with the outer connector body;
a free end of each of the first coaxial connectors is fitted within the trepan gap of the outer connector body;
the free end includes a radially outwardly chamfered edge;
the trepan gap includes a chamfered surface positioned to engage the chamfered edge of the free end .

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