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`May 27, 2003
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`

`

`US 6,568,964 B2
`
`1
`RCA-TYPE ELECTRICAL PLUG
`CONNECTOR
`
`CROSS REFERENCE TO RELATED
`APPLICATION
`
`The present application is a continuation-in-part of
`copending U.S. patent application Ser. No. 09/478,872,
`entitled "Electrical Plug and Jack Connectors", filed on Jan.
`7, 2000 and assigned to J. D'Addario & Company, Inc.
`
`BACKGROUND OF THE INVENTION
`
`The present invention relates generally to RCA type
`electrical plug and jack connectors and, more particularly, to
`electrical plug and jack connectors configured to provide
`reduced relative movement when connected together and
`thereby reduce the likelihood of intermittent electrical dis(cid:173)
`continuity.
`Plug connectors are well known for use in connecting,
`e.g., audio equipment. With RCA-type plugs, a ground
`sleeve or the like surrounds a central signal pin. One such
`plug is used for mono (single channel) transmission and two
`side-by-side plugs are used for stereo (two-channel) trans(cid:173)
`mission. Generally, the mating contacts for the pins and
`sleeves with associated jack structures are smooth. Because
`of, e.g., resiliency and tolerances between the structures, the
`plugs are somewhat moveable within the jack and through
`wear and the like the movement increases. This often leads
`to intermittent contact and a resulting disturbance in the
`quality of the audio signal.
`
`SUMMARY OF THE INVENTION
`
`2
`FIG. 1 is a perspective view of an RCA plug connector in
`accordance with a first preferred embodiment of the present
`invention;
`FIG. 2A is a plan view of the RCA plug connector,
`illustrated in FIG. 1.
`FIG. 2B is a cross-sectional view similar to FIG. 2A,
`simplified by the omission of the exterior spring portion for
`clarity.
`FIG. 3 is an exploded side elevation view of the left part
`of the RCA plug connector, illustrated in FIG. 2.
`FIG. 4 is an exploded side elevation view of the right part
`of the RCA plug connector, illustrated FIG. 2.
`FIG. 5 is an exploded side elevation view to an enlarged
`15 scale of the signal tip and banana spring section of the
`apparatus, illustrated in FIG. 3.
`FIG. 6 is an exploded side elevation view to an enlarged
`scale of the outer half shells, illustrated in FIG. 3.
`FIG. 7 is an exploded side elevation view to an enlarged
`20 scale of the inner insulator and color-coded ring, illustrated
`in FIG. 4.
`FIG. 8 is a side elevation view to an enlarged scale of the
`die cast shell, illustrated in FIG. 4.
`FIG. 9 is a partial schematic view of an RCA plug
`connector in accordance with a second embodiment of the
`present invention;
`FIG. 10 is a perspective view of a rudimentary jack for
`receiving an RCA plug according to an embodiment of the
`30 invention described herein;
`FIG. 11 is a perspective view of an RCA plug connector
`in accordance with a third embodiment of the present
`invention; and
`FIGS. 12 and 13 are sectional views taken along lines XII
`35 and XIII, respectively of FIG. 11.
`
`10
`
`25
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`A plug connector 10 in accordance with one embodiment
`of the present invention is illustrated in FIGS. 1-8. The plug
`connector 10 has a base 11 and an insulating ring 12
`interposed between a conductive ground sleeve 14 and a
`conductive signal probe member 16. The sleeve 14 is
`preferably formed from two mating half shells 14a and 14b
`that extend from the base and are disposed annularly about
`the probe member in substantially coaxial relation. The
`insulating ring 12 is preferably comprised of a molded
`plastic material such as a molded thermoplastic, e.g., acetyl
`50 resin, nylon, ABS resin and/or blends thereof. The sleeve 14
`is composed of a conductive material, may be formed from
`sheet stock and is disposed coaxially about the insulating
`ring 12. The sleeve 14 is electrically connected to e.g. the
`ground shield of an electrical wire or cable (not shown).
`The pin or probe member 16 extends from the base 11,
`along a central axis 13 and comprises a conductive body or
`core 19, having a rounded head 18 at the free end and an
`exterior spring portion 20. The spring portion 20 comprises
`axially extending slots or spaces 22, disposed between
`60 axially extending bulged portions 24. The spring portion 20
`is a generally cylindrical sleeve shaped member having an
`axially extending slit 21 to permit expansion for assembly
`onto the axial portion of the body 19 that is intermediate the
`shoulders 23, 25 thereof. In this manner, the probe member
`65 16 is formed in two pieces and is preferably composed
`entirely of metallic components whereby a signal may be
`conducted thereby.
`
`Accordingly, it is an object of the present invention to
`provide an RCA-type plug connector that achieves reduced
`relative movement when mated with a jack connector.
`In accordance with an embodiment of the present
`invention, an RCA plug connector has a radially outwardly
`extending spring carried by the pin, or elongated probe,
`which extends axially from the plug base or body. A con(cid:173)
`ductive ground sleeve also projects from the base, is dis- 40
`posed about the probe member in substantially coaxial
`relation, and insulated therefrom. As is typical, the RCA
`plug connector further includes an insulating ring. The
`insulating ring has a central aperture and is interposed
`between the probe member and the conductive sleeve. The 45
`conductive sleeve may also include a radially inward
`extending spring means, such as at least one spring finger
`having an arcuate or generally V-shaped cross section that
`extends radially inwardly.
`Preferably, the spring on the probe comprises at least one
`outward, bowed portion. The bowed portion may extend
`radially outward of the central axis of the probe member and
`may comprise a plurality of circumferentially spaced, bowed
`metal strips. The plug connector probe may thus have a
`central core with a nose or head portion at the free end, with 55
`the spring strips carried by the core intermediate the nose
`and the plug base.
`The probe member and the conductive sleeve may each
`comprise a material selected from the group consisting of
`brass, copper, phosphor, beryllium copper bronze, and steel
`plated with gold, nickel or silver.
`
`BRIEF DESCRIPTION OF DRAWINGS
`Other objects and advantages of the invention will be
`evident to one of ordinary skill in the art from the following
`detailed description made with reference to the accompany(cid:173)
`ing drawings, in which:
`
`Page 14 of 17 (PGR2021-00078)
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`

`

`US 6,568,964 B2
`
`3
`The plug connector 10 is dimensioned and configured for
`cooperation with a conventional RCA type jack connector
`310 (FIG. 10). The jack connector 310 comprises an insu(cid:173)
`lating cylinder 312, a conductive ground band or collar 314
`and a central cavity or bore 316.
`The insulating cylinder 312 may be formed of any suit(cid:173)
`ably strong and durable material such as a plastic, for
`example, a polyolefin and is dimensioned to fit within the
`sleeve 14, of the plug connector 10. The conductive band or
`collar 314 circumscribes the end of the insulating cylinder
`312, and electrically contacts the ground sleeve 14 when the
`plug connector 10 is mated with the jack connector 310. A
`conductive line 318 connects the collar 314 with, e.g., a
`ground wire (not shown). The central cavity 316 has a
`conductive signal wall 320, which may be coated or pro(cid:173)
`vided with a conductive, sleeve and is dimensioned to
`receive the probe member 16.
`When mated, the plug probe 16 is fully inserted into and
`engages the inner surface 320 of the central signal bore 316
`in the jack and the plug sleeve 14 engages the outer surface 20
`of the collar 314 on the jack. The spring portion 20 of the
`probe member 16 will be compressed against the signal bore
`wall 320 to provide increased friction and prevent undesir(cid:173)
`able disruption of electrical continuity. The outer diameter of
`the spring 20, with no external forces applied to it, is equal 25
`to or greater than the nominal internal diameter of the jack
`signal bore wall 320.
`In this embodiment (FIGS. 1-8), the assembled sleeve 14
`consists of a split ring portion 26, with tabs 28 engaging
`recesses 29 in the base 11. The split ring portion 26 has a
`plurality; e.g., four circumferentially spaced apart fingers 30.
`Each finger 30 has an arcuate stem portion or first axial
`portion 32 having an internal axis of curvature 34 substan(cid:173)
`tially coincident with the axis 13 and sized to match the
`outside diameter of the collar 314 on the jack 310. Each
`finger 30 has a tip portion or second axial portion 36 that has
`a radially inward curvature 38 having a center of curvature
`disposed outside the sleeve 14 outside diameter. When the
`plug connector 10 is not installed in a jack connector 310
`and thus, there is no external force applied to the fingers 30,
`the tips 36 of the fingers 30, with this radially inward
`curvature 38, define a circle that has a smaller diameter than
`the outside diameter of the collar 314. Thus, the spring(cid:173)
`tempered fingers 30 provide an inward force against the
`collar 314 when the plug connector 10 is installed on the
`collar 314 of the jack connector 310.
`The coaxial cable is preferably coupled to the plug 10 by
`a solder less connection. More particularly, a die cast cylin(cid:173)
`drical or barrel shaped body or base 11 is provided with a 50
`bore 40 dimensioned and configured for receiving the
`coaxial cable. A laterally extending threaded cross bore 42,
`having an optional counter bore (not shown) cooperates with
`a setscrew 44. In other embodiments of the invention, the
`setscrew 44 will have a head that cooperates with the counter 55
`bore. In the embodiment of the invention having a set screw
`with a head, the depth of the counter bore and the length of
`the set screw are dimensioned and configured to allow
`engagement of the shielding of the coaxial cable, while
`limiting the maximum travel of the set screw and thus 60
`preventing excessive travel of the set screw that would
`damage the coaxial cable. This dimensioning insures that a
`good contact is made with the coaxial cable and particularly
`the shielding, with no significant risk of damaging the
`coaxial cable.
`Before the set screw is advanced, the front of the coaxial
`cable is pushed fully into the bore 40 so that the point 52 of
`
`4
`the core 19 of probe 16 penetrates the cable and makes
`contact with the central, signal wire of the coaxial cable. The
`insulating ring 12 is secured within the sleeve 14 by pro(cid:173)
`trusions 15 that extend through the conductive ground sleeve
`14 and retain the conductive ground sleeve 14 in place when
`the base 11 is secured over the sleeve 14 and ring 12.
`The pin core 19 is insert molded within the insulating ring
`12. The ring 12 has a substantially cylindrical surface
`configured for mounting the split ring portion 26. Thereafter,
`10 the base 10 is pressed around the split ring portion 26. In
`other words, the base 10 is axially slid over the split ring
`portion until the opposed tabs 28 engage the opposed
`recesses 29 in the base 11. Thereafter, the ring 50 is
`positioned around the base 11 to cover the tabs 28 and
`15 recesses 29.
`Referring now to FIG. 9, another embodiment of a plug
`connector in accordance with the present invention is illus(cid:173)
`trated generally at 210. This embodiment differs from the
`embodiment of FIGS. 1-8 in that the outer sleeve 214 is a
`continuous cylindrical section. The plug connector 210 is
`formed in accordance with an RCA configuration and
`includes a spring contact such as that described with respect
`to the embodiment illustrated in FIGS. 1-8. The plug
`connector 210 comprises an insulating ring 212 interposed
`between a sleeve 214 and a probe member 216. The insu(cid:173)
`lating ring 212 is preferably comprised of a molded plastic
`material such as any of those discussed above. The sleeve
`214 is composed of a conductive material, may be formed
`from a sheet and is disposed about the insulating ring 212.
`30 The sleeve 214 may be electrically connected typically to
`the shield of an electrical cable (not shown).
`The probe member 216 comprises a rounded head 218
`and a spring portion 220. The spring portion 220 comprises
`slots or spaces 222 disposed between bulged portions 224 of
`the probe member 216. In this manner, the probe member
`216 is formed in one piece and is preferably composed of a
`metallic substance to provide conductive properties whereby
`a signal from a wire (not shown) may be conducted thereby.
`40 When the plug connector 210 is fitted together with a
`conventional jack connector 310 such as shown in FIG. 10,
`the probe member 216 fits within the central cavity thereof
`whereby the spring portion 220 will be compressed against
`wall 320 to provide increased friction and prevent undesir-
`45 able disruption of electrical continuity.
`A further embodiment of a plug connector in accordance
`with the present invention is illustrated generally at 410 in
`FIGS. 11-13. It will be appreciated that the plug connector
`410 has an RCA configuration. The plug connector 410
`comprises an insulating ring 412, interposed between a
`sleeve 414, and a probe member 416.
`The insulating ring 412 may be composed of a plastic
`material such as any thermoplastic material discussed above,
`and functions to separate the sleeve 414 and probe member
`416, which are both conductive.
`The sleeve 414 may be composed of, for example, copper,
`steel, or beryllium copper, plated with, e.g., nickel, copper,
`silver or even gold for a low resistance, brass, phosphor
`bronze or other material or alloy. The sleeve comprises
`contact fingers 418 and 420 that engage a correspondingly
`shaped jack connector such as the collar 314 (FIG. 10) of the
`jack connector 310. The contact fingers 418 each include a
`spring portion 422, having a radially inwardly directed,
`generally V-shaped cross section. In this embodiment, the
`65 fingers have been cut from the cylinder and the remaining
`portions of the cylinder remain as projections in alternation
`with the fingers and define web or the like between fingers.
`
`35
`
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`

`

`US 6,568,964 B2
`
`5
`The probe member 416 may be composed of a metallic
`substance such as any of those described above with respect
`to the sleeve 414 and comprises a tube portion 424, spring
`portion 426 and a nose portion 428. The spring portion 426
`includes circumferentially spaced strips 430 which may be
`tempered and may engage both the tube portion 424 and
`nose portion 428. Members 432 and 434 may be provided
`within the probe member 416 and may support the strips
`430.
`While the present invention has been described in con(cid:173)
`nection with what are presently considered to be the most
`practical and preferred embodiments, it is to be understood
`that the present invention is not limited to these herein
`disclosed embodiments. Rather, the present invention is
`intended to cover all of the various modifications and
`equivalent arrangements included within the spirit and scope
`of the appended claims.
`What is claimed is:
`1. An RCA plug connector comprising:
`a base;
`an elongated conductive probe member extending from
`the base along a central axis to a free end and having
`an exterior spring intermediate the free end and the
`base, said exterior spring including at least one axially
`extending radially outwardly bowed spring portion;
`and
`a conductive sleeve formed of two mating half shells
`extending from the base and disposed annularly about
`the probe member in substantially coaxial relation 30
`therewith and insulated therefrom.
`2. The RCA plug connector in accordance with claim 1
`comprising:
`an insulating ring supported by the base between the
`probe member and the sleeve and defining a central
`aperture penetrated by said probe.
`3. The RCA plug connector in accordance with claim 1,
`wherein the conductive sleeve includes at least one spring
`portion that extends inwardly in the absence of external
`forces.
`4. The RCA plug connector in accordance with claim 1,
`wherein the conductive sleeve includes at least one spring
`finger portion having a generally V-shaped cross section.
`5. The RCA plug connector in accordance with claim 1,
`wherein the at least one bowed spring portion comprises a 45
`plurality of circumferentially spaced bowed portions.
`6. The RCA plug connector in accordance with claim 5,
`wherein the probe comprises a core having a head at the free
`end and a pair of shoulders intermediate the free end and the
`base, and the exterior spring is a separate, unitary part 50
`supported by the core between said shoulders.
`7. The RCA plug connector in accordance with claim 1,
`wherein the probe member and the conductive sleeve each
`comprise a material selected from the group consisting of
`brass, copper, phosphor bronze, steel plated with gold and 55
`beryllium copper.
`8. The RCA plug connector in accordance with claim 3,
`wherein said at least one spring portion has a first axial part
`that is substantially a cylindrical section.
`9. The RCA plug connector in accordance with claim 8, 60
`wherein said first axial part is adjacent to said base.
`10. The RCA plug connector in accordance with claim 7,
`wherein said at least one spring portion includes a second
`axial part having an arcuate curve shape extending radially
`inwardly.
`11. The RCA plug connector in accordance with claim 8
`further including a plurality of additional spring portions, all
`
`6
`of said spring portions being collectively disposed in an
`array about said elongated conductive probe member, said
`array being substantially annular and substantially coaxial
`with said elongated conductive probe member.
`12. The RCA plug connector in accordance with claim 11,
`wherein said plurality of additional spring portions each
`include a first axial portion that is proximate to the tip
`thereof that is substantially a cylindrical section.
`13. The RCA plug connector in accordance with claim 12,
`10 wherein each of said plurality of additional spring portions
`further includes a second axial section that is adjacent to said
`first axial portion that is generally arcuate and that extends
`radially inwardly.
`14. The RCA plug connector in accordance with claim 8,
`15 wherein said first axial part that is a cylindrical section has
`an axis of curvature that is coincident with the axis of said
`probe member.
`15. The RCA plug connector in accordance with claim 1,
`wherein the base includes a first bore dimensioned and
`20 configured for receiving an associated coaxial cable, said
`base further including a second bore disposed in substan(cid:173)
`tially perpendicular relationship to said first bore, said
`second bore being threaded and said connector further
`including a threaded member dimensioned and configured
`25 for engaging said second bore for engagement with an
`associated coaxial cable.
`16. The RCA plug connector in accordance with claim 5,
`wherein the base includes a first bore dimensioned and
`configured for receiving an associated coaxial cable, said
`base further including a second bore disposed in substan(cid:173)
`tially perpendicular relationship to said first bore, said
`second bore being threaded and said connector further
`including a threaded member dimensioned and configured
`for engaging said second bore for engagement with an
`35 associated coaxial cable.
`17. The RCA plug connector in accordance with claim 8,
`wherein the base includes a first bore dimensioned and
`configured for receiving an associated coaxial cable, said
`base further including a second bore disposed in substan-
`40 tially perpendicular relationship to said first bore, said
`second bore being threaded and said connector further
`including a threaded member dimensioned and configured
`for engaging said second bore for engagement with an
`associated coaxial cable.
`18. The RCA plug connector in accordance with claim 1,
`wherein the base includes a first bore dimensioned and
`configured for receiving an associated coaxial cable, said
`base further including a second bore disposed in substan(cid:173)
`tially perpendicular relationship to said first bore, said
`second bore being threaded and said connector further
`including a threaded member dimensioned and configured
`for engaging said second bore for engagement with an
`associated coaxial cable.
`19. An RCA plug connector for a coaxial signal cable
`comprising:
`a base having a bore at one end for receiving a coaxial
`cable;
`an elongated conductive signal probe member extending
`from the other end of the base along a central axis to a
`free end and having an exterior spring extending lon(cid:173)
`gitudinally intermediate the free end and the base; and
`a conductive sleeve extending from the base and disposed
`annularly about the probe member in substantially
`coaxial, spaced, insulated relation therewith, said
`sleeve formed by two mating half-shells, at least one of
`which includes a radially extending tab dimensioned
`and configured for engagement with said base.
`
`65
`
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`

`US 6,568,964 B2
`
`7
`20. An RCA plug connector for a coaxial signal cable
`comprising:
`a base having a bore at one end for receiving a coaxial
`cable;
`an elongated conductive signal probe member supported
`at and extending outwardly from the base along a
`central axis to a free end and extending within the base
`to a sharp point on the end opposite the free end for
`engaging a central signal conductor of a coaxial cable,
`said probe member further having an exterior spring 10
`affixed thereto including a plurality of radially resilient
`spring elements extending longitudinally to a location
`on the probe closer to the free end than to the base; and
`
`8
`a radially resilient conductive sleeve supported at the base
`for electrical connection with the outer conductor of
`said coaxial cable, said sleeve disposed annularly about
`the probe member in substantially coaxial, spaced,
`insulated relation therewith, and extending outwardly
`from the base a lesser distance than the longitudinal
`extent of the exterior spring of the probe member.
`21. The RCA plug of claim 20 wherein the sleeve has tabs
`engaging said base; and
`an insulating ring located within said other end of the base
`has protrusions engaging the sleeve and is molded onto
`and rigidly supports the probe member.
`
`* * * * *
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`Page 17 of 17 (PGR2021-00078)
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