CA2225971A1 - Low profile modular phone jack and method of making same - Google Patents
Low profile modular phone jack and method of making same Download PDFInfo
- Publication number
- CA2225971A1 CA2225971A1 CA002225971A CA2225971A CA2225971A1 CA 2225971 A1 CA2225971 A1 CA 2225971A1 CA 002225971 A CA002225971 A CA 002225971A CA 2225971 A CA2225971 A CA 2225971A CA 2225971 A1 CA2225971 A1 CA 2225971A1
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- Canada
- Prior art keywords
- housing
- terminals
- phone jack
- modular phone
- portions
- Prior art date
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/60—Contacts spaced along planar side wall transverse to longitudinal axis of engagement
- H01R24/62—Sliding engagements with one side only, e.g. modular jack coupling devices
- H01R24/64—Sliding engagements with one side only, e.g. modular jack coupling devices for high frequency, e.g. RJ 45
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- Coupling Device And Connection With Printed Circuit (AREA)
- Connector Housings Or Holding Contact Members (AREA)
- Details Of Connecting Devices For Male And Female Coupling (AREA)
Abstract
A modular phone jack (10) includes an outer dielectric housing (12) having a plug-receiving opening (26) formed in a forward mating end (28) of the housing.
An inner dielectric insert (14) is positionable in the housing. A plurality of elongated terminals (16) are fixed to the dielectric insert. Each terminal includes a contact portion (16b) at one end extending diagonally into the plug-receiving opening and a tail portion (16c) at the opposite end extending from the housing. A comb structure (22a) secures the tail portions to the housing at predetermined spaced locations. A method of fabricating the modular phone jack (10) according to the above structure is contemplated.
An inner dielectric insert (14) is positionable in the housing. A plurality of elongated terminals (16) are fixed to the dielectric insert. Each terminal includes a contact portion (16b) at one end extending diagonally into the plug-receiving opening and a tail portion (16c) at the opposite end extending from the housing. A comb structure (22a) secures the tail portions to the housing at predetermined spaced locations. A method of fabricating the modular phone jack (10) according to the above structure is contemplated.
Description
CA 0222~971 1997-12-29 Patent SPECIFICATION
LOW PROFILE MODULAR PHONE JACK AND METHOD OF MAKING SAME
Field of the Invention This invention generally relates to the art of electrical connectors and, particularly, to a low profile modular phone jack, along with a method of fabricating the modular phone jack.
Background of the Invention Electrical connectors commonly called modular phone receptacles or jacks have been known in the art for many years. Although connectors of this type were originally designed for the telecommunications industry, and in particular for telephones, they have found wide acceptance in other areas. For example, modular jacks are commonly used as input/output (I/O) interface connectors for computers to communicate with each other and with a variety of peripheral equipment.
Modular jacks are used extensively as an interface between a standard modular plug and a printed circuit board. The modular jacks generally include a dielectric housing having a plug-receiving socket or opening therein. A plurality of stamped, metallic elongated terminals are mounted in the housing for engaging contacts of the corresponding plug. Typically, each terminal includes a contact portion at one end extending diagonally into the socket or opening, a tail portion at the other end extending from the housing and an intermediate portion between the contact portion and the tail portion.
Modular phone jacks may be formed either as a one-piece housing structure or as a two-piece assembly. In the one-piece structure, a one-piece or unitary dielectric housing has channels adapted to locate and hold the stamped CA 0222~971 1997-12-29 Patent metallic terminals. In the two-piece assembly, the terminals are mounted on a dielectric insert as a subassembly, and this subassembly is positioned in the housing. Typically, the terminals are at least partially formed or bent prior to positioning the subassembly into the housing. The finally assembled modular phone jack then can be mounted on a printed circuit board with the tail portions of the terminals inserted into precisely spaced holes in the printed circuit board.
One of the problems in the use of modular phone jacks as described above involves maintaining the tail portions of the terminals at the same precise location and spacing as the holes in the printed circuit board. This problem is particularly prevalent in two-piece assemblies where the terminals are preassembled on the insert prior to positioning the subassembly of the insert and the terminals into the jack housing. It is fairly easy to precisely locate the tail portions in a one-piece molded jack housing. However, in the two-piece assembly, the various preassembly steps, including bending and forming of the tail portions, handling and inserting the subassembly into the housing, tend to cause the tail portions to become misaligned. This problem is further complicated when filter elements are positioned about the tail portions of the terminals.
The present invention is directed to these problems by providing a unique system for maintaining proper spacing or alignment of the terminal tail portions in a modular phone jack particularly of the two-piece design.
Summary of the Invention An object, therefore, of the invention is to provide a new and improved modular phone jack of the character described, along with a method of fabricating the modular phone jack.
CA 0222~971 1997-12-29 Patent In the exemplary embodiment of the invention, the jack includes an outer dielectric housing having a plug-receiving opening formed in a forward mating end of the housing. An inner dielectric insert is positionable in the housing. A plurality of elongated terminals are fixed to the insert. Each terminal includes a contact portion at one end extending diagonally into the plug-receiving opening and a tail portion at the opposite end extending from the housing. Generally, means are provided for securing the tail portions to the housing at predetermined spaced locations.
More particularly, the terminals have intermediate portions between the contact portions and the tail portions. The intermediate portions are fixed to the dielectric insert. After this subassembly is positioned in the jack housing, the tail portions are secured to a comb structure of the housing to maintain the tail portions at precise, predetermined spaced locations.
As disclosed herein, the insert is generally planar and includes a forward end from which the contact portions of the terminal extend and a rearward end from which the tail portions of the terminals extend. A filter element is positioned about the tail portions of the terminals. In final assembly, the filter elements are sandwiched between first shoulder means on the housing and second shoulder means on the insert.
The invention also contemplates a method of fabricating a modular jack, including the steps of providing an outer dielectric housing with a plug-receiving opening in a forward mating end of the housing. The plurality of terminals are fixed to an inner dielectric insert to form a subassembly. The subassembly then is positioned in the housing with the contact portions of the terminals extending diagonally into the plug-receiving opening and with the tail portions of the terminals extending from the housing. After positioning the CA 0222~971 1997-12-29 Patent subassembly in the housing, the tail portions of the terminals are secured to the housing at their predetermined spaced locations.
The method may include the step of mounting a filter element about the tail portions of the terminals prior to positioning the subassembly into the housing.
During assembly, the filter elements are sandwiched between opposing shoulder means on the insert and the housing.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying draw-ings.
DEC - 26- 1997 07: 42 MOLEX CA rO 222 ~ 971 1997 - 12 - 29 . 630 416 4962 P .02/04 Patent 9?-001 Br;ef Des~riPtion of ~he ~raw;ng~
The fe~ures of this invention ~hich are believed ~o ~e novel are set forth with par~icul~rity in the append-ed claims. The invention, together wi~h its objects and the advantages ~hereof, may ~e ~e~ under~tood by ~eference to ~he following description ~aken in conjunction with the accompanying dxawings, in which lik~ xeference numer~
identify like elements in the figuxes an~ in which:
FIGURE 1 i~ a perCpe~tive ~iew of a modular phone jack inçorporatin~ the ~oncepts o$ the invention;
~IGUR~ 2 is a vertical, front-to rear ~ection through the phone jack;
. FIGURE 3 i~ a ~ront elevational ~iew o~ the ja~X:
FIGURE 4 is a bottom plan view of the jack;
F~GUR~ 5 i~ a vert$cal, fro~t-to-rear section through the jack housin~:
~IGURE 6 is a bottom plan view of the housing:
FIGURE 7 is a horizontal se~ion taken generally along line 7-7 of Flgure 6; ~nd FIGURE 8 ~ a top plan view of the dielectric insert with the terminal~ staked thereto, and prior to f orming the t~- in;~l g, D 1 '~ A ~ ~/A ~d ~ D ~ r ,r~ B~
t ~ A IJ~r~
r~6,,~ cr~ .
DEC - 26 - 1997 07:43 ~OLEX CArO222~971 1997-12-29. l 630 416 4962 P.03/04 Patent g7-001 ~A
~etail ed Descr~tion of the Pr~ferred ~mbodim.en~
Referring to the dr~wings in greater detail, and fir~ to Pigure~ 1-4, the invention is incorporated in a modular phone jack, generally designated 10. Generally, the iack $s a two-piece ~sse~bly incl~ding ~n outer diçle~tric housing, gener~lly designated 12, and an Lnner dielectric insert, generally designated 14. A plurality of elongated tPr~inals, generally designated 16, are mounted in the housing~ A filter in ~he form o~ a ferrite block 18 (Fig. 2~ is positioned over portions of the te~
~ ore particularly, referring to Figures ~-7 in conjunoti~n with ~igures ~4, outer diele~tric housing 12 o~ modular phone jack 10 is of ~ conven~ box-like configur~tion including a top wall ~0, a ~o~o~ wall 22 and a pair of side walls 24, all ~ombining to define ~ plug-~eceiving socket or opening, generally designated 26. The so~ket is open at a forwa~d ~ating end 28 of the housing The rea~ of the soc~et i5 ¢losed by an int~rnal partition 3~ ~paced inw~rdly or forwardly of a rear end 32 of t~e housing. The top of partition 30 includes a co~ e ~tructure 30a. The rear of bottom wall 22 also includes ~
comb-like ~tructure 22a. A pair of mounting pos~s 36 are inte~rally molded wi~h and proje~ downw~rdly from the housing. The posts are ~o~nted into locating holes in the prin~ed circuit board to precisely locate the h~in~ on the bo~rd, particularly relati~e to the terminal tai~ holes in the ~oard.
f __ As be~t ~een in Fig~res 2~, e~ch te ~ nal 16 in~ludes an intermediate portion l~a b~n a oontact portion 16b and a tail p~rtion l~c. ~he con~act portion of ea~h te~minal extends at one end o~ the intermedia~e portion diagon~lly into plug-reae~ving cpen~ng 2~. The tail por~ions 16c of the terminal~ are ~ent general}y perpendicular to intermediate por~ions 1~ at the opposite 3~ ends thereof downwardly and out of housing 12 for in~ert~on into holes in the printed circuit board. It can be seen in DEC-26-1997 07:43 ~OLEX CAr-0~222~971 1997-12-29 1 - 630 416 4962 P.04/~4 Pa~ent ~7-001 CA
Figure 2 that tail portions 16c of the tçxminals are fo~me~
so that alternating ones of the termina'~ 5 are in two differen~ rows ac is typical in the art. Lastly, Figure ~
shows ferrite filter blo~k 18 sandwiched between a fir~t ~houlder 38 def~ned by comb structure 22a of the housing ~nd ~ c~cond shoul~er 4~ def~ned ~y in~ert 14.
FigureS8~show~ dielectric insert 14 and ter~in~lc' 1~ in the process of ~eing joined to form a c~h~ssembly for inser~ion into ja~k hou~ing 12. More particularly, the dielectrio insert is formed as a generally planar, molded pl~stic component having a plurali~y o~ ups~ndin~
staggered locating pro;e~ion~ 42. Termina~s 16 are ~oun~ed on top of inser~ 14 and include o~al-chAre~ pilot holes 4~ which are ~taggered with respect to one anot~er ~n the alternating terminal~. Locat~ng p~oje~tions 42 are adapted to be received within pilot holes 44 ~o pre~i~ely posi~ion terminals 16 on the top of insert 14. A~ter pocitionin~ ~he terminals, lo~ating projections 4~ a~e cold s~-aked to rigidly ~ix the ~erminalC to the inser~.
~0After terminals 16 are fixed to dielectric insert 14 as shown in Fi ~ r~ll8, the terminals then are formed as _~
sho~n best in Figur~ ~. In other words, contact portions 1~ o~ the terminals are bent downwardly a~out a front ed~e ; 14a of the in~ert until the contact po~tions extend diagonally rearwardly beneath ~he insert. Tail portions 16c are bent do~nwardly generally at right ~ngle~ to intermedia~e portion~ 16a behind a rear edge 14b of the insert. Before the subas~embly of insert 14 and formed terminal~ 16 is positioned within ho~sing 12, fer.rite ~ilte~ ~lock 1~ is positioned onto tail portions 16c of the te~minals as ~een in Figure 2. The inside o~ side walls 24 of the housing are provided ~ith y.OOV~S 46 (see Figs. ~
and 5) ~or re~eiving the side edges o~ incert 14 when the subassembly ~f the insert and the termi~als are mount~d in the housing th~ough the rear end 32 of the housing~
TOTRL P . 04 CA 0222~971 1997-12-29 Patent The method of fabricating modular phone jack 10 can fairly be derived from the above description of the structural combination thereof. Nevertheless, the method can be summarized as follows:
providing outer dielectric housing 12 with plug-receiving opening 16 in forward mating end 28 of the housing;
fixing terminals 16 to dielectric insert 14 to form the subassembly of Figure 8;
forming the terminals with contact portions 16b and tail portions 16c as shown in Figure 2;
positioning this subassembly in housing 12 with contact portions 16b extending diagonally into plug-receiving opening 26 and with tail portions 16c extending from the housing; and securing tail portions 16c of terminals 16 to comb structure 22a at the rear of bottom wall 22 of the housing.
If filter element 18 is employed, the method includes the step of mounting the filter element about tail portions 16c of the terminals prior to positioning the subassembly of the insert and the terminals into the housing. During assembly, filter element 18 becomes sandwiched between opposing shoulders 38 and 40 of the housing and the dielectric insert, respectively.
As the subassembly of dielectric insert 14 and terminals 16 is positioned into housing 12, the tail portions enter comb structure 22a at the rear of bottom wall 22 to precisely position the tail portions at predetermined spaced locations corresponding to their respective holes in the printed circuit board. In order to assure precise positioning of the tail portions, the tail portions can be cold staked to the bottoms or bases of the slots in the comb structure. Contact portions 16b are separated by comb structure 3Oa.
CA 0222~971 1997-12-29 Patent The structural combination of the invention takes the advantages afforded by a one-piece jack structure as well as a two-piece assembly without creating any substantial disadvantages. In particular, it is known that a one-piece jack housing can best locate the tail portions of the terminals relative to their respective holes in the printed circuit board. This can be understood because mounting posts 36 precisely locate the housing on the board and the housing, in turn, precisely locates the tail portions of the terminals. However, a one-piece housing structure has considerable disadvantages in assembling conductors 16 and/or filter elements inside the one-piece structure.
on the other hand, a two-piece assembly including a dielectric insert, such as insert 14, considerably simplifies the assembly processes of a modular phone jack.
Unfortunately, the two-piece assembly suffers from the disadvantages of the tail portions of the terminals becoming misaligned during manufacture and handling.
The present invention takes advantage of the positive attributes of both types of designs. The invention uses the two-piece structure to provide a subassembly which is very easy to assemble within the jack housing, including the terminals and the filter block, if desired. The structure of the invention then relies on the housing (i.e. comb structure 22a) to precisely align and space the terminal tail portions for insertion into their respective holes in the printed circuit board.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
LOW PROFILE MODULAR PHONE JACK AND METHOD OF MAKING SAME
Field of the Invention This invention generally relates to the art of electrical connectors and, particularly, to a low profile modular phone jack, along with a method of fabricating the modular phone jack.
Background of the Invention Electrical connectors commonly called modular phone receptacles or jacks have been known in the art for many years. Although connectors of this type were originally designed for the telecommunications industry, and in particular for telephones, they have found wide acceptance in other areas. For example, modular jacks are commonly used as input/output (I/O) interface connectors for computers to communicate with each other and with a variety of peripheral equipment.
Modular jacks are used extensively as an interface between a standard modular plug and a printed circuit board. The modular jacks generally include a dielectric housing having a plug-receiving socket or opening therein. A plurality of stamped, metallic elongated terminals are mounted in the housing for engaging contacts of the corresponding plug. Typically, each terminal includes a contact portion at one end extending diagonally into the socket or opening, a tail portion at the other end extending from the housing and an intermediate portion between the contact portion and the tail portion.
Modular phone jacks may be formed either as a one-piece housing structure or as a two-piece assembly. In the one-piece structure, a one-piece or unitary dielectric housing has channels adapted to locate and hold the stamped CA 0222~971 1997-12-29 Patent metallic terminals. In the two-piece assembly, the terminals are mounted on a dielectric insert as a subassembly, and this subassembly is positioned in the housing. Typically, the terminals are at least partially formed or bent prior to positioning the subassembly into the housing. The finally assembled modular phone jack then can be mounted on a printed circuit board with the tail portions of the terminals inserted into precisely spaced holes in the printed circuit board.
One of the problems in the use of modular phone jacks as described above involves maintaining the tail portions of the terminals at the same precise location and spacing as the holes in the printed circuit board. This problem is particularly prevalent in two-piece assemblies where the terminals are preassembled on the insert prior to positioning the subassembly of the insert and the terminals into the jack housing. It is fairly easy to precisely locate the tail portions in a one-piece molded jack housing. However, in the two-piece assembly, the various preassembly steps, including bending and forming of the tail portions, handling and inserting the subassembly into the housing, tend to cause the tail portions to become misaligned. This problem is further complicated when filter elements are positioned about the tail portions of the terminals.
The present invention is directed to these problems by providing a unique system for maintaining proper spacing or alignment of the terminal tail portions in a modular phone jack particularly of the two-piece design.
Summary of the Invention An object, therefore, of the invention is to provide a new and improved modular phone jack of the character described, along with a method of fabricating the modular phone jack.
CA 0222~971 1997-12-29 Patent In the exemplary embodiment of the invention, the jack includes an outer dielectric housing having a plug-receiving opening formed in a forward mating end of the housing. An inner dielectric insert is positionable in the housing. A plurality of elongated terminals are fixed to the insert. Each terminal includes a contact portion at one end extending diagonally into the plug-receiving opening and a tail portion at the opposite end extending from the housing. Generally, means are provided for securing the tail portions to the housing at predetermined spaced locations.
More particularly, the terminals have intermediate portions between the contact portions and the tail portions. The intermediate portions are fixed to the dielectric insert. After this subassembly is positioned in the jack housing, the tail portions are secured to a comb structure of the housing to maintain the tail portions at precise, predetermined spaced locations.
As disclosed herein, the insert is generally planar and includes a forward end from which the contact portions of the terminal extend and a rearward end from which the tail portions of the terminals extend. A filter element is positioned about the tail portions of the terminals. In final assembly, the filter elements are sandwiched between first shoulder means on the housing and second shoulder means on the insert.
The invention also contemplates a method of fabricating a modular jack, including the steps of providing an outer dielectric housing with a plug-receiving opening in a forward mating end of the housing. The plurality of terminals are fixed to an inner dielectric insert to form a subassembly. The subassembly then is positioned in the housing with the contact portions of the terminals extending diagonally into the plug-receiving opening and with the tail portions of the terminals extending from the housing. After positioning the CA 0222~971 1997-12-29 Patent subassembly in the housing, the tail portions of the terminals are secured to the housing at their predetermined spaced locations.
The method may include the step of mounting a filter element about the tail portions of the terminals prior to positioning the subassembly into the housing.
During assembly, the filter elements are sandwiched between opposing shoulder means on the insert and the housing.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying draw-ings.
DEC - 26- 1997 07: 42 MOLEX CA rO 222 ~ 971 1997 - 12 - 29 . 630 416 4962 P .02/04 Patent 9?-001 Br;ef Des~riPtion of ~he ~raw;ng~
The fe~ures of this invention ~hich are believed ~o ~e novel are set forth with par~icul~rity in the append-ed claims. The invention, together wi~h its objects and the advantages ~hereof, may ~e ~e~ under~tood by ~eference to ~he following description ~aken in conjunction with the accompanying dxawings, in which lik~ xeference numer~
identify like elements in the figuxes an~ in which:
FIGURE 1 i~ a perCpe~tive ~iew of a modular phone jack inçorporatin~ the ~oncepts o$ the invention;
~IGUR~ 2 is a vertical, front-to rear ~ection through the phone jack;
. FIGURE 3 i~ a ~ront elevational ~iew o~ the ja~X:
FIGURE 4 is a bottom plan view of the jack;
F~GUR~ 5 i~ a vert$cal, fro~t-to-rear section through the jack housin~:
~IGURE 6 is a bottom plan view of the housing:
FIGURE 7 is a horizontal se~ion taken generally along line 7-7 of Flgure 6; ~nd FIGURE 8 ~ a top plan view of the dielectric insert with the terminal~ staked thereto, and prior to f orming the t~- in;~l g, D 1 '~ A ~ ~/A ~d ~ D ~ r ,r~ B~
t ~ A IJ~r~
r~6,,~ cr~ .
DEC - 26 - 1997 07:43 ~OLEX CArO222~971 1997-12-29. l 630 416 4962 P.03/04 Patent g7-001 ~A
~etail ed Descr~tion of the Pr~ferred ~mbodim.en~
Referring to the dr~wings in greater detail, and fir~ to Pigure~ 1-4, the invention is incorporated in a modular phone jack, generally designated 10. Generally, the iack $s a two-piece ~sse~bly incl~ding ~n outer diçle~tric housing, gener~lly designated 12, and an Lnner dielectric insert, generally designated 14. A plurality of elongated tPr~inals, generally designated 16, are mounted in the housing~ A filter in ~he form o~ a ferrite block 18 (Fig. 2~ is positioned over portions of the te~
~ ore particularly, referring to Figures ~-7 in conjunoti~n with ~igures ~4, outer diele~tric housing 12 o~ modular phone jack 10 is of ~ conven~ box-like configur~tion including a top wall ~0, a ~o~o~ wall 22 and a pair of side walls 24, all ~ombining to define ~ plug-~eceiving socket or opening, generally designated 26. The so~ket is open at a forwa~d ~ating end 28 of the housing The rea~ of the soc~et i5 ¢losed by an int~rnal partition 3~ ~paced inw~rdly or forwardly of a rear end 32 of t~e housing. The top of partition 30 includes a co~ e ~tructure 30a. The rear of bottom wall 22 also includes ~
comb-like ~tructure 22a. A pair of mounting pos~s 36 are inte~rally molded wi~h and proje~ downw~rdly from the housing. The posts are ~o~nted into locating holes in the prin~ed circuit board to precisely locate the h~in~ on the bo~rd, particularly relati~e to the terminal tai~ holes in the ~oard.
f __ As be~t ~een in Fig~res 2~, e~ch te ~ nal 16 in~ludes an intermediate portion l~a b~n a oontact portion 16b and a tail p~rtion l~c. ~he con~act portion of ea~h te~minal extends at one end o~ the intermedia~e portion diagon~lly into plug-reae~ving cpen~ng 2~. The tail por~ions 16c of the terminal~ are ~ent general}y perpendicular to intermediate por~ions 1~ at the opposite 3~ ends thereof downwardly and out of housing 12 for in~ert~on into holes in the printed circuit board. It can be seen in DEC-26-1997 07:43 ~OLEX CAr-0~222~971 1997-12-29 1 - 630 416 4962 P.04/~4 Pa~ent ~7-001 CA
Figure 2 that tail portions 16c of the tçxminals are fo~me~
so that alternating ones of the termina'~ 5 are in two differen~ rows ac is typical in the art. Lastly, Figure ~
shows ferrite filter blo~k 18 sandwiched between a fir~t ~houlder 38 def~ned by comb structure 22a of the housing ~nd ~ c~cond shoul~er 4~ def~ned ~y in~ert 14.
FigureS8~show~ dielectric insert 14 and ter~in~lc' 1~ in the process of ~eing joined to form a c~h~ssembly for inser~ion into ja~k hou~ing 12. More particularly, the dielectrio insert is formed as a generally planar, molded pl~stic component having a plurali~y o~ ups~ndin~
staggered locating pro;e~ion~ 42. Termina~s 16 are ~oun~ed on top of inser~ 14 and include o~al-chAre~ pilot holes 4~ which are ~taggered with respect to one anot~er ~n the alternating terminal~. Locat~ng p~oje~tions 42 are adapted to be received within pilot holes 44 ~o pre~i~ely posi~ion terminals 16 on the top of insert 14. A~ter pocitionin~ ~he terminals, lo~ating projections 4~ a~e cold s~-aked to rigidly ~ix the ~erminalC to the inser~.
~0After terminals 16 are fixed to dielectric insert 14 as shown in Fi ~ r~ll8, the terminals then are formed as _~
sho~n best in Figur~ ~. In other words, contact portions 1~ o~ the terminals are bent downwardly a~out a front ed~e ; 14a of the in~ert until the contact po~tions extend diagonally rearwardly beneath ~he insert. Tail portions 16c are bent do~nwardly generally at right ~ngle~ to intermedia~e portion~ 16a behind a rear edge 14b of the insert. Before the subas~embly of insert 14 and formed terminal~ 16 is positioned within ho~sing 12, fer.rite ~ilte~ ~lock 1~ is positioned onto tail portions 16c of the te~minals as ~een in Figure 2. The inside o~ side walls 24 of the housing are provided ~ith y.OOV~S 46 (see Figs. ~
and 5) ~or re~eiving the side edges o~ incert 14 when the subassembly ~f the insert and the termi~als are mount~d in the housing th~ough the rear end 32 of the housing~
TOTRL P . 04 CA 0222~971 1997-12-29 Patent The method of fabricating modular phone jack 10 can fairly be derived from the above description of the structural combination thereof. Nevertheless, the method can be summarized as follows:
providing outer dielectric housing 12 with plug-receiving opening 16 in forward mating end 28 of the housing;
fixing terminals 16 to dielectric insert 14 to form the subassembly of Figure 8;
forming the terminals with contact portions 16b and tail portions 16c as shown in Figure 2;
positioning this subassembly in housing 12 with contact portions 16b extending diagonally into plug-receiving opening 26 and with tail portions 16c extending from the housing; and securing tail portions 16c of terminals 16 to comb structure 22a at the rear of bottom wall 22 of the housing.
If filter element 18 is employed, the method includes the step of mounting the filter element about tail portions 16c of the terminals prior to positioning the subassembly of the insert and the terminals into the housing. During assembly, filter element 18 becomes sandwiched between opposing shoulders 38 and 40 of the housing and the dielectric insert, respectively.
As the subassembly of dielectric insert 14 and terminals 16 is positioned into housing 12, the tail portions enter comb structure 22a at the rear of bottom wall 22 to precisely position the tail portions at predetermined spaced locations corresponding to their respective holes in the printed circuit board. In order to assure precise positioning of the tail portions, the tail portions can be cold staked to the bottoms or bases of the slots in the comb structure. Contact portions 16b are separated by comb structure 3Oa.
CA 0222~971 1997-12-29 Patent The structural combination of the invention takes the advantages afforded by a one-piece jack structure as well as a two-piece assembly without creating any substantial disadvantages. In particular, it is known that a one-piece jack housing can best locate the tail portions of the terminals relative to their respective holes in the printed circuit board. This can be understood because mounting posts 36 precisely locate the housing on the board and the housing, in turn, precisely locates the tail portions of the terminals. However, a one-piece housing structure has considerable disadvantages in assembling conductors 16 and/or filter elements inside the one-piece structure.
on the other hand, a two-piece assembly including a dielectric insert, such as insert 14, considerably simplifies the assembly processes of a modular phone jack.
Unfortunately, the two-piece assembly suffers from the disadvantages of the tail portions of the terminals becoming misaligned during manufacture and handling.
The present invention takes advantage of the positive attributes of both types of designs. The invention uses the two-piece structure to provide a subassembly which is very easy to assemble within the jack housing, including the terminals and the filter block, if desired. The structure of the invention then relies on the housing (i.e. comb structure 22a) to precisely align and space the terminal tail portions for insertion into their respective holes in the printed circuit board.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
Claims (6)
1. A modular phone jack (10), comprising:
an outer dielectric housing (12) having a plug-receiving opening (26) formed in a forward mating end (28) of the housing;
an inner dielectric insert (14) positionable in the housing;
a plurality of elongated terminals (16) fixed to the dielectric insert (14), each terminal including a contact portion (16b) at one end extending diagonally into the plug-receiving opening (26) and a tail portion (16c) at the opposite end extending from the housing (12); and means (22a) for securing the tail portions (16c) to the housing (12) at predetermined spaced locations.
an outer dielectric housing (12) having a plug-receiving opening (26) formed in a forward mating end (28) of the housing;
an inner dielectric insert (14) positionable in the housing;
a plurality of elongated terminals (16) fixed to the dielectric insert (14), each terminal including a contact portion (16b) at one end extending diagonally into the plug-receiving opening (26) and a tail portion (16c) at the opposite end extending from the housing (12); and means (22a) for securing the tail portions (16c) to the housing (12) at predetermined spaced locations.
2. The modular phone jack of claim 1 wherein said terminals (16) have intermediate portions (16a) between said contact portions (16b) and said tail portions (16c), the intermediate portions being fixed to the dielectric insert (14).
3. The modular phone jack of claim 1 wherein said dielectric insert (14) is generally planar and includes a forward end (14a) from which the contact portions (16b) of the terminals (16) extend and a rearward end (14b) from which the tail portions (16c) of the terminals extend.
4. The modular phone jack of claim 1, including a filter element (18) about the tail portions (16c) of the terminals.
5. The modular phone jack of claim 4 wherein said filter element (18) is sandwiched between first shoulder (38) means on the housing (12) and second shoulder means (40) on the dielectric insert (14).
6. The modular phone jack of claim 1 wherein said housing (12) includes a comb structure (22a) forming said means for securing the tail portions (16c) of the terminals to the housing.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US77447596A | 1996-12-30 | 1996-12-30 | |
| US08/774,475 | 1996-12-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2225971A1 true CA2225971A1 (en) | 1998-06-30 |
Family
ID=25101351
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002225971A Abandoned CA2225971A1 (en) | 1996-12-30 | 1997-12-29 | Low profile modular phone jack and method of making same |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0851538A3 (en) |
| JP (1) | JP3082078B2 (en) |
| CA (1) | CA2225971A1 (en) |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4698025A (en) * | 1986-09-15 | 1987-10-06 | Molex Incorporated | Low profile modular phone jack assembly |
| US4772224A (en) * | 1987-09-02 | 1988-09-20 | Corcom, Inc. | Modular electrical connector |
| US5178563A (en) * | 1992-05-12 | 1993-01-12 | Amp Incorporated | Contact assembly and method for making same |
| US5310360A (en) * | 1993-05-18 | 1994-05-10 | Molex Incorporated | Circuit board mounted modular phone jack |
| WO1996007219A1 (en) * | 1994-08-31 | 1996-03-07 | Berg Technology, Inc. | Filtered modular jack assembly and method of use |
-
1997
- 1997-12-29 CA CA002225971A patent/CA2225971A1/en not_active Abandoned
- 1997-12-29 EP EP97122933A patent/EP0851538A3/en not_active Withdrawn
- 1997-12-29 JP JP09370375A patent/JP3082078B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP3082078B2 (en) | 2000-08-28 |
| JPH10233253A (en) | 1998-09-02 |
| EP0851538A3 (en) | 1999-01-20 |
| EP0851538A2 (en) | 1998-07-01 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |