US20170256895A1 - Communication connector - Google Patents
Communication connector Download PDFInfo
- Publication number
- US20170256895A1 US20170256895A1 US15/058,349 US201615058349A US2017256895A1 US 20170256895 A1 US20170256895 A1 US 20170256895A1 US 201615058349 A US201615058349 A US 201615058349A US 2017256895 A1 US2017256895 A1 US 2017256895A1
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- US
- United States
- Prior art keywords
- contacts
- communication
- plug
- jack
- connector
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- 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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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/66—Structural association with built-in electrical component
- H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
- H01R13/6658—Structural association with built-in electrical component with built-in electronic circuit on printed circuit board
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2107/00—Four or more poles
-
- 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
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09209—Shape and layout details of conductors
- H05K2201/09654—Shape and layout details of conductors covering at least two types of conductors provided for in H05K2201/09218 - H05K2201/095
- H05K2201/09709—Staggered pads, lands or terminals; Parallel conductors in different planes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S439/00—Electrical connectors
- Y10S439/9241—Contacts arranged for sequential connection
Definitions
- the present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment.
- PoE Power over Ethernet
- PoE allows a single cable to provide both electrical power and data connections, which may eliminate the need for additional power cables and devices such as transformers and AC outlets.
- Some non-limiting examples of PoE devices include Voice over Internet Protocol (VoIP) phones, wireless access points, network routers, switches, industrial devices (controllers, meters, sensors, etc.), nurse call stations, IP security cameras, televisions, LED lighting fixtures, remote point of sale kiosks, and physical security devices.
- VoIP Voice over Internet Protocol
- POE+ was launched into the market in 2009, standardized under IEEE 802.3at, and allowed for a power draw of 25.5 W and 600 mA per pair (Type 2).
- This electrical discharge can be an electrical arc (spark) or a corona discharge.
- spark is a fast single event that is time independent and may cause a large distinct crater on the plug contacts of the plug, the plug interface contacts (PICs) of the jack, or both.
- PICs plug interface contacts
- a corona discharge is a relatively slower event that is time dependent, has multiple events, and causes many shallow craters or pits that erode the plug contacts, PICs, or both.
- IEC 60603-7 requires a minimum of 750 plug insertions into a jack module. Many vendors test to a higher amount of insertion cycles as for some applications 750 plug insertions is relatively low. The effects of this damage can be seen in the form of physical damage, electrical interface degradation, and, over time, corrosion of the contacts.
- At least some embodiments of the present invention are directed towards devices, systems, and methods which are related to connectors designed to withstand current and future PoE demands.
- the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of the plug/jack mating point, while still allowing for a relatively short distance to compensation from the plug/jack mating interface.
- the present invention is an RJ45 plug assembly with an inter-plug connection method that has an electrical disengagement point outside of preferred mating points.
- the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a printed circuit board (PCB), the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion; and a plurality of third contacts, each of the third contacts having a mating section configured to interface with one of the mating portions and a disconnect section configured to interface with one of the disconnect portions.
- PCB printed circuit board
- the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a PCB, the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion, and a plurality of third contacts, each of the third contacts having a preferred mating leg configured to interface with one of the mating portions and a sacrificial leg configured to interface with one of the disconnect portions.
- the present invention is a communication connector connectable to at least one of a communication cable and communication equipment, the communication connector capable of transmitting power over Ethernet.
- the communication connector includes means for interfacing the communication connector with a corresponding connector, means for establishing an electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for establishing the electrical path being located within the communication connector and occurring over a first physical path, and means for breaking the electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for breaking the electrical path being located within the communication connector and occurring over a second physical path.
- the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts.
- the communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken while each of the plug contacts maintains contact with one of the PICs.
- the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts.
- the communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken at a point other than between each of the plug contacts and respective one of the PICs.
- the present invention is a communication system that includes, a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts.
- the communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, each the current path traversing one of the plug contacts and respective one of the PICs.
- the communication plug is further configured to disconnect from the communication jack such that at least one the current path is broken while respective one of the plug contacts maintains contact with respective one of the PICs.
- the present invention is a communication system including a communication plug and a communication jack.
- the communication system includes means for connecting the communication plug to a plug-cable having at least one conductor.
- the communication system also includes means for connecting the communication jack to a jack-cable having at least one conductor.
- the communication system also includes means for electrically and physically interfacing the communication plug with the communication jack.
- the communication system also includes means for transmitting a current between the at least one conductor of the plug-cable and the at least one conductor of the jack-cable.
- the communication system also includes means for breaking the current at a point that does not include the means for electrically and physically interfacing the communication plug with the communication jack.
- FIG. 1 is a communication system according an embodiment of the present invention.
- FIG. 2 is an isometric view of an RJ45 network jack mated with an RJ45 network plug according to an embodiment of the present invention.
- FIGS. 3-5 are isometric views of the RJ45 jack and the RJ45 plug of FIG. 2 in an unmated state.
- FIGS. 6-8 are isometric exploded views of an RJ45 jack according to an embodiment of the present invention.
- FIGS. 9-11 are isometric views of a sled assembly according to an embodiment of the present invention.
- FIGS. 12-14 are isometric exploded views of the sled assembly of FIGS. 9-11 .
- FIG. 15 is a rear isometric view of the RJ45 jack with back end assembly exploded.
- FIGS. 16 and 17 are isometric views of partial jack assembly and jack shield in the open state.
- FIGS. 18 and 19 are exploded views of a wire cap assembly.
- FIGS. 20 and 21 are views of first and second sides, respectively of a first rigid PCB according to an embodiment of the present invention.
- FIG. 22 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state.
- FIG. 23 is a front isometric view of RJ45 jack and RJ45 plug assembly in an over-travel state.
- FIG. 24 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state.
- FIG. 25 is a front isometric view of RJ45 jack and RJ45 plug assembly in a pre-release state.
- FIG. 26 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state.
- FIG. 27 is a front isometric view of RJ45 jack and RJ45 plug assembly in a release state.
- FIG. 28 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state.
- FIG. 29 is a front isometric view of RJ45 jack and RJ45 plug assembly in an unmated state.
- FIG. 30 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state.
- FIGS. 31 and 32 are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention.
- FIGS. 33 and 34 are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention.
- FIGS. 35 and 36 are isometric views of a sled assembly according to an embodiment of the present invention.
- FIGS. 37-39 are isometric exploded views of the sled assembly of FIGS. 35 and 36 .
- FIGS. 40 and 41 are trimetric views of dual contacts of the sled assembly of FIGS. 35 and 36 .
- FIGS. 42 and 43 are views of first and second sides, respectively, of a first rigid PCB of the sled assembly of FIGS. 35 and 36 .
- FIG. 44 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state.
- FIG. 45 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state.
- FIG. 46 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state.
- FIG. 47 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state.
- FIG. 48 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state.
- FIG. 49 is schematic for the plug/jack combination according to an embodiment of the present invention.
- FIG. 50 is an isometric view of an RJ45 plug according to an embodiment of the present invention.
- FIGS. 51-53 are isometric exploded views of an RJ45 plug according to an embodiment of the present invention.
- FIG. 54 is a first side of a first rigid PCB according to an embodiment of the present invention.
- FIG. 55 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state.
- FIG. 56 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state.
- FIG. 57 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state.
- FIG. 58 is schematic for the plug/jack combination according to an embodiment of the present invention.
- FIG. 1 shows a communication system 110 , which includes a patch panel 112 with RJ45 jacks 114 and corresponding RJ45 plugs 116 . Respective cables 120 are terminated to plugs 116 , and respective cables 118 are terminated to jacks 114 . Once a plug 116 mates with a jack 114 data can flow in both directions through these connectors.
- the communication system 110 is illustrated in FIG. 1 as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc.
- Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers and or telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers, and other peripherals as can be found in workstation areas.
- Communication system 110 can further include cabinets, racks, cable management and overhead routing systems, and other such equipment.
- FIG. 2 illustrates the RJ45 jack 114 and the RJ45 plug 116 in a mated configuration
- FIGS. 3-5 illustrate the RJ45 jack 114 and the RJ45 plug 116 in an unmated configuration with FIG. 4 being rotated 180° about the central axis of cable 118 relative to FIG. 3
- FIG. 5 illustrating a rear isometric view relative to FIGS. 3 and 4 .
- the RJ45 jack 114 includes identification icon 122 , jack shield 124 , conductive housing 126 , sled assembly 128 , insulation displacement contacts (IDCs) 154 , rear sled 156 , wire cap assembly 158 (which includes wire containment cap 160 , conductive rear cap 162 , and conductive strain relief clip 88 ).
- Jack 114 is used to terminate cable 118 which includes conductors 164 and conductive braid 166 .
- the sled assembly 128 is illustrated in greater detail in FIGS. 9-11 . As shown therein, it includes a first sled support 130 , first plug interface contacts (PICs) 132 , second PICs 134 , flexible PCB 136 , second sled support 138 , first rigid PCB 140 , springs 142 , first wiping contacts 144 , second wiping contacts 146 , first contact support 148 , second contact support 150 , and second rigid PCB 152 .
- PICs plug interface contacts
- first rigid PCB 140 is trapped between first rigid PCB 140 and first sled support 130 .
- Press posts 168 of first sled support 130 align with holes 170 and 172 of respective flexible PCB 136 and first rigid PCB 140
- flexible PCB 136 is wrapped around mandrel 173 of first sled support 130 .
- First PICs 132 and second PICs 134 are installed into vias 174 of first rigid PCB 140
- comb features 176 of second sled support 138 align with both first PICs 132 and second PICs 134 .
- Snaps 178 of second sled support 138 align with and join snap pockets 180 of first sled support 130 to secure the two pieces together.
- flexible PCB 136 , first PICs 132 , and second PICs 134 become trapped and are thereby secured.
- Front spring posts 182 of first sled support 130 and back spring posts 184 of second contact support 150 capture springs 142 during final assembly.
- First wiping contacts 144 align with respective contact slots 186 of first contact support 148 and have a controlled bend 188 around mandrel 190 .
- Second wiping contacts 146 align with respective contact slots 192 of second contact support 150 and have a controlled bend 194 around mandrel 196 .
- Relief slots 198 and 200 on respective first contact support 148 and second contact support 150 provide clearance for IDCs 154 during final assembly.
- IDCs 154 are placed in IDC slots 216 of rear sled 156 and are then secures to second rigid PCB 152 making the back end assembly 228 as shown in FIG. 15 .
- Back end assembly 228 is then assembled into conductive housing 126 forming partial jack assembly 229 show in FIG. 16 .
- rails 230 of conductive housing 126 align back end assembly 228 and match up with the edges of first rigid PCB 140 .
- Latch arms 232 and 234 of rear sled 156 align with and secure to latch pockets 236 and 238 of conductive housing 126 .
- Jack shield 124 wraps around partial jack assembly 229 and shield latches 240 align and join with shield snaps 242 to partially enclose the assembly. Thereafter, wire cap grounding flanges 244 of jack shield 124 are wrapped around grounding flange slots 246 of rear sled 156 . When assembled to a cable, wire cap grounding flanges 244 make contact with conductive rear cap 162 to provide an appropriate grounding connection. Plug grounding flange slots 248 , 250 , and 252 of conductive housing 126 align with respective plug grounding flanges 254 , 256 , and 258 of jack shield 124 .
- wire containment cap 160 is strung through rear conductive cap 162 and the wire containment cap 160 with conductor slots 210 enabling alignment of conductors 164 during assembly.
- Wire containment cap 160 is secured to conductive rear cap 162 through latches 202 and 204 which align with latch pockets 206 and 208 , respectively.
- flexible arms 212 of conductive strain relief clip 88 engage with teeth 214 of conductive rear cap 162 . To disengage, the flexible arms 212 are compressed inward towards each other.
- conductors 164 are positioned in preparation for joining with the partially assembled jack.
- wire cap assembly 158 is secured to rear sled 156 through the engagement of the flexible latch 218 of rear sled 156 with a corresponding latching feature 220 .
- the mating of the wire cap assembly 158 and the rear sled 156 causes the IDCs 154 to make contact with the conductors 164 of the cable 118 and thereby establish a communication link through the jack.
- jack 114 utilizes first and second wiping contacts 144 , 146 in conjunction with specifically designed contacts on the rigid PCB 140 .
- FIG. 20 is a first side of first rigid PCB 140 and
- FIG. 21 is a second side of first rigid PCB 140 .
- First rigid PCB 140 includes first contact pads 288 and second contact pads 290 .
- Each contact pad contains a mating portion and a disconnect portion.
- the mating portion is the section of the contact pad with which a respective wiping contact is engaged during the mated and over-travel states.
- the disconnect portion is the section of the contact pad with which a respective wiping contact is engaged between the pre-release and release states.
- contact pads 288 have a mating portion 292 and a disconnect portion 294
- contact pads 290 have a mating portion 296 and a disconnect portion 298 .
- the mating portion and the disconnect portion is positioned such that each portion comes into direct contact with an alternate side of a respective wiping contact. This configuration allows for potential arcing or corona damage to occur on one side of the wiping contact, leaving the other side unharmed.
- FIGS. 22-30 illustrate the interaction between the contact pads and the wiping contacts throughout various stages of the plug/jack mating process. It is worth noting that in the section views of FIGS. 22, 24, 26, 28, and 30 , sled assembly 128 and plug PCB assembly 274 are not sectioned to show the plug/jack mating interaction between wire contacts 276 , 278 and PICs 132 , 134 , and the interaction between the wiping contacts 144 and contact pads 288 . In addition, press posts 168 have been leveled off along the surface of respective first rigid PCB 140 in all section views for clarity.
- FIG. 22 is a cross-section view, taken along section line 22 - 22 of FIG. 2 , across the mating interface of shielded RJ45 network jack 114 and shielded RJ45 plug assembly 116 .
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134
- first wiping contacts 144 are in contact with mating portion 292 of first contact pads 288 .
- Second wiping contacts 146 are in contact with mating portion 296 of second contact pads 290 (not shown).
- wiping contacts 144 interface with the mating portion along the wiping contacts' first side. This is the static state of a mated RJ45 plug 116 /jack 114 combination.
- FIG. 23 is a front isometric view of RJ45 network jack 114 and RJ45 plug assembly 116 and respective cables 118 and 120 in the over-travel state.
- the over-travel state allows for insertion of RJ45 plug assembly 116 into shielded RJ45 network jack 114 .
- RJ45 plug assembly 116 is inserted roughly . 032 inches further into RJ45 network jack 114 when compared to the mated static state shown in FIG. 2 .
- FIG. 24 is a cross-section view, taken along section line 24 - 24 of FIG. 23 across the mating interface of RJ45 network jack 114 and RJ45 plug assembly 116 in the over-travel state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- First wiping contacts 144 are in contact with mating portion 292 of first contact pads 288 .
- Second wiping contacts 146 are in contact with mating portion 296 of second contact pads 290 (not shown). Similar to the static state, wiping contacts 144 interface with the mating portion along the wiping contacts' first side. In between the mated state and the over-travel state there is no mechanical/electrical disconnection between any plug/jack interfaces.
- FIG. 25 is a front isometric view of RJ45 network jack 114 and RJ45 plug assembly 116 and respective cables 118 and 120 in the pre-release state.
- the pre-release state is a period where the wiping contacts are in contact with the disconnect portion of their respective contact pads but prior to the release state in the retraction cycle (this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly 116 into shielded RJ45 network jack 114 prior to the over-travel and mated states).
- FIG. 26 is a cross-section view, taken along section line 26 - 26 of FIG. 25 across the mating interface of RJ45 network jack 114 and RJ45 plug assembly 116 in the pre-release state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- First wiping contacts 144 are in contact with disconnect portion 294 of first contact pads 288 .
- Second wiping contacts 146 are in contact with disconnect portion 298 of second contact pads 290 (not shown).
- wiping contacts 144 interface with the disconnect portion along the wiping contacts' second (alternate) side as compared to the static and over-travel states.
- FIG. 27 is a front isometric view of RJ45 network jack 114 and RJ45 plug assembly 116 and respective cables 118 and 120 in the release state.
- the release state is the moment before wire contacts 276 and 278 are no longer in electrical contact with respective first PICs 132 and second PICs 134 (this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly 116 into shielded RJ45 network jack 114 just after the wire contacts 276 and 278 come into electrical contact with respective first PICs 132 and second PICs 134 ).
- FIG. 28 is a cross-section view, taken along section line 28 - 28 of FIG. 27 across the mating interface of RJ45 network jack 114 and RJ45 plug assembly 116 in the release state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- First wiping contacts 144 are no longer in contact with disconnect portion 294 of first contact pads 288 .
- Second wiping contacts 146 are no longer in contact with disconnect portion 298 of second contact pads 290 (not shown).
- respective wiping contacts disconnect from contact pads along the disconnect portion of the contact pad. The electrical discharge that occurs upon disconnection of the wiping contacts and the contact pads occurs on the disconnect portion of the contact pad and corresponding side of the wiping contact. This is opposite of the mating side of the contact and controls where the damage to the contact occurs in the case of PoE damage during use.
- Contact point 300 between wire contacts 276 and 278 and respective first PICs 132 and second PICs 134 , remains relatively the same between mated, over-travel, pre-release, and release states with a minimal wiping zone as this helps reduce the electrical distance to compensation that may be implemented on the PCB 140 .
- FIG. 29 is a front isometric view of RJ45 network jack 114 and RJ45 plug assembly 116 and respective cables 118 and 120 in the unmated state.
- FIG. 30 is a cross-section view, taken along section line 30 - 30 of FIG. 29 across the mating interface of shielded RJ45 network jack 114 and shielded RJ45 plug assembly 116 in the unmated state.
- wire contacts 276 and 278 are no longer in electrical contact with respective first PICs 132 and second PICs 134 .
- First wiping contacts 144 are no longer in contact with first contact pads 288 .
- Second wiping contacts 146 are no longer in contact with second contact pads 290 (not shown).
- Sled assembly 128 is in approximately the same position in the unmated state as in the release state.
- first contact pads 288 or second contact pads 290 be raised with respect to the rest of the PCB in the area of contact.
- Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads 288 and 290 , or removing/lowering the adjacent solder mask.
- first rigid PCB 302 An alternative embodiment of the first rigid PCB 302 is shown in FIGS. 31 and 32 with FIG. 31 showing a first side of first rigid PCB 302 and FIG. 32 showing a second side of first rigid PCB 302 .
- First rigid PCB 302 includes first contact pads 304 and second contact pads 306 .
- each contact pad contains a mating portion and a disconnect portion, except there is no perpendicular section linking the two portions on the contact pads of PCB 302 .
- PCB 302 uses an angled section.
- the shape of the contact pads may take any form so long as the mating portion and the disconnect portion are positioned such that the wiping contact maintains a constant electrical bond with the contact pad as it travels between the mating and disconnect portions and such that different sections of the wiping contacts make contact with the mating and disconnect portions.
- FIGS. 33 and 34 Yet another alternative embodiment of the first rigid PCB 308 is shown in FIGS. 33 and 34 with FIG. 33 showing a first side of first rigid PCB 308 and FIG. 34 showing a second side of first rigid PCB 308 .
- First rigid PCB 308 includes first contact pads 310 and second contact pads 312 .
- Cutouts 314 and 316 on first rigid PCB 308 are a secondary mechanical alternative that is less dependent on minor changes in plating or solder mask to ensure reliable electrical contact on the specific side of wiping contacts and contact pads.
- the shape of the cut out sections can be any shape so long as the contact pads provide appropriate functionality as described previously.
- FIGS. 35-39 illustrate an alternative embodiment of a sled assembly 318 that could be used in jack 354 (which is similar in construction to jack 114 ).
- Sled assembly 318 includes first sled support 130 , first PICs 132 , second PICs 134 , flexible PCB 320 , second sled support 138 , first rigid PCB 322 , springs 142 , first dual wiping contacts 324 , second dual wiping contacts 326 , first dual contact support 328 , second dual contact support 330 , and second rigid PCB 332 . While flexible PCB 320 and second rigid PCB 332 may be mechanically the same as respective flexible PCB 136 and second rigid PCB 152 , with the added crosstalk the electrical design of these boards may be different.
- sled assembly 318 The primary difference between sled assembly 318 and the previously described sled assembly 128 is in the design of the wiping contacts and the design of the contact pads on the first rigid PCB 322 .
- FIG. 40 is a trimetric view of second dual contacts 326 and FIG. 41 is a trimetric view of first dual contacts 324 .
- Second dual wiping contacts 326 include two wiping contacts comprised of a preferred mating leg 338 and a sacrificial leg 340 .
- first dual wiping contacts 324 include two wiping contacts comprised of a preferred mating leg 334 and sacrificial leg 336 .
- FIG. 42 illustrates a first side of first rigid PCB 322 and FIG. 43 illustrates a second side of first rigid PCB 322 . It includes first dual contact pads 342 , which include a mating portion 344 and sacrificial portion 346 , and second dual contact pads 348 , which include a mating portion 350 and sacrificial portion 352 .
- FIGS. 44-48 illustrate cross-section views of jack 354 and plug 116 at different mating states.
- FIG. 44 shows the jack 354 and the plug 116 in a fully mated state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- Preferred mating leg 334 of first dual wiping contacts 324 is in contact with mating portions 344 of first dual contact pads 342 .
- Sacrificial mating leg 336 of first dual wiping contacts 324 is in superfluous contact with sacrificial portion 346 of first dual contact pads 342 .
- Preferred mating leg 338 of second dual wiping contacts 326 is in contact with mating portion 350 of second dual contact pads 348 (not shown).
- Sacrificial mating leg 340 of second dual wiping contacts 326 is in superfluous contact with sacrificial leg 352 of second dual contact pads 348 (not shown).
- FIG. 45 is a cross-section view of RJ45 network jack 354 and RJ45 plug assembly 116 , with respective cables 118 and 120 , shown in the over-travel state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- Preferred mating legs 334 of first dual wiping contacts 324 are in contact with mating portions 344 of first dual contact pads 342 .
- Sacrificial mating legs 336 of first dual wiping contacts 324 are in superfluous contact with sacrificial portions 346 of first dual contact pads 342 .
- Preferred mating legs 338 of second dual wiping contacts 326 are in contact with mating portions 350 of second dual contact pads 348 (not shown).
- Sacrificial mating legs 340 of second dual wiping contacts 326 are in superfluous contact with sacrificial portions 352 of second dual contact pads 348 (not shown). In between the mated state and the over-travel state there is no mechanical/electrical disconnection between the plug/jack interfaces.
- FIG. 46 is a cross-section view of RJ45 network jack 354 and RJ45 plug assembly 116 , with respective cables 118 and 120 , shown in the pre-release state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- Preferred mating legs 334 of first dual wiping contacts 324 are no longer in contact with mating portions 344 of first dual contact pads 342 .
- sacrificial mating legs 336 of first dual wiping contacts 324 are still in contact with sacrificial portions 346 of first dual contact pads 342 .
- FIG. 47 is a cross-section view of RJ45 network jack 354 and RJ45 plug assembly 116 , with respective cables 118 and 120 , shown in the release state.
- wire contacts 276 and 278 are in electrical contact with respective first PICs 132 and second PICs 134 .
- Preferred mating legs 334 of first dual wiping contacts 324 are no longer in contact with mating portions 344 of first dual contact pads 342 .
- Sacrificial mating legs 336 of first dual wiping contacts 324 are no longer in contact with sacrificial portions 346 of first dual contact pads 342 .
- Preferred mating legs 338 of second dual wiping contacts 326 are no longer in contact with mating portions 350 of second dual contact pads 348 (not shown).
- Sacrificial mating legs 340 of second dual wiping contacts 326 are no longer in contact with sacrificial portions 352 of second dual contact pads 348 (not shown).
- respective sacrificial mating legs disconnect from sacrificial portions of contact pads (during the insertion of the plug into the jack the respective sacrificial mating legs connect to sacrificial portions of contact pads).
- the electrical discharge upon disconnection/connection of the sacrificial mating legs and the sacrificial portions of the contact pads occurs outside of the preferred mating zone and in the sacrificial areas. This helps maintain the integrity of the preferred mating legs of the dual wiping contacts and the mating portion of the dual contact pads.
- FIG. 48 is a cross-section view of RJ45 network jack 354 and RJ45 plug assembly 116 , with respective cables 118 and 120 , shown in the unmated state.
- wire contacts 276 and 278 are no longer in electrical contact with respective first PICs 132 and second PICs 134 .
- Preferred mating legs 334 of first dual wiping contacts 324 are no longer in contact with mating portions 344 of first dual contact pads 342 .
- Sacrificial mating legs 336 of first dual wiping contacts 324 are no longer in contact with sacrificial portions 346 of first dual contact pads 342 .
- Preferred mating legs 338 of second dual wiping contacts 326 are no longer in contact with mating portions 350 of second dual contact pads 348 (not shown).
- Sacrificial mating legs 340 of second dual wiping contacts 326 are no longer in contact with sacrificial portions 352 of second dual contact pads 348 .
- Sled assembly 318 is in approximately the same position in the unmated state
- First wiping contacts 144 , second wiping contacts 146 , first dual wiping contacts 324 , and second dual wiping contacts 326 are shown with compliant pins but may be attached to respective second rigid PCBs through any non-limiting means.
- First PICs 132 and second PICs 134 are shown with solder connections but may be attached to respective first rigid PCBs through any non-limiting means.
- Cable 118 and 120 are shown as shielded cable but may be any other non-limiting form of cable including but not limited to F/UTP or UTP cabling.
- FIG. 49 An exemplary schematic for the plug 116 /jack 114 , 354 combination is shown in FIG. 49 .
- FIG. 50 illustrates an isometric view of one such plug 116 by way of an exemplary embodiment.
- Plug 116 includes front housing 122 , left housing 140 , right housing 142 , and bend radius control boot 144 .
- FIGS. 51-53 provide exploded views of the plug 116 .
- plug 116 also includes a first PCB assembly 124 with first plug contacts 126 , second plug contacts 128 , first rigid PCB 130 , and springs 132 , and a second PCB assembly 134 with wiping contacts 136 and second rigid PCB 138 .
- Back PCB pads 146 on second rigid PCB 138 are used to terminate cable 120 ; through other non-limiting means of termination may be used.
- first rigid PCB assembly 124 translates between different positions.
- the first rigid PCB 130 and second rigid PCB 138 are electrically linked to each other via wiping contacts 136 and contact pads 148 .
- FIG. 54 illustrates a first side of first rigid PCB 130 .
- Each contact pad 148 contains a mating portion 150 and a disconnect portion 152 .
- the mating portion is the portion of a contact pad that is engaged with a respective wiping contact during the mated and over-travel state (the over-travel state allows for insertion of RJ45 plug assembly 116 into RJ45 network jack 54 .
- the disconnect portion is the portion of a contact pad that is engaged with a respective wiping contact during the pre-release state. As will be made clear during the discussion of the following drawings, that each mating portion and respective disconnect portion are displaced laterally from each other.
- FIG. 55 is a cross-section view across the mating interface of shielded RJ45 network jack 54 and RJ45 plug assembly 116 (wiping contacts 136 and first rigid PCB 130 are not sectioned to show the interface between wiping contacts 136 and first rigid PCB 130 ).
- plug contacts 126 and 128 are in electrical contact with respective PICs 70 .
- Wiping contacts 136 are in contact with mating portion 150 of contact pads 148 .
- This is the static (mated) state of an RJ45 network plug 116 mated with an RJ45 network jack 54 .
- FIG. 56 is a cross-section view across the mating interface of shielded RJ45 network jack 54 and RJ45 plug assembly 116 shown in the pre-release state.
- plug contacts 126 and 128 are in electrical contact with respective PICs 70 .
- Wiping contacts 136 are in contact with disconnect portion 152 of contact pads 148 .
- In the pre-release state there is still an electrical connection throughout the channel, but it is not a static state of installed RJ45 network jack 54 and RJ45 plug assembly 116 . This state occurs either during insertion of RJ45 plug assembly 116 into RJ45 network jack 54 prior to the mated state, or upon retraction of RJ45 plug assembly 116 from RJ45 network jack 54 prior to the release state.
- FIG. 57 is a cross-section view across the mating interface of shielded RJ45 network jack 54 and RJ45 plug assembly 116 in the release state.
- this state while plug contacts 126 and 128 are in electrical contact with respective PICs 70 , wiping contacts 136 are no longer in contact with contact pads 148 .
- the release state there is no longer an electrical connection throughout the channel. This state occurs either during insertion of RJ45 plug assembly 116 into RJ45 network jack 54 prior to the pre-release state or upon retraction of RJ45 plug assembly 116 from RJ45 network jack 54 after the pre-release state.
- respective wiping contacts 136 disconnect from contact pads 148 along the disconnect portions 152 .
- the electrical discharge upon disconnection of wiping contacts 136 and contact pads 148 occurs on disconnect portion 152 and corresponding side of wiping contact 136 . This is opposite of the side of the wiping contact 136 that contacts the mating portion, controlling where the damage to the contact occurs in the case of PoE.
- the plug/jack interface In between the mated state and the release state there is approximately 0.040′′ of travel for first rigid PCB assembly.
- the plug/jack interface In the mated/over-travel state the plug/jack interface is approximately in the IEC-60603-7:2010 preferred electrical mating point location. In all other states the plug/jack interface is typically not in the IEC-60603-7:2010 preferred electrical mating point location, and the force between PICs 70 and plug contacts 126 and 128 overcomes the force from springs 132 .
- the unmated state follows in which plug contacts 126 and 128 are no longer in electrical contact with respective PICs 70 .
- contact pads 148 be raised with respect to the rest of the PCB in the area of contact.
- Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads 148 or removing/lowering the adjacent solder mask.
- FIG. 58 illustrates an exemplary schematic for the plug 116 /jack 54 combination.
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Abstract
The present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment. In an embodiment, the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of any electrical mating points, while still allowing for a relatively short distance to compensation from the plug/jack mating interface.
Description
- The present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment.
- It is common practice to use modular (e.g., RJ45) plugs and jacks in combination with twisted pair cabling to interconnect electronic equipment. While the primary purpose of this type of connectivity is to enable the flow of data, it is also possible to use the same medium to transmit limited amounts of power. This is generally referred to as Power over Ethernet (PoE).
- PoE allows a single cable to provide both electrical power and data connections, which may eliminate the need for additional power cables and devices such as transformers and AC outlets. Some non-limiting examples of PoE devices include Voice over Internet Protocol (VoIP) phones, wireless access points, network routers, switches, industrial devices (controllers, meters, sensors, etc.), nurse call stations, IP security cameras, televisions, LED lighting fixtures, remote point of sale kiosks, and physical security devices. PoE was launched into the market in 2003, standardized under IEEE 802.3af, and allowed for a power draw of 12.95 W and 350 mA per pair (Type 1). POE+ was launched into the market in 2009, standardized under IEEE 802.3at, and allowed for a power draw of 25.5 W and 600 mA per pair (Type 2). As the need for more and more power becomes apparent, non-standard applications, such as Cisco's Universal Power over Ethernet (UPoE) at 60 W and Power over HDBaseT (100 W), with 1000 mA per pair of current capacity, have arisen. As of 2015 there is a proposal for an IEEE 802.3bt (PoE++) standard with 49 W (Type 3) to 100 W (Type 4) of power draw and 600 mA (Type 3) to 1000 mA (Type 4) per pair of power, and other potential future applications may require a current capacity of 1500 mA per pair or more.
- While the earlier-designed connectors could withstand the rigors of the relatively low power required for earlier PoE applications, these connectors lack the design for durability needed to sustain the ever-increasing power demands. One particular issue is the need to reduce damage that occurs to the plug and/or jack during the mating and disconnection.
- In a PoE application, upon disconnection (and/or insertion) of the plug and jack connector combination there is an electrical discharge that can damage the plug and jack mating interfaces. This electrical discharge can be an electrical arc (spark) or a corona discharge. A spark is a fast single event that is time independent and may cause a large distinct crater on the plug contacts of the plug, the plug interface contacts (PICs) of the jack, or both. A corona discharge is a relatively slower event that is time dependent, has multiple events, and causes many shallow craters or pits that erode the plug contacts, PICs, or both. These effects are worsened after multiple insertions as erosion caused by mechanical abrasion also damages the plug/jack mating interfaces of both the plug contacts and the PICs. IEC 60603-7 requires a minimum of 750 plug insertions into a jack module. Many vendors test to a higher amount of insertion cycles as for some applications 750 plug insertions is relatively low. The effects of this damage can be seen in the form of physical damage, electrical interface degradation, and, over time, corrosion of the contacts.
- Additional constraints on the design are imposed by the need of the connectors to handle a certain amount of bandwidth while at the same time meeting particular parameters such as, for example, near end crosstalk (NEXT), far end crosstalk (FEXT), return loss, and insertion loss requirements. As such, these and other design concerns give rise to the need for robust connectors designed to withstand current and future demands of PoE.
- Accordingly, at least some embodiments of the present invention are directed towards devices, systems, and methods which are related to connectors designed to withstand current and future PoE demands.
- In an embodiment, the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of the plug/jack mating point, while still allowing for a relatively short distance to compensation from the plug/jack mating interface.
- In another embodiment, the present invention is an RJ45 plug assembly with an inter-plug connection method that has an electrical disengagement point outside of preferred mating points.
- In yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a printed circuit board (PCB), the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion; and a plurality of third contacts, each of the third contacts having a mating section configured to interface with one of the mating portions and a disconnect section configured to interface with one of the disconnect portions.
- In still yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a PCB, the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion, and a plurality of third contacts, each of the third contacts having a preferred mating leg configured to interface with one of the mating portions and a sacrificial leg configured to interface with one of the disconnect portions.
- In still yet another embodiment, the present invention is a communication connector connectable to at least one of a communication cable and communication equipment, the communication connector capable of transmitting power over Ethernet. The communication connector includes means for interfacing the communication connector with a corresponding connector, means for establishing an electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for establishing the electrical path being located within the communication connector and occurring over a first physical path, and means for breaking the electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for breaking the electrical path being located within the communication connector and occurring over a second physical path.
- In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken while each of the plug contacts maintains contact with one of the PICs.
- In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken at a point other than between each of the plug contacts and respective one of the PICs.
- In still yet another embodiment, the present invention is a communication system that includes, a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, each the current path traversing one of the plug contacts and respective one of the PICs. The communication plug is further configured to disconnect from the communication jack such that at least one the current path is broken while respective one of the plug contacts maintains contact with respective one of the PICs.
- In still yet another embodiment, the present invention is a communication system including a communication plug and a communication jack. The communication system includes means for connecting the communication plug to a plug-cable having at least one conductor. The communication system also includes means for connecting the communication jack to a jack-cable having at least one conductor. The communication system also includes means for electrically and physically interfacing the communication plug with the communication jack. The communication system also includes means for transmitting a current between the at least one conductor of the plug-cable and the at least one conductor of the jack-cable. The communication system also includes means for breaking the current at a point that does not include the means for electrically and physically interfacing the communication plug with the communication jack.
- These and other features, aspects, and advantages of the present invention will become better-understood with reference to the following drawings, description, and any claims that may follow.
-
FIG. 1 is a communication system according an embodiment of the present invention. -
FIG. 2 is an isometric view of an RJ45 network jack mated with an RJ45 network plug according to an embodiment of the present invention. -
FIGS. 3-5 are isometric views of the RJ45 jack and the RJ45 plug ofFIG. 2 in an unmated state. -
FIGS. 6-8 are isometric exploded views of an RJ45 jack according to an embodiment of the present invention. -
FIGS. 9-11 are isometric views of a sled assembly according to an embodiment of the present invention. -
FIGS. 12-14 are isometric exploded views of the sled assembly ofFIGS. 9-11 . -
FIG. 15 is a rear isometric view of the RJ45 jack with back end assembly exploded. -
FIGS. 16 and 17 are isometric views of partial jack assembly and jack shield in the open state. -
FIGS. 18 and 19 are exploded views of a wire cap assembly. -
FIGS. 20 and 21 are views of first and second sides, respectively of a first rigid PCB according to an embodiment of the present invention. -
FIG. 22 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. -
FIG. 23 is a front isometric view of RJ45 jack and RJ45 plug assembly in an over-travel state. -
FIG. 24 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state. -
FIG. 25 is a front isometric view of RJ45 jack and RJ45 plug assembly in a pre-release state. -
FIG. 26 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. -
FIG. 27 is a front isometric view of RJ45 jack and RJ45 plug assembly in a release state. -
FIG. 28 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. -
FIG. 29 is a front isometric view of RJ45 jack and RJ45 plug assembly in an unmated state. -
FIG. 30 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state. -
FIGS. 31 and 32 are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention. -
FIGS. 33 and 34 are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention. -
FIGS. 35 and 36 are isometric views of a sled assembly according to an embodiment of the present invention. -
FIGS. 37-39 are isometric exploded views of the sled assembly ofFIGS. 35 and 36 . -
FIGS. 40 and 41 are trimetric views of dual contacts of the sled assembly ofFIGS. 35 and 36 . -
FIGS. 42 and 43 are views of first and second sides, respectively, of a first rigid PCB of the sled assembly ofFIGS. 35 and 36 . -
FIG. 44 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. -
FIG. 45 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state. -
FIG. 46 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. -
FIG. 47 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. -
FIG. 48 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state. -
FIG. 49 is schematic for the plug/jack combination according to an embodiment of the present invention. -
FIG. 50 is an isometric view of an RJ45 plug according to an embodiment of the present invention. -
FIGS. 51-53 are isometric exploded views of an RJ45 plug according to an embodiment of the present invention -
FIG. 54 is a first side of a first rigid PCB according to an embodiment of the present invention. -
FIG. 55 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. -
FIG. 56 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. -
FIG. 57 is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. -
FIG. 58 is schematic for the plug/jack combination according to an embodiment of the present invention. - An exemplary embodiment of the present invention is illustrated in
FIG. 1 , which shows acommunication system 110, which includes apatch panel 112 withRJ45 jacks 114 and corresponding RJ45 plugs 116.Respective cables 120 are terminated toplugs 116, andrespective cables 118 are terminated tojacks 114. Once aplug 116 mates with ajack 114 data can flow in both directions through these connectors. Although thecommunication system 110 is illustrated inFIG. 1 as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers and or telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers, and other peripherals as can be found in workstation areas.Communication system 110 can further include cabinets, racks, cable management and overhead routing systems, and other such equipment. - With the
patch panel 112 removed,FIG. 2 illustrates theRJ45 jack 114 and theRJ45 plug 116 in a mated configuration, andFIGS. 3-5 illustrate theRJ45 jack 114 and theRJ45 plug 116 in an unmated configuration withFIG. 4 being rotated 180° about the central axis ofcable 118 relative toFIG. 3 , andFIG. 5 illustrating a rear isometric view relative toFIGS. 3 and 4 . - As shown in
FIGS. 6-8 , theRJ45 jack 114 includesidentification icon 122,jack shield 124,conductive housing 126,sled assembly 128, insulation displacement contacts (IDCs) 154,rear sled 156, wire cap assembly 158 (which includeswire containment cap 160, conductiverear cap 162, and conductive strain relief clip 88).Jack 114 is used to terminatecable 118 which includesconductors 164 andconductive braid 166. - The
sled assembly 128 is illustrated in greater detail inFIGS. 9-11 . As shown therein, it includes afirst sled support 130, first plug interface contacts (PICs) 132,second PICs 134,flexible PCB 136,second sled support 138, firstrigid PCB 140, springs 142,first wiping contacts 144,second wiping contacts 146,first contact support 148,second contact support 150, and secondrigid PCB 152. - Referring to the exploded views of the
sled assembly 128 shown inFIGS. 12-14 , during the assembly ofsled assembly 128, a portion of theflexible PCB 136 is trapped between firstrigid PCB 140 andfirst sled support 130. Press posts 168 offirst sled support 130 align withholes flexible PCB 136 and firstrigid PCB 140, andflexible PCB 136 is wrapped aroundmandrel 173 offirst sled support 130.First PICs 132 andsecond PICs 134 are installed intovias 174 of firstrigid PCB 140, and comb features 176 ofsecond sled support 138 align with bothfirst PICs 132 andsecond PICs 134.Snaps 178 ofsecond sled support 138 align with and joinsnap pockets 180 offirst sled support 130 to secure the two pieces together. Whensecond sled support 138 andfirst sled support 130 are secured,flexible PCB 136,first PICs 132, andsecond PICs 134 become trapped and are thereby secured. Front spring posts 182 offirst sled support 130 and back spring posts 184 ofsecond contact support 150 capture springs 142 during final assembly. First wipingcontacts 144 align withrespective contact slots 186 offirst contact support 148 and have a controlledbend 188 aroundmandrel 190.Second wiping contacts 146 align withrespective contact slots 192 ofsecond contact support 150 and have a controlledbend 194 aroundmandrel 196.Relief slots first contact support 148 andsecond contact support 150, provide clearance forIDCs 154 during final assembly. - After assembly of the
sled assembly 128,IDCs 154 are placed inIDC slots 216 ofrear sled 156 and are then secures to secondrigid PCB 152 making theback end assembly 228 as shown inFIG. 15 .Back end assembly 228 is then assembled intoconductive housing 126 formingpartial jack assembly 229 show inFIG. 16 . Referring again toFIG. 15 ,rails 230 ofconductive housing 126 alignback end assembly 228 and match up with the edges of firstrigid PCB 140. Latcharms rear sled 156 align with and secure to latchpockets conductive housing 126. Oncepartial jack assembly 229 is assembled, it is joined with thejack shield 124 as shown inFIGS. 16 and 17 .Jack shield 124 wraps aroundpartial jack assembly 229 and shield latches 240 align and join with shield snaps 242 to partially enclose the assembly. Thereafter, wirecap grounding flanges 244 ofjack shield 124 are wrapped around groundingflange slots 246 ofrear sled 156. When assembled to a cable, wirecap grounding flanges 244 make contact with conductiverear cap 162 to provide an appropriate grounding connection. Plug groundingflange slots conductive housing 126 align with respectiveplug grounding flanges jack shield 124. - Referring now to
FIGS. 18 and 19 , to connect the partially assembled jack to a data cable,cable 118 is strung through rearconductive cap 162 and thewire containment cap 160 withconductor slots 210 enabling alignment ofconductors 164 during assembly.Wire containment cap 160 is secured to conductiverear cap 162 throughlatches latch pockets flexible arms 212 of conductivestrain relief clip 88 engage withteeth 214 of conductiverear cap 162. To disengage, theflexible arms 212 are compressed inward towards each other. As thewire cap assembly 158 is assembled,conductors 164 are positioned in preparation for joining with the partially assembled jack. Thereafter,wire cap assembly 158 is secured torear sled 156 through the engagement of theflexible latch 218 ofrear sled 156 with acorresponding latching feature 220. The mating of thewire cap assembly 158 and therear sled 156 causes theIDCs 154 to make contact with theconductors 164 of thecable 118 and thereby establish a communication link through the jack. - To achieve the improved levels of reliability,
jack 114 utilizes first andsecond wiping contacts rigid PCB 140.FIG. 20 is a first side of firstrigid PCB 140 andFIG. 21 is a second side of firstrigid PCB 140. Firstrigid PCB 140 includesfirst contact pads 288 andsecond contact pads 290. Each contact pad contains a mating portion and a disconnect portion. The mating portion is the section of the contact pad with which a respective wiping contact is engaged during the mated and over-travel states. The disconnect portion is the section of the contact pad with which a respective wiping contact is engaged between the pre-release and release states. In the currently described embodiment,contact pads 288 have amating portion 292 and adisconnect portion 294, andcontact pads 290 have amating portion 296 and adisconnect portion 298. For each contact pad, the mating portion and the disconnect portion is positioned such that each portion comes into direct contact with an alternate side of a respective wiping contact. This configuration allows for potential arcing or corona damage to occur on one side of the wiping contact, leaving the other side unharmed. -
FIGS. 22-30 illustrate the interaction between the contact pads and the wiping contacts throughout various stages of the plug/jack mating process. It is worth noting that in the section views ofFIGS. 22, 24, 26, 28, and 30 ,sled assembly 128 and plugPCB assembly 274 are not sectioned to show the plug/jack mating interaction betweenwire contacts PICs contacts 144 andcontact pads 288. In addition, press posts 168 have been leveled off along the surface of respective firstrigid PCB 140 in all section views for clarity. -
FIG. 22 is a cross-section view, taken along section line 22-22 ofFIG. 2 , across the mating interface of shieldedRJ45 network jack 114 and shieldedRJ45 plug assembly 116. In thisstate wire contacts first PICs 132 andsecond PICs 134, andfirst wiping contacts 144 are in contact withmating portion 292 offirst contact pads 288.Second wiping contacts 146 are in contact withmating portion 296 of second contact pads 290 (not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wipingcontacts 144 interface with the mating portion along the wiping contacts' first side. This is the static state of a matedRJ45 plug 116/jack 114 combination. -
FIG. 23 is a front isometric view ofRJ45 network jack 114 andRJ45 plug assembly 116 andrespective cables RJ45 plug assembly 116 into shieldedRJ45 network jack 114.RJ45 plug assembly 116 is inserted roughly .032 inches further intoRJ45 network jack 114 when compared to the mated static state shown inFIG. 2 .FIG. 24 is a cross-section view, taken along section line 24-24 ofFIG. 23 across the mating interface ofRJ45 network jack 114 and RJ45 plug assembly 116 in the over-travel state. In thisstate wire contacts first PICs 132 andsecond PICs 134. First wipingcontacts 144 are in contact withmating portion 292 offirst contact pads 288.Second wiping contacts 146 are in contact withmating portion 296 of second contact pads 290 (not shown). Similar to the static state, wipingcontacts 144 interface with the mating portion along the wiping contacts' first side. In between the mated state and the over-travel state there is no mechanical/electrical disconnection between any plug/jack interfaces. -
FIG. 25 is a front isometric view ofRJ45 network jack 114 andRJ45 plug assembly 116 andrespective cables RJ45 plug assembly 116 into shieldedRJ45 network jack 114 prior to the over-travel and mated states).FIG. 26 is a cross-section view, taken along section line 26-26 ofFIG. 25 across the mating interface ofRJ45 network jack 114 and RJ45 plug assembly 116 in the pre-release state. In thisstate wire contacts first PICs 132 andsecond PICs 134. First wipingcontacts 144 are in contact withdisconnect portion 294 offirst contact pads 288.Second wiping contacts 146 are in contact withdisconnect portion 298 of second contact pads 290 (not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wipingcontacts 144 interface with the disconnect portion along the wiping contacts' second (alternate) side as compared to the static and over-travel states. -
FIG. 27 is a front isometric view ofRJ45 network jack 114 andRJ45 plug assembly 116 andrespective cables wire contacts first PICs 132 and second PICs 134 (this position is equivalent to the position during initial insertion of shieldedRJ45 plug assembly 116 into shieldedRJ45 network jack 114 just after thewire contacts first PICs 132 and second PICs 134).FIG. 28 is a cross-section view, taken along section line 28-28 ofFIG. 27 across the mating interface ofRJ45 network jack 114 and RJ45 plug assembly 116 in the release state. In thisstate wire contacts first PICs 132 andsecond PICs 134. First wipingcontacts 144 are no longer in contact withdisconnect portion 294 offirst contact pads 288.Second wiping contacts 146 are no longer in contact withdisconnect portion 298 of second contact pads 290 (not shown). In between the pre-release state and the release state respective wiping contacts disconnect from contact pads along the disconnect portion of the contact pad. The electrical discharge that occurs upon disconnection of the wiping contacts and the contact pads occurs on the disconnect portion of the contact pad and corresponding side of the wiping contact. This is opposite of the mating side of the contact and controls where the damage to the contact occurs in the case of PoE damage during use.Contact point 300, betweenwire contacts first PICs 132 andsecond PICs 134, remains relatively the same between mated, over-travel, pre-release, and release states with a minimal wiping zone as this helps reduce the electrical distance to compensation that may be implemented on thePCB 140. -
FIG. 29 is a front isometric view ofRJ45 network jack 114 andRJ45 plug assembly 116 andrespective cables FIG. 30 is a cross-section view, taken along section line 30-30 ofFIG. 29 across the mating interface of shieldedRJ45 network jack 114 and shieldedRJ45 plug assembly 116 in the unmated state. In thisstate wire contacts first PICs 132 andsecond PICs 134. First wipingcontacts 144 are no longer in contact withfirst contact pads 288.Second wiping contacts 146 are no longer in contact with second contact pads 290 (not shown).Sled assembly 128 is in approximately the same position in the unmated state as in the release state. - In order to ensure contact on a specific side of either
first contact pads 288 orsecond contact pads 290, it is preferred thatfirst contact pads 288 orsecond contact pads 290 be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness oncontact pads - An alternative embodiment of the first
rigid PCB 302 is shown inFIGS. 31 and 32 withFIG. 31 showing a first side of firstrigid PCB 302 andFIG. 32 showing a second side of firstrigid PCB 302. Firstrigid PCB 302 includesfirst contact pads 304 andsecond contact pads 306. As with firstrigid PCB 140, each contact pad contains a mating portion and a disconnect portion, except there is no perpendicular section linking the two portions on the contact pads ofPCB 302. Instead,PCB 302 uses an angled section. It should be noted that the shape of the contact pads may take any form so long as the mating portion and the disconnect portion are positioned such that the wiping contact maintains a constant electrical bond with the contact pad as it travels between the mating and disconnect portions and such that different sections of the wiping contacts make contact with the mating and disconnect portions. - Yet another alternative embodiment of the first
rigid PCB 308 is shown inFIGS. 33 and 34 withFIG. 33 showing a first side of firstrigid PCB 308 andFIG. 34 showing a second side of firstrigid PCB 308. Firstrigid PCB 308 includesfirst contact pads 310 andsecond contact pads 312.Cutouts rigid PCB 308 are a secondary mechanical alternative that is less dependent on minor changes in plating or solder mask to ensure reliable electrical contact on the specific side of wiping contacts and contact pads. The shape of the cut out sections can be any shape so long as the contact pads provide appropriate functionality as described previously. -
FIGS. 35-39 illustrate an alternative embodiment of asled assembly 318 that could be used in jack 354 (which is similar in construction to jack 114).Sled assembly 318 includesfirst sled support 130,first PICs 132,second PICs 134,flexible PCB 320,second sled support 138, firstrigid PCB 322, springs 142, firstdual wiping contacts 324, seconddual wiping contacts 326, firstdual contact support 328, seconddual contact support 330, and secondrigid PCB 332. Whileflexible PCB 320 and secondrigid PCB 332 may be mechanically the same as respectiveflexible PCB 136 and secondrigid PCB 152, with the added crosstalk the electrical design of these boards may be different. - The primary difference between
sled assembly 318 and the previously describedsled assembly 128 is in the design of the wiping contacts and the design of the contact pads on the firstrigid PCB 322. -
FIG. 40 is a trimetric view of seconddual contacts 326 andFIG. 41 is a trimetric view of firstdual contacts 324. Seconddual wiping contacts 326 include two wiping contacts comprised of apreferred mating leg 338 and asacrificial leg 340. Likewise, firstdual wiping contacts 324 include two wiping contacts comprised of apreferred mating leg 334 andsacrificial leg 336.FIG. 42 illustrates a first side of firstrigid PCB 322 andFIG. 43 illustrates a second side of firstrigid PCB 322. It includes firstdual contact pads 342, which include amating portion 344 andsacrificial portion 346, and seconddual contact pads 348, which include amating portion 350 andsacrificial portion 352. - The interaction of the dual wiping contacts and the dual contact pads is shown in
FIGS. 44-48 which illustrate cross-section views ofjack 354 and plug 116 at different mating states. FIG. 44 shows thejack 354 and theplug 116 in a fully mated state. In thisstate wire contacts first PICs 132 andsecond PICs 134.Preferred mating leg 334 of firstdual wiping contacts 324 is in contact withmating portions 344 of firstdual contact pads 342.Sacrificial mating leg 336 of firstdual wiping contacts 324 is in superfluous contact withsacrificial portion 346 of firstdual contact pads 342.Preferred mating leg 338 of seconddual wiping contacts 326 is in contact withmating portion 350 of second dual contact pads 348 (not shown).Sacrificial mating leg 340 of seconddual wiping contacts 326 is in superfluous contact withsacrificial leg 352 of second dual contact pads 348 (not shown). -
FIG. 45 is a cross-section view ofRJ45 network jack 354 andRJ45 plug assembly 116, withrespective cables state wire contacts first PICs 132 andsecond PICs 134.Preferred mating legs 334 of firstdual wiping contacts 324 are in contact withmating portions 344 of firstdual contact pads 342.Sacrificial mating legs 336 of firstdual wiping contacts 324 are in superfluous contact withsacrificial portions 346 of firstdual contact pads 342.Preferred mating legs 338 of seconddual wiping contacts 326 are in contact withmating portions 350 of second dual contact pads 348 (not shown).Sacrificial mating legs 340 of seconddual wiping contacts 326 are in superfluous contact withsacrificial portions 352 of second dual contact pads 348 (not shown). In between the mated state and the over-travel state there is no mechanical/electrical disconnection between the plug/jack interfaces. -
FIG. 46 is a cross-section view ofRJ45 network jack 354 andRJ45 plug assembly 116, withrespective cables state wire contacts first PICs 132 andsecond PICs 134.Preferred mating legs 334 of firstdual wiping contacts 324 are no longer in contact withmating portions 344 of firstdual contact pads 342. However,sacrificial mating legs 336 of firstdual wiping contacts 324 are still in contact withsacrificial portions 346 of firstdual contact pads 342. Likewise, whilepreferred mating legs 338 of seconddual wiping contacts 326 are no longer in contact withmating portions 350 of second dual contact pads 348 (not shown),sacrificial mating legs 340 of seconddual wiping contacts 326 are still in contact withsacrificial portions 352 of seconddual contact pads 348. Given that continuity between the dual wiping contacts and the dual contact pads is still maintained at this this stage, the disconnection (or connection in case of plug insertion) of the preferred mating legs from the respective mating portions of the dual contact pads does not result an arcing or corona discharge, preventing potential damage to the respective surfaces. -
FIG. 47 is a cross-section view ofRJ45 network jack 354 andRJ45 plug assembly 116, withrespective cables state wire contacts first PICs 132 andsecond PICs 134.Preferred mating legs 334 of firstdual wiping contacts 324 are no longer in contact withmating portions 344 of firstdual contact pads 342.Sacrificial mating legs 336 of firstdual wiping contacts 324 are no longer in contact withsacrificial portions 346 of firstdual contact pads 342.Preferred mating legs 338 of seconddual wiping contacts 326 are no longer in contact withmating portions 350 of second dual contact pads 348 (not shown).Sacrificial mating legs 340 of seconddual wiping contacts 326 are no longer in contact withsacrificial portions 352 of second dual contact pads 348 (not shown). In between the pre-release state and the release state respective sacrificial mating legs disconnect from sacrificial portions of contact pads (during the insertion of the plug into the jack the respective sacrificial mating legs connect to sacrificial portions of contact pads). The electrical discharge upon disconnection/connection of the sacrificial mating legs and the sacrificial portions of the contact pads occurs outside of the preferred mating zone and in the sacrificial areas. This helps maintain the integrity of the preferred mating legs of the dual wiping contacts and the mating portion of the dual contact pads. -
FIG. 48 is a cross-section view ofRJ45 network jack 354 andRJ45 plug assembly 116, withrespective cables state wire contacts first PICs 132 andsecond PICs 134.Preferred mating legs 334 of firstdual wiping contacts 324 are no longer in contact withmating portions 344 of firstdual contact pads 342.Sacrificial mating legs 336 of firstdual wiping contacts 324 are no longer in contact withsacrificial portions 346 of firstdual contact pads 342.Preferred mating legs 338 of seconddual wiping contacts 326 are no longer in contact withmating portions 350 of second dual contact pads 348 (not shown).Sacrificial mating legs 340 of seconddual wiping contacts 326 are no longer in contact withsacrificial portions 352 of seconddual contact pads 348.Sled assembly 318 is in approximately the same position in the unmated state and the release state. - First wiping
contacts 144,second wiping contacts 146, firstdual wiping contacts 324, and seconddual wiping contacts 326 are shown with compliant pins but may be attached to respective second rigid PCBs through any non-limiting means.First PICs 132 andsecond PICs 134 are shown with solder connections but may be attached to respective first rigid PCBs through any non-limiting means.Cable - An exemplary schematic for the
plug 116/jack FIG. 49 . - While the above-described embodiments illustrate examples of jacks with improved robustness for PoE, it is also possible to provide improved designs in the plug.
FIG. 50 illustrates an isometric view of onesuch plug 116 by way of an exemplary embodiment.Plug 116 includesfront housing 122, lefthousing 140,right housing 142, and bendradius control boot 144.FIGS. 51-53 provide exploded views of theplug 116. As shown therein, plug 116 also includes afirst PCB assembly 124 withfirst plug contacts 126,second plug contacts 128, firstrigid PCB 130, and springs 132, and asecond PCB assembly 134 with wipingcontacts 136 and secondrigid PCB 138. BackPCB pads 146 on secondrigid PCB 138 are used to terminatecable 120; through other non-limiting means of termination may be used. During mating/un-mating with a corresponding jack, while secondrigid PCB 138 remains stationary relative to the plug's housings, the firstrigid PCB assembly 124 translates between different positions. The firstrigid PCB 130 and secondrigid PCB 138 are electrically linked to each other via wipingcontacts 136 andcontact pads 148. -
FIG. 54 illustrates a first side of firstrigid PCB 130. Eachcontact pad 148 contains amating portion 150 and adisconnect portion 152. The mating portion is the portion of a contact pad that is engaged with a respective wiping contact during the mated and over-travel state (the over-travel state allows for insertion ofRJ45 plug assembly 116 intoRJ45 network jack 54. The disconnect portion is the portion of a contact pad that is engaged with a respective wiping contact during the pre-release state. As will be made clear during the discussion of the following drawings, that each mating portion and respective disconnect portion are displaced laterally from each other. This allows a single wiping contact that is wide enough to at least partially overlap both of the portions to rely on one side thereof to make contact with the mating portion and to rely on the second side thereof to make contact with the disconnect portion. This allows the second side (i.e., the side that makes contact with the disconnect portion) to sustain most of the damage that may be caused by PoE, leaving the first side (i.e., the side that makes contact with the mating portion) unscathed. -
FIG. 55 is a cross-section view across the mating interface of shieldedRJ45 network jack 54 and RJ45 plug assembly 116 (wipingcontacts 136 and firstrigid PCB 130 are not sectioned to show the interface between wipingcontacts 136 and first rigid PCB 130). In thisstate plug contacts contacts 136 are in contact withmating portion 150 ofcontact pads 148. This is the static (mated) state of anRJ45 network plug 116 mated with anRJ45 network jack 54. -
FIG. 56 is a cross-section view across the mating interface of shieldedRJ45 network jack 54 and RJ45 plug assembly 116 shown in the pre-release state. In thisstate plug contacts contacts 136 are in contact withdisconnect portion 152 ofcontact pads 148. In the pre-release state there is still an electrical connection throughout the channel, but it is not a static state of installedRJ45 network jack 54 andRJ45 plug assembly 116. This state occurs either during insertion ofRJ45 plug assembly 116 intoRJ45 network jack 54 prior to the mated state, or upon retraction of RJ45 plug assembly 116 fromRJ45 network jack 54 prior to the release state. -
FIG. 57 is a cross-section view across the mating interface of shieldedRJ45 network jack 54 and RJ45 plug assembly 116 in the release state. In this state, whileplug contacts contacts 136 are no longer in contact withcontact pads 148. In the release state there is no longer an electrical connection throughout the channel. This state occurs either during insertion ofRJ45 plug assembly 116 intoRJ45 network jack 54 prior to the pre-release state or upon retraction of RJ45 plug assembly 116 fromRJ45 network jack 54 after the pre-release state. In between the pre-release state and the release state,respective wiping contacts 136 disconnect fromcontact pads 148 along thedisconnect portions 152. The electrical discharge upon disconnection of wipingcontacts 136 andcontact pads 148 occurs ondisconnect portion 152 and corresponding side of wipingcontact 136. This is opposite of the side of thewiping contact 136 that contacts the mating portion, controlling where the damage to the contact occurs in the case of PoE. In between the mated state and the release state there is approximately 0.040″ of travel for first rigid PCB assembly. In the mated/over-travel state the plug/jack interface is approximately in the IEC-60603-7:2010 preferred electrical mating point location. In all other states the plug/jack interface is typically not in the IEC-60603-7:2010 preferred electrical mating point location, and the force between PICs 70 and plugcontacts springs 132. After the release state, the unmated state follows in which plugcontacts - To ensure contact on a specific side of
contact pads 148, it is preferred thatcontact pads 148 be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness oncontact pads 148 or removing/lowering the adjacent solder mask. -
FIG. 58 illustrates an exemplary schematic for theplug 116/jack 54 combination. - Note that while this invention has been described in terms of several embodiments, these embodiments are non-limiting (regardless of whether they have been labeled as exemplary or not), and there are alterations, permutations, and equivalents, which fall within the scope of this invention. For example, while references have been made to rigid PCBs, one of ordinary skill in the art would recognize that the use of flexible PCBs or combinations of flex/rigid PCBs would also be within the scope of the disclosure. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. Furthermore, in some cases same numbers are used to refer to similar elements in different embodiment. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.
Claims (25)
1. A communication connector comprising:
a connector housing;
a plurality of first contacts positioned at least partially within said connector housing, each of said first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector;
a printed circuit board (PCB), said plurality of first contacts being positioned on said PCB, said PCB further including a plurality of second contacts, each of said second contacts being connected to one of said first contacts and having a mating portion and a disconnect portion; and
a plurality of third contacts, each of said third contacts having a mating section configured to interface with one of said mating portions and a disconnect section configured to interface with one of said disconnect portions.
2. The communication connector of claim 1 , wherein each of said second contacts is a contact pad and wherein each of said third contacts is a wiping contact.
3. The communication connector of claim 1 , further comprising a second PCB, said plurality of third contacts being fixed within said second PCB.
4. The communication connector of claim 3 , further comprising a plurality of cable contacts, said cable contacts being secured within said second PCB.
5. The communication connector of claim 1 , wherein for each of said second contacts, each mating portion is offset laterally from said respective disconnect portion.
6. The communication connector of claim 5 , wherein for each of said second contacts, each mating portion is offset longitudinally from said respective disconnect portion.
7. The communication connector of claim 1 , wherein said PCB is configured to be moveable between a plurality of positions, said plurality of positions including a first position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and a second position corresponding to said plurality of first contacts being disconnected from said interface contacts of said corresponding connector, wherein in said first position each of said third contacts is interfaced with one of said second contacts via respective said mating section and respective said mating portion, and wherein in said second position each of said third contacts is disconnected from each of said second contacts.
8. The communication connector of claim 7 , wherein said plurality of positions further include a third position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and each of said third contacts being interfaced with one of said second contacts via respective said disconnect section and respective said disconnect portion.
9. The communication connector of claim 8 , wherein said plurality of positions further include a fourth position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and each of said third contacts being disconnected from each of said second contacts.
10. The communication connector of claim 1 , wherein said communication connector is an RJ45 jack.
11. The communication connector of claim 1 , wherein said communication connector is an RJ45 plug.
12. A communication connector comprising:
a connector housing;
a plurality of first contacts positioned at least partially within said connector housing, each of said first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector;
a printed circuit board (PCB), said plurality of first contacts being positioned on said PCB, said PCB further including a plurality of second contacts, each of said second contacts being connected to one of said first contacts and having a mating portion and a disconnect portion; and
a plurality of third contacts, each of said third contacts having a preferred mating leg configured to interface with one of said mating portions and a sacrificial leg configured to interface with one of said disconnect portions.
13. The communication connector of claim 12 , wherein each of said second contacts is a contact pad, wherein each of said preferred mating legs is a wiping contact, and wherein each of said sacrificial legs is a wiping contact.
14. The communication connector of claim 12 , further comprising a second PCB, said plurality of third contacts being fixed within said second PCB.
15. The communication connector of claim 14 , further comprising a plurality of cable contacts, said cable contacts being secured within said second PCB.
16. The communication connector of claim 12 , wherein for each of said second contacts, each mating portion is offset laterally from said respective disconnect portion.
17. The communication connector of claim 16 , wherein for each of said second contacts, each mating portion is offset longitudinally from said respective disconnect portion.
18. The communication connector of claim 12 , wherein said PCB is configured to be moveable between a plurality of positions, said plurality of positions including a first position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and a second position corresponding to said plurality of first contacts being disconnected from said interface contacts of said corresponding connector,
wherein in said first position each of said third contacts is interfaced with one of said second contacts via respective said preferred mating leg and respective said mating portion, and
wherein in said second position each of said third contacts is disconnected from each of said second contacts.
19. The communication connector of claim 18 , wherein said plurality of positions further include a third position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and each of said third contacts being interfaced with one of said second contacts via respective said sacrificial leg and respective said disconnect portion.
20. The communication connector of claim 19 , wherein said plurality of positions further include a fourth position corresponding to said plurality of first contacts being in contact with said interface contacts of said corresponding connector and each of said third contacts being disconnected from each of said second contacts.
21. A communication connector connectable to at least one of a communication cable and communication equipment, said communication connector capable of transmitting power over Ethernet, said communication connector comprising:
means for interfacing said communication connector with a corresponding connector;
means for establishing an electrical path between said corresponding connector and said at least one of said communication cable and said communication equipment, said means for establishing said electrical path being located within said communication connector and occurring over a first physical path; and
means for breaking said electrical path between said corresponding connector and said at least one of said communication cable and said communication equipment, said means for breaking said electrical path being located within said communication connector and occurring over a second physical path.
22. A communication system comprising:
a communication plug including a plurality of plug contacts and a plurality of plug cable contacts; and
a communication jack including a plurality of plug interface contacts (PICs) and a plurality of jack cable contacts,
said communication plug configured to mate with said communication jack such that each of said plug contacts comes into contact with one of said PICs, a current path being established between each of said plug cable contacts and one of said jack cable contacts when said communication plug is mated with said communication jack,
said communication plug being further configured to disconnect from said communication jack such that each said current path is broken while each of said plug contacts maintains contact with one of said PICs.
23. A communication system comprising:
a communication plug including a plurality of plug contacts and a plurality of plug cable contacts; and
a communication jack including a plurality of plug interface contacts (PICs) and a plurality of jack cable contacts,
said communication plug configured to mate with said communication jack such that each of said plug contacts comes into contact with one of said PICs, a current path being established between each of said plug cable contacts and one of said jack cable contacts when said communication plug is mated with said communication jack,
said communication plug being further configured to disconnect from said communication jack such that each said current path is broken at a point other than between each of said plug contacts and respective one of said PICs.
24. A communication system comprising:
a communication plug including a plurality of plug contacts and a plurality of plug cable contacts; and
a communication jack including a plurality of plug interface contacts (PICs) and a plurality of jack cable contacts,
said communication plug configured to mate with said communication jack such that each of said plug contacts comes into contact with one of said PICs, a current path being established between each of said plug cable contacts and one of said jack cable contacts when said communication plug is mated with said communication jack, each said current path traversing one of said plug contacts and respective one of said PICs,
said communication plug being further configured to disconnect from said communication jack such that at least one said current path is broken while respective one of said plug contacts maintains contact with respective one of said PICs.
25. A communication system including a communication plug and a communication jack, said communication system comprising:
means for connecting said communication plug to a plug-cable having at least one conductor;
means for connecting said communication jack to a jack-cable having at least one conductor;
means for electrically and physically interfacing said communication plug with said communication jack;
means for transmitting a current between said at least one conductor of said plug-cable and said at least one conductor of said jack-cable; and
means for breaking said current at a point that does not include said means for electrically and physically interfacing said communication plug with said communication jack.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/058,349 US20170256895A1 (en) | 2016-03-02 | 2016-03-02 | Communication connector |
US16/177,607 US10637199B2 (en) | 2016-03-02 | 2018-11-01 | Communication connector to withstand power over ethernet |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/058,349 US20170256895A1 (en) | 2016-03-02 | 2016-03-02 | Communication connector |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US16/177,607 Continuation US10637199B2 (en) | 2016-03-02 | 2018-11-01 | Communication connector to withstand power over ethernet |
Publications (1)
Publication Number | Publication Date |
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US20170256895A1 true US20170256895A1 (en) | 2017-09-07 |
Family
ID=59722980
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US15/058,349 Abandoned US20170256895A1 (en) | 2016-03-02 | 2016-03-02 | Communication connector |
US16/177,607 Active US10637199B2 (en) | 2016-03-02 | 2018-11-01 | Communication connector to withstand power over ethernet |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US16/177,607 Active US10637199B2 (en) | 2016-03-02 | 2018-11-01 | Communication connector to withstand power over ethernet |
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US (2) | US20170256895A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020160275A1 (en) | 2019-01-31 | 2020-08-06 | Commscope Technologies Llc | Anti-arc connector and pin array for a port |
Citations (3)
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US20130090011A1 (en) * | 2011-10-06 | 2013-04-11 | Panduit Corp. | Backward Compatible Connectivity for High Data Rate Applications |
US9419391B2 (en) * | 2013-08-20 | 2016-08-16 | Panduit Corp. | Communication connector |
US9531135B2 (en) * | 2013-03-15 | 2016-12-27 | CommScope Connectivity Spain, S.L. | Telecommunications jack with switchable circuit configurations |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1723702B1 (en) * | 2004-03-12 | 2015-10-28 | Panduit Corporation | Methods and apparatus for reducing crosstalk in electrical connectors |
-
2016
- 2016-03-02 US US15/058,349 patent/US20170256895A1/en not_active Abandoned
-
2018
- 2018-11-01 US US16/177,607 patent/US10637199B2/en active Active
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20130090011A1 (en) * | 2011-10-06 | 2013-04-11 | Panduit Corp. | Backward Compatible Connectivity for High Data Rate Applications |
US9531135B2 (en) * | 2013-03-15 | 2016-12-27 | CommScope Connectivity Spain, S.L. | Telecommunications jack with switchable circuit configurations |
US9419391B2 (en) * | 2013-08-20 | 2016-08-16 | Panduit Corp. | Communication connector |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020160275A1 (en) | 2019-01-31 | 2020-08-06 | Commscope Technologies Llc | Anti-arc connector and pin array for a port |
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US20190074647A1 (en) | 2019-03-07 |
US10637199B2 (en) | 2020-04-28 |
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