Abstract:
An electrical connection system is provided that makes patch cord connections with snap-in jack modules using a hinged plug and jack mating system which results in simple connections with low insertion forces and enhanced side to side stability for the patch cord connectors. The hinged connector keeps the label area clear of cordage while troughs between adjacent rows of connectors accommodate the patch cords and facilitate efficient cable management.

Description:
RELATED APPLICATIONS 
     The present patent application is related to U.S. patent application Ser. No. 09/575,969, entitled “HINGED CONNECTION SYSTEM”, being concurrently filed herewith and having a filing date of May 23, 2000; U.S. patent application Ser. No. 09/577,274, entitled, “CONTACTS FOR HINGED CONNECTION SYSTEM” being concurrently filed herewith and having a filing date of May 23, 2000; to U.S. patent application Ser. No. 09/575,902, entitled “CONNECTOR SYSTEM WITH RELEASABLE LATCH”, being concurrently filed herewith and having a filing date of May 23, 2000; to U.S. patent application Ser. No. 09/575,968, entitled “SLIDING CABLE FIXTURE”, being concurrently filed herewith and having a filing date of May 23, 2000; to U.S. patent application Ser. No. 09/577,273, entitled, “BOARD MOUNTED JACK MODULE”, being concurrently filed herewith and having a filing date of May 23, 2000; all of which have a common inventor and assignee and being incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to electrical connection systems, and more particularly to electrical connections systems for use in telecommunications. 
     BACKGROUND OF THE INVENTION 
     In the telecommunications industry, connecting systems comprising an array of insulation displacement contacts (IDC) are typically used in telephone company central offices and office buildings for electrical connection between cables and cross-connect wiring. These electrical connection systems are used throughout the telecommunications industry in order to interconnect corresponding wires in two sets of wires. The predominant connecting systems for building terminal cross-connect systems are currently the modular RJ45 connector system and the  110  connection system or variations of these connection systems. The modular type connector systems use a plug and jack type interface for making connections. 
     The RJ45 version of a modular connector system is a 4-pair connector system that cannot be broken down to smaller increments without wasting connector positions. A patch cord connection is made to a jack by deflecting a set of cantilevered spring wires in a jack with a mating set of fixed pressure contact surfaces in the plug, as the plug is pushed into the jack with a relatively low force. As the plug completes its insertion into the jack, it automatically latches with an audible click. By gripping the exposed back end of the plug, and depressing a lever, the latch can be released. Spring loaded wire contacts within the jack essentially push the plug out. The RJ45 modular systems have a panel with a flat front face. When a patch cord is installed, the cordage comes straight out from the panel. Cross-connect distribution rings bring the cordage back in along the face of the panel. 
     The  110  connector system is designed with insulation displacement connections (IDC) for both the cable connections and the cross-connect or patching connections. Therefore, a patching connection can be made by terminating cross-connect wires in the contacts IDC slots, or by inserting patch cord blades into those contact shots. 
     This Connector System forms a connector field that is front accessible, and is designed for wall mounting. Despite this design, the  110  system can be frame mounted, with the cables fed from the front in a manner similar to wall mounting. The cables can also be fed from the back of the frame. The front access is achieved by having a cross-connect field superimposed on a cable termination field; that is, superimposed on the cable routing. Cables are routed behind the wiring blocks, either in pre-mounted channels or between the rows of wiring block support legs. Cable ends are brought through their appropriate openings in the wiring block to the cable termination surface, and the exposed cable sheath is removed. The cable conductors are fanned out as twisted pairs to their appropriate termination ports in the index strips on the front face of a wiring block. 
     Connecting blocks, which include contacts having insulation displacement portions on two opposite ends, are brought down and snapped onto the index strip to form electrical connections between the contacts and conductors. The front surface formed by the connecting blocks is the cross-connect field. A designation strip is placed between alternate rows and is used to label the conductor terminations on the rows on either side of it. 
     When a cross-connect field is intended for use with patch cords, 100 pair wiring blocks typically alternate with horizontal troughs, with patch cords from the upper 2 rows going into an upper trough, and patch cords from the lower 2 rows going into a lower trough. When a high percentage of patch cord positions are populated, the patch cord connectors present an unruly appearance and the labeling becomes very difficult to read, making cord location a time consuming process. 
     Patch cords in the  110  connector system have contact blades that make connection by inserting into the top IDC slots of the contact elements. The IDC is designed to remove conductor insulation as it makes contact, and achieve a high enough contact force to make a stable long term connection to unplated wire. Repeated insertions of the patch cord blades past this entrance geometry, with its high contact force, reduces the life of the patch cord blades protective plating. This contact force (about 2 pounds) holds the patch cord blade by friction and prevents it from sliding out by about a third of a pound per contact. The contact slots are tapered so any vibration or wiggling of the patch cord would cause the blades to slowly walk out of the slots, unless something else held them in place. 
     Connecting blocks may have hemispherical buttons that match mating holes in the patch cords. By pulling on a mated patch cord, the side walls on the plug end flex as they slide over the connecting blocks&#39; buttons; a snap-on/snap-off type of latch is enabled, and the plug end is disconnected. The force to overcome this latch and remove a 4-pair patch cord, with a straight pull, can be as high as 25 pounds. Removal can be effected by a side to side rocking of the patch cord. Because patch cord plugs are in close proximity to each other, removal of one patch cord can easily result in the dislodging of a neighboring patch cord. Therefore, technicians must be very deliberate and careful during cord tracing to avoid inadvertently dislodging a patch cord. Furthermore, the high friction on the buttons can cause extensive wear of the surfaces so that the retention capability of the connecting blocks degrades after multiple insertions and removals. 
     SUMMARY 
     A device according to the principles of the invention provides a simple, modular, and efficient patch cord connection. An exemplary system according to the principles of the invention includes a support structure to which a plurality of jack receptacles can be attached. By providing a plug having a rotatable end and a jack having a corresponding rotatable end, the jack can be hooked into a corresponding receptacle, engaging the rotatable plug end with the corresponding rotatable jack end, thereby establishing a fulcrum. The plug is then rotated around the fulcrum point to achieve a connection. The ease of engaging the hinging mechanism and rotating the jack into a latched mated position enable simple and reliable connections to be made. 
     In an exemplary embodiment, the jack includes a label surface with all cord connections occurring behind the label surface. Thus, the plug, most of the jack and all of the cordage is behind the label surface, providing an unobstructed view of the label surface, permitting fast and accurate identification of all cordage. 
     The present invention can accommodate any number of modules. Importantly, the support structure provides the back plane with support to allow a fill row of 24 circuits in a row on an EIA 310 type 19 inch frame. Each support structure forms a patch cord trough, thereby providing efficient cable management and connection flexibility. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     A more complete understanding of the present invention may be obtained from consideration of the follow description in conjunction with the drawings, in which: 
     FIGS.  1 ( a )- 1 ( e ) are schematic diagrams of a plug and a jack in accordance with the present invention; 
     FIG. 2 is a side cross sectional view of a jack mounted on a support structure in accordance with the present invention; 
     FIGS.  3 ( a )- 3 ( c ) show multiple perspective views of the embodiment illustrated in FIG. 2; 
     FIGS.  4 ( a ) and  4 ( b ) are a rear and side cross sectional view of a mated plug and jack in accordance with the present invention; 
     FIGS.  5 ( a )- 5 ( c ) are perspective views of a slidable connector on a support system in accordance with the embodiment shown in FIGS.  4 ( a )- 4 ( b ); 
     FIGS.  6 ( a )- 6 ( c ) illustrate, from a cross-sectional perspective, the mounting of the jack module of FIGS.  5 ( a )- 5 ( c ) on to a support structure in accordance with the present invention; 
     FIGS.  7 ( a ) and  7 ( b ) are side views of a plug and jack in accordance with the present invention; 
     FIG.  8 ( a ) is a partial, cross-sectional top view of a mated jack and a one pair patch cord plug in accordance with the present invention; and 
     FIG.  8 ( b ) is a partial, cross-sectional top view of a jack and a four pair patch cord plug in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION 
     The detailed description initially discusses the general concept and principles of the novel cross-connect system. Exemplary embodiments of the cross connect system are then described. Single and multiple connect versions of the cross connect system are then presented. 
     The Cross-Connect System 
     A cross-connect system according to the invention makes a connection by having one end of a plug hooking onto a corresponding end of a jack to form a fulcrum. The plug then functions as a lever by rotating about that fulcrum until it mates with the jack. 
     A plug  100  is illustrated in FIG.  1 ( a ). The plug  100  includes a handle  105  on one end. When the plug  100  functions as a lever, the handle  105  serves as one end of that lever. The other end of the lever is the plug fulcrum section  120 . The plug  100  further includes a latch  110  that it is located proximate to the handle  105 . The latch extends somewhat perpendicularly from the plug  100 . A pair of contacts  115  are located between the latch  110  and the plug fulcrum section  120 . Cordage  125  is electrically connected to the contacts  115 . Although one pair of contacts  115  is shown in the plug  100 , it is understood that any plurality of contacts can be included within the plug  100 . 
     In one embodiment of the invention, cordage  125  exits plug  100  at plug fulcrum section  120 . As such, cordage  125  is automatically directed toward a back plane (not shown) through a trough  270  as detailed in FIGS.  2  and  3 ( a )-( c ). This keeps the immediate area clear of cordage  125 , thereby providing a neat appearance and making it easier for the craftsperson to locate specific jack positions. Also, because the cordage  125  does not come straight out, the latch engagement is unaffected when cordage  125  is manipulated, for cord tracing for example. Latching in this configuration can be implemented using a snap action latch mechanism. 
     Referring now to FIG.  1 ( b ), a plug  130  can also have cordage  135  exit at a handle  140 . Since cordage  135  directs away from the back plane in this instance, care must be taken to keep cordage  135  from interfering with patch cord installation or removal. A wider trough may be required and a positive latch with a release mechanism may be required. The remaining illustrations and description employ a snap action latch, however, a positive latch with a release mechanism could also be used. 
     Referring now to FIGS.  1 ( c )- 1 ( e ), mating of plug  100  to a jack  145  is illustrated. As shown jack  145  includes a corresponding latch  150 , corresponding contacts  155  and a jack fulcrum section  160 . Referring specifically to FIG.  1 ( c ), plug fulcrum section  120  engages jack fulcrum section  160 . The angle of engagement is sufficiently offset to prevent engagement of latch  110  with corresponding latch  150  and contacts  115  with corresponding contacts  155 . Engagement of the latches and contacts is prevented until the fulcrum sections  120  and  160  are fully engaged and the plug rotated towards the jack. Referring now to FIGS.  1 ( d ) and  1 ( e ), handle  105  is used as a lever to rotate plug  100  towards jack  145  until corresponding latch and contact connection is achieved. 
     As illustrated in FIG.  1 ( c ), corresponding jack  145  further includes a label surface  165 . One of the advantages of the cross connect system is that label surface  165  is positioned frontward as shown below and the resulting connection is implemented behind label surface  165 . This implementation maximizes the area in the cross connect field that is devoted to either the label or trough space. This advantage is shown in more detail with respect to FIGS.  2  and  3 ( a )- 3 ( c ). Referring to FIG. 2, a cross sectional view of a printed wiring board utilizing the cross connect system according to the principles of the invention is shown. Cross connect system  200  has a backplane printed wiring board (PWB)  210  and at least one printed wiring board  220  connected to board  210  using support structures  230  and edge card connectors  240 . Connection blocks  250  are attached to board  210  to permit connections with other boards (not shown). Specifically, a jack  260  is connected to the board  220 . Jack  260  has a label surface  265  that faces away from the board  210 . 
     As previously shown in FIG.  1 ( e ) the connection between a plug and a jack  260  is made behind label surface  265 . If cross connect system  200  further utilizes a scheme where cordage exits at a fulcrum end  275  towards board  210  and into a trough  270 , then the only visible object beyond label surface  265  is the relatively small handle of the plug. This is shown in FIGS.  3 ( a )- 3 ( c ). Specifically, FIG.  3 ( a ) shows a perspective view of a cross connect system  300  with a mated plug and a jack  310 . Cordage  320  exits away from label surface  330  and into a trough area  340 . FIG.  3 ( b ) shows a bottom up view of FIG.  3 ( a ) and FIG.  3 ( c ) shows a dose up view of a mated plug and jack  310 . FIGS.  3 ( a ) and  3 ( c ) show that label surface  330  is unobstructed except for the minor presence of handle  350  of mated plug and jack  310 . An easy to read label surface is highly valued during cord tracing and other such activities. 
     Exemplary Cross Connect System 
     Referring to FIGS.  4 ( a ),  4 ( b ) and  5 ( a )- 5 ( c ), there is shown an exemplary embodiment of a cross connect system  400  in a snap in module configuration. In general, system  400  consists of a jack  410 , plug  415 , and support structure  500 . 
     Referring specifically to FIGS.  4 ( a ) and  4 ( b ), a jack  410  is a 4-pair jack that includes an attached cable termination field or wire termination port slots  420 , guide posts  425  to keep the wires properly spaced and routed, cable jacket stop shelf  430  and a cable retainer  435 . Jack  410  also includes a label surface  440  and jack contacts  445 . Jack  410  further includes a hinge bearing hook  450  for rotatably connecting with the plug  415 . 
     Referring still to FIGS.  4 ( a ) and  4 ( b ), plug  415  includes a handle  455 , plug contacts  460 , a latch  465 , a plug bearing hook  470  and an anti-snag rib  475  that prevents the plug bearing hook from snagging on cables as the jack is installed or removed. 
     Referring now to FIGS.  5 ( a )- 5 ( c ), a support structure  500  is illustrated. Support structure  500  forms the patch cord trough and also provides additional support for the backplanes when implementing a full row of 24 circuits (not shown). The cross connect system further includes receptacles  505  for receiving jacks  510 . The jacks  510  slide into the front end of the receptacles  505  of the support structure  500 . Operationally, a jack  510  snaps into the receptacles  510  of the support structure  500 . These jacks can be easily inserted, removed and replaced from the support structure  500 . Side walls  520  of the receptacles  505  project out beyond the main part of the jack body and function as partitioning walls to keep a plug from making contact to the circuits in the two jacks at the same time. This is illustrated in more detail below with respect to partitioning walls FIG.  8 ( a ). 
     Referring now to FIGS.  6 ( a )- 6 ( c ), a support structure  605  is attached to a backplane  600 . Support structure  605  extends out about four inches from backplane  600  to form a patch cord trough  610 . Support structure  605  has receptacles  620  for receiving jacks. Each receptacle has a latch  625 , rail  630  and stop shelf  635 . Operationally, a jack  640  is inserted through a hole  645  in backplane  600  and snapped into a receptacle  620  on a front end of support structure  605 . There is a groove  648  in jack  640  for mating with rail  630  in receptacle  620 . The groove  648  and the rail  630  serve to guide the jack  640  onto support structure  605  until the stop shelf  635  is encountered and the latch  625  engages jack  640 . The rail  630 , stop shelf  635 , and latch  625  act in combination to hold the jack  640  in receptacle  620  on support structure  605 . 
     Referring now to FIGS.  7 ( a ) and  7 ( b ), a patch cord or plug  700  is mated with a jack  710  in accordance with the principles of the present invention. The following operational description is accurate for any jack and plug utilizing the concepts of the present invention. A plug bearing hook  720  is hooked onto a hinge bearing surface  725 , formed by the hinge bearing hook  730 , which are both behind the partitioning wall  820  of FIG.  8 ( a ). The plug  700  is then rotated into its position by using the handle  735  as a lever to force the plug contacts  740  to mate with the jack contacts  745 . 
     Specifically, as plug  700  rotates about the fulcrum point  750  toward the jack  710 , the plug spring latch  780  engages a latch  770 , and snaps into place. Guide surfaces control the rotation path so that the contacts mate in a precise manner. Specifically, the plug  700  engages the side guide surfaces  830  of FIG.  8 ( a ) before the plug  700  fully engages the hinge bearing hook  730 . After the hook  730  is engaged, the jack  710  starts to rotate about the bearing hook  730 . Prior to any contact engagement, plug  700  engages a guide surface  495  of FIG.  4 ( b ) approximately perpendicular to the side guide surfaces  830  of FIG.  8 ( a ). The guide surfaces  490  and  495  of FIG.  4 ( b ) serve as a guide insuring that jack  710  remains fully seated onto hinge bearing hook  730 , as plug  700  completes a full rotation. 
     The side guide surfaces  830  of FIG.  8 ( a ) extend beyond the hinge bearing hook  730  as well as the jack contacts  745 . Thus, when the plug contacts  740  are mated with the jack contacts  745 , the connections are completed below the outer edges of the side guide surfaces  830  of FIG.  8 ( a ). This protects the contacts for both the plug  700  and the jack  710 . Because the side guide surfaces  830  of FIG.  8 ( a ) are separated in distance to accommodate the width of the plug  700 , the side guide surfaces of FIG.  8 ( a ) also provide lateral support, holding the plug  700  firmly in place. Therefore, manipulating the patch cord&#39;s cordage has very little effect on the security of the patch cord&#39;s connection. The only practical way to disengage a patch cord is by pushing on the handle  735 . If an attempt is made to disengage the patch cord at the point where the cordage enters the plug  700 , pushing with several pounds of force is required because the mechanical advantage is working against that attempt. 
     Design for Single or Multiple Connections 
     As illustrated in FIGS.  8 ( a ) and  8 ( b ), the jacks of the present invention permit connections with plugs of different sizes, varying from 1-pair to 4-pair. Referring to FIG.  8 ( a ) a jack  800  has at least one 4-pair connection site  810 . Jack  800  includes a partitioning wall  820  after every 4-pair connection sites  810 . Partitioning walls  820  prevent plugs from crossing over and making connections to contacts in two jacks simultaneously. Each 4-pair connection site further includes the previously described side guide walls  830 . Each site  810  can accommodate a single plug  840 , a 4-pair plug  850  as shown in FIG.  8 ( b ), or any pair size in between. 
     Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. Details of the structure may be varied substantially without departing from the spirit of the invention and the exclusive use of all modifications that come within the scope of the appended claim is reserved.