Abstract:
The present invention generally relates to communication connectors and internal components thereof. In one embodiment, the present invention is a communication jack comprising hack rotated plug interface contacts having variable cross-sectional widths. In another embodiment, the present invention is a communication jack having back-rotated plug interface contacts where at least two of the plug interface contacts have a differing beam length. In yet another embodiment, the present invention is a communication jack having back-rotated plug interface contacts where at least two of the plug interface contacts have opposing bends in a deflection zone.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/186,697, filed Feb. 21, 2014, which claims the benefit of U.S. Provisional Patent Application No. 61/771,600, filed Mar. 1, 2013, the subject matter of which is hereby incorporated by reference in its entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention generally relates to the field of communication connectors, and more specifically to plug interface contact arrangements, and communication jacks which employ such plug interface contact arrangements. 
       BACKGROUND 
       [0003]    Communication connectors, such as RJ45 jacks, have been and continue to be readily employed in the communication industry. These jacks generally comprise a housing having an aperture for receiving a corresponding plug at one end, a means for terminating a communication cable at another end, and a means for transferring electrical signals between the plug and the communication cable. 
         [0004]    In an RJ45 jack, the means tor transferring the electrical signals typically include eight plug interface contacts (PICs). While the eight PICs are designed to interface eight plug contacts positioned in an eight-position RJ45 plug, respectively, it is also possible to connect a six-position plug (e.g., RJ12, RJ25) or a four-position plug (e.g., RJ9) to an RJ45 jack. However, when compared to an eight-position plug, plug contacts  1  and  8  do not exist in a six-position plug, and plug contacts  1 ,  2 ,  7 , and  8  do not exist in a four-position plug. Therefore, in the locations where the plug contacts are not present, the jack PICs must deflect approximately an additional 0.027 inches as compared to locations where the plug contacts do exist. This additional deflection can cause the outer PICs to plastically deform and cause damage (or otherwise prevent operation within certain specifications) to the jack if the deformation is significant enough. Additionally, in some instances the positioning/arrangement of the PICs may have some effect on the amount of undesired crosstalk produced within the jack and/or how the undesired crosstalk is compensated for. 
         [0005]    Thus there exists a need for communication jacks with improved designs. 
       SUMMARY 
       [0006]    Accordingly, embodiments of the present invention are directed to communication connectors and/or internal components thereof. 
         [0007]    In one embodiment, the present invention is a communication jack having back-rotated plug interface contacts where at least one plug interface contact has a non-uniform cross-sectional width. 
         [0008]    In another embodiment, the present invention is a communication jack having back-rotated plug interface contacts where at least two of the plug interface contacts have a differing beam length. 
         [0009]    In yet another embodiment, the present invention is a communication jack having back-rotated plug interface contacts where at least of the plug interface contacts have opposing bends in a deflection zone. 
         [0010]    In still yet another embodiment, the present invention is a communication connector comprising a housing with an aperture for receiving a plug, and a plurality of plug interface contacts (PICs) at least partially received in the aperture. The plurality of plug interface contacts include respective ends proximal the aperture and ends distal the aperture, the distal ends fixed within the connector, the proximal ends rotating relative to the distal ends, wherein at least some of the plurality of plug interface contacts have a non-uniform cross-sectional width. In a variation of this embodiment, the connector is included in a communication system 
         [0011]    In still yet another embodiment, the present invention is a communication connector comprising a housing with an aperture for receiving a plug and a plurality of plug interface contacts (PICO at least partially received in the aperture. The plurality of plug interface contacts include respective ends proximal the aperture and respective ends distal the aperture, the distal ends fixed within the connector, the proximal ends rotating relative to the distal ends, the proximal ends configured, when the connector being mated to the plug, such that some of the proximal ends are deflected more than other of the proximal ends. 
         [0012]    In still yet another embodiment, the present invention is a communication connector comprising a housing with an aperture for receiving a plug and a plurality of plug interface contacts (PICs) at least partially received in the aperture. The plurality of plug interface contacts include respective ends proximal the aperture and respective ends distal the aperture, the distal ends fixed within the connector, the proximal ends rotating relative to the distal ends, the distal end being hemmed. 
         [0013]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  illustrates a communication system according to an embodiment of the present invention. 
           [0015]      FIG. 2  illustrates a plug and jack combination according to an embodiment of the present invention. 
           [0016]      FIG. 3  illustrates an exploded view of a communication jack according to an embodiment of the present invention. 
           [0017]      FIG. 4  illustrates the jack of  FIG. 3  with the front housing removed. 
           [0018]      FIG. 5  illustrates a side view of the jack of  FIG. 4 . 
           [0019]      FIG. 6  illustrates the PICs of the jack from  FIG. 3 . 
           [0020]      FIG. 7A  illustrates some of the PICs assembled to the printed circuit board of the jack of  FIG. 3 . 
           [0021]      FIG. 7B  illustrates a side view of the jack of  FIG. 3  mated with a plug, with the front housing removed. 
           [0022]      FIG. 8  illustrates the assembly of a PIC to the printed circuit board of the jack of  FIG. 3 . 
           [0023]      FIG. 9  illustrates a rear isometric view of the front housing of the jack of  FIG. 3 . 
           [0024]      FIG. 10  illustrates a front isometric partial section view of  FIG. 2 . 
           [0025]      FIG. 11  illustrates a jack having a PIC arrangement/form according to another embodiment of the present invention. 
           [0026]      FIG. 12  illustrates the PICs of the jack of  FIG. 11 . 
           [0027]      FIG. 13  illustrates an exploded view of a communication jack according to yet another embodiment of the present invention. 
           [0028]      FIG. 14  illustrates the jack of  FIG. 13  with the front housing removed and the PICs exploded. 
           [0029]      FIG. 15  illustrates the jack of  FIG. 13  with the front housing removed. 
           [0030]      FIG. 16  illustrates a side vide of  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    An exemplary embodiment of the present invention is illustrated in  FIG. 1 , which shows a communication system  30 , which includes a patch panel  32  with jacks  34  and corresponding RJ45 plugs  36 . Respective cables  38  are terminated to plugs  36 , and respective cables  40  are terminated to jacks  34 . Once a plug  36  mates with a jack  34  data can flow in both directions through these connectors. Although the communication system  30  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  30  can further include cabinets, racks, cable management and overhead routing systems, and other such equipment. 
         [0032]    The jack and plug combination of  FIG. 1  is also shown in  FIG. 2  which illustrates the network jack  34  mated with the RJ45 plug  36 . Note that in this figure, the orientation of the network jack  34  and the RJ45 plug  36  is rotated 180° about the central axis of cable  40  as compared to the orientation of  FIG. 1 . 
         [0033]      FIG. 3  illustrates an exploded view of the network jack  34 , which includes a front housing  42 , plug interface contacts (PICs)  44 , a printed circuit board (PCB)  46  (which in some embodiments may have crosstalk compensation components thereon), an insulation displacement contact (IDC) support  48 , IDCs  50 , a rear housing  52 , and a wire cap  54 . In the currently described embodiment, the PICs may be referred to as “back-rotated” which implies that the PICs are fixed at the (PCB) and generally flex about the location where each respective PIC connects to the PCB.  FIG. 4  illustrates the assembled state of PICs  44  to PCB  46  of the network jack  34  with the front housing  42  removed for clarity. The subscript number for each PIC  44  corresponds to the RJ45 pin positions as defined by ANSI/TIA-568-C.2. A side view of  FIG. 4  is depicted in  FIG. 5 , and PICs  44  are illustrated individually in  FIG. 6 . 
         [0034]    As noted previously, when an RJ45 jack is mated with a six-position or a four-position plug, the outer PICs (PICs  44   1  and  44   8  for a six-position plug, and PICs  44   1 ,  44   2 ,  44   7 , and  44   8  for a four-position plug) must be able to deflect an additional 0.027″ over PICs  44   3 ,  44   4 ,  44   5 , and  44   6 , and have sufficient elasticity to return to an unloaded state once the six-position or the four-position plug is removed. This can help provide proper future functionality by ensuring that sufficient normal force exists to mate with all corresponding plug contact  56  of an RJ45 plug (see  FIG. 10 ). In order to reduce at least some amount of plastic deformation of the PICs, it is beneficial to distribute the mechanical stresses over at least a significant portion of the deflection zone, which in the current embodiment spans between the plug contact zone  58  and the PCB  46  as shown in  FIGS. 6 and 7A . This may avoid localized stress peaks and may result in an increased material yield. 
         [0035]    One way of achieving a desired distribution of mechanical stress is by varying the width of the PICs. An example of this is shown in PIC  44   4 , which has a pocket  604  which serves to assist in distributing stresses by varying the cross-sectional width of PIC  44   4 . The cross-section is varied by adding more material to PIC  44   4  as the distance is increased from the plug contact zone  58 . This effectively causes the stiffness of PIC  44   4  to increase as distance is increased from the plug contact zone  58 , resulting in a distribution of stresses over an increased portion of the deflection zone. Although PIC  44   4  is shown as an example, this varying cross-section is also applied to the remaining PICs  44   1 ,  44   2 ,  44   3 ,  44   5 ,  44   6 ,  44   7 , and  44   8 . However, PICs  44   2 ,  44   3 , and  44   7  vary their cross-sectional width by adjusting respective outer faces  62 , while PICs  44   1 ,  44   4 ,  44   5 ,  44   6 , and  44   8  vary their cross-sectional width with an internal pocket  60 . 
         [0036]    PICs  44  vary their cross-sectional widths differently in order o control the relative amount of crosstalk as well as account for their full range of deflection. For example, PICs  44   1 ,  44   2 ,  44   7 , and  44   8  deflect more than PICs  44   3 ,  44   4 ,  44   5 , and  44   6  if a four position plug is inserted. Such a difference in deflection may cause the distance between PICs  44   2  and  44   3 , and  44   6  and  44   7  to become sufficiently small to cause a risk of an electrical short or a hipot failure. To reduce the potential of these risks, the cross sectional width of the PICs can be varied such that sufficient distance remains between adjacent PICs even in the event of varying levels of deflection. For example, referring to  FIG. 6 , one will notice that the outer face  62   2  of PIC  44   2  and the outer face  62   3  of PIC  44   3  are tapered towards the contact zone  58 . Such tapering may increase the minimum distance between the respective PICs when these PICs are deflected differently. 
         [0037]    In addition to a varying cross-sectional width, the PICs  44  employ different bend profiles. This can he seen in the side view of  FIG. 5 . PICs  44   1  and  44   7  have a first bend profile, PICs  44   3  and  44   5  have a second bend profile, and PICs  44   2 ,  44   4 ,  44   6 , and  44   8  have a third bend profile. Because PICs  44   1  and  44   7  may deflect more than PICs  44   3  and  44   5  in the event of mating with four-position plug, PICs  44   1  and  44   7  have a longer deflection zone (than PICs  44   3  and  44   5 ) which may allow them to sustain additional deflection without plastic deformation. 
         [0038]    In addition to having mechanical resiliency, in certain cases it may be important to focus on the electrical performance of the PIC arrangement. For example, compensating for the crosstalk that occurs between differential signal pairs 4:5 and 3:6 is typically more difficult to achieve because the plug pair combination 4:5-3:6 is required by the ANSI/TIA-568-C.2 standard to have the largest magnitude of crosstalk out of all pair combinations in the plug. The reason for this is that pair 4:5 runs between split pair 3:6 for a distance that starts in the RJ45 plug  36  and ends at the first compensation zone in the jack  34 . Therefore, the ensuing discussion focuses on the ability of PICs  44  to assist in obtaining the desired electrical performance, particularly for signal pairs 4:5 and 3:6. 
         [0039]    The capacitive and inductive coupling that occurs between signal line  3  and signal line  4  in the RJ45 plug  36  adds crosstalk between differential pair combinations 4:5 and 3:6. Similarly, the capacitive and inductive coupling that occurs between signal line  5  and signal line  6  also adds crosstalk between differential pair combinations 4:5 and 3:6. It is possible to reduce the negative effects of crosstalk via several ways. First, it is advantageous to reduce the initial amount of capacitive and inductive crosstalk coupling occurring between the 3:4 and 5:6 signal lines. This can be achieved by having PICs  44   3  and  44   5  bend down (relative to orientation shown in  FIG. 7A ) and having PICs  44   4  and  44   6  bend up between the plug contact zone  58  and the PCB  46 . Because PIC  44   3  bends down and PIC  44   4  bends up, distance  57  (see  FIG. 5 ) between the two PICs is increased, resulting in a decreased amount of crosstalk coupling. An equivalent relationship exists between PICs  44   5  and  44   6 . 
         [0040]    Another example of reducing the initial amount of crosstalk is illustrated in  FIG. 7B  where the network jack  34  (with front housing removed), is shown with PICs  44  having respective proximal ends  47  and distal ends  43 . When a plug  36  is mated to the jack  34 , some proximal ends  47  (e.g., corresponding to PICs  44   1 ,  44   3 ,  44   5 , and  44   7 ) deflect more than other proximal ends  47  (e.g., corresponding to PICs  44   2 ,  44   4 ,  44   6 , and  44   8 ). Consequently electrical coupling between adjacent PICs  44  can be reduced in the vicinity of proximal ends  47 . 
         [0041]    Second, it is advantageous to provide a compensation signal. To compensate for the offending crosstalk between the 3:4 and 5:6 pairs, compensative capacitive coupling is required between signal lines  3  and  5 , and signal lines  4  and  6 , respectively. The closer the compensative capacitive coupling is to the offending crosstalk (e.g., the RJ45 plug contacts  56 ) the more effective the compensation and therefore better performance may be attainable. At least some of the desired. compensative capacitive coupling can be achieved by placing PICs  44   4  and  44   5  within a near proximity of PICs  44   6  and  44   3 , respectively. The increase in the cross-sectional width in the deflection zone allows the outer face  62   4  of PIC  44   4  to be closer to outer face  62   6  of PIC  44   6  (shown crosshatched) than if PICs  44  were of uniform width. This relative closeness results in increased compensative capacitive coupling between signal lines  4  and  6 . Similarly the increased width of PICs  44   3  and  44   5  results in increased compensative capacitive coupling between signal lines  3  and  5 . 
         [0042]    While additional compensation may be required to further reduce the offending crosstalk between signal lines 3:4 and 5:6 (this additional compensation can occur on PCB  46 ), the compensation provided by PICs  44  lessens the amount of compensation that may be needed on the PCB  46 . It also brings the effective compensation region closer to plug contacts  56 , which may result in higher electrical performance potential. 
         [0043]    Referring to  FIG. 8 , a compliant pin  64  is used on PIC  44   1  to provide a mechanical retention as well as an electrical bond between the PIC  44   1  and the PCB  46 . Compliant pin  64  has an “eye of the needle” shape, having an elongated oval slit, and is hemmed back upon itself to effectively double the material thickness as shown in the detail view of  FIG. 8 . PIC  44   1  is fabricated from a sufficiently thin material to obtain the necessary deflection while not incurring plastic deformation. Hemming the compliant pin  64  may increase the strength of the hemmed region and provides a more robust interface to PCB  46 . Although  FIG. 8  illustrates only PIC  44   1 , the same compliant pin  64  may be used on any of the remaining PICs. 
         [0044]    Besides ensuring proper vertical movement and resiliency of the PICs  44 , it may also be advantageous to at least partially restrain their lateral movement.  FIG. 9  illustrates a rear isometric view of the front housing  42 . Front combs  66  are integrated into the front housing  42  to control the relative spacing among PICs  44  and prevent PICs  44  from crossing, electrically shorting, and/or getting sufficiently close to one another where a hipot failure can occur. Front combs  66  are large enough to ensure that PICs  44  are combed during the entire state of deflection, including solid plug insertion if a four or six position plug is inserted.  FIG. 10  illustrates the deflection of the PICs  44  during normal operation via a front isometric partial section view of  FIG. 2 . In this figure, an exemplary RJ45 plug housing  68  is shown in dashed lines for clarity. When an RJ45 plug  36  is inserted into the network jack  34 , plug contacts  56  interface with PICs  44  as shown. PICs  44  deflect downward within front combs  66  and create pressure at the interface between respective plug contacts  56  and PICs  44 , resulting in an electrical bond sufficient for data to flow. 
         [0045]    A variation of the currently described embodiment of the network jack  34  and its PICs is shown in  FIGS. 11 and 12 .  FIG. 11  illustrates the alternate PICs  70  assembled to PCB  46 , and  FIG. 12  illustrates the alternate PICs  70  individually, As seen in these figures, PICs  70  do not contain pockets  60 . Instead, at least in some cases, the cross-sectional width is varied by adjusting the overall width of the respective PICs as measured from one side to the other. The omission of pockets may simplify the manufacture of PICs  70  while still providing a similar effect of distributing bending stresses over the deflection zone and reducing plastic deformation. 
         [0046]    Another embodiment of a jack having PICs in accordance with an embodiment of the present invention is shown in  FIG. 13 . This figure shows an exploded view of a jack  134 , which includes a front housing  142 , back-rotated PICs  144 , a PCB  146  (which in some embodiments may have crosstalk compensation components thereon), an IDC support  148 , IDCs  150 , a rear housing  152 , and a wire cap  154 . 
         [0047]    As shown more clearly in the perspective views illustrated in  FIGS. 14 and 15 , and the side profile view illustrated in  FIG. 16 , the PICs  144  are comprised of four different types of PICs  160 ,  162 ,  162 , and  164 . These PICs  144  are attached to a PCB  146  via a top and bottom row. The top row includes PICs  162  and  166 , and the bottom row includes PICs  160  and  164 . 
         [0048]    As shown in  FIG. 16 , PICs  160  and  162  include downward-facing concave loops  170  and  172 , respectively, positioned near the point of attachment to the PCB (which is also the pivot point for the PICs when said PICs are deflected during mating). These loops  170  and  172  may increase the mechanical performance of the jack  134 . In particular, when the jack  134  is mated with an eight-position plug, PICs  160  interface plug contacts  2  and  8 , PICs  162  interface plug contacts  1  and  7 , PICs  164  interface with plug contacts  4  and  6 , and PICs  166  interface plug contacts  3  and  5 . However, when the jack  134  is mated with a four-position plug, PICs  160  and  162  make contact with the plug body and are subject to a higher degree of deformation than PICs  164  and  166  which mate with plug contacts  1 ,  2 ,  3  and  4 . Loops  170  and  172  provide PICs  160  and  162  with an increased beam length, which helps accommodate the additional displacement and also helps provide the necessary normal force to potentially prevent at least some plastic deformation. Similar benefits can be realized during the insertion of a six-position plug which causes the outer-most PICs to undergo the greatest degree of deflection. 
         [0049]    Since PICs  164  and  166  are not expected to withstand the same degree deflection as PICs  160  and  162 , their beams length can be shorter than the beam length of PICs  160  and  162 . The shorter beam length may simplify the manufacturing process and may also improve the electrical performance of the jack  134  as it may help bring any crosstalk compensation components which may be present on the PCB  146  closer to the origin of any offending crosstalk. 
         [0050]    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. Furthermore, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. 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.