Abstract:
A communication system has a support and a communication connector attached to the support wherein the connector assembly has a termination lever. The system can further include a wire cap connected to a plurality of cable conductors. The wire cap can include a cover cap. The cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly. The support can be one of a faceplate, a patch panel, a surface mount box, or a media distribution unit.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/934,234, filed Jan. 31, 2014 and U.S. Provisional Patent Application Ser. No. 62/031,927, filed Aug. 1, 2014, which are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to wiring for audio visual installations and specifically to a wiring solution for audio visual installations that uses 4-twisted pair cabling. 
     BACKGROUND OF THE INVENTION 
     The AV (audio visual) market is expanding due to increased use of computer graphics and visual telecommunication media in educational, business, healthcare, government, and other applications. There are a variety of cable and connector types such as VGA, RCA, 3.5 mm, and digital connections such as HDMI, and these connectors are generally not field terminable. Another problem with these solutions is that the connectors generally are not suitable for pulling through an electrical conduit, and consequently are not suitable for a pre-configured solution, i.e., a cable assembly employing such connectors generally are not suitable for pre-assembly offsite and then installation as an assembly at the installed location. 
     SUMMARY OF THE INVENTION 
     In one embodiment, a communication system has a support and a communication connector attached to the support wherein the connector assembly has a termination lever. 
     In some embodiments, the system can further include a wire cap connected to a plurality of cable conductors. The wire cap can include a cover cap. 
     In some embodiments, the cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly. 
     In some embodiments, the support can further include a mounting surface for mounting the communication connector assembly, and the communication connector assembly can include a port for receiving the wire cap and the plurality of cable conductors such that a central axis of the port is non-normal to the front surface. In some embodiments the central axis can be 45° to the front surface. 
     In some embodiments, the communication connector assembly can further include a plurality of isolated quadrants within the port. 
     In some embodiments, the wire cap can include at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that the pair inhibits a respective connected conductor release. 
     In some embodiments, the wire cap includes a divider crossbar and the divider crossbar can include cable posts. 
     In some embodiments, the support is at least one of a faceplate, a patch panel, a surface mount box, and a media distribution unit. 
     In one embodiment, a method of connecting a communication cable to a communication connector assembly includes the steps of: wire mapping a plurality of conductors into a wire cap, inserting the wire cap into the communication connector assembly, pressing a termination lever of the communication connector assembly onto the wire cap, and terminating the plurality of conductors into the communication connector assembly. 
     In some embodiments, the termination step also connects each of the plurality of conductors to respective ones of a plurality of insulation displacement contacts. 
     In one embodiment, a wire cap for terminating a plurality of conductors of a communication cable to communication connector has at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that at least one the pair having the primary hook is oriented opposite to respective the secondary hook. 
     In some embodiments, the primary hook and the respective secondary hook inhibit a respective connected the conductor release. 
     In some embodiments, the wire cap includes a divider crossbar and the divider crossbar can include cable posts. 
     In one embodiment, a wire cap assembly for terminating a plurality of conductors of a communication cable to communication connector has a wire cap having a termination cap including a plurality of termination slots and a protective cover having integral tabs which align with respective the termination slots. 
     In some embodiments, the integral tabs inhibit movement of the plurality of conductors. 
     In one embodiment, a communication system can include a support and a communication connector assembly connected to the support. The connector assembly can include a female connector assembly configured for receiving a plurality of cable conductors with a central axis of the female connector assembly being non-normal to the front surface. The female connector assembly can further include a plurality of isolated quadrants. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a front isometric view of an audio visual faceplate with an integrated hinged termination method for a circular connector. 
         FIG. 2  is a rear isometric view of the audio visual faceplate of  FIG. 1   
         FIGS. 3 and 4  are exploded views of the faceplate of  FIG. 1 . 
         FIG. 5  is an isometric view of a circular connector assembly for use with the audio visual faceplate of  FIG. 1 . 
         FIG. 6  is a front isometric view of the circular connector assembly of  FIG. 5  exploded along the central axis. 
         FIG. 7  is a rear isometric view of the circular assembly of  FIG. 5  exploded along the central axis. 
         FIG. 8  is a cross-sectional view of the circular assembly of  FIG. 5 . 
         FIG. 9  is an isometric view of the circular connector assembly without a pulling cap. 
         FIGS. 10 a  and 10 b    are top views of the circular connector assembly of  FIG. 9  ( FIG. 5  without the pulling cap). 
         FIG. 11  is a front isometric view of a female connector assembly for use with the audio visual faceplate of  FIG. 1 . 
         FIG. 12  is a rear isometric view of the female connector assembly of  FIG. 11 . 
         FIG. 13  is an exploded rear isometric view of the female connector assembly of  FIG. 11 . 
         FIG. 14  is an exploded side view of the female connector assembly of  FIG. 11 . 
         FIG. 15  is a top view of the female connector assembly of  FIG. 11  with terminated conductors shown. 
         FIG. 16  is a bottom view of the female connector assembly of  FIG. 11 . 
         FIG. 17  is a top view of the circular connector assembly of  FIG. 5  mated to the female connector assembly of  FIG. 11 . 
         FIG. 18  is a cross-sectional view of the mated connectors of  FIG. 17  taken along line B-B. 
         FIG. 19  is a top view of the mated connector assembly of  FIG. 17  showing the keying of the connectors. 
         FIG. 20  is a cross-sectional view of the mated connectors of  FIG. 17  taken along line C-C of  FIG. 19 . 
         FIG. 21  is an exploded view of the mated connector assembly of  FIG. 17 . 
         FIGS. 22 a  and 22 b    are cross-sectional views of the mated connector assembly of  FIG. 17  taken along line D-D of  FIG. 21 . 
         FIGS. 23 and 24  are rotated rear and side view of the faceplate  FIG. 1  with the termination levers in two different orientations. 
         FIG. 25  is a front view of a first alternate faceplate. 
         FIG. 26  is a rear isometric view of the faceplate of  FIG. 25 . 
         FIG. 27  is a top level isometric view a second alternate faceplate. 
         FIG. 28  is a rear isometric view of the faceplate of  FIG. 27 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is a circular connector that utilizes twisted pair cabling that can either be field or factory terminated depending on customer preference, can be fed through conduit with a pull cap without damage to the connector, is fully shielded, and may be utilized in a pre-configured AV solution. The present invention utilizes an integrated hinged termination method that provides for a fast termination while securing the connector. The connector on the back of the faceplate is angled such that cable management is easier as to not violate cable bend radius requirements. 
       FIG. 1  is a front isometric view of communication system  40 , according to the present invention, which includes faceplate assembly  42  connected to wall  44 .  FIG. 2  is a rear isometric view of communication system  40  (wall  44  has been removed for clarity) in which a circular wire cap assembly  46  is connected to female connector assembly  48  on the rear of faceplate assembly  42 , via termination lever  50 . In a complete installation patch and/or horizontal cable assemblies typically are installed on the back and front of the faceplate in order to complete communication system  40 , the exclusion of these is not limiting and any form of patching/cabling method may be used to complete the final assembly. 
     Referring now to  FIG. 3  and  FIG. 4 , exploded views of faceplate assembly  42  (front and rear isometrics respectively) includes screws  52 , faceplate  54 , connector  56 , circuit board  58 , faceplate backing  60 , keystone RJ45 jack  62 , keystone USB coupler  64 , termination levers  50 , female connector assembly  48 , and circular wire cap assembly  46 . Keystone RJ45 jack  62  and keystone USB coupler  64  are shown but may include any non-limiting variety of keystone modules. Connector  56  is shown as an HDMI connector; however, other non-limiting connectors may be routed through female connector assembly  48  and circuit board  58 , examples of which include RCA, VGA, DVI, and stereo connectors. 
       FIG. 5  is an isometric view of circular wire cap assembly  46 , which is protected by pulling cap  66 .  FIG. 6  is a front isometric view of circular wire cap assembly  46  and pulling cap  66  that is exploded along central cable axis  68 .  FIG. 7  is a rear isometric view of circular connector assemblies  46  and pulling cap  66  that is exploded about central cable axis  68 . Circular wire cap assembly  46  includes wire termination cap  70 , connecting block  72 , grounding ring  74 , cover cap  76 , and twisted pair cable  78 . Twisted pair cable  78  is shown as a shielded twisted pair cable but termination can be achieved with an unshielded termination cable as well in circular wire cap assembly  46 . Pulling cap  66  has tabs  80  that align with termination slots  82  ( FIG. 10 ) on termination cap  70 . Termination cap  70  secures to connecting block  72  via latches  84  which align with latch pockets  86 . Grounding ring  74  bottoms out on ledge  87  when placed in connecting block  72 . Grounding base tabs  88  align with pockets  90  during assembly. Once terminated grounding base tabs  88  deflect and consequently increase in length along central cable axis  68 . Recessed pockets  92  on termination cap  70  and recessed pockets  94  on connecting block  72  allow for this extension and prevent grounding base tabs  88  from being tangled during installation or while feeding circular wire cap assembly  46  thru conduit. Grounding cable tabs  96  make contact with cable braid  98  during assembly to make the connection between circular wire cap assembly  46  and cable braid  98 . Flexible latches  100  on cover cap  76  align with latch pockets  102  on connecting block  72 . Once cover cap  76  is installed it prevents grounding ring  74  from being removed from wire cap assembly  46 . Circular wire cap assembly  46  needs to be keyed such that during assembly it is in the correct orientation with respect to female connector assembly  48 . In order to accomplish this alignment, slot  104  on termination cap  70  aligns with alignment slot  106  on connecting block  72  which aligns with alignment slot  108  on cover cap  76 . Twisted pair cable  78  includes conductors  110 , cable braid  98 , and cable jacket  112 . 
       FIG. 8  is a cross-section view of circular wire cap assembly  46  protected by pulling cap  66 . From this view it can be seen that tabs  80  align with termination slots  82  such that conductors  110  are compressed and held in place during installation thru conduit. Also, primary wire hooks  114  can be seen such that conductors  110  are underneath and further hold conductors  110  during installation through conduit. 
       FIG. 9  is an isometric view of circular wire cap assembly  46 , (this is similar to  FIG. 5  but with pulling cap  66  removed).  FIG. 10 a    and  FIG. 10 b    is a top view of circular wire cap assembly  46  along central cable axis  68 . Conductors  110  align with termination slots  82 , such that each conductor  110  fits into a separate termination slot  82 . Both primary wire hooks  114  and secondary wire hooks  116  flex out of the way during conductor  110  assembly and help secure conductors  110  during both install and termination. Primary wire hooks  114  and secondary wire hooks  116  flex in opposite directions such that during installation conductor  110  is fed through one hook at a time. Primary wire hooks  114  and secondary wire hooks  116  are in opposite directions to insure that no conductor  110  falls out of wire slot  82  during installation. Cable divider  118  has a twofold purpose in that it controls the depth at which cable  78  is inserted into circular wire cap assembly  46  and separates conductor pairs  110  into individual quadrants  120 . Cable posts  122  on cable divider  118  control the variation in wire cap assembly  46 , by controlling the spacing and orientation of conductor pairs  110  on opposite ends of cable  48 . One end of cable  48  is shown in  FIG. 10 a    and the opposite end of the cable in which conductors  110  need to cross is shown in  FIG. 10 b   . Alternate non-limiting wiring patterns can be achieved through different routings on circuit board  58 . Relief slots  124  on termination cap  70  align with grounding spacers  126  on grounding base  128  of female connector assembly  48 . 
       FIG. 11  is a front isometric view of female connector assembly  48 , and  FIG. 12  is a rear isometric view of female connector assembly  48 . Female connector assembly  48  includes grounding base  128 , standoff  130 , and eight IDCs  132 .  FIG. 13  is an exploded rear isometric view of female connector assembly  48 .  FIG. 14  is an exploded side view of female connector assembly  48 . Grounding base  128  has keying rib  134  which aligns with alignment slot  104 ,  106 , and  108 , which insure circular wire cap assembly  46  is correctly aligned with female connector assembly  48 . Ledge  136  on grounding base  128  is used for manufacturing purposes such that it gives a flat edge for handling and a place to push on when inserting female connector assembly  48  into circuit board  58 . In order to complete the ground connection between female connector assembly  48  and circuit board  58 , posts  138  on female connector assembly are pressed into circuit board  58 . Posts  138  are shown as a solder connection but may be secured to circuit board  58  by other non-limiting ways such as a press fit. Cutout  140  on grounding base  128  and cutoff  142  on standoff  130  shorten the overall length of the connector assembly  48  which saves space on circuit board  58 . Support ribs  144  on standoff  130  support IDCs  132  from buckling when compliant pins  146  of IDCs  132  are pressed into circuit board  58 . IDCs  132  are shown with compliant pins  146  for being secured to the circuit board but may use other non-limiting ways of being secured to the circuit board such as soldering. Grounding spacers  126  on grounding base  128  align with relief slots  124  on termination cap  70  such that each pair of conductors  110  is isolated during termination from the adjacent pair of conductors  110 . Grounding spacers  126  are angled towards the center to allow for the end to end effect of twisted pair cables and let pairs of conductors  110  crossover on opposite ends of female connector assembly  48 . Grounding bars  148  of grounding base  128  are below surface  150  (see  FIG. 15 ) of standoff  130 , and isolate IDC pairs  132  from each other similar to how grounding spacers  126  isolate conductor pairs  110  above surface  150 . Center divider  152  of grounding base  128  creates a uniform spacing between ground and IDC pairs  132 . IDCs  132  are a mirror image about datum  154  (shown as cross-section B-B of  FIG. 17 ), so as to keep a uniform spacing to ground and reduce the amount of unique components within female connector assembly  48 . Cutouts  156  on standoff  130  align with grounding spacers  126 , and cutouts  158  align with grounding bars  148  to allow for clearance between standoff  130  and grounding base  128 . 
       FIG. 15  is a top view of female connector assembly  48 ; this is the same orientation as circular wire cap assembly  46  would be installed along central cable axis  68 .  FIG. 15  shows the isolation of pairs of conductors  110  due to grounding spacers  126 .  FIG. 16  is a bottom view of female connector assembly  48 ; this is the same orientation as circular wire cap assembly  46  is installed along central cable axis  68 . This is also the orientation in which standoff  130  is loaded into grounding base  128 , and IDCs  132  are loaded into standoff  30  along central cable axis  68  to complete female connector assembly  48 . Cutouts  160  in standoff  130  allow for posts  138  to not interfere during assembly. Ribs  162  add material between grounding base  128  and IDCs  132  so as to reduce chances of failure during dielectric withstand voltage or “Hipot” testing. 
       FIG. 17  is a top view of female connector assembly  48  and circular wire cap assembly  46 .  FIG. 18  is a cross-section B-B from  FIG. 17  of the assembly of female connector assembly  48  and circular wire cap assembly  46 .  FIG. 18  view further demonstrates the isolation of pair of conductors  110  due to grounding spacers  126 , and also shows the relative space in the center of grounding spacers  126  due to the angled center to allow for crossover pairs on opposite ends of female connector assembly  48 .  FIG. 19  is a top view that demonstrates how female connector assembly  48  is keyed during the installation of circular wire cap assembly  46  via keying rib  134  which aligns with alignment slots  104 ,  106 , and  108 . 
       FIG. 20  is a cross-section C-C from  FIG. 19  of the assembly of female connector assembly  48  and circular wire cap assembly  46 . This view illustrates the full electrically bonded path between shielded braid  98  of twisted pair cable  78  and posts  138  of grounding base  128 . Grounding cable tabs  96  of grounding ring  74  make contact with braid  98  of twisted pair cable  78  at contact point  164 . Grounding base tabs  88  of grounding ring  74  make contact with grounding base  128  at contact point  166 . Posts  138  of grounding base  128  connect to circuit board  58  (for clarity circuit board  58  is not shown in  FIG. 19 ) thus completing the full path to ground. 
       FIG. 21  is an exploded view of female connector assembly  48  and circular wire cap assembly  46 .  FIG. 22 a    and  FIG. 22 b    are cross-section views of  FIG. 21  about Section D-D in which  FIG. 22 a    and  FIG. 22 b    show circular wire cap assembly  46  assembled with opposite ends (two scenarios) of cable  78 . These views further show how grounding spacers  126  is angled center to allow for crossover pairs on opposite ends of female connector assembly  48 , while still maintaining electrical isolation. 
       FIG. 23  is a rotated rear and side views of faceplate assembly  42 , with termination levers  50  in two different orientations. Termination lever  50   a  is in the unloaded position, and termination lever  50   b  is the position needed to insert circular wire cap assembly  46  through large slot  168  of termination lever  50 . Termination lever  50  rotates about hinge  170 , and is secured by hook  172 .  FIG. 24  is a rotated view of communication system  40  and its projection, with termination levers  50  in two different orientations. Termination lever  50   a  is in the unloaded position, and termination lever  50   b  is in the terminated position. Termination lever  50  is rotated such that the bottom surface pushes on cover cap  76  of circular wire cap assembly  46  in order to generate the force needed such that IDCs  132  make electrical contact with conductors  110 . Once circular wire cap assembly  46  is terminated, twisted pair cable  78  passes through small slot  173  without interference. In order to insure a complete termination lip  174  must clear flexible latch  176 , which forces termination cap  70  to bottom out on surface  150  of standoff  130 . 
     As described above, the present invention can have mounting options for keystone modules.  FIG. 25  is a front isometric view of communication system  178  according to a first alternate embodiment of the present invention.  FIG. 26  is a rear isometric view of communication system  178 . Communication system  178  replaces faceplate backing  60  with faceplate backing  180 , and faceplate  54  with faceplate  179 , and no longer has an option for mounting of keystone modules. 
     The present invention has been shown used in single gang faceplates only, however this solution may be used in any non-limiting gang of faceplates.  FIG. 27  is a top level isometric view of a second alternate embodiment showing communication system  182 .  FIG. 28  is a rear isometric view of communication system  182 . Communication system  182  is shown paired with a GFCI faceplate  184  populated with RJ45 modules  186  which is mounted to double gang faceplate  188 . Although communication systems  182  is shown paired with a GFCI faceplate, system  182  can include other faceplate backing  60  or  180  in any non-limiting combination. Modules  186  are shown as Panduit Mini-Com RJ45 network jacks however they may have included any non-limiting modules examples of which include USB, Fiber, AV modules, and others. 
     The present invention has been shown as a fully shielded assembly; however, in many applications shielding may not be required so in order to reduce the amount of components and end cost of the assembly, the solution can be used as an unshielded solution. 
     While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing without departing from the spirit and scope of the invention as described.