Abstract:
An electrical connector ( 100 ) for being mounted on a main PCB comprises an insulative housing ( 1 ) having a plurality of cavities ( 11, 12 ) and a rear opening ( 13 ), a plurality of insert module ( 3 ) received in the rear opening of the housing, and a shell member ( 21, 22 ) substantially surrounding the housing. Each insert module includes a plurality of contacts ( 31, 32 ) including contact portions ( 312, 321 ) extending into a corresponding cavity of the housing, and a power module ( 9 ). Each power module includes a hole ( 93 ) in a rear portion thereof. The shell member includes retaining tabs ( 213 ) in a rear portion for engaging with the openings of the power modules.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a related to U.S. patent application entitled “ELECTRICAL CONNECTOR WITH REAR GROUND PLATE”, which is contemporaneously filed, and assigned to the common assignee. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to electrical connectors and more particularly, to a multi-port modular jack for mounting to a printed circuit board (PCB).  
           [0004]    2. Description of the Prior Art  
           [0005]    High-speed modular jacks usually have shells for avoiding electromagnetic interference (EMI). U.S. Pat. No. 5,775,946 issued to Briones on Jul. 7, 1998 disclosed a conventional multi-port RJ-type electrical connector. The Briones connector includes a molded housing which defining a plurality of ports in side-by-side relationship for receiving a plurality of mating connectors, and a one-piece stamped shield substantially surrounding the housing. The Briones housing defines a plurality of cavities in a bottom portion thereof. The shield includes a plurality of latches. Each latch engages with a corresponding cavity of the housing.  
           [0006]    However, in high speed application, filter devices for signal conditioning, such as magnetic coils or PCBs with capacitive arrays, may arranged in a rear portion of the housing with conductors extending downwardly. The Briones latches of the shield engaging with the cavities in a bottom portion of the housing disclosed in the Briones connector complicated the arrangement of the filter devices. Moreover, the overall one-piece stamped shield as disclosed in the Briones connector must be substituted when adding an extra part in the jack, which is a disadvantage to decrease the cost.  
           [0007]    Hence, an electrical connector with an improved shell arrangement is needed to overcome the foregoing shortcomings.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    A main object of the present invention is to provide an electrical connector with rear retention means for securing a shell to an insulative housing.  
           [0009]    An electrical connector for being mounted on a main PCB comprises an insulative housing having a plurality of cavities and a rear opening, a plurality of insert module received in the rear opening of the housing, and a shell member substantially surrounding the housing. Each insert module includes a plurality of contacts including contact portions extending into a corresponding cavity of the housing, and a power module. Each power module includes a hole in a rear portion thereof. The shell member includes retaining tabs in a rear portion for engaging with the openings of the power modules. 
       
    
    
       [0010]    Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a perspective view of a modular jack according to the present invention, wherein two insert modules are received in the housing.  
         [0012]    [0012]FIG. 2 is a perspective view of an insert module.  
         [0013]    [0013]FIG. 3 is an exploded view of FIG. 2.  
         [0014]    [0014]FIG. 4 is another exploded view of FIG. 2 taken from a bottom aspect.  
         [0015]    [0015]FIG. 5 is a partially exploded view of a magnetic and power assembly, wherein an internal ground plate engaging with a first magnetic module.  
         [0016]    [0016]FIG. 6 is another partially exploded view of the magnetic and power assembly similar to FIG. 5, taken from a different view of point.  
         [0017]    [0017]FIG. 7 is still another partially exploded view of the magnetic and power module assembly similar to FIGS. 5, 6 from a different view of point.  
         [0018]    [0018]FIG. 8 is a partially assembled view of the modular jack, wherein only two insert modules are received in the housing.  
         [0019]    [0019]FIG. 9 is an assembled view of FIG. 8.  
         [0020]    [0020]FIG. 10 is another assembled view of FIG. 8 taken from a bottom aspect. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    Referring to FIGS. 1 and 8, a modular jack  100  mounted on a main printed circuit board (PCB, not shown) includes an insulative housing  1 , a plurality of insert modules  3  (shown in FIG. 2) received in the housing  1 , a rear ground plate  4 , and a front and rear outer shells  21 ,  22  substantially surrounding and shielding the housing  1 . The modular jack  100  is preferably a multi-port modular jack, which defining a plurality of upper and lower cavities  11 ,  12  for receiving a plurality of mating modular plugs (not shown) and a rear opening  13  for receiving the insert modules  3 . The main PCB has a plurality of signal through holes for signal transmitting, grounding through holes for grounding, and power holes for providing power with a predetermined voltage.  
         [0022]    Referring to FIGS. 1, 8 and  10 , The housing  1  is substantially rectangular-shaped and forms a plurality of protrusions  14  on a lower surface for securing the front outer shell  21  to the housing  1 .  
         [0023]    The front outer shell  21  is stamped from one metal sheet and is folded for surrounding a front portion of the housing  1 . The front outer shell  21  defines a plurality of retaining barbs  213  in opposite sides thereof. A plurality of lower tabs  211  projects downwardly from a lower portion of the front outer shell  21  by stamping, thereby defining a plurality of holes  212 . The rear outer shell  22  is stamped from one metal sheet and is folded for surrounding a rear portion of the housing  1 . The rear outer shell  22  defines a plurality of retaining cutouts  223  corresponding to the retaining barbs  213  of the front outer shell  21 . A plurality of solder tails  221  descent from a lower portion of the rear outer shell  22 . A plurality of retaining tabs  222  are formed on a middle portion of the rear outer shell  22 .  
         [0024]    Referring to FIGS. 2, 3 and  4 , each insert module  3  includes a plurality of upper and lower contacts  31 ,  32 , a first, second, third and fourth internal PCBs  51 ,  52 ,  53 ,  54 , and a magnetic and power assembly  6 . The upper and lower contacts  31 ,  32  respectively includes upper and lower solder portions  311 ,  321  respectively surface mounted to the second and first internal PCBs  52 ,  51 , and upper and lower contact portions  312 ,  322  respectively extending into the upper and lower cavities  11 ,  12  for electrically engaging with corresponding modular plugs.  
         [0025]    The first, second, third and fourth PCBs  51 ,  52 ,  53 ,  54  respectively define a plurality of through holes  510 ,  520 ,  530 ,  540  and a plurality of soldering holes  511 ,  521 ,  531 ,  541 . The third and fourth internal PCBs  53 ,  54  respectively include a plurality of electronic elements  5350 ,  5440  on a lower surface  535  of the third internal PCB  53  and an upper surface  544  of the fourth internal PCB  54 . The electronic elements  5350 ,  5440  are preferably resistors and capacitances. The third and the fourth PCBs  53 ,  54  respectively includes a grounding soldering hole  536  and a grounding pads  543  for grounding.  
         [0026]    Referring to FIGS. 5, 6 and  7 , the magnetic and power assembly  6  includes a first and a second magnetic modules  61 ,  62 , a power module  9  and an internal ground plate  7 . The power module  9  includes an insulative block  90  and a plurality of upper and lower conductors  91 ,  92  respectively extending from upper and lower portions of the insulative block  90 . The insulative block  90  defines a vertical recess  901  through upper and lower surfaces thereof, and a rear hole  93  in a rear portion thereof.  
         [0027]    The first and second magnetic modules  61 ,  62  respectively include a first and second insulative boxes  610 ,  620 . A plurality of short and long conductors  81 ,  82  are mounted in an upper portion of the first and second insulative boxes  610 ,  620  and extend upwardly. A plurality of lower pins  84  are mounted in a lower portion of the first and the second insulative boxes  610 ,  620  and extend downwardly. Each of the first and second insulative boxes  610 ,  620  defines a chamber  600  for receiving a plurality of magnetic coils (not shown) therein. The magnetic coils are electrically connected with the conductors  81 ,  82 ,  84 .  
         [0028]    The first and second insulative boxes  610 ,  620  respectively define a plurality of recesses  611 ,  621  in upper portions thereof and indentions  612 ,  622  in lower portions thereof. The ground plate  7  has a generally planar body portion  70 , a side plate  71 , and a connecting portion  76  connecting the side plate  71  with the planar portion  70 . A plurality of barbs  711  are formed on opposite sides of the side plate  71 . A grounding pin  72  extends upwardly from an upper portion of the body portion  70 . A grounding tail  73  extends downwardly from a lower portion of the body portion  70  and offsets from the body portion  70 . A pair of upper retaining barbs  74  extends from an upper edge of the body portion  70  and respectively toward the first and the second insulative boxes  610 ,  620 . A pair of lower barbs  75  extends from a lower edge of the body portion  70  and respectively toward the first and the second insulative boxes  610 ,  620 .  
         [0029]    Referring to FIGS. 3, 4 and  5 , the upper retaining barbs  74  of the internal ground plate  7  respectively engage with a corresponding recess  611  of the first insulative box  610  and a corresponding recess  621  of the second insulative box  620 . The lower retaining barbs  75  respectively engaging with the indention  612  of the first insulative box  610  and the indention  622  of the second insulative box  620 . A planar side surface  902  of the power module  9  abuts against planar side surfaces  613 ,  623  of the first and the second magnetic modules  61 ,  62 . The side plate  71  extends into the recess  901  of the power module  9  with the barbs  711  interferentially engaging with an inner surface of the recess  901 , whereby the first and the second magnetic modules  61 ,  62  and the power module  9  are tightly assembled as a magnetic and power assembly  6  as shown in FIG. 3 or FIG. 4.  
         [0030]    Referring to FIGS. 2, 3 and  4 , the short conductors  81  of the first magnetic module  61  extend through the first internal PCB  51 , and are soldered in the soldering holes  521  of the second internal PCB  51 . The short conductors  81  of the second magnetic module  62  extend through and soldered in the soldering holes  511  of the first internal PCB  51 . Therefore, electrical connections between the upper contacts  31  with the first magnetic module  61  and the lower contacts  32  with the second magnetic module  62  are established by the short conductors  81 , whereby the magnetic modules  61 ,  62  act as signal conditioning devices for respectively suppressing noises induced by the upper and the lower contacts  31 ,  32 , which is well know to those skilled in the art.  
         [0031]    As shown in FIG. 2, the third and fourth internal PCBs  53 ,  54  are closely stacked with a lower surface  545  of the fourth internal PCB  54  close to an upper surface  534  of the third internal PCB  53 . Lower ends of the long conductors  82  electrically connect with corresponding magnetic coils of the first and the second magnetic modules  61 ,  62 . A number of the long conductors  82  extend through the corresponding through holes  510 ,  520  of the first and the second internal PCBs  51 ,  52  and are soldered in the corresponding soldering holes  521  of the third internal PCB  53 . The other long conductors  82  extend through the corresponding through holes  510 ,  520 ,  530  of the first, second and third internal PCBs  51 ,  52 ,  53  and soldered in the corresponding soldering holes  541  of the fourth internal PCBs  54 . Two of the long conductors  82  extend through and soldered in corresponding soldering holes  531 ,  541  of both the third and fourth PCBs  53 ,  54 , thereby electrically connecting the third and fourth PCBs  53 ,  54  and forming a resistive and capacitive array between the electronic elements  5350 ,  5440  and performing as a noise suppressing module. The arrangement of the electrical elements  5350 ,  5440  is well known to those skilled in the art, a detailed description is omitted herein. The grounding pin  72  of the ground plate  7  extends through the corresponding through holes  510 ,  520  of the first and the second internal PCBs  51 ,  52  and soldered in a corresponding soldering hole  536  of the third internal PCB  53 , and the grounding tail  73  extending through and soldering in the corresponding grounding hole of the main PCB for grounding. The upper conductors  91  of the power module  9  extend through the corresponding through holes  510 ,  520  of the first and second internal PCBs  51 ,  52  and soldered in the corresponding soldering holes  536  of the third PCB, and the lower conductors  92  of the power module  9  are soldered in the corresponding power holes of the main PCB, thereby carrying power signal with a predetermined voltage to the third and the fourth internal PCBs  53 ,  54 . The first, second, third and fourth PCBs  51 ,  52 ,  53 ,  54  and the magnetic and power assembly are tightly assembled as an insert module  3  as shown in FIG. 2.  
         [0032]    Referring to FIG. 8, the rear ground plate  4  includes a generally planar body plate  40 , a plurality of upper grounding contact  41  projecting forwardly from an upper portion of the body plate  40  and generally perpendicular to the body plate  40 , a plurality of lower grounding contacts  42  extending downwardly from a lower portion of the body plate  40 . The body plate  40  defines a plurality of hollow portions  401  in a lower portion thereof. The grounding contact  41  is preferably forked with an upper and a lower tabs  411 ,  412 .  
         [0033]    In assembly, the insert modules  3  are inserted into the insulative housing  1  from the rear opening  13  of the insulative housing  1 . The rear ground plate  4  is attached to the insert modules  3  with the upper and lower tabs  411 ,  412  of the upper ground contacts  41  receiving a rear portion of the fourth internal PCB  54  therein and engaging with grounding tabs  543  of the fourth internal PCB  54 .  
         [0034]    Referring to FIGS. 1, 9 and  10 , the front outer shell  21  substantially surrounds the front portion of the insulative housing  1  and the rear shell  22  substantially surrounds the rear portion of the insulative housing  1 . The holes  212  of the front outer shell  21  engage with corresponding protrusions  14  of the insulative housing  1 . The retaining cutouts  223  of the rear outer shell  22  engage with the retaining barbs  213  of the front outer shell  21 . The retaining tabs  222  of the rear outer shell engage with the rear hole  93  of the power module  9  through the hollow portion  401  of the rear ground plate  4 , thereby securing both the rear ground plate  4  and the rear outer shell  22  to the housing  1 . Each lower grounding contact  42  of the rear ground plate  4  abuts against a corresponding solder tail  221  of the rear outer shell  22  and soldered in the same corresponding grounding through holes of the main PFCB. The grounding tails  73  are soldered to corresponding grounding holes of the main PCB.  
         [0035]    In another embodiment of the invention, the power module  9  includes two parts. The two parts of the power module are respectively integrally made with the first and the second magnetic modules  61 ,  62  to form a first and a second magnetic and power modules. The first and second magnetic and power modules are secured to each other by the internal ground plate  7 .  
         [0036]    It is to be understood, however, that even though numerous, characteristics and advantages of the present invention have been set fourth in the foregoing description, together with details of the structure and function of the invention, the disclosed is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.